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
533-105, 535-v125, 540-140,
01 - Machine
540-170, 540-200, 540-v140,
540-v180, 550-140, 550-170 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 - 9813/9100 - ISSUE 1 - 11/2017
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 2017 © 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:
9813/9100-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
533-105, 535-v125, 540-140, 533-105, 535-v125, 540-140,

540-170, 540-200, 540-v140, 540-170, 540-200, 540-v140,
540-v180, 550-140, 550-170 540-v180, 550-140, 550-170
EN 9813/9100 EN 9813/9100
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
533-105, 535-v125, 540-140, 533-105, 535-v125, 540-140,

540-170, 540-200, 540-v140, 540-170, 540-200, 540-v140,
540-v180, 550-140, 550-170 540-v180, 550-140, 550-170
EN 9813/9100 EN 9813/9100
9813/9100-1
Notes:
9813/9100-1
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 .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-15
01-06-06 Using the Manual ........................................................................................................... 01-16
01-09 Description
01-09-00 General ........................................................................................................................... 01-19
01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-31
9813/9100-1
2017-11-16
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9813/9100-1
2017-11-16
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 .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01 - 1 9813/9100-1 01 - 1
Notes:
01 - 2 9813/9100-1 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 9813/9100-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual and on the machine, 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 (shown) also helps to identify

important safety messages in this manual and on the
machine. When you see this symbol, be alert, your
safety is involved, carefully read the message that
follows, and inform other operators.
Figure 1. The safety alert system
01 - 4 9813/9100-1 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. If you are a new operator, get yourself drop and injure you if the hydraulic system fails
trained in the skills of using a machine before trying or if the control is operated (even with the engine
to work with it. If you don't, you will not do your job stopped).
well, and you will be a danger to yourself and others. Make sure that no-one goes near the machine while
In some markets and for work on certain jobsites you you install or remove the mechanical device.
may 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 9813/9100-1 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 0.6m.
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 9813/9100-1 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 9813/9100-1 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety Worksites

Worksites can be hazardous. Examine the site
Introduction before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
Training and hidden debris, logs, ironwork etc. Any of these
Make sure that you have had adequate training and could cause you to lose control of your machine.
that you are confident in your ability to operate the Check for utilities such as electric cables (overhead
machine safely before you use it. Practice using the and underground), gas and water pipes etc. Mark
machine and its attachments until you are completely the positions of the underground cables and pipes.
familiar with the controls and what they do. With Make sure that you have enough clearance beneath
a careful, well trained and experienced operator, overhead cables and structures.
your machine is a safe and efficient machine. With Communications
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others, Bad communications can cause accidents. Keep
at risk by using the machine irresponsibly. Before you people around you informed of what you will be
start to work, tell your colleagues what you will be doing. If you will be working with other people,
doing and where you will be working. On a busy site, make sure any hand signals that may be used are
use a signalman. understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Before doing any job not covered in this manual, find
out the correct procedure. Your local JCB distributor Parking
will be glad to advise you. An incorrectly parked machine can move without an
Fuel operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Banks and Trenches
leak is suspected. Do not smoke while refuelling or Banked material and trenches can collapse. Do not
working on the fuel system. Do not refuel with the work or drive too close to banks and trenches where
engine running. Completely wipe off any spilt fuel there is danger of collapse.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. Safety Barriers
Machine Condition Unguarded machines in public places can be
dangerous. In public places, or where your visibility
A defective machine can injure you or others. Do not is reduced, place barriers around the work area to
operate a machine which is defective or has missing keep people away.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Sparks
Machine Limits Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Operating the machine beyond its design limits can machine in closed areas where there is flammable
damage the machine, it can also be dangerous. material, vapour or dust.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Hazardous Atmospheres
unapproved modifications or additional equipment. This machine is designed for use in normal out
Engine/Steering Failure door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
If the engine or steering fails, stop the machine as Do not use the machine in a potentially explosive
quickly as possible. Do not operate the machine until atmosphere, i.e. combustible vapours, gas or dust,
the fault has been corrected. without first consulting your JCB dealer.
Exhaust Gases Regulations
Machine exhaust gases can harm and possibly kill Obey all laws, worksite and local regulations which
you or bystanders if they are inhaled. Do not operate affect you and your machine.
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
01 - 8 9813/9100-1 01 - 8
01 - Machine
03 - Safety
18 - Operating Safety
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine.
the machine or its attachments too close to electrical When using the machine, keep your hands and feet
power cables. clear of moving parts. Keep your hands and feet
You are strongly advised to make sure that the safety within the operator compartment while the vehicle is
arrangements on site comply with the local laws in motion.
and regulations concerning work near electric power Controls
lines.
You or others can be killed or seriously injured
Before you start using the machine, check with your if you operate the control levers from outside the
electricity supplier if there are any buried power machine. Operate the control levers only when you
cables on the site. are correctly seated.
There is a minimum clearance required for working Passengers
beneath overhead power cables. You must obtain
details from your local electricity supplier. Passengers in or on the machine can cause
accidents. Do not carry passengers.
Working Platform
Fires
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured. If your machine is equipped with a fire extinguisher,
Never use the machine as a working platform make sure it is checked regularly. Keep it in the
unless with approved man-basket or man-crate (if correct machine location until you need to use it.
applicable). Do not use water to put out a machine fire, you could
Machine Safety spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
Stop work at once if a fault develops. Abnormal extinguishers. Contact your nearest fire department
sounds and smells can be signs of trouble. Examine as quickly as possible.
and repair before resuming work.
Roll Over Protection
Hot Components
If the machine starts to roll over, you can be crushed
Touching hot surfaces can burn skin. The engine and if you try to leave the cab. If the machine starts to roll
machine components will be hot after the unit has over, do not try and jump from the cab. Stay in the
been running. Allow the engine and components to cab, with your seat belt fastened.
cool before servicing the unit.
Confined Areas
Travelling at High Speeds
Pay extra attention to proximity hazards when
Travelling at high speeds can cause accidents. operating in confined areas. Proximity hazards
Always travel at a safe speed to suit working include buildings, traffic and bystanders.
conditions.
Safe Working Loads
Hillsides
Overloading the machine can damage it and make it
Operating the machine on hillsides can be unstable. Study the specifications in the Operator's
dangerous if the correct precautions are not taken. Manual before using the machine.
Ground conditions can be changed by rain, snow, ice
etc. Check the site carefully. When applicable, keep Lightning
all attachments low to the ground. If you are inside the machine during a lightning storm
Visibility stay in the machine until the storm has passed. If
you are outside of the machine during a lightning
Accidents can be caused by working in poor visibility. storm stay away from the machine until the storm
Use your lights to improve visibility. Keep the road has passed. Do not attempt to mount or enter the
lights, windows and mirrors clean. machine.
Do not operate the machine if you cannot see clearly. If the machine is struck by lightning do not use the
Modification of the machine's configuration by the machine until it has been checked for damage and
user (e.g. the fitting of large and non-approved malfunction by trained personnel.
attachments) may result in a restriction of the
machine visibility.
01 - 9 9813/9100-1 01 - 9
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 - 10 9813/9100-1 01 - 10
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 - 11 9813/9100-1 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12 For: 533-105 [T4F], 540-170 [T4F], 540-200
[T4F], 550-140 [T4F], 550-170 [T4F]
Health and Safety .......................................... 01-13 ................................................... Page 01-12
For: 535-v125 [T4F], 540-v140 [T4F], 540-
v180 [T4F] ................................. Page 01-13
(For: 533-105 [T4F], 540-170 [T4F],

540-200 [T4F], 550-140 [T4F], 550-170
[T4F])
You can complete most of the maintenance
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. Retract and lower the lift arm.
4. Put the attachment flat on the ground.
5. Release the hydraulic pressure.
6. Stop the engine and remove the ignition key. If
the keyless ignition option is installed stop the
engine and wait the specified time.
Duration: 15s
7. Disconnect the battery to prevent accidental
operation of the engine.
8. Make sure there are no loose articles in the
enclosure.
9. If necessary, put blocks against the two ends of
the wheels before you get below the machine.
Figure 2.
A Lift arm lowered
01 - 12 9813/9100-1 01 - 12
01 - Machine
03 - Safety
27 - Maintenance Positions
Lift Arm Raised Health and Safety

1. Install the maintenance strut. WARNING Maintenance must be done only by
Refer to: PIL 06-69. suitably qualified and competent persons.
Before doing any maintenance make sure the
(For: 535-v125 [T4F], 540-v140 [T4F], 540- machine is safe, it must be correctly parked on
v180 [T4F]) solid, level ground.
To prevent anyone starting the engine, remove
You can complete most of the maintenance the ignition key. Disconnect the battery when you
procedures with the lift arm lowered. Unless a are not using electrical power. If you do not take
maintenance procedure instructs you differently, you these precautions you could be killed or injured.
must lower the lift arm.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
Lift Arm Lowered the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
1. Park the machine on level, solid ground.
the battery.
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 the specified time.
Duration: 15s
8. Make sure there are no loose articles in the
enclosure.
9. If necessary, put blocks against the two sides of
Figure 3.
A Lift Arm Lowered
Lift Arm Raised

1. Install the maintenance strut.
01 - 13 9813/9100-1 01 - 13
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-15

01-06-06 Using the Manual ........................................................................................................... 01-16
01 - 14 9813/9100-1 01 - 14
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:
533-105 2460601
2902000
535-v125 2460601
2902000
540-140 2460601
2902000
540-170 2460601
2902000
540-200 2460601
2902000
540-v140 2460601
2902000
540-v180 2460601
2902000
550-140 2460601
2902000
550-170 2460601
2902000
01 - 15 9813/9100-1 01 - 15
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 30-00-50 Schematic Circuit
Electrical System 33-03-03 Battery - Isolator Switch
33-09-00 Power Distribution (including fuses
and relays)
33-00-50 Schematic Circuit
Electronic Diagnostic 33-57 Electronic Diagnostic (including
Servicemaster)
Machine Variants • Use the applicable Servicemaster diagnostics

tools. Refer to PIL 33-57-03.
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,
Information in this manual can help you diagnose use the standard torque tightening values. Refer
machine faults. to Fasteners and Fixings, Screws, Bolts, Nuts,
Technical Data (PIL 72-00). For the torque setting to
Before attempting to diagnose possible faults check be effective, do the following before you install the
the following. fixings.
• Ensure that the operator understands the • Make sure that all the applicable component
machine controls, functions and use. Refer to assemblies are correct.
the applicable Operator Manual. • Make sure that the applicable fixings are to the
• Check that the maintenance record complies correct specification. If necessary discard the
with the applicable schedule for the operating original fixings and replace them with new ones.
environment. Refer to PIL 78-24. The relevant procedures indicate when this is
• Check that the fluids in use comply with the necessary.
standards specified. Refer to PIL 75-00. • Make sure that the applicable fixings and
• Ensure that the machine electronic set-up is threaded holes are free from contamination.
applicable. Use the applicable Servicemaster This includes dirt, debris, old sealants and
vehicle set-up tool. Refer to PIL 33-57-03. compounds, fluids and lubricants.
01 - 16 9813/9100-1 01 - 16
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-00 General ........................................................................................................................... 01-19

01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01 - 17 9813/9100-1 01 - 17
Notes:
01 - 18 9813/9100-1 01 - 18
01 - Machine
09 - Description
00 - General
00 - General Introduction
Introduction .................................................... 01-19 The JCB Loadall is a self propelled, seated operator,
Operation ....................................................... 01-20 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 - 19 9813/9100-1 01 - 19
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 - 20 9813/9100-1 01 - 20
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 - 21 9813/9100-1 01 - 21
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 - 22 9813/9100-1 01 - 22
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Component Identification
Figure 4.
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 - 23 9813/9100-1 01 - 23
01 - Machine
09 - Description
15 - Service Point Locations
Engine Compartment
Figure 5.
A B
H
C
G D
E
F
A Air filter B Transmission oil dipstick

C Water separator D Radiator
E Engine oil filter F Drive belt guard
G Engine oil dipstick H Engine oil filler cap
J Coolant expansion tank
01 - 24 9813/9100-1 01 - 24
01 - Machine
09 - Description
Battery Isolator
Figure 6.
A
A
A Battery isolator
01 - 25 9813/9100-1 01 - 25
01 - Machine
09 - Description
Hydraulic Oil Level Indicator and Filler
Figure 7.
C
A
A Hydraulic oil level indicator B Label - hydraulic oil filling point

C Hydraulic tank filler cap
Figure 8. Machines with External Sight Gauge

On some machines the sight gauge is mounted
externally.
A
Figure 9.
A
A Hydraulic oil level indicator
A Secondary hydraulic tank filler cap - If applicable
01 - 26 9813/9100-1 01 - 26
01 - Machine
09 - Description
Axles
Arrangement
Figure 10. Machines with Powered Track Rods
A A
A Axle fill/level plug
01 - 27 9813/9100-1 01 - 27
01 - Machine
09 - Description
Alternate arrangement
Figure 11. Machines with Powered Track Rods
A A
Figure 12. Machines with Double Acting Cylinders
A
A
01 - 28 9813/9100-1 01 - 28
01 - Machine
09 - Description
Filling the Tank

Figure 13.
A Fuel cap
01 - 29 9813/9100-1 01 - 29
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-31
01 - 30 9813/9100-1 01 - 30
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-31 or other chemicals, you must adhere to
Preparation .................................................... 01-32 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 - 31 9813/9100-1 01 - 31
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 - 32 9813/9100-1 01 - 32
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
9813/9100-1
2017-08-14
Notes:
9813/9100-1
2017-08-14
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/9100-1 03 - 1
Notes:
03 - 2 9813/9100-1 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 9813/9100-1 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 9813/9100-1 03 - 4
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-7

03-33-03 Carriage .......................................................................................................................... 03-10
03 - 5 9813/9100-1 03 - 5
Notes:
03 - 6 9813/9100-1 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 9813/9100-1 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 9813/9100-1 03 - 8
33 - Fork
00 - General
Figure 14.
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 9813/9100-1 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 15.
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 9813/9100-1 03 - 10
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-13

03-82-06 Shackle ........................................................................................................................... 03-15
03 - 11 9813/9100-1 03 - 11
Notes:
03 - 12 9813/9100-1 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 9813/9100-1 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 9813/9100-1 03 - 14
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 17.

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 16.
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 9813/9100-1 03 - 15
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 18.
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 9813/9100-1 03 - 16
84 - Hook
84 - Hook
Contents Page No.
03-84-06 Snatch Block .................................................................................................................. 03-19
03 - 17 9813/9100-1 03 - 17
Notes:
03 - 18 9813/9100-1 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 9813/9100-1 03 - 19
84 - Hook
06 - Snatch Block
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 19.
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 9813/9100-1 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
06-06-06 Engine Compartment ..................................................................................................... 06-12
06-06-12 Front Cover .................................................................................................................... 06-15
06-06-14 Rear Cover ..................................................................................................................... 06-17
06-06-15 Top Cover ....................................................................................................................... 06-18
06-06-30 Undershield .................................................................................................................... 06-19
06-06-33 Lift Arm ........................................................................................................................... 06-20
06-06-39 Cab/Canopy ................................................................................................................... 06-22
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-27
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-78
06-12-18 Angle Indicator ............................................................................................................... 06-79
06-12-24 Shim ............................................................................................................................... 06-80
06-12-66 Chain ............................................................................................................................ 06-108
06-30 Pivot Pins
06-30-00 General ......................................................................................................................... 06-147
06-42 Stabiliser
06-42-00 General ......................................................................................................................... 06-151
06-49 Step
06-49-00 General ......................................................................................................................... 06-157
06-54 Fender
06-54-00 General ......................................................................................................................... 06-159
06-57 Counterweight
06-57-00 General ......................................................................................................................... 06-163
06-60 Mirror
06-60-00 General ......................................................................................................................... 06-165
06-63 Identification Label
06-63-00 General ......................................................................................................................... 06-169
06-63-03 Machine ........................................................................................................................ 06-170
06-63-06 Engine .......................................................................................................................... 06-172
06-63-09 Axle .............................................................................................................................. 06-174
06-63-12 Gearbox ........................................................................................................................ 06-175
06-63-15 Operator Protective Structure ...................................................................................... 06-176
06-66 Tools
06-66-00 General ......................................................................................................................... 06-179
06-69 Maintenance Strut
06-69-00 General ......................................................................................................................... 06-181
9813/9100-1
2017-10-30
06-69-03 Lift Arm ......................................................................................................................... 06-182
06-75 Fire Extinguisher
06-75-00 General ......................................................................................................................... 06-187
06-89 Window Guard
06-89-00 General ......................................................................................................................... 06-189
9813/9100-1
2017-10-30
Acronyms Glossary
FOPS Falling Object Protective Structure

HBCV Hose Burst Check Valve
OECD Organization for Economic
Cooperation and Development
PIN Product Identification Number
9813/9100-1
2017-10-30
Notes:
9813/9100-1
2017-10-30
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9813/9100-1 06 - 1
Notes:
06 - 2 9813/9100-1 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 9813/9100-1 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 9813/9100-1 06 - 4
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 5 9813/9100-1 06 - 5
Notes:
06 - 6 9813/9100-1 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 9813/9100-1 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 9813/9100-1 06 - 8
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-11

06-06-06 Engine Compartment ..................................................................................................... 06-12
06-06-12 Front Cover .................................................................................................................... 06-15
06-06-14 Rear Cover ..................................................................................................................... 06-17
06-06-15 Top Cover ....................................................................................................................... 06-18
06-06-30 Undershield .................................................................................................................... 06-19
06-06-33 Lift Arm ........................................................................................................................... 06-20
06-06-39 Cab/Canopy ................................................................................................................... 06-22
06 - 9 9813/9100-1 06 - 9
Notes:
06 - 10 9813/9100-1 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 9813/9100-1 06 - 11
06 - Engine Compartment
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 - 12 9813/9100-1 06 - 12
Figure 20.
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 - 13 9813/9100-1 06 - 13
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 - 14 9813/9100-1 06 - 14
12 - Front Cover
12 - Front Cover Figure 21.
Remove and Install
(For: 533-105 [T4F], 540-170 [T4F],

540-200 [T4F], 540-v140 [T4F], 540-v180
[T4F], 550-170 [T4F])
Remove
2. Isolate the battery and remove the isolator key.
Refer to (PIL 33-03-03).
3. Open the top cover to gain access to the cover
securing bolts.
4. Remove the bolts (x3) located outside the cab
beneath the front window. A
5. Remove the bolts (x3) located inside the cab.

6. Disconnect any pipes or electrical connectors.
7. Lift and remove the cover.
B
A Cab
B Front cover assembly
06 - 15 9813/9100-1 06 - 15
12 - Front Cover
Figure 22.
C C
C
B
D D
B Front cover assembly
C Bolt locations- from outside cab
D Bolt locations- from inside cab (floor pan not
shown)
Install
steps.
2. Tighten the fasteners to the correct torque value.
3. Make sure the washer fluid level is correct and
that the window wash/wipe system operates
correctly.
06 - 16 9813/9100-1 06 - 16
14 - Rear Cover
14 - Rear Cover
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v140 [T4F], 550-140 [T4F],
550-170 [T4F])
Open the rear cover for access to the filler cap and
sight glass.
Open
2. Use the key to unlock the rear cover.
3. Open the rear cover.
Figure 23.
B
A Key
B Rear cover
Close
1. Position the rear cover.
2. Use the key to lock the rear cover.
06 - 17 9813/9100-1 06 - 17
15 - Top Cover
15 - Top Cover
Remove and Install
(For: 540-140 [T4F], 540-170 [T4F], 540-200 [T4F])
Figure 24.
C
A
A Bolts and washers B Sealing strips

C Deck plate
Remove 2. Make sure the sealing strips are installed - if

damaged replace with new strips.
1. Make the machine safe with the lift arm raised,
refer to PIL (01-03).
2. Install the maintenance strut, refer to (PIL 06-69).
3. Remove the bolts and washers.
4. Remove the deck plate from the machine.
Install
step.
06 - 18 9813/9100-1 06 - 18
30 - Undershield
30 - Undershield
(For: 533-105 [T4F])
Figure 25. Belly Guards- R28 Tyres

H J
C
E H
K
F
J
J
B
G
G
G A G J
D
A Side rail- pod side B Side rail- cab side

C Front panel- 28" tyre D Centre guard
E Rubber cover F Pop rivet and washer
G Edge seal
06 - 19 9813/9100-1 06 - 19
33 - Lift Arm
33 - Lift Arm Figure 27. Lift Arm Harness Guard
Remove and Install

For: 533-105 [T4F] .................... Page 06-20
For: 540-170 [T4F] .................... Page 06-20
For: 540-v180 [T4F] .................. Page 06-20
(For: 533-105 [T4F])
Remove- Lift Arm Nose Cover

1. Make the machine safe. Refer to (PIL 01-03). C
2. Fully lower the lift arm.
A B
3. Remove the securing bolts.
C
4. Remove the cover from the inner lift arm nose.
Figure 26.
C B
A Lift arm
B Lift arm harness guard
C Bolts (X3)
Install
1 Securing bolts step.
2 Cover
1.1. Tighten all the fastenings to the correct
torque value.
Install
1. The installation procedure is the opposite of the (For: 540-v180 [T4F])
removal procedure.
Remove
(For: 540-170 [T4F])
Remove 2. Hold the lift arm rear cover, then remove the
bolts.
3. Lower the cover.
2. Hold the cover, then remove the bolts.
3. Lower the cover.
06 - 20 9813/9100-1 06 - 20
33 - Lift Arm
Figure 28.
A
B
A Lift arm
B Bolts
Install
step.
1.1. Tighten all fastenings to the correct torque
value.
06 - 21 9813/9100-1 06 - 21
39 - Cab/Canopy
39 - Cab/Canopy
Remove and Install
(For: 533-105 [T4F], 540-170 [T4F], Install

540-200 [T4F], 540-v140 [T4F], 550-140
[T4F], 550-170 [T4F]) removal procedure. Additionally do the following
step.
Remove
1.1. Tighten the floor cover bolts to the correct
1. Make the machine safe. Refer to (PIL 01-03). torque value.
2. Isolate the battery and remove the isolator key.
Refer to (PIL 33-03-03). Cab Rear Cover
3. Lift and remove the floor mat. Remove

4. Remove the floor cover bolts (X6). 1. Make the machine safe. Refer to (PIL 01-03).
5. Remove the cover. 2. Isolate the battery and remove the isolator key.
Figure 29. Access Plate- Cab Floor
3. Remove the rear cover bolts (X5).
4. Remove the cover.
B
A Cab
B Access plate- cab floor
06 - 22 9813/9100-1 06 - 22
39 - Cab/Canopy
Figure 30. Cab Rear Cover

A
C
A Cab B Rear cover

C Bolts (X5) D Rubber flap
06 - 23 9813/9100-1 06 - 23
39 - Cab/Canopy
Install
steps.
1.1. Make sure that the rubber flap is located
in the recess on the fuel tank during
installation.Refer to Figure 30.
1.2. Tighten the bolts to the correct toque value.
06 - 24 9813/9100-1 06 - 24
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-27

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-78
06-12-18 Angle Indicator ............................................................................................................... 06-79
06-12-24 Shim ............................................................................................................................... 06-80
06-12-66 Chain ............................................................................................................................ 06-108
06 - 25 9813/9100-1 06 - 25
Notes:
06 - 26 9813/9100-1 06 - 26
12 - Lift Arm
00 - General
Introduction .................................................... 06-27
Health and Safety .......................................... 06-29
Hydraulic Ram Operated Lift Arms
Technical Data ............................................... 06-29 The lift arms on these machines are extended and
Component Identification ............................... 06-32 retracted by hydraulic rams. No chain system is
Operation ....................................................... 06-47 used. There are differences in the configuration
and location of components depending on machine
Operation (Hydraulic) .................................... 06-52
model. Refer to Table 4.
Repair ............................................................ 06-58
Adjust ............................................................ 06-58 Refer to body and framework, lift arm, general,
Calibrate ........................................................ 06-59 component identification (PIL 06-12-00).
Lubricate ........................................................ 06-60 All lift arm sections are identified in a similar way
Remove and Install ....................................... 06-69 irrespective of the number of sections or method of
Disassemble and Assemble .......................... 06-77 operation.
Table 4.
Machine Lift Arm
535-105 3 Section, 3 stage
535-v125 3 Section, 3 stage
540-v140 3 Section, 3 stage
Hydraulic Ram and Chain Operated Lift system acts to extend or retract the sections of the lift
Arms arm. The configuration and location of components
will depend on the machine model. Refer to Table 5.
The lift arms on these machines incorporate chains
and pulleys and a single hydraulic ram. The chain Refer to body and framework, lift arm, general,
component identification (PIL 06-12-00).
Table 5.
Machine Lift Arm
540-v180 4 Section, 4 stage (chain)
540-200 5 Section, 5 stage (chain)
06 - 27 9813/9100-1 06 - 27
12 - Lift Arm
00 - General
Figure 31.
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
All intermediate and inner lift arm sections slide

against adjustable / replaceable wear pads installed
in the lift arm sections. Refer to body and framework,
lift arm, general, (PIL 06-12-00) and body and
framework, lift arm, shims and wear pads, (PIL
06-12-24 and 06-12-30).
06 - 28 9813/9100-1 06 - 28
12 - Lift Arm
00 - General
Health and Safety Technical Data

Lifting Equipment For: 535-v125 [T4F], 540-v140 [T4F], Hi-Viz
................................................... Page 06-29
You can be injured if you use incorrect or faulty lifting For: 540-v180 [T4F] .................. Page 06-30
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong For: 540-200 [T4F] .................... Page 06-30
enough and suitable for the job. Make sure that lifting For: 533-105 [T4F] .................... Page 06-30
equipment is in good condition and complies with all For: 540-140 [T4F], 550-140 [T4F]
local regulations. ................................................... Page 06-30
DANGER! Before removing the boom from the For: 540-170 [T4F], 550-170 [T4F]
machine, make sure that the counterweight is ................................................... Page 06-31
adequately supported as in certain ground conditions For: 535-v125 [T4F] .................. Page 06-31
the machine could tip backwards. Never travel or
transport the machine with the boom removed. (For: 535-v125 [T4F], 540-v140 [T4F], Hi-
CAUTION! Make sure you know the weight of the Viz)
load before trying to lift it. Raise the load only a
few centimetres at first, to check that the machine is Wear Pad Clearance- 3 Stage (3 section)
stable. Lower the load straight away if the machine Lift Arm
begins to feel unstable. Do not exceed the loading
limits shown on the Load Charts. Make sure that the wear pads are installed correctly
CAUTION! This component is heavy. It must only be to prevent fouling. Refer to body and framework-
removed or handled using a suitable lifting method wear pads, refer to (PIL 06-30).
and device.
Refer to Table 6.
WARNING! The limits shown on the load charts are
for a stationary, level machine. Do not raise or extend Figure 32.
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 A
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 B
slings. B
WARNING! You could be killed or injured if the boom
drops while you are working under it. Install the A
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.
A
WARNING! Make sure the machine cannot tip
over when this component (or components) is (are)
removed during this operation.
Table 6. Measurements
Dimension A
Front Vertical clearance max
3mm
Rear Vertical clearance max
1.5mm
Dimension B
06 - 29 9813/9100-1 06 - 29
12 - Lift Arm
00 - General
Front Vertical clearance max (For: 533-105 [T4F])

3mm
Rear Vertical clearance max Wear Pad Clearance- 3 Stage (3 section)
1.5mm Lift Arm
(For: 540-v180 [T4F]) Make sure that the wear pads are installed in the
correct way round to prevent fouling. Refer to body
and framework- wear pads, refer to (PIL 06-30).
Table 7. 540-V180 Wear Pad Clearances
Refer to Table 9.
Maximum wear pad 1.5mm
clearance in vertical and Figure 34. 3 Stage Lift Arm
horizontal planes
A
(For: 540-200 [T4F])
Figure 33. 5 Stage Lift Arm
B B B
C C C C
A
D
D
Table 9. Wear Pad Clearance-

3 Stage (3 Section) Lift Arm
B Dimension Maximum Gap

B
A 1.5mm
C C B 1.5mm
C C
(For: 540-140 [T4F], 550-140 [T4F])
E Wear Pad Clearance- 3 Stage (3 section)

F Lift Arm (P1)
Make sure that the wear pads are installed correctly
to prevent fouling. Refer to body and framework-
wear pads, refer to (PIL 06-30).
Table 8. Wear Pad Clearances Machines Refer to Table 10.
Dimension
(1)
Maximum Minimum
A 59mm 55mm
B 3mm
C 1.5mm
D 34mm 32mm
E 40mm 38mm
F 44mm 42mm
(1) Refer to Figure 1
06 - 30 9813/9100-1 06 - 30
12 - Lift Arm
00 - General
Figure 35. Figure 36. 3 Stage (4 section) Lift Arm
A A
A
B
B
B
B
A A
B
Table 10. Measurements

Dimension A
Front Vertical clearance max
3mm
Rear Vertical clearance max
1.5mm
Dimension B Table 11. Maximum Gap
Front Vertical clearance max Dimension Maximum Gap
3mm A 3mm
Rear Vertical clearance max B 3mm
1.5mm
(For: 535-v125 [T4F])
(For: 540-170 [T4F], 550-170 [T4F])
Table 12. 535v-125
Wear Pad Clearance- 4 Stage (4 section)
Maximum clear- Vertical 3mm
Lift Arm ance- front
pads
Make sure that the wear pads are installed correctly
to prevent fouling. Refer to body and framework- (Section A-A) Horizontal 3mm
wear pads, refer to (PIL 06-30). - - -
Maximum clear- Vertical 1.5mm
Refer to Table 11. ance- rear pads
(Section B-B) Horizontal 1.5mm
- - -
Wear pad bolt M10 bolts 56N·m
torque M12 Bolts 98N·m
- - -
Thread engage- 8–12mm
ment (Between
bolt and wear
pad assembly)
(1)
(1) Make sure the end of the bolt does not protrude
beyond the wear pad threaded insert.
06 - 31 9813/9100-1 06 - 31
12 - Lift Arm
00 - General
For: 540-v180 [T4F] .................. Page 06-32

For: 540-200 [T4F] .................... Page 06-40
(For: 540-v180 [T4F])

Figure 39. Lift Arm- 540-v180................................................................................................ Page 06-35
06 - 32 9813/9100-1 06 - 32
12 - Lift Arm
00 - General
Figure 37. Chains and Rollers
400/F6880-2
A Extension chains B Retract chains

C Lift arm D Extend / retract ram
06 - 33 9813/9100-1 06 - 33
12 - Lift Arm
00 - General
Figure 38.
F
G
E
A
400/F6880-2
A Extension chains B Retract chains

E Retract chain pulleys F Extension chain pulleys
G Extension chain pulleys H Retract chain pulley
J Retract chain pulley
06 - 34 9813/9100-1 06 - 34
12 - Lift Arm
00 - General
Page 06-36 Figure 39. Lift Arm- 540-v180 Page 06-37

B C
A E
F
d2
K D G
L
J H d1
06 - 35 9813/9100-1 06 - 35
12 - Lift Arm
00 - General
Page Page
06-36 06-37
Figure 39. (Part 1 of 2)

B C
A
K
J
Page 06-37
06 - 36 9813/9100-1 06 - 36
12 - Lift Arm
00 - General
Page Page
06-36 06-37
C Figure 39. (Part 2 of 2)

E
F
d2
K D G
L
H d1
Page 06-36
06 - 37 9813/9100-1 06 - 37
12 - Lift Arm
00 - General
A Lift ram B Lift arm outer section

C Large extend chains D Lift arm- intermediate section 1
E Small extend chains F Lift arm- intermediate section 2
G Lift arm- intermediate section 3 H Small retract chains
J Large retract chains d1 Dimension 1 (Refer to PIL 06-12-66)
d2 Dimension 2 (Refer to PIL 06-12-66)
Figure 40. E- Retract Chain Pulleys Figure 42. G- Extension Chain Pulleys
14
15
14 Pin- split cotter

15 Pin- split
Figure 41. F- Extension Chain Pulleys
400/F6880-2
130 Roller pivot pin

140 Spacer 2 x 45.5 x 70
150 Seal 45 x 55 x 5
280 Grease nipple
480 Spacer 3 X 45.5 X 70
Figure 43. H- Retract chain pulley
400/F6880-2
20 Pivot pin
30 Spacer 3mm
360 Spacer- 2.0 mm
390 Chain guide roller
410 Insert plug
10 ABI Kit 1 Chains and pulleys

220 Pivot pin- 1st inter chain
360 Spacer 2mm
390 Chain Guide Roller 60X85.5
410 Insert Plug
06 - 38 9813/9100-1 06 - 38
12 - Lift Arm
00 - General
Figure 44. J- Retract chain pulley 400 Chain Guide Roller 45 X 55

410 Insert Plug
420 Spacer Roller 15mm
10 ABI Kit 1 Chains and pulleys

250 Pivot Pin- 2nd inter chain
290 Pin;Split 1/8 X 1
310 Pin;Split 3/32 X 5/8
320 Pin;Split 5/64 X 1/2
06 - 39 9813/9100-1 06 - 39
12 - Lift Arm
00 - General
(For: 540-200 [T4F])
Figure 45. Lift Arm
06 - 40 9813/9100-1 06 - 40
12 - Lift Arm
00 - General
Figure 46. Lift Arm Chains and Pulleys
B
D
E
C
A F
A Extension chain B Extension chain

C Extension chain D Retract chain
E Retract chain F Retract chain
06 - 41 9813/9100-1 06 - 41
12 - Lift Arm
00 - General
Figure 47.
A
B
C
D
A B D
C
G
E F
E F G
Table 13.
A Extension Chain Roller
B Extension Chain Roller
C Extension Chain Roller
D Link
E Retract chain roller
(1)
F Retract chain roller

(1)
G Retract chain roller

(1)
(1) The Illustration shows grease nipples- these are not installed and the bearing does not require lubrication.
Do not attempt to lubricate this bearing.
06 - 42 9813/9100-1 06 - 42
12 - Lift Arm
00 - General
Figure 48. Extension Chain Roller Figure 50. Extension Chain Roller
Figure 51. Retract Chain Roller
Figure 49. Extension Chain Roller
100 The Illustration shows grease nipples- these

are not installed and the bearing does not
require lubrication. Do not attempt to lubricate
this bearing.
06 - 43 9813/9100-1 06 - 43
12 - Lift Arm
00 - General
Figure 52. Retract Chain Roller Figure 53. Retract Chain Roller

this bearing.

this bearing.
Figure 54.
Table 14. Components

Item Description Notes
10 ABI Chains And Pulleys
20 Pin:Split 1/8 X 1/2
30 Pin;Split 5/32 X 1.1/2
40 Split Pin 3/16" X 1-3/4"
50 Pin Split Cotter 5/32" X 1 3/4" 1 3/4"
60 Pin;Split 1/4 X 2.1/4
70 Pin Split Cotter 5/32" X 7/8" 7/8"
80 Pin;Split 1/8 X 5/8
90 Pin Split Cotter 5/32" X 1 1/4" 1 1/4"
100 Grease Nipple 1/8" BSP Not installed on some rollers on
some machines
06 - 44 9813/9100-1 06 - 44
12 - Lift Arm
00 - General

110 Split Pin 3/32 X 1/2 LG
120 Pin;Split 3/32 X 5/8
130 Chain Guide Roller 60 X 85 0.5 0.5
140 Ext Roller Wide P421
150 Ext Roller P421
160 SA Ram Roller
170 Pin W.A. Large Retract
180 Pin - 2Nd Inter Chain Pivot
190 Pin W.A. Small Retract
200 W.A. Pivot Pin
210 W.A. Pivot Pin
220 W.A. Pivot Pin
230 Pivot Pin
240 Pivot Pin
250 Pivot Pin
260 Chain Guide Roller 40 X 35
270 Spacer
280 Chain Guide Roller 45 X 55
290 Spacer Outer Roller 46
300 Spacer 3mm
310 Spacer
320 Pin;Split 1/8 X 1
330 Pin;Split 5/64 X 1/2
340 Keep Plate 30.5
350 Shim 1mm OD 90 ID41
360 Washer Spherical Seating
370 Washer Spherical Seating 0
380 Washer Spherical Seating 0
390 Washer Spherical Seating
400 Washer
410 Setscrew M10 X16 Nylonpatch Nylonpatch G8.8
G8.8
G8.8
G8.8
440 Roller Washer
450 Chain Lubricant Aerosol
460 Set Screw M16 X 30 Endcap S. G8
470 Set Screw M16 X 45
480 Bolt M20 X 50 Endcaps. G8
490 Plain Washer M10
530 Pin;Split 1/8 X 3/4
540 Shim
560 M30 X 3.5 Self Lock Nut
06 - 45 9813/9100-1 06 - 45
12 - Lift Arm
00 - General

590 M48 X 5 Self Lock Nut
600 Seal 45 X 55 X5
610 Seal 60 X 70 X5
630 Spacer 2mm
640 Chain Tension Measure Label
06 - 46 9813/9100-1 06 - 46
12 - Lift Arm
00 - General
Operation
For: 533-105 [T4F], 535-v125 [T4F], 540-140

[T4F] .......................................... Page 06-47
For: 540-v180 [T4F] .................. Page 06-48
For: 540-200 [T4F] .................... Page 06-48
(For: 533-105 [T4F], 535-v125 [T4F], 540-140 [T4F])
Figure 55. 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 If the inner and intermediate booms move out of
inner, intermediate and outer section. phase the telescopic service hoses will be damaged.
Should a hose of the incorrect length be fitted
When the boom is extended or retracted the inner damage can also occur.
and outer sections move simultaneously. This is
achieved by hydraulically interconnecting the inner To ensure the reliable operation of the telescopic
and outer extension rams. For an explanation of the function it is critical that the hoses are routed and
hydraulic operation refer to (PIL 30-00). fitted correctly.
From the diagrams we can see that the hydraulic To ensure the correct clearances and smooth
hoses connected to the tilt ram, auxiliary service movement between the boom sections, special wear
and inner extension ram (telescopic services) are pads together with shims are fitted. Wear pads are
arranged to follow the movement of the inner and fitted at the top, bottom and sides at both ends of
intermediate boom sections. As the boom extends the boom sections. The inner extension ram is also
the hose runs at the bottom of the inner boom are fitted with a wear pad since the inner boom moves in
drawn around the guide roller and along the top of relation to the ram cylinder.
the inner extension ram.
06 - 47 9813/9100-1 06 - 47
12 - Lift Arm
00 - General
(For: 540-v180 [T4F]) Clearance between the lift arm sections is

maintained by sets of wear pads and shims.
The lift arm extend and retract system is actuated
by a single hydraulic ram installed on the top of the The 1st intermediate lift arm section extends and
lift arm. The hydraulic ram is attached to the lift arm retracts by means of an internal hydraulic extension
outer section at one end and the first intermediate ram.
section at the other end.
The 2nd and 3rd intermediate lift arm sections and
As the ram moves to extend or retract the first the inner lift arm section extend and retract by means
intermediate section, the other 2 sections are of extension and retraction chain sets.
operated by a chain and pulley system working in
response to the action of the hydraulic ram. The extension chain sets anchor at the top of the lift
arm sections. The front chain anchors are visible on
the outside of the lift arm.
(For: 540-200 [T4F])
The retraction chain sets anchor at the bottom of the
The telescopic lift arm has five sections. The lift arm lift arm sections. When the lift arm extends a short
outer section locates on the machine chassis by distance the front chain anchors are visible on the
means of a pivot pin. outside of the lift arm
Figure 56.
A B
A
A
G F E
J H
K D
A
A
A
E E E
A Front extension chain anchors B Pivot pin

C Retraction chain D Extension chain
E Retraction chain anchors F Outer lift arm section
G 1st intermediate lift arm section H 2nd intermediate lift arm section
J 3rd intermediate lift arm section K Inner lift arm section
Hydraulic Components A single extension ram is located inside the lift

arm. The ram cylinder has a support rollers at the
The lift ram operates the lift arm raise and lower bottom of the inner lift arm. The cylinder end cap
function. Twin displacement rams are hydraulically incorporates a guide to ensure smooth location with
connected to the tilt ram and operate a parallel lift the support roller.
feature.
The hydraulic hoses for the tilt ram and auxiliary
service locate in hose trays inside the lift arm. The
06 - 48 9813/9100-1 06 - 48
12 - Lift Arm
00 - General
hose trays ensure reliable hose control during lift arm For more details of hydraulic operation, refer to Lift
extension and retraction. Arm- Operation (hydraulics) (PIL 06-12-00).
The lift ram incorporates a dual counterbalance

valve. The extension ram incorporates a
counterbalance valve.
Figure 57.
B C
E D
G F
A Tilt ram B Guide

C Extension ram D Extension ram counterbalance valve
E Displacement rams F Lift ram dual counterbalance valve
G Lift ram H Hose tray
J Hydraulic hoses
06 - 49 9813/9100-1 06 - 49
12 - Lift Arm
00 - General
Telescopic Operation fixed to the outer lift arm the cylinder pushes the 1st
intermediate lift arm section out from the outer lift arm
The telescopic lift arm function is actuated by a single by means of its trunnion mounting.
hydraulic extension ram which extends or retracts
the 1st intermediate lift arm section. At the same time the chain roller attached to the 1st
intermediate lift arm section, causes the extension
As the ram moves the 1st intermediate lift arm chain to pull the 2nd intermediate lift arm section out
section a system of chains extend or retract the other from the 1st intermediate lift arm section.
lift arm sections.
At the same time the chain roller attached to the 2nd
All the lift arm sections extend/retract at the same intermediate lift arm section, causes the extension
time. chain to pull the 3rd intermediate lift arm section out
from the 2nd intermediate lift arm section.
The piston rod of the extension ram is fixed to the lift
arm outer section. The ram cylinder is fixed to the 1st At the same time the chain roller attached to the 3rd
intermediate lift arm section by means of a trunnion. intermediate lift arm section, causes the extension
chain to pull the inner lift arm section out from the 3rd
Lift Arm Extend intermediate lift arm section.
When the controls operate to extend the lift arm,

the hydraulic ram extends. Since the ram rod is
Figure 58. Lift arm extend

A A1
B B1 1
C C1 2
3
4 D
5
1 Outer lift arm section 2 1st intermediate lift arm section

3 2nd intermediate lift arm section 4 3rd intermediate lift arm section
5 Inner lift arm section A Extension chain roller (1st intermediate lift arm)
A1 Extension chain B Extension chain roller (2nd intermediate lift
arm)
B1 Extension chain C Extension chain roller (3rd intermediate lift
arm)
C Extension chain D Hydraulic extension ram
06 - 50 9813/9100-1 06 - 50
12 - Lift Arm
00 - General
Lift Arm Retract At the same time the chain roller attached to the 2nd
intermediate lift arm section, causes the retraction
When the controls operate to retract the lift arm, chain to pull the 3rd intermediate lift arm section
the hydraulic ram retracts. The cylinder pulls the 1st inside the 2nd intermediate lift arm section.
intermediate lift arm section inside the outer lift arm.
At the same time the chain roller attached to the 3rd
At the same time the chain roller attached to the 1st intermediate lift arm section, causes the retraction
intermediate lift arm section, causes the retraction chain to pull the inner lift arm section inside the 3rd
chain to pull the 2nd intermediate lift arm section intermediate lift arm section.
inside the 1st intermediate lift arm section.
Figure 59. Lift arm retract

1
2
3
4 D
5
C1 C B1 B A1 A
1 Outer lift arm section 2 1st intermediate lift arm section

3 2nd intermediate lift arm section 4 3rd intermediate lift arm section
5 Inner lift arm section A Retract chain roller (1st intermediate lift arm)
A1 Retract chain B Retract chain roller (2nd intermediate lift arm)
B1 Retract chain C Retract chain roller (3rd intermediate lift arm)
C Retract chain D Hydraulic extension ram
06 - 51 9813/9100-1 06 - 51
12 - Lift Arm
00 - General
Operation (Hydraulic)
(For: 540-200 [T4F]) At the same time oil flows from the pump to the
pilot port of the counterbalance valve via the flow
Lift arm Lift and Lower restrictor. When the pump pressure reaches the
specified pressure the counterbalance valve starts to
The lift arm raise and lower service operates open. 150bar (2,173.9psi)
by means of service spool in the main control
If the load on the lift arm generates more than the
valve block. The hydraulic circuit includes a dual
specified pressure in the head side of the lift ram, the
counterbalance valve block mounted on the lift ram.
pump pressure continues to rise until it overcomes
The check valve 1 also functions as a HBCV (Hose
the load on the lift arm. The check valve 1 opens and
Burst Check Valve).
oil flows to the head side of the lift ram. This causes
the lift ram to extend, raising the lift arm.
Lift Arm Raise
At the same time oil flows from the rod side of the
When the service spool moves to select lift arm raise, lift ram to the service spool via the counterbalance
oil from the hydraulic pump flows to the check valve valve. Oil returns to tank in the normal way.
1. Controlling the oil flow to and from the lift ram in this
way ensures that the lift arm raise operates smoothly.
Figure 60. Lift arm raise
B
C
A D E
G
K F
A Main control valve service spool B Dual counterbalance valve block

C Check valve 1 D Lift / lower control valve
E Lift ram F Recirculation valve
G Check valve 2 H Check valve 3
J Counterbalance valve K Flow restrictor
06 - 52 9813/9100-1 06 - 52
12 - Lift Arm
00 - General
Lift Arm Lower At the same time oil from the service spool pilot port
flows to the pilot port of the lift / lower control valve.
When the service spool moves to select lift arm lower, This causes the valve to open and oil flows from the
oil from the hydraulic pump flows to the rod side of head side of the lift ram to the service spool via the
the lift ram via the check valve 3. check valve 2. This causes the lift ram to retract,
lowering the lift arm.
Figure 61. Lift arm lower
B
C
A
D E
G
F
K
J

06 - 53 9813/9100-1 06 - 53
12 - Lift Arm
00 - General
Emergency Operation Regeneration

In the event of an engine failure or hose burst, the lift / When the lift arm lower service operates with a heavy
lower control valve will allow lowering of the lift arm load on the lift arm, oil flows quickly from the head
in the normal way. Oil at pilot pressure stored in the side of the lift ram. This causes the oil pressure on the
servo accumulator allows pilot operation of the lift / rod side to fall causing the recirculation valve to open.
lower control valve without the engine running. The Some oil flows from the head side and supplements
valve will operate several times before exhausting the flow from the pump to the rod side of the ram.
the pilot pressure.
This ensures fast (regeneration) and smooth (anti
cavitation) operation of the lift arm lower service.
Figure 62. Regeneration

B
C
A D E
G
F
K
J

Lift Arm Extend and Retract valve 2. When the oil pressure is higher than the
pressure in the head side of the extension ram the
The lift arm extend and retract service operates check valve 2 opens and oil flows to the head side
by means of service spool in the main control of the ram. This causes the extension ram to extend,
valve block. The hydraulic circuit includes a extending the lift arm.
counterbalance valve block mounted on the
extension ram. The check valve 2 also functions as At the same time oil flows from the rod side of
a HBCV. the extension ram to the service spool via the
counterbalance valve block. Oil returns to tank in the
Lift Arm Extend normal way.
When the service spool moves to select lift arm

extend, oil from the hydraulic pump flows to the check
06 - 54 9813/9100-1 06 - 54
12 - Lift Arm
00 - General
Figure 63. Lift arm extend

C
F D
G
E
A Main control valve service spool B Counterbalance valve block

C Extension ram D Recirculation valve
E Check valve 1 F Counterbalance control valve
G Check valve 2
06 - 55 9813/9100-1 06 - 55
12 - Lift Arm
00 - General
Lift Arm Retract of the ram. This causes the extension ram to extend,
extending the lift arm.
When the service spool moves to select lift arm
extend, oil from the hydraulic pump flows to the check At the same time oil flows from the rod side of
valve 2. When the oil pressure is higher than the the extension ram to the service spool via the
pressure in the head side of the extension ram the counterbalance valve block. Oil returns to tank in the
check valve 2 opens and oil flows to the head side normal way.
Figure 64. Lift arm retract

C
F D
G
E

G Check valve 2
06 - 56 9813/9100-1 06 - 56
12 - Lift Arm
00 - General
Emergency Operation Regeneration

In the event of an engine failure or hose burst When the lift arm retract service operates with a
with the lift arm raised, the counterbalance control heavy load on the lift arm, oil flows quickly from
valve will allow retraction of the lift arm using the head side of the extension ram and oil pressure
gravity to assist retraction. Oil at pilot pressure on the rod side of the ram falls. This causes the
stored in the servo accumulator allows pilot operation recirculation valve to open, allowing some oil to flow
of the counterbalance valve without the engine from the head side and supplement the flow from the
running. The valve will operate several times before pump to the rod side of the ram.
exhausting the pilot pressure.
This ensures fast (regeneration) and smooth (anti -
cavitation) operation of the lift arm retract service.
Figure 65. Regeneration

C
F D
G
E

G Check valve 2
06 - 57 9813/9100-1 06 - 57
12 - Lift Arm
00 - General
Repair Adjust
(For: 540-170 [T4F], 540-v180 [T4F], (For: 540-200 [T4F], 540-v180 [T4F])
550-170 [T4F])
For lift arm phasing and chain tensioning, refer to
body and framework, lift arm, chain, (PIL 06-12-66).
4 Stage (4 Section) lift arm
Unless the lift arm fabrications are damaged there
is normally no requirement to separate the lift arm
sections. The lift arm sections can be separated with
the lift arm assembly removed or fitted to the machine
as required.
• The following procedures can be carried out

without the need to separate the lift arm
sections or remove the lift arm from the
machine:
• Hose removal and replacement. Refer to
(PIL 30-93-03).
• Tilt ram removal and replacement. Refer
to (PIL 30-15).
• Outer extension ram removal and
replacement. Refer to (PIL 30-15).
• Inner extension ram removal and
replacement (Not installed on 540-180
machines). Refer to (PIL 30-15).
• Wear pads and shims. Refer to (PIL
06-12).
• The following procedures need to be carried out
by separating the lift arm sections:
• To remove and install the chains for
540-170 and 540-180 machines, the lift
arm sections will need to be separated to
access the chains.
06 - 58 9813/9100-1 06 - 58
12 - Lift Arm
00 - General
Calibrate 7. Add or remove the shim 1 and shim 2 as

necessary to align the carriage. Refer to adjust
(PIL 06-12-30).
(For: 533-105 [T4F], 535-v125 [T4F], 8. Make sure that the difference in shim thickness of
540-140 [T4F], 540-170 [T4F], 540-v140 shim 1 and shim 2 does not exceed the specified
[T4F], 550-170 [T4F]) value.
When the boom is assembled, do a check of Length/Dimension/Distance: 3.2mm

the carriage alignment to make sure that the 9. Make sure that the maximum wear pad clearance
measurement is accurate. does not exceed the specified value.
1. Make the machine safe. Refer to (PIL 01-03). Length/Dimension/Distance: 3mm
2. Make sure that the tyre pressures are correct. Figure 68.
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 66.
A
A Inclinometer
5. Measure the left and right side carriage height C F
D E
from the ground to the top of the carriage and
note the dimensions. B Maximum wear pad clearance
C Lower wear pad 1
Figure 67. 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.
06 - 59 9813/9100-1 06 - 59
12 - Lift Arm
00 - General
Lubricate
For: 533-105 [T4F] .................... Page 06-60

For: 540-140 [T4F], 540-170 [T4F], 550-140
[T4F], 550-170 [T4F] ................. Page 06-61
For: 535-v125 [T4F], 540-v140 [T4F]
................................................... Page 06-62
For: 540-v180 [T4F] .................. Page 06-64
For: 540-200 [T4F] .................... Page 06-66
(For: 533-105 [T4F])
Figure 69.
A
H
06 - 60 9813/9100-1 06 - 60
12 - Lift Arm
00 - General
2. Apply the correct grease to all the points and applying Waxoyl. Waxoyl can take a few weeks
linkages. to dry completely. Keep flames away during the
drying period.
(For: 540-140 [T4F], 540-170 [T4F], Do not weld near the affected area during the
550-140 [T4F], 550-170 [T4F]) drying period. Take the same precautions as for
oil to keep Waxoyl off your skin. Do not breathe
CAUTION Waxoyl contains turpentine substitute the fumes. Apply in a well-ventilated area.
which is flammable. Keep flames away when
Grease Points
Figure 70.

2. Apply grease to all the points and linkages.
Lift Arm- Waxoyl

2. Extend the boom fully.
3. Spray Waxoyl evenly over all the sliding surfaces
of the inner and outer boom sections.
4. Allow the specified drying time before retracting
the boom.
Duration: 3h
06 - 61 9813/9100-1 06 - 61
12 - Lift Arm
00 - General
Figure 71. Typical Lift Arm

B
B A B
B
B
A Lift arm section

B Lift arm section
(For: 535-v125 [T4F], 540-v140 [T4F])

Consumables
Description Part No. Size
Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
06 - 62 9813/9100-1 06 - 62
12 - Lift Arm
00 - General
Grease Points
Figure 72.
A
B
C
D
1. Make the machine safe. Refer to (PIL 01-03). Figure 74.

2. Apply grease to all the points and linkages. Refer
to (PIL 75).
B
Lift Arm Internal Lubrication
2. Fully extend the lift arm on a level plane. Make
sure there is no weight on the front attachment.
Figure 73.
B Access panel
6. Make sure that all debris and residual grease are
removed from inside the lift arm.
3. If applicable, lower the stabiliser legs to stabilise

the machine.
4. Remove the bolts on the back of the lift arm.
5. Remove the access panel. Refer to (PIL 06-06).
06 - 63 9813/9100-1 06 - 63
12 - Lift Arm
00 - General
Figure 75. Figure 77.
10. Fully cycle the lift arm three times, make sure the
hoses take a sufficient coating of grease and that
the hoses do not cross over.
7. Add a full tube of grease in the rear of the lift arm. Figure 78.
Consumable: Special HP Grease
8. Use a telescopic extension handle and a paint
roller to spread the grease along the bottom and
the adjacent sides of the lift arm.
Figure 76.
C E
11. Install the access panel.
C Grease
D Telescopic extension handle 12. Install the bolts on the back of the lift arm.
E Paint roller
(For: 540-v180 [T4F])
9. Make sure you apply the grease evenly.
Use the correct grease. Refer to: PIL 75-00-00.
06 - 64 9813/9100-1 06 - 64
12 - Lift Arm
00 - General
Figure 79.
D
B
A
K
G
J
H F
A Tilt cylinder lower pivot grease point B Carriage pivot grease point
C Tilt cylinder upper pivot grease point D Front extend roller grease point
E Lift cylinder upper grease point F Lift cylinder lower grease point
G Displacement cylinder upper grease point H Displacement cylinder lower grease point
J Rear grease points x2 K Locking pin grease points
Lift Arm Pivots Chain Rollers

There are two grease points on the rear of the lift arm The internal retract chain rollers do not require
- these can be accessed with the rear cover installed. greasing as these have a plastic wear insert.
The tilt cylinder, carriage locking pins and carriage The front extend roller as shown requires greasing
pivot pins have grease points. but the larger extend rollers do not require greasing
as these have a plastic wear insert.
06 - 65 9813/9100-1 06 - 65
12 - Lift Arm
00 - General
Figure 80. Front extend chain roller
A Lift arm front extend roller grease point.
(For: 540-200 [T4F]) Do not weld near the affected area during the
drying period. Take the same precautions as for
CAUTION Waxoyl contains turpentine substitute oil to keep Waxoyl off your skin. Do not breathe
which is flammable. Keep flames away when the fumes. Apply in a well-ventilated area.
applying Waxoyl. Waxoyl can take a few weeks
to dry completely. Keep flames away during the
drying period.
06 - 66 9813/9100-1 06 - 66
12 - Lift Arm
00 - General
Figure 81.
B
A
E On later machines these grease points are not

installed and greasing is not needed
Make the machine safe. Lift Arm- Waxoyl

Apply grease to all the points and linkages where 1. Make the machine safe.
applicable.
06 - 67 9813/9100-1 06 - 67
12 - Lift Arm
00 - General
2. Extend the boom fully.

3. Spray Waxoyl evenly over all the sliding surfaces
of the inner and outer boom sections.
4. Allow the specified drying time before retracting
the boom.
Duration: 3h
Figure 82. Typical Lift Arm
B
B A B
B
B
A Lift arm section

B Lift arm section
06 - 68 9813/9100-1 06 - 68
12 - Lift Arm
00 - General
Remove and Install
For: 535-v125 [T4F], 540-140 [T4F], 550-140 3. Lower the lift arm onto a suitable support in the
[T4F] .......................................... Page 06-69 semi raised position to get access to the lift ram
For: 533-105 [T4F] .................... Page 06-72 rod end.
For: 540-200 [T4F] .................... Page 06-74 4. Support the lift arm from above with lifting
For: 540-v180 [T4F] .................. Page 06-76 shackles of suitable capacity attached to the
forward lifting points if the carriage is installed,
(For: 535-v125 [T4F], 540-140 [T4F], or to the rear lifting points if the carriage is not
550-140 [T4F]) attached.
Special Tools 5. Remove the lift arm rear cover (if installed). Refer
Description Part No. Qty. to Body and Framework- Moveable cover. Refer
to (PIL 06-06).
Slide Hammer Kit 993/68100 1
6. Support the lift ram and disconnect the lift ram
Consumables rod end by removing the nut 1, the bolt 1 and the
Description Part No. Size washer 1 (if installed).
7. Use the slide hammer kit to remove the pivot pin
4003/2006 12.5kg 1. Refer to (PIL 06-30).
4003/2005 50kg
Special Tool: Slide Hammer Kit (Qty.: 1)
3 Stage Lift Arm 8. Operate the lift arm lower control to fully retract
the ram. Lower the ram onto suitable packing
CAUTION You can be injured if you use incorrect
material to protect the piston rod.
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting 9. Release the hydraulic pressure. Refer to
equipment that is strong enough and suitable for Hydraulic System- General, Discharge. Refer to
the job. Make sure that lifting equipment is in good (PIL 30-00).
condition and complies with all local regulations.
WARNING Hydraulic fluid at system pressure 10. Support the displacement ram. Loosen the filler
can injure you. Before connecting or removing cap to vent the hydraulic tank.
any hydraulic hose, residual hydraulic pressure 11. Put label on the hydraulic hoses and connections
trapped in the service hose line must be vented. for correct installation.
Make sure the hose service line has been vented
before connecting or removing hoses. Make sure 12. Disconnect the displacement ram hoses at point
the engine cannot be started while the hoses are F and point G.
open.
13. Remove the nut 2, the bolt 2 and the washer 2
WARNING Never position yourself or any part (if installed).
of your body under a raised machine which is
not properly supported. If the machine moves 14. Use the slide hammer kit to remove the pivot pin
unexpectedly you could become trapped and 2. Refer to (PIL 06-30).
suffer serious injury or be killed.
Remove 15. Lower the ram onto suitable packing material to

protect the piston rod.
The complete lift arm assembly has a mass of
approximately 3,250kg. The lift ram has a mass 16. Put label on the hydraulic hoses and connections
of approximately 280kg and the displacement ram for correct installation.
31kg. Support the ram at all times to prevent personal
17. Make sure that the lift arm is fully supported.
injury and damage to the machine and equipment.
1. Make the machine safe. Refer to (PIL 01-03). (if installed).
2. Remove the fork carriage. Refer to Attachments- 19. Use the slide hammer kit to remove the pivot pin
Fork. Refer to (PIL 03-33). 3. Refer to (PIL 06-30).
06 - 69 9813/9100-1 06 - 69
12 - Lift Arm
00 - General
20. Carefully remove the lift arm clear of 21. Lower the lift arm onto suitable packing material.
the machine, checking for any remaining
connections.
Figure 83.
G
E F
J
C
D
A Nut 1, bolt 1, washer 1 B Pivot pin 1

C Nut 2, bolt 2, washer 2 D Pivot pin 2
E Hydraulic hose F Point F
G Point G H Nut 3, bolt 3, washer 3
06 - 70 9813/9100-1 06 - 70
12 - Lift Arm
00 - General
J Pivot pin 3
06 - 71 9813/9100-1 06 - 71
12 - Lift Arm
00 - General
Install forward lifting points if the carriage is installed,

or to the rear lifting points if the carriage is not
1. The installation procedure is the opposite of the attached.
steps. 5. Support the lift ram and disconnect the lift ram
rod end by removing the nut 1, the bolt 1 and the
1.1. Check the hydraulic oil level and refill if washer 1 (if installed).
necessary. Refer to (PIL 30-00).
1.2. Put grease on all the pivot pins. Refer to 1. Refer to (PIL 06-30).
(PIL 75-06).
7. Operate the lift arm lower control to fully retract
The details for 3 stage lift arm is shown. The details the ram. Lower the ram onto suitable packing
for 4 stage lift arms is also similar. material to protect the piston rod.
(For: 533-105 [T4F]) 8. Discharge the hydraulic pressure. Refer to (PIL

30-00).
Special Tools
Description Part No. Qty. 9. Support the displacement ram. Loosen the filler
Slide Hammer Kit 993/68100 1 cap to vent the hydraulic tank.
10. Put labels on the hydraulic hoses and
Consumables connections to help installation.
Special HP Grease 4003/2017 0.4kg 11. Disconnect the displacement ram hoses at point
4003/2006 12.5kg F and point G.
4003/2005 50kg 12. Remove the nut 2, the bolt 2 and the washer 2
(if installed).
3 Stage (3 Section) Lift Arm 13. Use the slide hammer kit to remove the pivot pin
2. Refer to (PIL 06-30).
Remove
14. Lower the ram onto suitable packing material to
The complete lift arm assembly has a mass of protect the piston rod.
approximately 3,250kg. The lift ram has a mass
of approximately 280kg and the displacement ram 15. Put a label on the hydraulic hoses and
31kg. Support the ram at all times to prevent personal connections for correct installation.
injury and damage to the machine and equipment.
16. Make sure that the lift arm is fully supported.
2. Remove the fork carriage or lift arm attachments. (if installed).
Refer to (PIL 03-33).
3. Lower the lift arm onto a suitable support in the 3. Refer to (PIL 06-30).
semi raised position to get access to the lift ram
rod end. 19. Carefully remove the lift arm clear of
the machine, checking for any remaining
4. Support the lift arm from above with lifting connections.
shackles of suitable capacity attached to the
20. Lower the lift arm onto suitable packing material.
06 - 72 9813/9100-1 06 - 72
12 - Lift Arm
00 - General
Figure 84.
G
J
E F
C
D
D
B
B
A
A
A Nut 1, bolt 1, washer 1 B Pivot pin 1

C Nut 2, bolt 2, washer 2 D Pivot pin 2
E Hydraulic hose F Point F
G Point G H Nut 3, bolt 3, washer 3
J Pivot pin 3
06 - 73 9813/9100-1 06 - 73
12 - Lift Arm
00 - General
Install 2. Raise the lift arm to the horizontal position and

fully retract the lift arm. Support the front of the
1. The installation procedure is the opposite of the lift arm.
steps. 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
1.1. Check the hydraulic oil level and refill if
necessary. Refer to (PIL 30-00). 4. Remove the retract proximity switch. Refer to
(PIL 33-84-41).
1.2. Put grease on all the pivot pins. Refer to
(PIL 75-06). 5. Remove the lift arm angle sensor. Refer to (PIL
Consumable: Special HP Grease 33-84-41).
The details for 3 stage (3 section) lift arm are shown. 6. Remove the lift arm rear cover (if installed). Refer
The details for 4 stage (4 section) lift arm are also to Refer to body and framework- access cover,
similar. refer to (PIL 06-06).
7. Remove the fork carriage. Refer to attachments-
(For: 540-200 [T4F]) Fork. Refer to (PIL 03-33).
Special Tools 8. Support the lift arm from above with lifting
Description Part No. Qty. shackles of suitable capacity attached to the
Slide Hammer Kit 993/68100 1 forward lifting points if the carriage is installed,
or to the rear lifting points if the carriage is not
Consumables attached.
9. Disconnect the hydraulic hoses at pipe
Special HP Grease 4003/2017 0.4kg connections at the rear of the lift arm.
4003/2006 12.5kg
4003/2005 50kg 9.1. Put a label on the hoses to help installation.
9.2. Plug all the open ports and hoses to prevent
5 Stage Lift Arm contamination.
CAUTION You can be injured if you use incorrect 10. Disconnect lift arm electrical connectors from the
or faulty lifting equipment. You must identify the chassis harness.
weight of the item to be lifted then choose lifting
equipment that is strong enough and suitable for 11. Support the lift ram and disconnect the lift ram
the job. Make sure that lifting equipment is in good rod end by removing the pivot pin securing nut,
condition and complies with all local regulations. bolt and washer (if installed).
WARNING Hydraulic fluid at system pressure 12. Use the slide hammer kit to remove the pivot pin.
can injure you. Before connecting or removing Refer to (PIL 06-30).
any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented. Special Tool: Slide Hammer Kit (Qty.: 1)
Make sure the hose service line has been vented 13. Support the displacement ram with a suitable
before connecting or removing hoses. Make sure lifting equipment
the engine cannot be started while the hoses are
open. 14. Remove the displacement ram rod end by
WARNING Never position yourself or any part removing the pivot pin securing nut, bolt and
of your body under a raised machine which is washer (if installed).
not properly supported. If the machine moves 15. Use the slide hammer kit to remove the pivot pin.
unexpectedly you could become trapped and Refer to (PIL 06-30).
suffer serious injury or be killed.
Remove 16. Lower the ram onto suitable packing material to
protect the piston rod.
The complete lift arm assembly has a mass of
approximately 3,100kg. Use suitable and approved 17. Make sure that the lift arm is fully supported.
lifting equipment.
18. Remove the lift arm pivot pin securing nut, bolt
1. Make the machine safe. Refer to (PIL 01-03). and washer (if installed).
06 - 74 9813/9100-1 06 - 74
12 - Lift Arm
00 - General
19. Use the slide hammer kit to remove the pivot pin. 20. Carefully remove the lift arm clear of
Refer to (PIL 06-30). the machine, checking for any remaining
connections.
21. Lower the lift arm onto suitable packing material.
Figure 85.
B
C
F
E
E
E
E E
A Lift arm assembly B Displacement ram rod end

C Lift arm pivot pin D Angle sensor
E Pipe to hose connections F Retract proximity switch
G Lift ram rod end
06 - 75 9813/9100-1 06 - 75
12 - Lift Arm
00 - General
Install 2. The illustration shows the lift arm viewed from the
rear of the machine.
removal procedure. Additionally do the following 2.1. Measure and record the dimensions shown
steps. on the illustration.
1.1. Check and if necessary adjust the lift arm 2.2. Add the measurements together: X + Y.
pivot clearance. 2.3. The total of X + Y must be equal to or less
1.2. Check the hydraulic oil level and top up as than the specified distance.
required. Refer to (PIL 30-00). Distance: 3mm
1.3. Lubricate the pivot pins. 2.4. If necessary add the correct quantity of
Consumable: Special HP Grease washers to get the correct measurement.
Add the washers equally at the two sides to
make sure the lift arm is central on the pivot.
Figure 86. Lift Arm Pivot Clearance
X Y
(For: 540-v180 [T4F])
06 - 76 9813/9100-1 06 - 76
12 - Lift Arm
00 - General
Disassemble and Assemble

For: 540-200 [T4F] .................... Page 06-77
For: 540-v180 [T4F] .................. Page 06-77
(For: 540-200 [T4F])

Unless the lift arm fabrications are damaged there
is normally no requirement to separate the lift arm
sections. The lift arm sections can be separated with
the lift arm assembly removed or installed on the
machine as required.
The following procedures can be performed without

the requirement to separate the lift arm sections or
remove the lift arm from the machine:
• Tilt ram removal and replacement. Refer to (PIL

30-15-11).
• Extension ram removal and replacement. Refer
to (PIL 30-15-07).
• Displacement ram removal and replacement.
• Lift ram removal and replacement. Refer to (PIL
30-15-06).
• Wear pads and shims. Refer to (PIL 06-12-30).
(For: 540-v180 [T4F])

For details of disassemble and assemble procedures
refer to the applicable section.
For hose removal refer to (PIL 30-93-03).
For chain removal refer to (PIL 06-12-66).
For wear pads and shim removal refer to (PIL

06-12-24).
For hydraulic cylinder removal refer to (PIL 30-15).
06 - 77 9813/9100-1 06 - 77
12 - Lift Arm
12 - Pivot Link Lever (Upper)
12 - Pivot Link Lever (Upper)
Adjust
(For: 533-105 [T4F], 535-v125 [T4F], 4. If the gap is more than the specified value, add
540-140 [T4F], 540-170 [T4F], 540-200 the correct quantity of shims to get the correct
measurement. Add the shims equally at the two
[T4F], 540-v180 [T4F], 550-170 [T4F]) sides to make sure that the lift arm is at the centre
of the pivot.
The figure (Refer to Figure 87. ) shows the lift arm
viewed from the rear of the machine. Length/Dimension/Distance: 3mm
1. Measure the gap 1 and the gap 2 as shown in the 4.1. Later shims do not have handles.
figure. Refer to Figure 87.
5. When the total gap is of the correct value, if the
2. Add the values of gap 1 and the gap 2. Total gap shim has handles, snap the handle from the shim
= gap 1 + gap 2. at the crease.
3. Make sure that the total gap is not more than the
specified value.
Length/Dimension/Distance: 3mm
Figure 87.
X Y
X Gap 1 Y Gap 2
Figure 88.
B
A Handled shim (earlier type)

B Crease
C Handle
06 - 78 9813/9100-1 06 - 78
12 - Lift Arm
18 - Angle Indicator
18 - Angle Indicator
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-v140
[T4F], 540-v180 [T4F], 550-170 [T4F], Hi-
Viz)
Remove
2. Remove the locknuts.
3. Remove the bolt 1 and the pointer arm.
4. Remove the bolts 2 to remove the dial.
Figure 89.
B C
A Locknuts
B Bolt 1
C Pointer arm
D Bolts 2
E Dial
F Decal
Install
steps.
1.1. If the scale is worn then remove the decal
and install a new decal.
1.2. Apply grease to the bolt 1, to make sure of
the smooth operation of the pointer arm.
06 - 79 9813/9100-1 06 - 79
12 - Lift Arm
24 - Shim
24 - Shim Technical Data

Technical Data ............................................... 06-80 For: 540-v180 [T4F] .................. Page 06-81
Adjust .......................................................... 06-101 For: 540-200 [T4F] .................... Page 06-89
For: 533-105 [T4F] .................... Page 06-94
For: 540-140 [T4F], 550-140 [T4F]
................................................... Page 06-96
For: 540-170 [T4F], 550-170 [T4F]
................................................... Page 06-98
For: 535-v125 [T4F], 540-v140 [T4F]
................................................... Page 06-99
06 - 80 9813/9100-1 06 - 80
12 - Lift Arm
24 - Shim
(For: 540-v180 [T4F])
Figure 90. Lift Arm- Front Outer 540-180 Machines
AA Front of outer lift arm R Shim position, see Table 1

T Shim position, see Table 1
06 - 81 9813/9100-1 06 - 81
12 - Lift Arm
24 - Shim
Figure 91. Lift Arm- Front of First Inter Section 540-180 Machines
BB Front of first inter lift arm section K Shim position, see Table 1 (always install at
least one shim here)
06 - 82 9813/9100-1 06 - 82
12 - Lift Arm
24 - Shim
U Shim position, see Table 1 100 Shim (always install at least one)
Figure 92. Lift Arm- Front of Second Inter Section 540-180 Machines
CC Front of second inter lift arm section DD Rear of first inter lift arm section
J Shim position, see Table 1 M Shim position, see Table 1
P Shim position, see Table 1
06 - 83 9813/9100-1 06 - 83
12 - Lift Arm
24 - Shim
Figure 93. Lift Arm- Rear of First Inter Section 540-180 Machines
DD Rear of first inter lift arm section J Shim position, see Table 1
L Shim position, see Table 1 160 Shim (always install at least one)
S Shim position, see Table 1
06 - 84 9813/9100-1 06 - 84
12 - Lift Arm
24 - Shim
Figure 94. Lift Arm- Rear of Second Inter Section 540-180 Machines
06 - 85 9813/9100-1 06 - 85
12 - Lift Arm
24 - Shim
EE Rear of second inter lift arm section Q Shim position, see Table 1
V Shim (always install at least one) W Shim (always install at least one)
Figure 95. Lift Arm- Rear of Inner Section 540-180 Machines
06 - 86 9813/9100-1 06 - 86
12 - Lift Arm
24 - Shim
10 Note that no washers (item 10) are installed FF Rear of inner lift arm section
under the lift arm section. Washers, (item 10)
are installed as required to achieve the correct
setting on the bolt (item 170)
H Shim position, see Table 1 (The shim is J Shim position, see Table 1
not shown) (The wear pad and shim have
offset holes and must be installed in the
correct orientation). (Note that no washers
are installed under the lift arm section. The
washers are only installed on the bolt as
required to achieve the correct depth of
engagement in to the wear pad).
N Shim position, see Table 1
The quantity of shims required depends on the

clearance of the wear pads to the lift arm sections.
Table 15. 540-180 Machines

Item Description Quantity Fastener Grade Notes
10 Plain Washer M12 78 - -
30 Setscrew M10 X35 8 G8.8 -
Nylon patch
40 Setscrew M8 X20 8 G8.8
Nylon patch
60 Wear Pad assembly 18 - -
- 11 Thick
70 Setscrew M10X50 4 - -
80 Spacer - Wear Pad 2 - -
10 Thick
90 Setscrew M12 X45 12 G8.8 -
Nylon patch
100 Wear Pad Shim 3.0 - - As required + Refer
Thick to drawing
110 Setscrew M10 X25 4 G8.8 -
Nylon patch
120 Wear Pad assembly 5 - This item has offset
20 Thick holes. Make sure
the item is installed
correctly.
130 Wear Pad Shim 1.6 - - As required
Thick
140 Spacer Wear Pad 2 - -
Support
15 Thick
160 Wear Pad Shim 1.6 - - As required + Refer
Thick to drawing
170 Bolt M12 X 50 -Ny- 10 8.8 -
lon patch G
180 Wear pad Shim - - As required
70mm X 180mm X
3mm
- 14 Thick
06 - 87 9813/9100-1 06 - 87
12 - Lift Arm
24 - Shim

20 Thick
- 24 Thick
220 Setscrew M12 X40 4 G8.8 -
Nylon patch
15 Thick
150mm X 95mm
260 Wear Pad Shim 3 - - As required + Refer
Thick to drawing
280 Wear Pad Support 2 - -
Plate
12 Thick
300 Wear Pad Support 2 - -
- 24 Thick
320 Wear Pad Shim - - As required
150mm X 45mm X
3mm
150mm X 45mm X
1.6mm
360 Shim 150mm X - - As required
95mm X 0.7mm
95mm X 1.6mm
95mm X 3mm
Thick
Thick
150mm X 45mm X
0.5mm
150mm X 90mm X
3mm
150mm X 75mm X
3mm
180mm X 70mm X
1.6mm
06 - 88 9813/9100-1 06 - 88
12 - Lift Arm
24 - Shim

14 Thick
490 Bolt - M8X25 - Ny- 28 - -
lon Patch
500 Setscrew M10 X30 4 G8.8 -
Nylon patch
(For: 540-200 [T4F]) replace the wear pads as necessary. Refer to body
and framework- wear pads, refer to (PIL 06-30)
Wear Pad Clearance- 5 Stage (5 section) Make sure that the wear pads are installed in the
Lift Arm correct way round to prevent fouling. Refer to body
and framework- wear pads, refer to (PIL 06-30).
If the wear pad clearances exceed the maximum or
fall below the minimum stated dimensions, shim or For wear pad clearances, refer to technical data (PIL
06-12-00)
06 - 89 9813/9100-1 06 - 89
12 - Lift Arm
24 - Shim
Figure 96. 5 Stage (5 section) Lift Arm- Front Wear Pads
A
B C D
D
C
B M M
J A
Z Z
Z Z
Z Z
Z Z
L L
N N
AA
BB
S S
P P
Z Z
Z Z
Z Z
Z Z
R R
N N
CC DD
06 - 90 9813/9100-1 06 - 90
12 - Lift Arm
24 - Shim
Figure 97. 5 Stage (5 section) Lift Arm- Rear Wear Pads
H
G
F
E
E
F
G
H
P P
T T
W W
X X
S S
Y Y
EE FF
P P
P P
W W
W W
U U
U U
GG HH
06 - 91 9813/9100-1 06 - 91
12 - Lift Arm
24 - Shim
Table 16. Number of Plain Washers to be Installed Under bolt

Detail Shim thickness Number of washers Size of securing bolts
mm
J 0–3mm 6 M12X35 TUF-LOK
3–6mm 5
6–9mm 4
9–12mm 3
12–15mm 2
L 0–2mm 3 M12 x 65 -NYLONPATCH
2–5mm 2 g8.8
5–8mm 1
8–10mm 0
M 0–3mm 7 M10X30 TUF-LOK
3–6mm 5
6–10mm 3
10–14mm 1
14–16.5mm 0
N and R 0–3mm 4 M12X40 TUF-LOK (N),
3–5mm 3 M12X45 TUF-LOK (R)
5–8mm 2
8–10mm 1
10–13mm 0
P 0–1.6mm 5 M12X45 TUF-LOK
1.6–3mm 4
3–6mm 3
6–9mm 2
9–11mm 1
11–14mm 0
S 0–0.7mm 5 M12 x 65 -NYLONPATCH
0.7–3mm 4 g8.8
3–5mm 3
5–7mm 2
7–9mm 1
9–11mm 0
T 0–3mm 5 M10X40 TUF-LOK
3–6mm 4
6–8mm 3
8–10mm 2
10–12mm 1
12–14mm 0
U and X 0–3mm 3 M10X40 TUF-LOK (U),
3–5mm 2 M8 x 20 NYLONPATCH
G8 (X)
5–7mm 1
7–9mm 0
W and Z 0–1mm 4 M8 x 20 NYLONPATCH
1–2.6mm 3 G8
2.6–4.2mm 2
4.2–5.8mm 1
5.8–7.4mm 0
Y 0–3mm 2 M8X30 NYLON PATCH
06 - 92 9813/9100-1 06 - 92
12 - Lift Arm
24 - Shim
Detail Shim thickness Number of washers Size of securing bolts

mm
3–5mm 1
5–7mm 0
06 - 93 9813/9100-1 06 - 93
12 - Lift Arm
24 - Shim
(For: 533-105 [T4F])
Figure 98. 3 Stage (3 section) Lift Arm
F
B
D
H J
K E
C
K
J
06 - 94 9813/9100-1 06 - 94
12 - Lift Arm
24 - Shim
Table 17. Number of Plain Washers to be Installed Under bolt

Detail Shim Thickness Number of Washers Size of securing bolts
mm
A
(1)
0mm 4 M10X25 Tuf-Lok
1.6–3.2mm 3
over 3.2mm 2
B
(1)
1.6–3.2mm 1
Over 3.2mm 0
C
(1)
0mm 2 M10X20
1.6–3.2mm 1
Over 3.2mm 0
D
(1)
1.6–3.2mm 0
Over 3.2mm 0
E
(1)
1.6–3.2mm 3
4.8–6.4mm 2
Over 6.4mm 1
F
(2)
1.6–3.2mm 3
over 3.2mm 2
G
(2)
1.6–3.2mm 1
over 3.2mm 0
H
(2)
0mm 2 M10X20
1.6–3.2mm 1
Over 3.2mm 0
J
(1, 2)
(1)
1.6–3.2mm 0 M10X25 Tuf-Lok

(2)
Over 3.2mm 0
K
(2)
1.6–3.2mm 3
4.8–6.4mm 2
Over 6.4mm 1
(1) Intermediate to the outer lift arm.
(2) Inner to the intermediate lift arm.
06 - 95 9813/9100-1 06 - 95
12 - Lift Arm
24 - Shim
(For: 540-140 [T4F], 550-140 [T4F])
Figure 99. 3 Stage (3 section) Lift Arm (P1)
F
B
D
H J
K E
C
K
J
B Use dome headed Tuf-Lok bolts C Use dome headed Tuf-Lok bolts
06 - 96 9813/9100-1 06 - 96
12 - Lift Arm
24 - Shim
Table 18. Number of Plain Washers to be Installed Under Bolt

Detail Total Shim Thickness Washers Required Size of securing bolts
mm
A 0 3 M12X30 Tuf-Lok
1.6–4.6mm 1
over 4.6mm 0
B, F 0 4 M12X30 Tuf-Lok (B),
2–3mm 3 M12X30 Tuf-Lok (F)
4–6mm 2
7–8mm 1
C, H 0–1.6mm 2 M12X25 Tuf-Lok (C),
3–5mm 1 M12X25 Tuf-Lok (H)
6mm 0
D 0mm 4 M12X35 Tuf-Lok (D side
1.6–3.2mm 3 top), M12X30 Tuf-Lok (D
side lower)
3.6–6mm 2
E 0mm 4 M12X45 Tuf-Lok (E front),
1.6–3.2mm 3 M12X25 Tuf-Lok (E rear -
front of pad), M12 X 50 -
3.6–6mm 2
Nylon-patch G8.8 (E rear
- middle of pad), M12X35
Tuf-Lok (E rear - rear of
pad)
G 0 0 Dome Head Bolt M12X30
2–5mm 0 Tuf-Lok
6–8mm 0
J 0mm 4 M12X35 Tuf-Lok (J side),
1.6–3.2mm 3 M12X30 Tuf-Lok (J lower)
3.6–6mm 2
06 - 97 9813/9100-1 06 - 97
12 - Lift Arm
24 - Shim
(For: 540-170 [T4F], 550-170 [T4F])
Figure 100. 4 Stage (4 section) Lift Arm
Table 19. Number of Plain Washers to be Installed Under Bolt

mm
D 0 3 M12X30 Tuf-Lok
1.6–4.6mm 2
over 4.6mm 1
06 - 98 9813/9100-1 06 - 98
12 - Lift Arm
24 - Shim

mm
B, C, H, J 0 2 M12X25 Tuf-Lok (B)
2–3mm 1 (C),M12X25 Tuf-Lok (H),
Dome Head Bolt Tuf-Lok
4–6mm 1
(J)
7–8mm 0
K 0 2 M10X20
2–5mm 1
6–8mm 0
A, G 0 2 M10X20
1.6–3mm 1
E, F, L, M 0 2 M12X25 Tuf-Lok (E),
1.6–3.2mm 1 M12X45 Tuf-Lok (F),
M12X25 Tuf-Lok (L),
3.6–8mm 0
M12X45 Tuf-Lok (M)
Washer and shim configurations are variable due to

individual sizing.
(For: 535-v125 [T4F], 540-v140 [T4F])
Figure 101. Lift Arm

300 4 OFF
130 8 OFF
110 16 OFF
2 OFF 300
Aı 180 A/R
4 OFF 120 Bı
190 A/R 300 2 OFF

8 OFF 110
A/R 180 190 A/R
A/R 190 180 A/R
700 4 OFF
110 4 OFF
100 2 OFF Bı
220 A/R
Aı
230 A/R
900 4 OFF
160 2 OFF
800 4 OFF
120 4 OFF
200
110 12 OFF
2 OFF 160 140 A/R
4 OFF 120 150 A/R
8 OFF 110
4 OFF 120
A/R 140
A/R 210
A/R 150
300 2 OFF
A/R 200
120 4 OFF
2 OFF 600
110 12 OFF
8 OFF 110
180 A/R
4 OFF 300 190 A/R
2 OFF 300
8 OFF 130
4 OFF 120
16 OFF 110 400 2 OFF
16 OFF 110
A/R 180 500 2 OFF
A/R 180
A/R 190 900 2 OFF
A/R 190
100 2 OFF
SECTION I B-B
SCALE ı 1:2 800 8 OFF
345/00567-5
2 OFF 120
2 OFF 170
A/R 150
A/R 140
SECTION I A-A
8 OFF 110 SCALE ı 1:2
06 - 99 9813/9100-1 06 - 99
12 - Lift Arm
24 - Shim
Table 20.
Item Qty Description
10 1 Wearpad Support Plate
20 2 Wear Pad Assy 150 X 95MM
30 14 Wear Pad Assy. Nylube
40 2 Spacer - Wear Pad
50 2 Wear Pad Assy 200X58MM
60 2 Wear Pad Assembly
70 4 Set Screw M10X35 Tuf-Lok
80 12 Plain Washer M12
90 6 Bolt M12X45 Tuf-Lok
100 2 Bolt M12X50 Tuf-Lok
110 108 Plain Washer M10
140 0
(1)
Wear Pad Shim
150 0
(1)
Wear Pad Shim
160 4 Wear Pad Assy
170 2 Wear Pad Assy
180 0
(1)
Wear Pad Shim
190 0
(1)
Wear Pad Shim
200 0
(1)
Shim, 1.6
210 0
(1)
Shim
220 0
(1)
Shim 150 X 95 X 0.7MM
230 0
(1)
Shim 150 X 95 X 1.6MM
260 0
(1)
Axle Shim
270 0
(1)
Bolt
280 0
(1)
Axle Shim 3 Thk
290 0
(1)
Shim 280 X 80 X 3MM
300 2 Wear Pad Assy. Nylube
(1) Refer to adjust, (PIL 06-12-30).
06 - 100 9813/9100-1 06 - 100

12 - Lift Arm
24 - Shim
Adjust (For: 540-200 [T4F])

For: 540-v180 [T4F] ................ Page 06-101 Typical shimming Procedure
For: 540-200 [T4F] .................. Page 06-101
For: 533-105 [T4F], 535-v125 [T4F], 540-140 This procedure details a typical method for shimming
[T4F], 540-v140 [T4F], 550-140 [T4F] a lift arm. For shim specifications, refer to Body and
................................................. Page 06-104 Framework, Lift Arm, General, Technical Data (PIL
06-12-00).
(For: 540-v180 [T4F]) The shims are installed under the pads for the
adjustment of the lift arm clearance. Partly worn pads
Shimming Information may be shimmed to restore correct lift arm clearance.
Refer to technical data (PIL 06-12-00) and wear pads Shim each lift arm section to the adjacent arm
(PIL 06-12-30). section.
1. Shims installed in side positions must locate Install new wear pads when the clearances are out
the inner section centrally in the second of specification. The clearances must be measured,
intermediate section, the second intermediate the chamfer is not a guide to the amount of wear
section centrally in the first intermediate and the remaining.
first intermediate section centrally in the outer
section. Make sure that the threaded insert remains a tight fit
in the wear pad and does not rotate when tightened.
2. Shims to be used as necessary where shown If the insert is loose in the wear pad, install a new
to make sure that the total overall gap between wear pad and threaded insert.
sections and wearpads do not exceed the
specified value in vertical and horizontal planes. The wear pad bolts are not all the same. Make sure
Length/Dimension/Distance: 1.5mm you use the correct bolts for each wear pad. Refer to
Body and framework- lift arm, refer to (PIL 06-12).
3. Install washers Refer to Table 21. where shown
and as necessary to give the correct thread Some wear pad assemblies have a spacer block
engagement between the screw and wear pad between the wear pad and lift arm section. When
assembly. Make sure the end of the screw does applicable install shims between the spacer block
not protrude beyond the surface of the wear pad and wear pad. Always install the original spacer
insert. block.
4. Make sure you tighten all the fasteners to the The number of washers under the bolt changes
correct torque value. Refer to Table 22. depending on the shim thickness. Make sure you
install the correct number of washers for the
thickness of shims. Refer to Body and framework- lift
Table 21. Washers arm, refer to Technical data (PIL 06-12-30).
Washer Item Number
(1)
Correct Thread en-
Do not install spring washers.
gagement Necessary
(2)
10 6.5–10 Removal of the wear pad assemblies can cause the

20 boom section to drop suddenly. Remove and replace
50 one wear pad assembly at a time. If necessary install
temporary wedges between the applicable boom
(1) Refer to Component Identification, (PIL sections.
06-12-30).
(2) Make sure the end of the screw does not protrude
Lower wear pads- Shimming
beyond the surface of the wear pad insert.
Front lower wear pads
Table 22. Fastener Torques 1. Make the machine safe. Refer to (PIL 01-03).
Fastener Size Torque
2. Follow all the safety procedures. Refer to (PIL
M8 28N·m 01-03).
M10 56N·m
M12 98N·m 3. Raise the lift arm slightly so that forks are just off
the ground.
06 - 101 9813/9100-1 06 - 101

12 - Lift Arm
24 - Shim
4. Measure the distances between the lift arm lower 7. Add or remove plain washers under the heads
faces which must be in the limit given. Refer to of wear pad bolts. Make sure that the thread
(PIL 06-12). engages sufficiently. Refer to (PIL 06-12).
5. If this dimension is less than the limit, then install 8. Do not install spring washers.
shims under the lower wear pads to restore the
dimension. 9. Remove the wedges, install the shims again and
tighten the bolts to the specified torque value.
6. Rest the forks on the ground so that there is no
weight on the lower wear pads. Figure 103.
2
7. Remove the wear pad bolts and add shims as 1
required.
F
8. Measure the total thickness of shims under each
pad.
9. Add or remove the correct number of plain G
washers under the heads of wear pad bolts.
Make sure that the thread engages sufficiently.
E
Use the correct number of washers. Refer to (PIL
06-12). E Wear pad bolt
10. Do not install spring washers. F Shim
G Washer
11. Install the shims again and tighten the bolts to the
specified torque value. Top wear pads- Shimming
Figure 102. Front top wear pads
2
1 1. Rest the forks on the ground.
F 2. Measure the distances between lift arm faces

which must be in the limit given. Refer to Body
and framework- Lift Arm, Technical Data (PIL
06-12).
G
3. If this dimension is less than the limit, then
install shims under the wear pads to restore the
E dimension.
E Wear pad bolt 4. Raise the lift arm slightly so that forks are just off
F Shim the ground and place wedges under the inner lift
G Washer arm.
Rear lower wear pads 5. Remove the wear pad bolts and add shims as
required.
1. Rest the forks on the ground.
2. Measure the distances between lift arm lower pad.
faces which must be in the limit given. Refer to
Technical Data (PIL 06-12). 7. Add or remove plain washers under the heads
of wear pad bolts. Make sure that the thread
3. If this dimension is less than the limit, then install engages sufficiently. Refer to (PIL 06-12).
shims under the lower wear pads to restore the
dimension. 8. Do not install spring washers.
4. Raise the lift arm slightly so that forks are just off 9. Remove the wedges, install the shims again and
the ground and place wedges under the inner lift tighten the bolts to the specified torque value.
arm.
5. Remove the wear pad bolts and add shims as
required.
pad.
06 - 102 9813/9100-1 06 - 102

12 - Lift Arm
24 - Shim

2 2
1 1
F F
G G
E E
E Wear pad bolt E Wear pad bolt

F Shim F Shim
G Washer G Washer
Rear top wear pads Side wear pads- Shimming

1. Make the machine safe. Refer to (PIL 01-03). The following procedure applies to both front and
2. Follow all the safety procedures. Refer to (PIL rear side wear pads.
01-03).
1. Pull the lift arm to one side.
3. Raise the lift arm slightly so that forks are just off
2. Measure the distances between the lift arm side
the ground.
4. Measure the distances between the lift arm (PIL 06-12).
3. If this dimension is less than the limit, install
Technical Data (PIL 06-12-00).
shims under the side wear pads to restore the
5. If this dimension is less than the limit, then dimension.
install shims under the wear pads to restore the
4. Slacken the side wear pad bolts and install shims
dimension.
as required. Divide the number of shims equally
6. Rest the forks on the ground so that there is no each side to ensure that inner lift arm runs
weight on the wear pads. centrally within the outer lift arm.
7. Remove the wear pad bolts and add shims as 5. Measure the total thickness of shims under each
required. pad.
8. Measure the total thickness of shims under each 6. Add or remove the correct number of plain
pad. washers under the heads of wear pad bolts.
9. Add or remove the correct number of plain Refer to Technical Data (PIL 06-12).
Make sure that the thread engages sufficiently. 7. Do not install spring washers.
Use the correct number of washers. Refer to (PIL
06-12).
10. Do not install spring washers.
06 - 103 9813/9100-1 06 - 103

12 - Lift Arm
24 - Shim
Figure 106. The wear pad bolts are not all the same. Make sure
2 you use the correct bolts for each wear pad. Refer to
1 Body and Framework- Lift Arm (PIL 06-12).
F The number of washers under the bolt changes

depending on the shim thickness. Make sure you
install the correct number of washers for the
thickness of shims. Refer to Body and Framework-
G
Lift Arm, Technical data (PIL 06-12-30).
E Do not install spring washers.
E Wear pad bolt Figure 107.

F Shim D
G Washer
Table 23. Torque Information

Item Description Torque
E For wear pads 98N·m
with M12 bolts
E For wear pads 56N·m D Chamfer depth
with M10 bolts
E For wear pads 28N·m Figure 108. 2 Section, 2 Stage Lift Arm
with M8 bolts
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-v140 [T4F], 550-140
[T4F])
Typical shimming Procedure

This procedure details a typical method for shimming
a lift arm. For shim specifications, refer to (PIL
06-12).
The shims are installed under the pads for the

adjustment of the lift arm clearance. Partly worn pads
may be shimmed to restore correct lift arm clearance.
Shim the intermediate lift arm to outer lift arm. Repeat

the procedure for inner lift arm to the intermediate lift A Inner boom
arm. B Outer boom
Install new wear pads when the clearances are out
of specification. The clearances must be measured,
the chamfer is not a guide to the amount of wear
remaining.Refer to Figure 107.
Make sure that the threaded insert remains a tight fit

in the wear pad and does not rotate when tightened.
If the insert is loose in the wear pad, install a new
wear pad and threaded insert.
On 2 stage (2 section) machines, shim the inner

boom to the outer boom.
On 3 stage (3 section) machines, shim the

intermediate boom to the outer boom, then repeat the
procedure for the inner to the intermediate boom.
06 - 104 9813/9100-1 06 - 104

12 - Lift Arm
24 - Shim
Figure 109. 3 Section 3 Stage Lift Arm 7. Remove the wear pad bolts and add shims as
required.
pad.
B 9. Add or remove the correct number of plain

Use the correct number of washers. Refer to
Technical Data (PIL 06-12).
A
C
Figure 111.
2
1
A Intermediate lift arm F
B Outer lift arm
C Inner lift arm
Figure 110. G
2
1
E
F E Wear pad bolt
F Shim
G Washer
G 1 Wear pad
2 Threaded insert
E Rear lower wear pads
E Wear pad bolt 1. Rest the forks on the ground.
F Shim
G Washer 2. Remove the lift arm rear cover. Refer to (PIL
1 Wear pad 06-06).
2 Threaded insert
3. Measure the distances between lift arm lower
Lower wear pads- Shimming faces which must be in the limit given. Refer to
(PIL 06-12).
Front lower wear pads
4. If this dimension is less than the limit, then install
1. Make the machine safe. Refer to (PIL 01-03). shims under the lower wear pads to restore the
dimension.
2. Follow all safety procedures. Refer to (PIL
01-03). 5. Raise the lift arm slightly so that forks are just off
the ground and place wedges under the inner lift
3. Raise the lift arm slightly so that forks are just off arm.
the ground.
6. Remove the wear pad bolts and add shims as
4. Measure the distances between the lift arm lower required.
Technical Data (PIL 06-12). 7. Measure the total thickness of shims under each
pad.
5. If this dimension is less than the limit, then install
shims under the lower wear pads to restore the 8. Add or remove plain washers under the heads
dimension. of wear pad bolts. Make sure that the thread
engages sufficiently. Refer to (PIL 06-12).
6. Rest the forks on the ground so that there is no
weight on the lower wear pads. 9. Do not install spring washers.
06 - 105 9813/9100-1 06 - 105

12 - Lift Arm
24 - Shim
10. Remove the wedges, install the shims again and Figure 113.
tighten the bolts to the specified torque value. 2
1
Figure 112.
2 F
1
F
G
G E
E Wear pad bolt

E F Shim
G Washer
E Wear pad bolt 1 Wear pad
F Shim 2 Threaded insert
G Washer
1 Wear pad Side wear pads- Shimming
2 Threaded insert
The following procedure applies to both front and
Top wear pads- Shimming rear side wear pads.
The following procedure applies to both front and 1. Measure the distances between the lift arm side
rear top wear pads. faces which must be in the limit given. Refer to
1. Raise the lift arm until the inner lift arm is resting
on the lower wear pads. 2. If this dimension is less than the limit, install
shims under the side wear pads to restore the
2. Measure the distances between the lift arm upper dimension.
(PIL 06-12-00). 3. Slacken the side wear pad bolts and install shims
as required. Divide number of shims equally each
3. If this dimension is less than the limit, install side to ensure that inner lift arm runs centrally
shims under the top wear pads to restore the within the outer lift arm.
dimension.
4. Install or remove shims to obtain the correct pad.
vertical clearance.
5. Add or remove the correct number of plain
5. Measure the total thickness of shims under each washers under the heads of wear pad bolts.
pad. Make sure that the thread engages sufficiently.
6. Add or remove the correct number of plain
washers under the heads of wear pad bolts. 6. Do not install spring washers.
Refer to Technical Data (PIL 06-12). 7. Install the shims again and tighten the bolts to the
06 - 106 9813/9100-1 06 - 106

12 - Lift Arm
24 - Shim
Figure 114.
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert

Item Description Torque
with M12 bolts
with M10 bolts
E 550-80 Ma- 56N·m
chines only
06 - 107 9813/9100-1 06 - 107

12 - Lift Arm
66 - Chain
66 - Chain Introduction
Introduction .................................................. 06-108
Health and Safety ........................................ 06-109
(For: 540-200 [T4F], 540-v180 [T4F])
Technical Data ............................................. 06-109 Inspect the chains at the correct intervals. Do
Preparation .................................................. 06-111 the chain maintenance procedures at the correct
Check (Condition) ........................................ 06-116 intervals. Refer to maintenance schedules (PIL
78-24).
Adjust .......................................................... 06-123
Lubricate ...................................................... 06-139 Once the lift arm has done a number of cycles with
Remove and Install ..................................... 06-140 some weight involved, some ‘bedding in’ occurs and
the chains slacken off. Recheck and if necessary,
adjust using the adjustment procedure. Refer to
adjust (PIL 06-12-66).
06 - 108 9813/9100-1 06 - 108

12 - Lift Arm
66 - Chain

For: 540-200 [T4F] .................. Page 06-109
(For: 540-200 [T4F], 540-v180 [T4F]) For: 540-v180 [T4F] ................ Page 06-109
WARNING The practice of joining chains is
not recommended and chains from different (For: 540-200 [T4F])
manufacturers must not be used together on the
same application. Chain Wear Limits
If a chain requires shortening, make sure that
the pin to be extracted has its head completely Refer to check condition, (PIL 06-12-66).
removed and deburred to make sure the link bore
is not scored. Table 25. Wear Limits
Chains should be renewed in pairs because in Nominal Pitch Min. Plate Max. Length C
the event of a single chain breakage, the stress A Depth B (measure 25
imposed at the time of breakage usually causes links)
the unbroken chain to stretch. 19mm 16.89mm 485mm
Because chains are made from heat treated steel, 25.4mm 22.69mm 648mm
they must not be annealed. 31.75mm 28.3mm 810mm
WARNING Renew defective chains and
associated components immediately. Do not use Figure 115.
the machine until the chains and components are A
replaced with new ones. Make sure you follow the
correct procedures.
associated components immediately. Do not use B
the machine until the chains and components are
correct procedures. C
Notice: Carry out chain inspection A Chain pitch
and maintenance procedures at more B Link plate depth
frequent intervals when operating in extreme C Length of 25 links
environmental conditions or when the machine is
subjected to shock loads.
(For: 540-v180 [T4F])
Notice: When a chain is removed for inspection,
it must be installed in exactly the same working Chain Wear Limits
position.
Notice: Once the lift arm has done a number of Refer to check condition, (PIL 06-12-66).
cycles with some weight involved, some ‘bedding
in’ occurs and the chains slacken off. Further Table 26. Wear Limits
tightening using the adjustment procedure will be Nominal Pitch Min. Plate Max. Length C
required. A Depth B (measure 25
links)
19mm 16.89mm 485mm
25.4mm 22.69mm 648mm
31.75mm 28.3mm 810mm
06 - 109 9813/9100-1 06 - 109

12 - Lift Arm
66 - Chain
Figure 116.
A
C
A Chain pitch
B Link plate depth
C Length of 25 links
06 - 110 9813/9100-1 06 - 110

12 - Lift Arm
66 - Chain
Preparation
For: 540-200 [T4F] .................. Page 06-111 3. Adjust each of the three extension chain anchor
For: 540-v180 [T4F] ................ Page 06-114 bolts to the specified dimensions. Make sure the
chain anchors do not twist. Refer to Figure 117.
Refer to Table 27.
(For: 540-200 [T4F])
4. Slowly extend the lift arm to lift arm marker 4.
Initial Chain Set Up
5. Adjust the retract chain anchor bolts to the
1. After replacement of one or more chains do the specified setting. Make sure the chain and
this initial set up procedure and then do the full anchors do not twist. Refer to Figure 117. Refer
set up procedure. to Table 27.
1.1. For the full set up procedure, refer to body 6. Extend the lift arm out to lift arm marker 6 and
and framework, lift arm, chain, adjust. then slowly retract the lift arm until it reaches the
fully closed position.
Refer to: PIL 06.
7. Make sure you do the full set up procedure, refer
2. The lift arm should be nearly fully retracted. The to body and framework, lift arm, chain, adjust.
maximum extension is
Refer to: PIL 06-12-66.
Length: 300mm
06 - 111 9813/9100-1 06 - 111

12 - Lift Arm
66 - Chain
Figure 117.
A B C
C
B
A
5 6 7 8 9
D E F
D
E
F
A Extension chain anchor B Extension chain anchor

C Extension chain anchor D Retract chain anchor
E Retract chain anchor F Retract chain anchor
5 Inner lift arm section 6 Intermediate lift arm section 3
7 Intermediate lift arm section 2 8 Intermediate lift arm section 1
9 Outer lift arm section
06 - 112 9813/9100-1 06 - 112

12 - Lift Arm
66 - Chain
Figure 118.
J K
G H 4
1 2 3
M N
G Third inter measurement point (labelled SE- H Second inter measurement point (labelled ME-
small extend) medium extend)
J First inter measurement point (labelled LE- large K Retract decal 0.5m (labelled R- represents
extend) lift arm position after full extension and then
retracting by 0.5m)
L Lift arm M Measurement
N Chain P Lift arm
Q Retract decal 1 Inner lift arm section distance
2 Intermediate 2 lift arm section distance 3 Intermediate 1 lift arm section distance 1
4 Intermediate 1 lift arm section distance 2
06 - 113 9813/9100-1 06 - 113

12 - Lift Arm
66 - Chain
Adjustment
Table 27.
Gap Dimension Adjuster
A 36mm D
B 35mm E
C 35mm F
(For: 540-v180 [T4F]) anchors do not twist. Refer to Figure 119. Refer
to Table 28.
Initial Chain Setup 540-v180 4. Slowly extend the lift arm to lift arm marker 4.
1. After replacement of one or more chains do the 5. Adjust the retract chain anchor bolts to the
this initial set up procedure and then do the full specified setting. Make sure the chain and
set up procedure. anchors do not twist. Refer to Figure 119. Refer
to Table 28.
1.1. For the full set up procedure, refer to body
and framework, lift arm, chain, adjust. 6. Extend the lift arm out to lift arm marker 6 and
Refer to: PIL 06. then slowly retract the lift arm until it reaches the
fully closed position.
2. The lift arm should be nearly fully retracted. The
maximum extension is 7. Make sure you do the full set up procedure, refer
to body and framework, lift arm, chain, adjust.
Length: 300mm
Refer to: PIL 06.
3. Adjust each of the extension chain anchor bolts
to the specified dimensions. Make sure the chain
Figure 119.
A B
C
D
E F
A Extension chain anchor 1 B Extension chain anchor 2

C Retract chain anchor 3 D Retract chain anchor 4
E Measurement point 1 F Measurement point 2
06 - 114 9813/9100-1 06 - 114

12 - Lift Arm
66 - Chain
Adjustment
Table 28. 540-180
Gap Maximum Dimensions
A 36mm
B 35mm
C 46mm
D 20mm
06 - 115 9813/9100-1 06 - 115

12 - Lift Arm
66 - Chain
Check (Condition)
For: 540-200 [T4F] .................. Page 06-116 Do not steam clean the chain.
For: 540-v180 [T4F] ................ Page 06-119 Use of solvents or steam cleaning will remove
lubricant from the internal bearing surfaces and
(For: 540-200 [T4F]) seriously reduce the service life of the chain.
Notice: Before inspecting chain components it WARNING Do not attempt to repair defective
may be necessary to clean them. Make sure you chain components with components from another
only use paraffin or a paraffin derivative to clean chain.
the chain.
Make sure you do not use chemical solvents. Inspect the components for wear and defects listed
in the table.
Table 29.
Inspection Action
Pitting due to rust and corrosion. Check the chain links and pins. If one or more component has pit-
ting on its surface, install a new
chain.
Tight chain joints Disconnect the chains from the If one or more joint is tight, install a
boom to inspect for tight chain new chain.
joints. Articulate each link, if it does
not pivot under its own weight the
joint is tight. Refer to Figure 120.
Missing link plates Refer to Figure 121. Do not attempt to replace missing
link plates. If one or more link plate
is missing, install a new chain.
Cracked or fractured link plates Small fatigue fractures and cracks If one or more link plate is defec-
are difficult to see. Make sure the tive, install a new chain.
chain is clean. Refer to Figure 122.
Loose pins with enlarged pin holes Refer to Figure 123. If one or more pin or link plate is
defective, install a new chain.
Protruding or rotated pins Refer to Figure 124. If one or more pin is defective, in-
stall a new chain.
Wear or damage to the outer faces Check for defects caused by im- If one or more pin or link plate is
of the link plates or pin heads pact with other components. Refer defective install a new chain. In-
to Figure 125. spect the machine for defects that
may be causing chain damage or
abnormal chain wear. Rectify as
applicable.
Wear on the link plate edges This wear is caused by the chain Check the chain, follow the correct
running over the chain guide rollers procedure. If one or more link ex-
and is normal over time. ceeds the wear limit, install a new
chain. For wear limits refer to (PIL
06-12-66).
Chain elongation Elongation is caused by wear be- Check the chain, follow the correct
tween the pins and plates and is procedure. If the chain exceeds the
normal over time. Make sure the wear limit, install a new chain. For
chain does not exceed the wear wear limits refer to (PIL 06-12-66).
limit. For wear limits refer to (PIL
06-12-66).
06 - 116 9813/9100-1 06 - 116

12 - Lift Arm
66 - Chain
Inspection Action
Anchor integrity- Extension chains Do the following checks for each of Renew a defective anchor pin or
rear the six anchor assemblies: Check clevis. Replace damaged or miss-
the anchor pins and clevis for wear ing split pins.
damage and corrosion. Check the
locking split pins (there is a split
pin at each end of anchor pin).
Check the security of the two fixing
bolts 1.Refer to Figure 126.
Anchor integrity- Extension chains Do the following checks for each Renew a defective anchor pin or
front of the three anchor assemblies: clevis. Renew a defective pivot
Check the anchor pins and cle- plate. Replace damaged or miss-
vis at each chain for wear, dam- ing split pins.
age and corrosion. Check the lock-
ing split pins (there are split pins at
each end of anchor pins). Check
the pivot plate and clevis for wear,
locking split pin. Refer to Figure
127.
Anchor integrity- Retraction chains Do the following checks for each Renew a defective anchor pin or
rear of the three anchor assemblies: clevis. Replace damaged or miss-
Check the anchor pins and clevis ing split pins.
for wear, damage and corrosion.
Check the locking split pins (there
are split pins at each end of the an-
chor pins). Refer to Figure 128.
front of the three anchor assemblies: clevis. Replace damaged or miss-
Check the anchor pin and clevis ing split pins. Renew defective
for wear, damage and corrosion. components as applicable.
is a split pin at each end of the an-
chor pins). Check the split pin . In-
spect nylock locking nuts. Refer to
Figure 129.
Chain guide rollers Check the rollers for worn bear- Renew defective components as
ings and grooving caused by the applicable.
chains.
Figure 123.
Figure 121.
06 - 117 9813/9100-1 06 - 117

12 - Lift Arm
66 - Chain

1 2
Figure 125.
3
1 Clevis
2 Anchor pin
3 Anchor pin
Figure 129.
2
1 3
Figure 126. 4
1 Split pin
2 Clevis
3 Anchor pin
4 Locking split pin
1 Chain Wear Limits

4 3 2
1 Fixing bolts WARNING Renew defective chains and
2 Clevis associated components immediately. Do not use
3 Split pin the machine until the chains and components are
4 Anchor pins replaced with new ones. Make sure you follow the
correct procedures.
Figure 127.
2 Measure the nominal chain pitch and read off the
3
1 corresponding wear limits from the table. Refer to
body and framework- lift arm, refer to technical data
(PIL 06-12-66) Refer to Figure 130. .
Check that link plate depth is not less than the

specified value, particularly on the sections of the
chain which run over the pulleys.
4
5 Examine the chain over its full length to find a
6
7 minimum of three sections having the most wear
(usually sections which run over a pulley). Put each
1 Clevis section on a flat surface and make sure that the chain
2 Anchor pin is in tension. Measure the length as shown in the
3 Clevis figure for the number of links specified.
4 Locking split pin
5 Pivot plate If all, or part of the chain is worn to more than the
6 Anchor pin specified limits, renew the chain. Refer to Figure 130.
7 Anchor pin
06 - 118 9813/9100-1 06 - 118

12 - Lift Arm
66 - Chain
Figure 130. only use paraffin or a paraffin derivative to clean

A the chain.
Make sure you do not use chemical solvents.
Do not steam clean the chain.
B
Use of solvents or steam cleaning will remove
lubricant from the internal bearing surfaces and
seriously reduce the service life of the chain.
C
WARNING Do not attempt to repair defective
A Chain pitch chain components with components from another
B Link plate depth chain.
C Length- 25 links
Inspect the components for wear and defects listed
(For: 540-v180 [T4F]) in the table.
Notice: Before inspecting chain components it
may be necessary to clean them. Make sure you
Table 30. 540-180 Machines

Inspection Action
Pitting due to rust and corrosion. Check the chain links and pins. If one or more component has pit-
ting on its surface, install a new
chain.
Tight chain joints Disconnect the chains from the If one or more joint is tight, install a
boom to inspect for tight chain new chain.
joints. Articulate each link, if it does
not pivot under its own weight the
joint is tight. Refer to Figure 131.
Missing link plates Refer to Figure 132. Do not attempt to replace missing
link plates. If one or more link plate
is missing, install a new chain.
Cracked or fractured link plates The extend chains on 540-180 ma- If one or more link plate is defec-
chines have washers installed on tive, install a new chain.
the chain pins. This can make it
hard to see cracks. Small fatigue
fractures and cracks are difficult to
see. Make sure the chain is clean
to assist with the inspection. Refer
to Figure 133.
Loose pins with enlarged pin holes Refer to Figure 134. If one or more pin or link plate is
defective, install a new chain.
Protruding or rotated pins
(1)
The extend chains on 540-180 ma- If one or more pin is defective, in-
chines have washers installed on stall a new chain.(1)
the chain pins. The chain is ser-
viceable if the pins rotate. The pins
in the retract chains that do not
have washers and the pins must
not rotate. The chain must be re-
newed if the pins rotate. Refer to
Figure 135.
Wear or damage to the outer faces Check for defects caused by im- If one or more pin or link plate is
of the link plates or pin heads pact with other components. Refer defective install a new chain. In-
to Figure 137. spect the machine for defects that
may be causing chain damage or
abnormal chain wear. Rectify as
applicable.
06 - 119 9813/9100-1 06 - 119

12 - Lift Arm
66 - Chain
Inspection Action
Wear on the link plate edges This wear is caused by the chain Check the chain, follow the correct
running over the chain guide rollers procedure. If one or more link ex-
and is normal over time. ceeds the wear limit, install a new
chain. For wear limits refer to (PIL
06-12-66).
Chain elongation Elongation is caused by wear be- Check the chain, follow the correct
tween the pins and plates and is procedure. If the chain exceeds the
normal over time. Make sure the wear limit, install a new chain. For
chain does not exceed the wear wear limits refer to (PIL 06-12-66).
limit. For wear limits refer to (PIL
06-12-66).
rear the four anchor assemblies: Check clevis. Replace damaged or miss-
the anchor pins and clevis for wear ing split pins.
locking split pins (there is a split
pin at each end of anchor pin).
Check the security of the two fixing
bolts 1.Refer to Figure 138.
front the four anchor assemblies: Check clevis. Replace damaged or miss-
the anchor pins and clevis at each ing split pins.
chain for wear, damage and corro-
sion. Check the locking split pins
(there are split pins at each end of
anchor pins). Refer to Figure 140.
rear of the two anchor assemblies: clevis. Replace damaged or miss-
Check the anchor pins and clevis ing split pins.
for wear, damage and corrosion.
are split pins at each end of the an-
chor pins). Refer to Figure 139.
Anchor integrity- Retraction chains Do the following checks for each of Renew a defective anchor pin or
front the two anchor assemblies: Check clevis. Replace damaged or miss-
the anchor pin and clevis for wear, ing split pins. Renew defective
damage and corrosion. Check components as applicable.
the locking split pins (there is a
split pin at each end of the anchor
pins). Check the split pin . Inspect
nylock locking nuts. Refer to Figure
140.
Chain guide rollers Check the rollers for worn bear- Renew defective components as
ings and grooving caused by the applicable.
chains.
Conical washers Check the conical washers and Renew defective components as
fastenings for cracking and shape applicable. Install new locking nuts
and make sure the correct number and devices.
is installed. Refer to Figure 141.
(1) 540-180 has 2 types of chain, the pins in the chain with washers installed can rotate. The pins in chain with
no washers installed must not rotate.
Chain inspection is identical for all types of chain.
06 - 120 9813/9100-1 06 - 120

12 - Lift Arm
66 - Chain
Figure 132.
Figure 138.
Figure 133.
1
4 3 2
1 Fixing bolts
2 Clevis
Figure 134. 3 Split pin
4 Anchor pins
Figure 139.
1 2
Figure 135. 540-180 Extend Chains
A
3
1 Clevis
A Washer (pin can rotate) extend Chains Only 2 Anchor pin
Figure 136. 540-180 Retract Chains 3 Anchor pin
Figure 140.
2
1 3
4
1 Split pin
2 Clevis
3 Anchor pin
4 Locking split pin
06 - 121 9813/9100-1 06 - 121

12 - Lift Arm
66 - Chain
Figure 141.
A A
A Conical washers
Chain Wear Limits

associated components immediately. Do not use
the machine until the chains and components are
correct procedures.
Measure the nominal chain pitch and read off the

corresponding wear limits from the table. Refer to
body and framework- lift arm, refer to technical data
(PIL 06-12-66) Refer to Figure 142. .
Check that link plate depth is not less than the

specified value, particularly on the sections of the
chain which run over the pulleys.
Examine the chain over its full length to find a

minimum of three sections having the most wear
(usually sections which run over a pulley). Put each
section on a flat surface and make sure that the chain
is in tension. Measure the length as shown in the
figure for the number of links specified.
If all, or part of the chain is worn to more than the

specified limits, renew the chain. Refer to Figure 142.
Figure 142.
A
C
A Chain pitch
B Link plate depth
C Length- 25 links
06 - 122 9813/9100-1 06 - 122

12 - Lift Arm
66 - Chain
Adjust
For: 540-v180 [T4F] ................ Page 06-123

For: 540-200 [T4F] .................. Page 06-132
(For: 540-v180 [T4F])
Figure 143. Lift Arm- 540-180.............................................................................................. Page 06-125
Lift Arm Phasing and Tensioning to increased wear or serious damage to the
machine.
Notice: The following information should always
be followed correctly. Failure to do so could lead
06 - 123 9813/9100-1 06 - 123

Notes:
06 - 124 9813/9100-1 06 - 124

12 - Lift Arm
66 - Chain
Page 06-126 Figure 143. Lift Arm- 540-180 Page 06-127

B C
A E
F
d2
K D G
L
J H d1
06 - 125 9813/9100-1 06 - 125

12 - Lift Arm
66 - Chain
Page Page
06-126 06-127

B C
A
K
J
Page 06-127
06 - 126 9813/9100-1 06 - 126

12 - Lift Arm
66 - Chain
Page Page
06-126 06-127
C Figure 143. (Part 2 of 2)

E
F
d2
K D G
L
H d1
Page 06-126
06 - 127 9813/9100-1 06 - 127

12 - Lift Arm
66 - Chain
A Extension ram B Lift arm outer section

C Large extend chains D Lift arm- intermediate 1 (section 1)
E Small extend chains F Lift arm- intermediate 2 (section 2)
G Lift arm- inner section (section 3) H Small retract chains
J Large retract chains K Chain extend label
L Chain extend label d1 Dimension 1 (see text)
d2 Dimension 2 (see text)
Figure 144. Lift Arm Layout
A B C E
d2
C d1 E
A B
A Inner lift arm (section 3) B Intermediate lift arm section 2 (inter 2)

C Intermediate lift arm section 1 (inter 1) d1 Measurement position
d2 Measurement position E Outer lift arm section
X Lift arm viewed from the top Y Lift arm viewed from the underside
06 - 128 9813/9100-1 06 - 128

12 - Lift Arm
66 - Chain
Figure 145.
H
J
A B C E
F G
A Inner lift arm section (section 3) B Intermediate lift arm section 2 (inter 2)
C Intermediate lift arm section 1 (inter 1) E Outer lift arm section
F Chain extension decal positions G Chain extend decal position
H Chain extend decal 'B' J Chain extend decal 'A'
06 - 129 9813/9100-1 06 - 129

12 - Lift Arm
66 - Chain
Key Process Points respective inter boom Extension Chain

Roller pin centre, back along the boom):
The following points should always be obeyed whilst 13.2. Inter 1
phasing & tensioning the lift arm. Failure to do so
could lead to increased wear or serious damage to Distance: 1,610mm
the machine. 13.3. Inter 2
1. Always conduct phasing & tensioning with the Distance: 2,040mm
lift arm unladen (all loads, tools and attachments
removed). Before you Begin Adjustments
2. The lift arm should always be level, unless 1. Make sure the lift arm is level and fully retracted
adjusting the retract chains.
2. Remove the rear lift arm cover.
3. The stabilisers must be deployed.
4. Always extend and retract the lift arm with the
3. Unlock both of the lift arm back bolts. Turn both
engine operating at idle during the process.
bolts anti clockwise until the there is the minimum
5. Monitor the chains carefully whilst operating the specified gap between the bolt head the and the
lift arm. back plate. The gap must always be maintained
during phasing and tensioning.
6. The extend chains should never be allowed to Distance: 10mm
impact the lift arm.
6.1. If this happens, stop immediately and Sequence of Adjustments
tighten the corresponding retract chains.
1. Make sure you read the entire procedure first.
7. After any chain adjustment the lift arm must
2. Phasing Intermediate Section 1 to Section 2.
always be extended & then retracted.
3. Phasing Intermediate Section 2 to Section 3.
8. Both chains should always maintain the same
height, any difference could cause damage to the 4. Tensioning Large Extend Chains.
lift arm chain system.
5. Tensioning Small Extend Chains.
9. When adjusting the chains it may not be possible
to carry full adjustment in one go, the boom 6. Make sure you carry out the post phasing and
may require a extend & retract cycle to allow the tensioning points when the adjustments are
chains system to balance out. completed correctly.
10. When adjusting the chains measures should be Phasing Intermediate Section 1 to Section 2
taken to prevent the chain anchor from rotating.
After any chain adjustment the chain anchor 1. Carry out the key process points as required.
should be inspected for rotation & corrected
before the boom is moved. 2. Fully retract the lift arm and measure the distance
d1. Refer to Figure 145. Refer to Figure 144.
11. When measuring chain heights the boom must
always complete the following cycle, 3. Is the distance less than the specified distance?
If yes, go to procedure 1. Refer to Table 31.
11.1. From fully retracted, extend to maximum Distance: 10mm
reach, retract to decal A. The cycle can not
be altered, failing to adhere to the cycle will 4. Is the distance more than the specified distance?
cause false readings. If yes go to procedure 2. Refer to Table 32.
12. If decal A is not present: Extend the boom Distance: 12mm
fully and then retract the specified distance
(measuring the distance back from the carriage). 5. Is the distance within the specified range? If it
is, refer to 'Phasing Intermediate Section 2 to
Distance: 1,000mm Section 3'
13. If decal B is not present: Distance: 10–12mm
13.1. These are to be installed in the following

locations, (each measured from the
06 - 130 9813/9100-1 06 - 130

12 - Lift Arm
66 - Chain
Table 31. Procedure 4 (greater than 286mm)

Procedure 1 (less than 10mm) Tighten the small retract chains by the distance
Extend the lift arm fully out and retract to decal A. between (286mm- d2)
Loosen the large retract chains by the distance be- Extend fully and retract the lift arm
tween (12mm- d1) Re-measure d2, if necessary, repeat
Tighten the large extend chains by the distance
between (12mm- d1) Tensioning Large Extend Chains
Extend fully and retract the lift arm 1. Carry out the key process points as required.
Re-measure d1, if necessary, repeat the proce-
dure 2. Fully extend the lift arm and retract to decal A.
Refer to Figure 145.
Table 32.
3. Measure height of each large extension chain
Procedure 2 (greater than 12mm) at the position indicated by the sticker B on
Extend the lift arm fully out intermediate section 1. Refer to Figure 143.
Loosen the large extend chains by the distance 4. Is the distance less than the specified distance?
between (12mm- d1) If yes go to procedure 5. Refer to Table 35.
Tighten the large retract chains by the distance be-
tween (12mm- d1) Distance: 75mm
Extend fully and retract the lift arm 5. Is the distance more than the specified distance?
Re-measure d1, if necessary, repeat the proce- If yes go to procedure 6. Refer to Table 36.
dure Distance: 75mm
Phasing Intermediate Section 2 to Section 3 6. Is the distance within the specified range? If yes
go to procedure 7. Refer to Table 37.
1. Carry out the key process points as required.
Distance: 75–85mm
2. Fully retract the lift arm and measure the distance
d2. Refer to Figure 145. Refer to Figure 144. Table 35.
3. Is the distance less than the specified amount. If Procedure 5 (less than 75mm)
yes, go to procedure 3. Refer to Table 33. Extend the lift arm fully out
Distance: 283mm Tighten the large retract chain to obtain the speci-
fied height. 75mm
4. Is the distance more than the specified amount. Extend and fully retract the lift arm
If yes, go to procedure 4. Refer to Table 34.
Repeat the chain tension check
Distance: 286mm Repeat the large extend chains check procedure
5. Is the distance within the specified range? if yes
go to 'Tensioning Large Extend Chains '. Table 36.
Distance: 283–286mm Procedure 6 (greater than 85mm)

Extend the lift arm fully out and retract to decal A
Table 33. Loosen the large retract chain to obtain the speci-
Procedure 3 (less than 283mm) fied height. 85mm
Extend the lift arm fully out and retract to decal A. Extend and fully retract the lift arm
Loosen the small retract chains by the distance Repeat the chain tension check
between (283mm- d2) Repeat the large extend chains check procedure
Tighten the small extend chains by the distance
between (283mm- d2) Table 37.
Extend fully and retract the lift arm Procedure 7 Equal Height Check
Re-measure d2, if necessary, repeat Extend the lift arm fully out and retract the speci-
fied distance 1,000mm.
Table 34.
Check each long extension chain for equal height.
Procedure 4 (greater than 286mm) The maximum difference is (± 1mm)
Extend the lift arm fully out Adjust appropriate large extension chain until an
Loosen the small extend chains by the distance equal chain height is achieved
between (286mm- d2) Extend and fully retract the lift arm
06 - 131 9813/9100-1 06 - 131

12 - Lift Arm
66 - Chain
Procedure 7 Equal Height Check Procedure 9 (greater than60mm)

Repeat the start procedure Remeasure the small retract chain height and if
When the chain height equalisation is correct, go necessary repeat the adjustment
to 'tensioning small extend chains' Repeat the small extend chains check procedure
Tensioning Small Extend Chains Table 40.

1. Carry out the key process points as required. Procedure 10 Equal Height Check
Extend the lift arm fully out and retract the speci-
2. Fully extend the lift arm and retract to decal A. fied distance 1,000mm.
Refer to Figure 143. Check each short extension chain for equal height.
3. Measure height of each large extension chain The maximum difference is (± 1mm)
at the position indicated by the sticker B on Adjust appropriate short extension chain until an
intermediate section 1. Refer to Figure 143. equal chain height is achieved
Extend and fully retract the lift arm
4. Is the distance less than the specified distance?
Repeat the chain tension check, if necessary re-
If yes go to procedure 8. Refer to Table 38.
peat adjustment.
Distance: 75mm When the chain height equalisation is correct, car-
ry out the post phasing and tensioning steps
5. Is the distance more than the specified distance?
If yes go to procedure 9. Refer to Table 39.
Post Phasing and Tensioning Steps
Distance: 75mm
1. Make sure the lift arm is level and retracted.
6. Is the distance within the specified range? If yes
go to procedure 10. Refer to Table 40. 2. Turn both bolts clockwise until bolts are finger
tight against the boom back plate.
Distance: 75–85mm
3. Torque Lock the boom back bolts.
Table 38. 4. Install the rear lift arm cover
Procedure 8 (less than50mm) 5. Make sure all anchors are level and have not
Extend the lift arm fully out twisted.
Tighten the small retract chain to obtain the speci-
fied height. 50mm 6. Make sure all anchors have split pins correctly
installed in the retaining pins.
Repeat the chain tension check, if necessary re- 7. Check chain lubrication and grease all roller pins
peat adjustment. using the correct lubricants.
Repeat the small extend chains check procedure Refer to: PIL 75-00-00.
Table 39. (For: 540-200 [T4F])

Procedure 9 (greater than60mm) Notice: Once the lift arm has done a number of
cycles with some weight involved, some ‘bedding
Extend the lift arm fully out and retract to decal A
in’ occurs and the chains slacken off. Further
Loosen the large retract chain to obtain the speci- tightening using the adjustment procedure will be
fied height. 60mm required.
06 - 132 9813/9100-1 06 - 132

12 - Lift Arm
66 - Chain
Figure 146. Lift arm section identification
B C D
A
E
A Outer lift arm B First intermediate lift arm

C Second intermediate lift arm D Third intermediate lift arm
E Inner lift arm
1. Refer to Initial chain set-up, preparation, (PIL 2.10. If Decal B x 3 are not present install them
06-12-66). in the specified locations, each measured
from the respective inner lift arm extension
2. Make sure you always adhere to the below key chain roller pin centre, back along the lift
points when phasing and tensioning the lift arm arm. Refer to Figure 147. Refer to Figure
chains. Failure to do so could lead to increased 149. Refer to Figure 148.
wear or serious damage to the machine.
Figure 147.
2.1. Always conduct phasing and tensioning Decal A Decal B
with the machine unladen.
2.2. The lift arm should always be level.
2.3. Stabilisers must be deployed.
2.4. Always extend and retract the lift arm at idle
during the process.
2.5. Extra attention should be paid to the chains
while operating the lift arm.
2.6. Never allow the extend chains to impact the
lift arm, if this happens stop immediately, A Decal A- 400/G0895
and tighten the corresponding retract B Decal B- 400/G0713
chains.
2.7. After any chain adjustment the lift arm must
always be extended and then retracted.
2.8. When adjusting the chains, measures
should be taken to prevent the chain anchor
from rotating. After any chain adjustment
inspect the chain anchor for rotation and
correct before the lift arm is moved.
2.9. If Decal A is not present: Extend the boom
fully and then retract 0.5m (measuring the
distance back from the carriage). Refer to
Figure 147. Refer to Figure 149. Refer to
Figure 148.
06 - 133 9813/9100-1 06 - 133

12 - Lift Arm
66 - Chain
Figure 148. Decal B- Large Extend Position
Figure 149.
AH
AH
AH
AE AF AG AJ
AK AK
AH
AK AL
AE 1,700mm AF 1,710mm
AG 1,680mm AH 80mm
AJ 1,554mm AK Decal A
AL Decal B
Inspect the chains at the correct intervals. Do Figure 150. Measurements X and Y
the chain maintenance procedures at the correct F G H
intervals. Refer to maintenance schedules (PIL
78-24).
X
Pre Phasing and Tensioning Y
1. This must be carried out when the lift arm is level.
2. Check and record all the lift arm extend and
retract, top and bottom anchor thread lengths
before you carry out this procedure.
Measurements F Third intermediate lift arm underside

G Second intermediate underside
Fully retract the lift arm and record the H First intermediate underside
measurements below. X 35–40mm
Y 30–35mm
• Measurements X and Y are checked on the
under side of the lift arm set when fully
retracted. Refer to Figure 150. Refer to Figure
152. Refer to Figure 153. Refer to Figure 154.
• Measurement Z is checked on the top side of
the lift arm set when fully retracted. Refer to
Figure 151. Refer to Figure 155.
06 - 134 9813/9100-1 06 - 134

12 - Lift Arm
66 - Chain
Figure 151. Measurement Z Figure 154. Measurement Y set up

J K
J Inner top side

K Third intermediate top side
Z 30–35mm Figure 155. Measurement Z set up
Figure 152. Measurement X set upside view
Figure 153. Measurement X set up-

view from underside of machine
Phasing and Tensioning Procedure.
Figure 156. Extend Chains

P N M
L
L Retract decal marker A 0.5m M First intermediate measuring point 73–83mm
06 - 135 9813/9100-1 06 - 135

12 - Lift Arm
66 - Chain
N Second intermediate measuring point 80–90mm P Third intermediate measuring point 62–72mm
Figure 157. V Second intermediate lift arm

AD W First intermediate lift arm
AA Small retract chains
AB Mid retract chains
AC Large retract chains
AD Outer lift arm
Phasing First Intermediate Lift Arm to

Second Intermediate Lift Arm
1. Carry out and record the measurements in the
initial adjustment and measurement.
2. If the distance X is between the stated
dimensions then continue to the phasing
procedure for the second and third intermediate
lift arms.
Length/Dimension/Distance: 35–40mm
3. If the distance X is below the stated dimension,
follow the below procedure:
3.1. Extend the lift arm fully, and then retract to
decal A. Refer to Figure 156.
3.2. Loosen the large retract chain by the
distance between the 35mm mark and the
position of X. Refer to Figure 150.
3.3. Tighten the large extend chain by the
position of X. Refer to Figure 150.
3.4. Extend the lift arm fully and then retract it
fully.
3.5. Measure the distance X to check if it is
within the specified limits. Refer to Figure
150.
AC Length/Dimension/Distance: 35–40mm
S
4. If the distance X is greater than the stated
AB dimension, follow the below procedure:
R AA
4.1. Extend the lift arm fully.
W 4.2. Loosen the large extend chain by the
Q distance between the position of X and the
V
40mm mark. Refer to Figure 150.
U
4.3. Tighten the large retract chain by the
distance between the position of X and the
T
4.4. Retract the lift arm fully.
Q Small extend chains
R Mid extend chains 4.5. Measure the distance X to check if it is
S Large extend chains within the specified limits. Refer to Figure
T Inner lift arm 150.
U Third intermediate lift arm Length/Dimension/Distance: 35–40mm
06 - 136 9813/9100-1 06 - 136

12 - Lift Arm
66 - Chain
Phasing Second Intermediate Lift Arm to 2. If the distance Z is below the stated dimension,
Third Intermediate Lift Arm follow the below procedure:
1. If the distance Y is between the stated
dimensions then continue to the phasing 2.1. Extend the lift arm fully, and then retract to
procedure for the inner and third intermediate lift decal A. Refer to Figure 156.
arms.
2.2. Loosen the small retract chain by the
Length/Dimension/Distance: 30–35mm distance between the 30mm mark and the
position of Z. Refer to Figure 151.
2. If the distance Y is below the stated dimension,
follow the below procedure: 2.3. Tighten the small extend chain by the
Length/Dimension/Distance: 30mm distance between the 30mm mark and the
position of Z. Refer to Figure 151.
2.1. Extend the lift arm fully, and then retract to 2.4. Extend the lift arm fully and then retract it
decal A. Refer to Figure 156. fully.
2.2. Loosen the mid retract chain by the distance 2.5. Measure the distance Z to check if it is
between the 30mm mark and the position of within the specified limits. Refer to Figure
Y. Refer to Figure 150. 151.
2.3. Tighten the mid extend chain by the Length/Dimension/Distance: 30–35mm
position of Y. Refer to Figure 150. 3. If the distance Z is greater than the stated
dimension, follow the below procedure:
fully. Length/Dimension/Distance: 35mm
2.5. Measure the distance Y to check if it is 3.1. Extend the lift arm fully.
within the specified limits. Refer to Figure
150. 3.2. Loosen the small extend chain by the
distance between the position of Z and the
Length/Dimension/Distance: 30–35mm 35mm mark. Refer to Figure 151.
3. If the distance Y is greater than the stated 3.3. Tighten the small retract chain by the
dimension, follow the below procedure: distance between the position of Z and the
Length/Dimension/Distance: 35mm 35mm mark. Refer to Figure 151.
3.5. Measure the distance Z to check if it is
3.2. Loosen the mid extend chain by the within the specified limits. Refer to Figure
distance between the position of Y and the 150.
3.3. Tighten the mid retract chain by the distance
between the position of Y and the 35mm Tensioning Large Extend Chains
mark. Refer to Figure 150.
3.4. Retract the lift arm fully. 1. Extend the lift arm fully, and then retract to decal
A. Refer to Figure 156.
3.5. Measure the distance Y to check if it is
within the specified limits. Refer to Figure 2. Measure the height of each large extend chain at
150. measurement point on first intermediate lift arm.
3. If the height of each chain is between the stated
Phasing Third Intermediate Lift Arm to Inner dimensions proceed to the medium extend chain
Lift Arm tensioning procedure.
1. If the distance Z is between the stated Length/Dimension/Distance: 73–83mm
dimensions then continue to the tensioning
4. If the height of the chain is greater than the stated
procedures.
dimension follow the below procedure:
06 - 137 9813/9100-1 06 - 137

12 - Lift Arm
66 - Chain
4.2. Loosen the large retract chain by the Tensioning Small Extend Chains
current height of the chain. 1. Extend the lift arm fully, and then retract to decal
A. Refer to Figure 156.
fully. 2. Measure the height of each small extend chain
4.4. Check the chain tension. at the measurement point on third intermediate
lift arm. Refer to Figure 156.
5. If the height of the chain is below the stated
dimension follow the below procedure: 3. If the height of each chain is between the
stated dimensions proceed to the phasing and
Length/Dimension/Distance: 73mm tensioning checks.
5.1. Extend the lift arm fully. Length/Dimension/Distance: 62–72mm
5.2. Tighten the large retract chain by the 4. If the height of the chain is greater than the stated
distance between the 73mm mark and the dimension follow the below procedure:
current height of the chain.
5.4. Check the chain tension. decal A. Refer to Figure 156.
Tensioning Medium Extend Chains 4.2. Loosen the small retract chain by the
1. Extend the lift arm fully, and then retract to decal current height of the chain.
A. Refer to Figure 156. 4.3. Extend the lift arm fully and then retract it
2. Measure the height of each mid extend chain fully.
at the measurement point on the second 4.4. Check the chain tension.
intermediate lift arm. Refer to Figure 156.
5. If the height of the chain is below the stated
3. If the height of each chain is between the stated dimension follow the below procedure:
dimensions proceed to the small extend chain
tensioning procedure. Length/Dimension/Distance: 62mm
Length/Dimension/Distance: 80–90mm 5.1. Extend the lift arm fully.
4. If the height of the chain is greater than the stated 5.2. Tighten the small retract chain by the
dimension follow the below procedure: distance between the 62mm mark and the
current height of the chain.
5.4. Check the chain tension.
4.2. Loosen the mid retract chain by the distance Phasing and Tensioning Checks
between the 90 mm mark and the current
height of the chain. When the Phasing and Tensioning procedure is
completed, carry out the following checks:
fully. 1. Check that all anchors are level and are not
4.4. Check the chain tension. twisted.
5. If the height of the chain is below the stated 2. Check that all the anchors have split pins
dimension follow the below procedure: installed with retaining pins.
Length/Dimension/Distance: 80mm 3. Check the chain lubrication and apply grease on
all the roller pins.
5.2. Tighten the mid retract chain by the distance
between the 80mm mark and the current
height of the chain.
5.4. Check the chain tension.
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12 - Lift Arm
66 - Chain
Lubricate
(For: 540-200 [T4F]) 1. Extend boom.
The boom drive chains should be sprayed with JCB 2. With the boom extended spray the drive chains
Chain Lubricant at the periods stated in the Service and retract chains with JCB chain lubricant.
Schedules 3. Retract boom.
Spray the chain with an even coating, avoid over
oiling.
Figure 158.
A
A Drive Chains
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12 - Lift Arm
66 - Chain
Remove and Install
For: 540-v180 [T4F] ................ Page 06-140 1. Make sure the washers are arranged as shown.
For: 540-200 [T4F] .................. Page 06-142
2. Make sure the lift arm sections are phased
correctly. Refer to adjust (PIL 06-12-66).
(For: 540-v180 [T4F])
3. With the retract chains loose, the extension chain
Chain Removal and Installation of anchors should be set to the specified distance.
Existing Chain Distance: 30mm
If the chains are being removed and reused, make 4. On first extension, tighten the points until no
sure you measure and record the position of the movement is felt in the anchor.
adjustment nuts and washers. Reinstall the chains
5. Carry out the full adjustment procedure. Refer to
using these settings and follow the initial chain set up
preparation (PIL 06-12-66) and then adjust (PIL
below. Then carry out the full adjustment procedure.
06-12-66).
Refer to adjust (PIL 06-12-66).
Chain Replacement- Initial Chain Set Up

This is the initial chain set up, carry out the full
adjustment procedure after. Refer to adjust (PIL
06-12-66).
06 - 140 9813/9100-1 06 - 140

12 - Lift Arm
66 - Chain
Figure 159.
W
X
J K
L
L
J Retract chain anchor location K Retract chain anchor location

Y Extension chain anchor- setting Z Extension chain anchor- setting
measurement point measurement point
440 M30 Conical washer 450 M30 Plain washer
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12 - Lift Arm
66 - Chain
460 M20 Conical washer 470 M20 Plain washer
(For: 540-200 [T4F]) 1. Make the machine safe. Refer to (PIL 01-03).
Consumables 2. Raise the lift arm to the horizontal position.
Description Part No. Size Retract the lift arm.
JCB Chain Lubricant 4004/0237A 0.3L
3. Make sure the lift arm is supported correctly.
WARNING The practice of joining chains is 4. Remove the lift arm rear cover.
not recommended and chains from different
manufacturers must not be used together on the 5. Remove split pin 1 and adjustment nut. Record
same application. the orientation of the seating washer and then
remove it. Release the chain tension.
If a chain requires shortening, make sure that
the pin to be extracted has its head completely 6. Remove split pin 6 and the pin. Remove the chain
removed and deburred to make sure the link bore from the clevis. Remove the chain from the roller.
is not scored.
Chains should be renewed in pairs because in 7. Tie strong cord of sufficient length to the front
the event of a single chain breakage, the stress of the chain. The cord will be used during the
imposed at the time of breakage usually causes replacement procedure.
the unbroken chain to stretch. 7.1. Put wire through the holes in the end of the
Because chains are made from heat treated steel, chain and then attach the cord to the wire.
they must not be annealed.
8. Working at the rear of the lift arm, remove the two
Notice: When a chain is removed for inspection, fixing bolts. Disengage the anchor block and pull
it must be installed in exactly the same working the chain out of the lift arm. Make sure the cord
position. is accessible at both ends of the lift arm.
WARNING Nyloc type adjustment nuts and split
pins must not be re-used. Always install the 9. Inspect the chain and components for defects
correct new ones. and wear. Refer to (PIL 06-12-66).
Extension Chain Install

Extension Chain Removal
Refer to initial chain setup, preparation, (PIL
Record the working position of the chains on the 06-12-66).
machine before removal. If a chain is to be re-
installed it must be installed in its original working 1. The installation procedure is the opposite of the
position. removal procedure. Additionally do the following
steps.
The following procedures are for one extension
chain. The procedures are the same for all the
extension chains.
Figure 160. Extension Chain

2 3 5 6 7
1
8
10 9
1 Split pin 1 2 Adjustment nut

3 Seating washer 4 Pin
5 Clevis 6 Split pin 6
06 - 142 9813/9100-1 06 - 142

12 - Lift Arm
66 - Chain
7 Roller 8 Extension chain

9 Fixing bolts (x2) 10 Anchor block
1.1. Keep chains clean, do not let them drag on 4. Remove the lift arm rear cover.
the ground when installing.
5. Remove split pin 1 and adjustment nut from the
1.2. At the rear of the lift arm, attach the chain to anchor bolt. Record the orientation of the seating
the cord used during removal. washers and then remove them.
1.3. From the front of the machine use the cord
6. Tie strong cord of sufficient length to the front
to pull the chain through the lift arm.
of the chain. The cord will be used during the
1.4. Adjust nut until the anchor bolt protrudes the replacement procedure.
specified distance.
6.1. Put wire through the hole in the anchor bolt
Length/Dimension/Distance: 30mm in place of split pin, then attach the cord
1.5. Adjust the chains. Refer to (PIL 06-12-66). to the wire. This will allow the cord to pass
through the anchor bolt brackets.
1.6. Apply JCB Chain Lubricant to all chains.
Consumable: JCB Chain Lubricant 7. Working at the rear of the lift arm, remove split
pin 2 and the pin and remove the chain from the
roller, if necessary remove the guide roller and
Retraction Chain Removal washers (if installed).
Record the working position of the chains on the 8. From the rear of the machine pull the chain out
machine before removal. If a chain is to be re- of the lift arm. Make sure the cord is accessible
installed it must be installed in its original working at both ends of the lift arm.
position.
9. Inspect the chain and components for defects
The following procedures are for one retraction and wear. Refer to check (condition) (PIL
chain. The procedures are the same for all the 06-12-66).
retraction chains.
Retraction Chain Install
2. Raise the lift arm to the horizontal position. Refer to initial chain setup, preparation, (PIL
Extend the lift arm. 06-12-66).
3. Make sure the lift arm front end is supported 1. The installation procedure is the opposite of the
correctly. removal procedure. Additionally do the following
steps.
Figure 161. Retraction Chain
1
2 3 4 5
8
7 6
1 Guide roller (and washers if installed) 2 Split pin 2

3 Pin 4 Retraction chain
5 Split pin 1 and adjustment nut 6 Front retraction chain anchor bolts
7 Seating washers 8 Roller
1.1. Keep chains clean, do not let them drag on 1.3. From the front of the machine use the cord
the ground when installing. to pull the chain through the lift arm.
1.2. At the rear of the lift arm, attach the chain to 1.4. Adjust the chains. Refer to (PIL 06-12-66).
the cord used during removal.
06 - 143 9813/9100-1 06 - 143

12 - Lift Arm
66 - Chain
Consumable: JCB Chain Lubricant
06 - 144 9813/9100-1 06 - 144

30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ......................................................................................................................... 06-147
06 - 145 9813/9100-1 06 - 145

Notes:
06 - 146 9813/9100-1 06 - 146

30 - Pivot Pins
00 - General
Introduction .................................................. 06-147 Pivot pins are a short shaft or pin that supports
Remove and Install ..................................... 06-148 something that turns. Pivot pins are installed in
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 - 147 9813/9100-1 06 - 147

30 - Pivot Pins
00 - General
Remove and Install Figure 162. Typical Machine
Special Tools
Description Part No. Qty.
C
Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
look different.
1. Prepare the pivot pin for removal, remove the

locking device e.g. pivot pin retaining bolt.
2. Prepare the slide hammer kit.
2.1. Install the slide hammer onto the slide bar.
2.2. Determine the thread size of the pivot pin A Adaptor
and then install the appropriate adaptor. B End stop
Use the spanner flats to securely install the C End stop
adaptor. D Spanner flats
2.3. Install an end stop onto the other end of the E Slide bar
adaptor (M20 thread size), make sure that F Slide hammer
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.
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.
06 - 148 9813/9100-1 06 - 148

42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ......................................................................................................................... 06-151
06 - 149 9813/9100-1 06 - 149

Notes:
06 - 150 9813/9100-1 06 - 150

42 - Stabiliser
00 - General
Introduction .................................................. 06-151 The stabilisers are a safety device to stop the
Health and Safety ........................................ 06-152 machine tipping over when the lift arm is extended.
Remove and Install ..................................... 06-152
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 - 151 9813/9100-1 06 - 151

42 - Stabiliser
00 - General
Health and Safety Remove and Install

WARNING The stability of the machine can For: 540-140 [T4F], 540-200 [T4F], 550-140
be reduced when you use the lift arm without [T4F] ........................................ Page 06-152
stabilisers. Before using the lift arm make sure the For: 533-105 [T4F], 535-v125 [T4F], 540-140
stabilisers are set on stable ground. [T4F], 540-200 [T4F], 540-v180 [T4F],
WARNING You must be sitting in the operators 550-170 [T4F], Hi-Viz .............. Page 06-154
seat when operating the machines lift arm,
stabiliser or drive controls. (For: 540-140 [T4F], 540-200 [T4F],
WARNING Bystanders could be crushed and 550-140 [T4F])
obstacles could be damaged if they are beneath Special Tools
the stabilisers while they are being lowered. Description Part No. Qty.
Before lowering the stabilisers, make sure any
bystanders are clear of the machine. Also make Slide Hammer Kit 993/68100 1
sure that there are no obstacles beneath the
stabilisers. Consumables
Notice: Before you extend the boom make sure
that the stabiliser legs are deployed to the ground Special HP Grease 4003/2017 0.4kg
and the weight of the machine is supported. 4003/2006 12.5kg
4003/2005 50kg
The illustration and the procedure describes the

removal and installation procedure for one stabiliser
leg. The procedure for the second leg is identical.
Remove
2. Lower the stabilisers as close as possible to
the ground. Do not allow them to support the
machine.
3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
4. Support the ram and the stabiliser leg with
suitable lifting equipment.
5. Put a label on the hydraulic hoses to help
installation.
6. Disconnect the stabiliser ram hydraulic hoses.
7. Plug all the open ports and hoses to prevent
contamination.
8. Disconnect the pressure switch harness
connector.
9. Remove the pressure switch and the washer
from the ram.
06 - 152 9813/9100-1 06 - 152

42 - Stabiliser
00 - General
C H
B
A
J
A Connector
B Pressure switch
C Washer
10. Remove the screws which secure the ram pivot
pin retaining plates.
11. Use the slide hammer kit to remove the pivot pin. D
CAUTION! This component is heavy. It must only

be removed or handled using a suitable lifting E
method and device.
12. Remove the stabiliser leg pivot pin securing nut

and bolt. F
13. Use the slide hammer kit to remove the pivot pin.
G
14. Remove the complete stabiliser leg and the ram
from the machine.
D Stabiliser ram pivot pin

E Stabiliser leg pivot pin
F Ram
G Stabiliser leg
H Retaining plates
J Screws
Install
steps.
1.1. Put grease on the ram and the stabiliser leg
pivot pins.
1.2. Install a new washer.
06 - 153 9813/9100-1 06 - 153

42 - Stabiliser
00 - General
1.3. Check the hydraulic fluid level. Refer to (PIL Figure 165.
30-00).
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-200 [T4F], 540-v180
[T4F], 550-170 [T4F], Hi-Viz)
C
Special Tools
Description Part No. Qty. B
Slide Hammer Kit 993/68100 1 A
Consumables
Description Part No. Size A Connector
Special HP Grease 4003/2017 0.4kg B Pressure switch
C Washer
4003/2006 12.5kg
4003/2005 50kg 10. Remove the ram pivot pin securing nut and bolt.
The illustration and procedure describes the removal 11. Use the slide hammer to remove the pivot pin.
and installation for one stabiliser leg. The procedure Refer to (PIL 06-30).
for the second leg is identical. Special Tool: Slide Hammer Kit (Qty.: 1)
Remove CAUTION! This component is heavy. It must only

1. Make the machine safe. Refer to (PIL 01-03). method and device.
2. Lower the stabilisers to rest on the ground. 12. Remove the stabiliser leg pivot pin securing nut
Make sure that the stabilisers do not support the and bolt.
machine.
13. Use the slide hammer to remove the stabiliser leg
3. Discharge the hydraulic pressure. Refer to pivot pin. Refer to (PIL 06-30).
Hydraulic System- General, Discharge Pressure
(PIL 30-00). Special Tool: Slide Hammer Kit (Qty.: 1)
4. Support the ram and the stabiliser leg. 14. Remove the complete stabiliser leg and the ram
from the machine.
5. Put a label on the hydraulic hoses to help
installation.
6. Disconnect the stabiliser ram hydraulic hoses.
contamination.
8. Disconnect the pressure switch harness
connector.
9. Remove the pressure switch and washer from
the ram.
06 - 154 9813/9100-1 06 - 154

42 - Stabiliser
00 - General
Figure 166.
D Ram pivot pin

E Stabiliser leg pivot pin
F Ram
G Stabiliser leg
H Nut and bolt
Install
steps.
1.1. Put grease on the ram and the stabiliser leg
pivot pins.
1.2. Check the hydraulic fluid level. Refer to (PIL
30-00).
06 - 155 9813/9100-1 06 - 155

49 - Step
49 - Step
Contents Page No.
06-49-00 General ......................................................................................................................... 06-157
06 - 156 9813/9100-1 06 - 156

49 - Step
00 - General
00 - General 1.1. Tighten fasteners to the correct torque

value.
Remove and Install
(For: 533-105 [T4F], 540-170 [T4F],

550-170 [T4F])
Remove
2. Remove the bolts and washers (x4) that secure
the steps to the machine.
3. Remove the assembly from the machine.
Figure 167. Side Step
A Side step
B Bolts
Install
1. The installation procedure is the opposite of
step.
06 - 157 9813/9100-1 06 - 157

54 - Fender
54 - Fender
Contents Page No.
06-54-00 General ......................................................................................................................... 06-159
06 - 158 9813/9100-1 06 - 158

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 168.
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 169.
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 - 159 9813/9100-1 06 - 159

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: 14N·m
7. Remove the bracket from the trunnion studs.
Complete Fender Assembly
Remove
Figure 170.
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 41. Torque table

1. The installation procedure is the opposite of the Item Value
removal procedure. Additionally do the following M 28N·m
step. S
(1)
139–154N·m
1.1. Tighten the bracket nuts to the correct S
(2)
28N·m
torque value. (1) 550-80 machines.
(2) Other machines.
06 - 160 9813/9100-1 06 - 160

57 - Counterweight
57 - Counterweight
Contents Page No.
06-57-00 General ......................................................................................................................... 06-163
06 - 161 9813/9100-1 06 - 161

Notes:
06 - 162 9813/9100-1 06 - 162

57 - Counterweight
00 - General
00 - General
Health and Safety

method and device.
CAUTION You can be injured if you use incorrect
or faulty lifting 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 equipment is in good
condition and complies with all local regulations.
WARNING Make sure the machine cannot be
used with the counterweight removed. Make sure
the ignition key is removed and the battery is
isolated.
WARNING Make sure the machine cannot tip
over when this component (or components) is
(are) removed during this operation.
06 - 163 9813/9100-1 06 - 163

60 - Mirror
60 - Mirror
Contents Page No.
06-60-00 General ......................................................................................................................... 06-165
06 - 164 9813/9100-1 06 - 164

60 - Mirror
00 - General
00 - General Component Identification

Component Identification ............................. 06-165
Adjust .......................................................... 06-166
(For: 540-v180 [T4F])
Figure 171. Mirrors- 540-180 Machines
400/E2531-1
10 Mirror arm (X1) 20 Mirror (X1)

30 Mirror- class V (X2) 40 Set screw M8 x 50 G8.8 (X2)
50 Plain washer M8 (X4) 60 Locknut M8 (X2)
70 RH Mirror arm (X1)
06 - 165 9813/9100-1 06 - 165

60 - Mirror
00 - General
Adjust
(For: 540-v180 [T4F])

Refer to the operators manual for the correct
adjustment settings.
06 - 166 9813/9100-1 06 - 166

63 - Identification Label
Contents Page No.
06-63-00 General ......................................................................................................................... 06-169

06-63-03 Machine ........................................................................................................................ 06-170
06-63-06 Engine .......................................................................................................................... 06-172
06-63-09 Axle .............................................................................................................................. 06-174
06-63-12 Gearbox ........................................................................................................................ 06-175
06-63-15 Operator Protective Structure ...................................................................................... 06-176
06 - 167 9813/9100-1 06 - 167

Notes:
06 - 168 9813/9100-1 06 - 168

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 - 169 9813/9100-1 06 - 169

03 - Machine
03 - Machine Table 43.

Digit 1 to 3 World Manufacturer
Component Identification Identification
JCB United Kingdom
GEO Georgia, US
(For: 535-v125 [T4F], 540-140 [T4F], HAR Haryana, India
540-170 [T4F], 540-200 [T4F], 540-v180 SOR Sorocaba, Brazil
[T4F], 550-140 [T4F], 550-170 [T4F]) GET Gatersleben, Germany
PUN Pune, India
Machine Identification Plate
SHA Shanghai, China
Your machine has an identification plate mounted in JBP JCB Branded Products
one of two positions as shown. The serial numbers
of the machine and its major units are shown on the Table 44.
plate.
Digit 4 to 6 Machine Model
The machine model and build specification is 5AF 540-170
indicated by the PIN (Product Identification Number) 5AL 540-140
The serial number of each major unit is also shown 5AN 535-125 HiViz
on the unit itself. If a major unit is replaced by a 5AP 535-140 HiViz
new one, the serial number on the identification plate 5AX 540-200
will be wrong. Either get a replacement identification 5A8 540-140 HiViz
plate from your JCB Dealer or simply remove the
5AG 550-140
old number. This will prevent the wrong unit number
being quoted when replacement parts are ordered. 5AM 550-170
The machine and engine serial numbers can help 5MA Man basket machines
identify exactly the type of equipment you have. 5MF Man basket machines
5MX Man basket machines
Figure 172.
5M8 Man basket machines
5MN Man basket machines
5RA 540-180 HiViz
Table 45.
Digit 7 Engine Type
JCB Dieselmax (Tier 4):
2 (T4F) 81kW
3 (T4F) 93kW
4 (T4F) 108kW
7 (T4F) 55kW
8 (T4F) 68kW
A (T4F) 55kW
B (UN3/GB3) 68kW
C (UN3/GB3) 81kW
D (UN3/GB3) 93kW
Typical Product Identification Number E (UN3/GB3) 108kW
The machine model and build specification are
indicated by the PIN. The PIN has 17 digits and must Table 46.
be read from left to right. Digit 8 Gearbox Model
E 3 Speed (PS750)
Table 42. Typical PIN
F 3 Speed (PS760)
JCB 5AA 7 E C G 1234567
G 4 Speed (PS750)
H 4 Speed (PS760)
J 6 Speed (PS760)
06 - 170 9813/9100-1 06 - 170

03 - Machine
Digit 8 Gearbox Model

M 4 Speed (SS700)
N 4 Speed (PS750)
Table 47.
Digit 9
Random check letter. The check letter is used to
verify the authenticity of a machine's PIN
Table 48.
Digit 10
Year of manufacture. G = 2016, H = 2017 etc.
Table 49.
Digit 11 to 17
Machine serial number. Each machine has a
unique serial number.
06 - 171 9813/9100-1 06 - 171

06 - Engine
06 - Engine
The engine data labels are attached to the cylinder

block as shown.
Figure 173.
B
A C
A Engine data label - rocker cover B Engine identification number

C Stamp
The data label includes the engine identification

number.
Table 50. Example of the engine identification number
SH 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 51.
Digit 1-2 Engine Type
DA 4.8L naturally aspirated mechanical fuel injection (Tier 2)
DB 4.8L turbocharged mechanical fuel injection (Tier 2)
DC 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 2)
DE 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 2)
DD 4.8L turbocharged mechanical fuel injection (Tier 3)
DF 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 3)
DK 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
DH 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
DJ 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
FL 3L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
SEF >55kW)
SA 4.4L naturally aspirated mechanical fuel injection (Tier 2)
SB 4.4L turbocharged mechanical fuel injection (Tier 2)
SC 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 2)
SD 4.4L turbocharged mechanical fuel injection (Tier 3)
SE 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
06 - 172 9813/9100-1 06 - 172

06 - Engine
Digit 1-2 Engine Type

SF 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 3)
SH 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
SJ 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
SL 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
55kw)
Table 52. 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 173.
06 - 173 9813/9100-1 06 - 173

09 - Axle
09 - Axle
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F])
The axles have a serial number stamped on a data
plate as shown.
Figure 174. Front axle
A Data plate - front axle

Figure 175. Rear axle
B Data plate - rear axle
06 - 174 9813/9100-1 06 - 174

12 - Gearbox
12 - Gearbox
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F])
The gearbox has a serial number stamped on a data
plate as shown.
Figure 176. Power-shift Transmission
A
A Data plate
06 - 175 9813/9100-1 06 - 175

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 177.
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 178.
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 - 176 9813/9100-1 06 - 176

15 - Operator Protective Structure
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 - 177 9813/9100-1 06 - 177

66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ......................................................................................................................... 06-179
06 - 178 9813/9100-1 06 - 178

66 - Tools
00 - General
00 - General
Introduction
All tools must be kept in the toolbox (if installed) when

not in use.
06 - 179 9813/9100-1 06 - 179

69 - Maintenance Strut
Contents Page No.
06-69-00 General ......................................................................................................................... 06-181

06-69-03 Lift Arm ......................................................................................................................... 06-182
06 - 180 9813/9100-1 06 - 180

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 - 181 9813/9100-1 06 - 181

03 - Lift Arm
03 - Lift Arm Installing the Maintenance Strut

Remove and Install
2. Retract the lift arm.
For: 533-105 [T4F] .................. Page 06-182
3. Raise the lift arm.
For: 540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 550-140 [T4F], 550-170 [T4F] 4. Stop the engine and remove the ignition key.
................................................. Page 06-183
For: 535-v125 [T4F], 540-v140 [T4F], 540- 5. Remove the maintenance strut from its stowage
v180 [T4F] ............................... Page 06-184 position.
(For: 533-105 [T4F]) Figure 180.
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 A
raised. Keep people away from the machine while
you install or remove the lift arm maintenance
strut.
WARNING Make sure that you use the correct
JCB maintenance strut for the machine. Make
sure that the safety strut is only used with the
correct JCB retaining bolt or securing device.
Never substitute this bolt or securing device, A Maintenance strut
always use the correct JCB part.
Make sure that the strut and bolt/securing device
is installed correctly. Never use a strut intended 7. Place the strut around the lift ram piston rod.
for another machine. If in doubt, consult your JCB Secure it in position with the strap.
dealer.
Figure 181.
WARNING Do not drive the machine with the
maintenance strut fitted.
CAUTION You will have to climb onto the B
machine to install or remove the strut. Take care,
especially if the machine is wet. Remove mud and
oil before climbing onto the machine. Do not use A
the exhaust as a handhold. It can burn you.
If you raise the lift arm to get access for maintenance,

you must install the maintenance strut on the lift arm.
Before you install the maintenance strut remove any
load on the forks and empty shovels or attachments. A Maintenance strut
B Lift arm
Figure 179.
8. To prevent any chance of the lift arm creeping
down and trapping your fingers, the lift arm
should be lowered onto the strut. Lower the arm
carefully, to prevent possible damage to the strut.
Stop as soon as the weight of the lift arm is on
the strut.
Lift arm raised the wheels before you get below the machine.
06 - 182 9813/9100-1 06 - 182

03 - Lift Arm
Removing the Maintenance Strut 2. Retract the lift arm.
1. Raise the lift arm to take the weight off of the strut. 3. Raise the lift arm.
2. Stop the engine and remove the ignition key. 4. Stop the engine and remove the ignition key.
3. Remove the maintenance strut. 5. Remove the maintenance strut from its stowage
position.
4. Secure the strut in its stowage position.
Figure 183. 510-44, 510-55,
5. Lower the lift arm to the ground. 540-140, 550-140, 540-170, 550-170
(For: 540-140 [T4F], 540-170 [T4F],

540-200 [T4F], 550-140 [T4F], 550-170
[T4F])
doing any maintenance work with the lift arm
strut.
WARNING Make sure that you use the correct A
A Maintenance strut
Never substitute this bolt or securing device, Figure 184. 508-66, 540-200
is installed correctly. Never use a strut intended
for another machine. If in doubt, consult your JCB
dealer.
CAUTION You will have to climb onto the
oil before climbing onto the machine. Do not use
If you raise the lift arm to get access for maintenance,

you must install the maintenance strut on the lift arm. A
load on the forks and empty shovels or attachments.
Figure 182.
A Maintenance strut
7. Place the strut around the lift ram piston rod.
Secure it in position with the strap.
Lift arm raised
Install the Maintenance Strut

06 - 183 9813/9100-1 06 - 183

03 - Lift Arm
Figure 185. CAUTION You will have to climb onto the

B oil before climbing onto the machine. Do not use
A If you raise the lift arm to get access for maintenance,

you must install the maintenance strut on the lift arm.
load on the forks and empty shovels or attachments.
Figure 186.
A Maintenance strut
B Lift arm
the strut.
9. Disconnect the battery to prevent accidental lift arm raised
10. If necessary, put blocks against the two sides of Installing the Maintenance Strut
Removing the Maintenance Strut 2. Retract the lift arm.
1. Raise the lift arm to take the weight off of the strut. 3. Raise the lift arm.
2. Stop the engine and remove the ignition key. 4. Stop the engine and remove the ignition key.
3. Remove the maintenance strut. 5. Remove the maintenance strut from its stowage
position.
Figure 187.
5. Lower the lift arm to the ground.
(For: 535-v125 [T4F], 540-v140 [T4F], 540-

v180 [T4F])
doing any maintenance work with the lift arm
strut.
WARNING Make sure that you use the correct A
Never substitute this bolt or securing device, A Maintenance strut
is installed correctly. Never use a strut intended 7. Place the strut around the lift ram piston rod.
for another machine. If in doubt, consult your JCB Secure it in position with the strap.
dealer.
06 - 184 9813/9100-1 06 - 184

03 - Lift Arm
Figure 188.
A Maintenance strut
B lift arm
the strut.
Removing the Maintenance Strut

1. Raise the lift arm to take the weight off of the strut.
2. Stop the engine and remove the ignition key.
3. Remove the maintenance strut.
5. Lower the lift arm to the ground.
06 - 185 9813/9100-1 06 - 185

75 - Fire Extinguisher
Contents Page No.
06-75-00 General ......................................................................................................................... 06-187
06 - 186 9813/9100-1 06 - 186

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 189.
A Gauge
B Safety Pin
06 - 187 9813/9100-1 06 - 187

89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ......................................................................................................................... 06-189
06 - 188 9813/9100-1 06 - 188

89 - Window Guard
00 - General
00 - General Figure 190. 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 - 189 9813/9100-1 06 - 189

Notes:
06 - 190 9813/9100-1 06 - 190

Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-6
09-09 Window
09-09-00 General ........................................................................................................................... 09-13
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-21
09-12-03 Seat Base ...................................................................................................................... 09-23
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-25
09-18 Door
09-18-00 General ........................................................................................................................... 09-31
09-18-03 Lock ................................................................................................................................ 09-34
09-18-12 Handle ............................................................................................................................ 09-35
09-27 Controls
09-27-21 Stabiliser ......................................................................................................................... 09-37
09-27-36 Accelerator Pedal ........................................................................................................... 09-41
09-27-57 Park Brake ..................................................................................................................... 09-43
09-30 Trim Panel
09-30-03 Roof Trim ....................................................................................................................... 09-45
09-30-09 Dashboard ...................................................................................................................... 09-46
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-51
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-55
09-48 Floor mat
09-48-03 Front Floor mat .............................................................................................................. 09-57
9813/9100-1
2017-11-07
Acronyms Glossary
ECU Electronic Control Unit

HVAC Heating Ventilation Air Conditioning
LLMI Longitudinal Load Moment Indicator
TXV Thermal Expansion Valve
9813/9100-1
2017-11-07
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-6
09 - 1 9813/9100-1 09 - 1
Notes:
09 - 2 9813/9100-1 09 - 2
00 - General
00 - General Health and Safety

Health and Safety ........................................... 09-3 Raised Equipment
Component Identification ................................. 09-4 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 is in good condition and complies with all
local regulations.
09 - 3 9813/9100-1 09 - 3
00 - General
(For: 533-105 [T4F], 535-v125 [T4F], Cab Layout

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F], The layout shown below is for a typical machine.
550-170 [T4F]) There are different variants of hydraulic control
levers. The cab layout is the same except the control
This cab is certified to category 1 according to levers.
EN15695-1-2009.
Figure 191. Cab Layout - Dual lever control
A
A
P
P S
S
R
P
B
B
TT
C
C N
N
M
M
D
D
L
U
R
E
E
G
G
F
HH
J
A Steering wheel B Transmission Lever and Gear Selection

C Console switches D Steer mode selector
E Service brake pedal F Park brake lever
G Control locks H Immobiliser
J Hydraulic tow hitch K Load charts
09 - 4 9813/9100-1 09 - 4
00 - General
L HVAC (Heating Ventilation Air Conditioning) M Console switches

N Ignition switch P Instrument panel
R Inclinometer S LLMI (Longitudinal Load Moment Indicator)
T Load control system
Single lever control variant

The single lever control can be mounted on the right
side console, in the arm rest or in an adjustable
control pod.
Figure 192.
1
2
3
1 Hydraulic control lever

2 Transmission dump switch
3 Drive direction selection switch
Servo lever control variant (If installed, not

available on all models)
Figure 193.
3
1
3

2 Stabiliser control levers
3 Hydraulic control levers
09 - 5 9813/9100-1 09 - 5
03 - Cab Frame
03 - Cab Frame
Remove and Install
(For: 533-105 [T4F], 540-140 [T4F], Some machines are installed with a cab roof
540-170 [T4F], 540-200 [T4F], 550-140 mounted air conditioning condenser. Disconnect
the condenser hoses at the rear of the cab.
[T4F], 550-170 [T4F])
Working Under the Machine 9. Disconnect the engine accelerator cable (if
installed).
Make sure that any attachments on the machine are Refer to: PIL 09-27.
correctly attached. Engage the park brake, remove 10. Disconnect the accelerator pedal electrical
the ignition key, disconnect the battery. If the machine connectors (if installed).
movement. Refer to: PIL 09-27.
Air Conditioning Maintenance 11. Make sure that all wheels are blocked to prevent
The air conditioning system is a closed loop system movement of the machine. Release the park
and contains pressurised refrigerant. No part of the brake and disconnect the park brake cable.
system should be disconnected until the system
12. On machines with dual lever controls, disconnect
the control levers from the control valve
or a suitably trained person. You can be severely
connection rods.
frostbitten or injured by escaping refrigerant.
Refer to: PIL 30.
Notice: Make sure you label all hoses / pipes and
electrical connectors (if installed) before removal to 13. On machines with parallel servo control levers,
aid identification during subsequent installation. label and disconnect the hoses at the servo
control valves. Disconnect the control levers from
Cab the control valve connection rods.
Refer to: PIL 30.
Remove
14. Disconnect the manual steer mode valve cable
1. Make the machine safe. (if installed) from the lever.
15. Disconnect the chassis electrical harness and
2. Install the safety strut. cab earth strap.
Refer to: PIL 06-69. 16. Undo the fuel filler hose clip. Loosen the fuel tank
filler hose on fuel tank filler neck so that the two
3. Discharge the hydraulic pressure. separate later.
Refer to: PIL 30-00-00. Refer to: PIL 18-03.
4. Remove the battery cover and disconnect the 17. Disconnect the braking system components.
battery.
Refer to: PIL 33-03. 17.1. 550-80 and 560-80 Machines- For details
of disconnecting the brake valve.
5. Remove the bolts and remove the cab front
17.2. On machines with cab mounted brake
cover.
servo, disconnect the brake pipe and
Refer to: PIL 09-27. servo hose. Cap all open hoses and pipes
to prevent fluid loss and ingress of dirt.
6. Disconnect all hydraulic hoses from the steering
unit. Cap all open hoses and ports to prevent fluid 17.3. Disconnect brake pipe at the master
loss and ingress of dirt. cylinder. Cap all open hoses and pipes to
prevent fluid loss and ingress of dirt.
7. Remove the heater cover (if installed). Undo the
hose clips and disconnect the heater hoses. 18. Disconnect hitch cable (if installed).
8. If applicable, once the system has been 19. For machines with manual transmission
discharged, disconnect the air conditioning disconnect the cables to the gear lever.
hoses at the TXV (Thermal Expansion Valve). Refer to: PIL 09-27.
09 - 6 9813/9100-1 09 - 6
03 - Cab Frame
20. Unscrew and remove the cab mounting bolts. 1.3. Adjust the accelerator cable and pedal (if
installed).
21. Attach appropriate lifting equipment to the ROPS
(Roll-Over Protective Structure). Refer to: PIL 09-27.
1.4. Correctly connect and adjust the cables to
22. Carefully lift the cab from the machine, make sure the gear lever (if installed).
that all connections have been released and are
clear of any obstruction. Cap off fuel tank filler Refer to: PIL 09-27.
neck to prevent contamination. 1.5. If applicable, recharge the air conditioning
system.
Install
Refer to: PIL 12.
1.6. Check the hydraulic fluid level.
steps. Refer to: PIL 30-00.
1.1. Tighten the cab mounting bolts to the 1.7. Make sure that all cables are connected and
correct torque value. correctly adjusted. Make sure that they are
routed and secured correctly.
Refer to: PIL 72.
1.8. Make sure that all electrical and hydraulic
1.2. Bleed the brakes. services operate correctly.
09 - 7 9813/9100-1 09 - 7
03 - Cab Frame
Figure 194.
B
J B
G
B
C
D
E
F
B
A Park brake cable B Cab mounting bolts

C Cab front cover D Steering unit
E Cab earth strap F Chassis electrical harness
G Hitch cable H Fuel tank filler neck
J Filler hose clip
09 - 8 9813/9100-1 09 - 8
03 - Cab Frame
Figure 195.
K
K
R
Z
W
X
K Dual lever controls M Transmission gear lever
09 - 9 9813/9100-1 09 - 9
03 - Cab Frame
O Manual steer mode lever P

R Heater cover (if installed) S Heater hose clips
T Air conditioning hoses at TXV U Servo hose clip
V Brake pipe W View- cab mounted servo
X View- master cylinder Y Brake pipe
Z Single lever control
09 - 10 9813/9100-1 09 - 10
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-13
09 - 11 9813/9100-1 09 - 11
Notes:
09 - 12 9813/9100-1 09 - 12
09 - Window
00 - General
Introduction .................................................... 09-13 The service procedures, explain how to correctly
Health and Safety .......................................... 09-14 remove and install panes of glass that are directly
Preparation .................................................... 09-14 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-16 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 - 13 9813/9100-1 09 - 13
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 0.1L
Use only hand operated tools when working with
toughened glass. Polyurethane Adhesive 4103/2110 0.31L
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: 5min
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 - 14 9813/9100-1 09 - 14
09 - Window
00 - General
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: 5min
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: 25mm
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 199.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 197.
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 - 15 9813/9100-1 09 - 15
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 200.
Consumables
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
Surface Cleaning Fluid 4103/1204 1L
A 12.5mm
B 9mm
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: 10min
2.1. Laminated glass - leave installed until the
Figure 201. 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 - 16 9813/9100-1 09 - 16
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 203.

the sealant will melt.
Figure 202.
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 204.
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 - 17 9813/9100-1 09 - 17
09 - Window
00 - General
Figure 205. 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 207. 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 208.
face of the cab frame aperture.
Figure 206.
A 1.5mm
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 - 18 9813/9100-1 09 - 18
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 - 19 9813/9100-1 09 - 19
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-21

09-12-03 Seat Base ...................................................................................................................... 09-23
09 - 20 9813/9100-1 09 - 20
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-21 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-22 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 - 21 9813/9100-1 09 - 21
12 - Operator Seat
00 - General
Remove and Install Install

(For: 533-105 [T4F], 535-v125 [T4F], removal procedure. Additionally do the following
step.
540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F], 1.1. Tighten the bolts to the correct torque value.
550-170 [T4F]) Refer to: PIL 72.
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 209.
A
A Bolt (x4)
4. Attach suitable lifting equipment to the seat.
5. Use the lifting equipment to remove the seat from
the machine.
09 - 22 9813/9100-1 09 - 22
12 - Operator Seat
03 - Seat Base
03 - Seat Base
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F])
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 - 23 9813/9100-1 09 - 23
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-25
09 - 24 9813/9100-1 09 - 24
15 - Seat Belt
00 - General
WARNING When a seat belt is installed on your
Introduction .................................................... 09-25 machine replace it with a new one if it is damaged,
Check (Condition) .......................................... 09-26 if the fabric is worn, or if the machine has been in
Remove and Install ....................................... 09-27 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 - 25 9813/9100-1 09 - 25
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 - 26 9813/9100-1 09 - 26
15 - Seat Belt
00 - General
Remove and Install
The illustrations show the seat belt buckle with and Some machines will have two spacers on the buckle
without the sensor installed. and belt securing bolt - make sure to retain and
replace with the correct spacers as removed.
The sensor is not installed on all machines.
Figure 210.
A1 B C D E J
G H
A2
H G D C B
A1 Buckle assembly - without sensor A2 Buckle assembly - with sensor
09 - 27 9813/9100-1 09 - 27
15 - Seat Belt
00 - General
B Cover cap C Securing bolt

D Washer E Sensor connector bracket (if installed)
F Buckle G Spacer 1
H Spacer 2 (if installed) J Sensor electrical connector (if installed)
K Seat belt assembly
Remove
2. Get access to the seat belt.
3. Remove the plastic cap covering the securing
bolt on the belt and the buckle.
4. Disconnect the sensor electrical connector (if
installed).
5. Remove the buckle and belt securing bolts.
5.1. Make sure to retain the spacer or spacers.
6. Remove the buckle and belt from the machine.
Install
steps.
2. Inspect the belt and fixing for damage - replace
if necessary.
3. Make sure the sensor cable (if installed) is routed
correctly and will not be trapped by the buckle.
4. Tighten the seat belt nuts and bolts to the correct
torque value. Refer to Table 53.
5. Test the operation of the seat belt.

Item Nm
C 50
09 - 28 9813/9100-1 09 - 28
18 - Door
18 - Door
Contents Page No.
09-18-00 General ........................................................................................................................... 09-31

09-18-03 Lock ................................................................................................................................ 09-34
09-18-12 Handle ............................................................................................................................ 09-35
09 - 29 9813/9100-1 09 - 29
Notes:
09 - 30 9813/9100-1 09 - 30
18 - Door
00 - General
00 - General
Remove and Install
Consumables 5.1. Use a thin punch and hammer to tap the

Description Part No. Size securing pin from the hinge assembles.
Extreme Performance 4003/1327 0.4kg 5.2. Remove the grub screw.
Moly Grease 4003/1326 12.5kg
6. Use a thin punch and hammer to tap the hinge
pin from the hinge assembles.
Remove
7. Do steps 4 and 5 for all other hinges on the door.
8. Carefully remove the door from the hinge
2. Follow the general health and safety procedures. assembly.
9. If necessary, remove the hinge assembly by
3. Divide the doors by releasing the locking handle removing the nuts from inside the cab.
(Two piece doors only- if installed).
10. Do procedures 3 to 7 for the lower part of the
4. Make sure that the door upper is supported door. (Two piece doors only- if installed).
correctly.
11. If necessary the door catch assembly can be
5. To remove the hinge pin securing device, removed by removing the nuts, bolts and locking
depending on your machine, do one of the plate.
following actions:
09 - 31 9813/9100-1 09 - 31
18 - Door
00 - General
Figure 211. Two piece door assembly

C
F E
A Locking handle B Hinge assembly

C Hinge pin D Door- upper
E Door- lower F Door catch assembly
G Securing pin (or grub screw)
09 - 32 9813/9100-1 09 - 32
18 - Door
00 - General
Install
steps.
1.1. Lubricate the door hinge. Refer to (PIL
75-06).
Consumable: Extreme Performance Moly
Grease
09 - 33 9813/9100-1 09 - 33
18 - Door
03 - Lock
03 - Lock
Remove and Install
09 - 34 9813/9100-1 09 - 34
18 - Door
12 - Handle
12 - Handle Figure 212.
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 - 35 9813/9100-1 09 - 35
27 - Controls
27 - Controls
Contents Page No.
09-27-21 Stabiliser ......................................................................................................................... 09-37

09-27-36 Accelerator Pedal ........................................................................................................... 09-41
09-27-57 Park Brake ..................................................................................................................... 09-43
09 - 36 9813/9100-1 09 - 36
27 - Controls
21 - Stabiliser
21 - Stabiliser Operation
Operation ....................................................... 09-37
Remove and Install ....................................... 09-39
(For: 540-200 [T4F])
The Stabiliser Lever converts the movement from the
lever into an electrical signal for interpretation by the
Hydraulic Control ECU (Electronic Control Unit).
The lever is supplied with a 5V supply from the ECU.

The lever moves along a resistor and the output from
the lever changes according to the lever position on
the resistor.
Two signals are output from the unit, signal 1 and

signal 2. The voltage changes when the lever is
moved. Both signals will always add up to 5V, for
example Refer to Figure 213.
Figure 213.
A B C
5V
2
2.5V
1
0V
A B C
Table 54. Lever output

Lever position Voltage output
A Signal 1 = 5V
Signal 2 = 0V
B (Neutral) Signal 1 = 2.5V
Signal 2 = 0V
C Signal 1 = 0V
Signal 2 = 5V
09 - 37 9813/9100-1 09 - 37
27 - Controls
21 - Stabiliser
Figure 214.
A E
78
A 7
1 3
74 D
2 4 18
73
B
A
1 3 31
76
2 4 19
75
C
A 28
77
ECU
-VE
A Chassis Harness to Panel Harness Connector B Right stabiliser control lever

C Left stabiliser control lever D Work platform ECU Connector J1
E ECU earth
09 - 38 9813/9100-1 09 - 38
27 - Controls
21 - Stabiliser
Remove and Install
(For: 540-200 [T4F]) connectors to the rear of the emergency stop and
console switches.
The lever is a non serviceable part. If it is faulty it
must be renewed. 4. Put a label on the electrical connectors to help
installation
Remove 5. Disconnect the stabiliser lever electrical
connectors.
6. Turn the trim panel over to get access to the
2. Discharge the hydraulic pressure. Refer to (PIL stabiliser lever securing screws.
30-00).
7. Remove the lever securing screws and remove
3. Remove the trim panel screws and lift the trim the levers from the trim panel.
panel sufficiently to get access to the electrical
Figure 215.
F
B C
A
G
B
D
A H
A Trim panel screws B Levers

C Trim panel D Emergency stop switch
E Side console switches F Lever position reference
G Lever securing screws H Lever electrical connectors
09 - 39 9813/9100-1 09 - 39
27 - Controls
21 - Stabiliser
Install
step.
2. Make sure that the stabiliser levers are
positioned as shown at (the - terminal pointing
towards the front of the machine and the +
terminal towards the rear).
09 - 40 9813/9100-1 09 - 40
27 - Controls
36 - Accelerator Pedal
Remove and Install
Consumables
JCB Threadlocker 4101/0250 0.01L
and Sealer (Medium 4101/0251 0.05L
Strength)
Figure 216.
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 - 41 9813/9100-1 09 - 41
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 - 42 9813/9100-1 09 - 42
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 217.
A Rubber gaiter
B Switch
C Electrical connector
D Switch connector
E Screw
F Switch location dowel
G Hole in mounting bracket
09 - 43 9813/9100-1 09 - 43
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-03 Roof Trim ....................................................................................................................... 09-45

09-30-09 Dashboard ...................................................................................................................... 09-46
09 - 44 9813/9100-1 09 - 44
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 218.
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 - 45 9813/9100-1 09 - 45
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F], 17. Remove the lower left hand panel.
540-140 [T4F], 540-170 [T4F], 540-v180 Figure 219.
[T4F], 550-140 [T4F], 550-170 [T4F])
C C
Remove
2. Remove the steering wheel.
D B D
3. Remove the two button head screws 1.
4. Remove the steering column lower surround.
5. Remove the two button head screws 2 and the
two screws 1.
00: 00: 05
6. Remove the steering column upper surround.

7. Remove the two screws 2 that hold the centre
display panel in place, disconnect all connections
and remove the panel.
8. If the steer mode select switch has a lockable A
surround, then remove it as follows: A Button head screw 1
B Button head screw 2
8.1. Remove the two screws that secure the C Screw 1
steer mode select switch panel. D Screw 2
8.2. Disconnect all connections and remove the
Figure 220.
panel.
8.3. Remove the steer mode control knob.
9. Remove the heater control panel.
E
10. Remove the radio (if installed).
11. Remove the right hand Instrument panel.
12. Remove the left hand switch panel.
13. Remove the centre display panel.
F
14. Remove the screw 3, screw 4, screw 5 and screw
6 and then remove the upper right hand panel.
Take care not to damage the harness when you
move it through the hole in the panel.
15. The screw 5 is removed from the front of the
panel, i.e. the opposite side to that shown.
E Steer mode select switch panel
16. Remove the screw 7, screw 8 and screw 9. F Steer mode control switch
09 - 46 9813/9100-1 09 - 46
30 - Trim Panel
09 - Dashboard
Figure 221.
G Q H
M
N
G Screw 3 H Screw 4
J Screw 5 K Screw 6
L Screw 7 M Screw 8
N Screw 9 P Lower left hand panel
Q Upper right hand panel
09 - 47 9813/9100-1 09 - 47
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 48 9813/9100-1 09 - 48
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-51
09 - 49 9813/9100-1 09 - 49
Notes:
09 - 50 9813/9100-1 09 - 50
00 - General
Introduction .................................................... 09-51 The safety labels are strategically placed around the
Health and Safety .......................................... 09-52 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 - 51 9813/9100-1 09 - 51
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 - 52 9813/9100-1 09 - 52
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-55
09 - 53 9813/9100-1 09 - 53
Notes:
09 - 54 9813/9100-1 09 - 54
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 223.
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 222.
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 - 55 9813/9100-1 09 - 55
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-57
09 - 56 9813/9100-1 09 - 56
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 224.
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 - 57 9813/9100-1 09 - 57
Notes:
09 - 58 9813/9100-1 09 - 58
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
9813/9100-1
2017-09-08
Acronyms Glossary
FEAD Front End Accessory Drive

PAG Polyalkyline Glycol
RPM Revolutions Per Minute
TXV Thermal Expansion Valve
9813/9100-1
2017-09-08
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9813/9100-1 12 - 1
Notes:
12 - 2 9813/9100-1 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 9813/9100-1 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 9813/9100-1 12 - 4
00 - General
Technical Data
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v140 [T4F], 540-v180 [T4F],
550-170 [T4F])
Table 55. Binary pressure switch settings
Item Specification
Low pressure 2bar (29.0psi)
High pressure 26bar (376.8psi)
Table 56. 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 57. Refrigerant

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

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

(2) Systems with roof mounted condenser.
Table 58. Oil

Item Specification
Type PAG (Polyalkyline Gly-
col) oil
Charge amount
(3)
-
Complete system 0.0426L
Condenser remove and 0.0284L
install
Evaporator remove and 0.0568L
install
Hoses remove and in- 0.0085L
stall
Receiver drier remove 0.0142L
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 9813/9100-1 12 - 5
00 - General
Heater Only
Figure 225.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 59.
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 9813/9100-1 12 - 6
00 - General
Machines with Air Conditioning
Figure 226.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 60.
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 61. 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 9813/9100-1 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 9813/9100-1 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 227.
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 9813/9100-1 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 228.
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 clutch
1. The manual air conditioning on/off switch in the disengages, closing down the refrigeration cycle.
control console. As the temperature of the probe increases the
12 - 10 9813/9100-1 12 - 10
00 - General
thermostat switch contacts close. The compressor

clutch engages and refrigeration re-starts.
Figure 229.
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 9813/9100-1 12 - 11
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 62. Page 12-12
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 63. Page 12-12
Compressor clutch continually cuts out Table 64. Page 12-12
Poor performance- Compressor function tests Table 65. Page 12-13
Compressor not achieving 24 bar pressure Table 66. Page 12-13
No air conditioning Table 67. Page 12-13
Table 62. 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 63. 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 64. 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 9813/9100-1 12 - 12
00 - General
Table 65. 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 66. 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 67. 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 9813/9100-1 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 9813/9100-1 12 - 14
00 - General
Discharge and Pressurise 10. Close the valves and remove all equipment.
Figure 230.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
or a suitably trained person. You can be severely
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: 10min in) mercury vacuum reads on both gauges.
12 - 15 9813/9100-1 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: 30min 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 231. Use only PAG oil in R-134a systems.
Figure 232.

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 9813/9100-1 12 - 16
00 - General
Be sure to connect to the liquid port when Figure 234.

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 233.
A396790
Table 68.
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 9813/9100-1 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
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 9813/9100-1 12 - 18
00 - General
Adjust
For compressor drive belt adjustment, please see

(PIL 15-18).
12 - 19 9813/9100-1 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 9813/9100-1 12 - 20
03 - HVAC Unit
00 - General
00 - General 9. For 526-56 machines only:

9.1. Remove the cab frame from the machine.
Remove and Install Refer to: PIL 09-00-03.
9.2. Remove the chassis side cover from the
(For: 533-105 [T4F], 535-v125 [T4F], machine.
540-140 [T4F], 540-170 [T4F], 540-200 Refer to: PIL 06-06-13.
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F]) 10. Remove the bolt 1 and bolt 2 which secure the
HVAC unit to the machine.
11. Carefully remove the unit sufficiently to access
The air conditioning system is a closed loop system the electrical harness connector at the rear.
and contains pressurised refrigerant. No part of the
system should be disconnected until the system 12. The electrical harness connector is located
has been discharged by a refrigeration engineer behind the unit and cannot be disconnected until
or a suitably trained person. You can be severely the unit is pulled away from the machine.
13. Disconnect the electrical connector.
The heating and ventilation unit (HV) contains a
blower unit and heat exchanger matrix. It is located 14. Remove the assembly from the machine.
under the right front side of the cab. Figure 235.
The HVAC (Heating Ventilation Air Conditioning) unit
is the same as the HV unit but also contains an F
evaporator matrix and thermostat.
G
Put labels on all the hoses before removal for easy
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.

E
2. Install the safety strut.
Refer to: PIL 06-69. A C B D
3. To remove the HVAC unit it is necessary to A Heater valve
discharge the refrigerant from the system. B Heater matrix
C TXV (If installed)
Refer to: PIL 12. D Bolt 1
E Bolt 2
4. Drain the cooling system.
F Clip
Refer to: PIL 21. 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.
steps.
7. Disconnect the HVAC hoses from the TXV (if
1.1. Make sure that the TXV is installed correctly
installed).
with the diaphragm, located below the
8. Remove the clip and disconnect the cable from valve.
the heater valve.
12 - 21 9813/9100-1 12 - 21
03 - HVAC Unit
00 - General
Figure 236.
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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 12 - 24
03 - HVAC Unit
Check (Operation) Figure 237.
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 9813/9100-1 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 238.
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 9813/9100-1 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 9813/9100-1 12 - 27
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 69. Page 12-28
Blower does not operate Table 70. Page 12-28
Table 69. 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 70. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 28 9813/9100-1 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 239.
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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 12 - 31
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-33
12 - 32 9813/9100-1 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 9813/9100-1 12 - 33
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 71. Page 12-34
Blower does not operate Table 72. Page 12-34
Table 71. 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 72. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 34 9813/9100-1 12 - 34
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-37
12 - 35 9813/9100-1 12 - 35
Notes:
12 - 36 9813/9100-1 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.
Refer to Component Identification. Refer to: PIL

12-00-00.
12 - 37 9813/9100-1 12 - 37
09 - Compressor
00 - General
Remove and Install
Remove 5.1. Put a label on the hoses to help installation.

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 240.
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 9813/9100-1 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 9813/9100-1 12 - 39
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-41
12 - 40 9813/9100-1 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 Component Identification. Refer to: PIL

12-00-00.
12 - 41 9813/9100-1 12 - 41
12 - Receiver Drier
00 - General
Check (Condition) Figure 242.
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 243.
5. Make sure that the pipes are correctly clamped.
Figure 243.
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.
Figure 241.
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 242.
12 - 42 9813/9100-1 12 - 42
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-45
12 - 43 9813/9100-1 12 - 43
Notes:
12 - 44 9813/9100-1 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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 12 - 47
15 - Condenser
00 - General
Figure 244.
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 9813/9100-1 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 9813/9100-1 12 - 49
15 - Condenser
00 - General
Figure 245.
A C
B
C
A Condenser matrix B Pipe stub

C Nuts
12 - 50 9813/9100-1 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 9813/9100-1 12 - 51
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-53

12-18-06 Fresh Air ........................................................................................................................ 12-54
12 - 52 9813/9100-1 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 9813/9100-1 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
1. Make the machine safe with the lift arm raised.
2. Install the safety strut.
3. Remove the screw and the cover to access the
filter.
4. Remove the filter.
Figure 246.
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 9813/9100-1 12 - 54
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-57
12 - 55 9813/9100-1 12 - 55
Notes:
12 - 56 9813/9100-1 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 247.
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 9813/9100-1 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: 5min
3. Stop the engine and check for any coolant leaks.
12 - 58 9813/9100-1 12 - 58
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-61
12 - 59 9813/9100-1 12 - 59
Notes:
12 - 60 9813/9100-1 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 9813/9100-1 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 9813/9100-1 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 ........................................................................................................................... 15-57
15-12-03 Main Bearing .................................................................................................................. 15-69
15-12-06 Front Oil Seal ................................................................................................................. 15-71
15-12-09 Rear Oil Seal ................................................................................................................. 15-74
15-12-12 Pulley .............................................................................................................................. 15-76
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-79
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-87
15-18-03 Drive Belt ....................................................................................................................... 15-89
15-18-21 Tensioner ........................................................................................................................ 15-94
15-18-24 Idler Pulley ..................................................................................................................... 15-95
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-97
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-105
15-24-09 Dust Valve .................................................................................................................... 15-108
15-28 Crankcase Breather
15-28-00 General ......................................................................................................................... 15-111
15-30 Valve
15-30-00 General ......................................................................................................................... 15-115
15-30-12 Valve Spring ................................................................................................................. 15-120
15-30-24 Stem Seal .................................................................................................................... 15-121
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-123
15-33-06 Big-End Bearing ........................................................................................................... 15-127
15-36 Piston
15-36-00 General ......................................................................................................................... 15-133
15-36-03 Piston Ring ................................................................................................................... 15-144
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-147
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-149
9813/9100-1
2017-11-24
15-42-06 Rocker Cover ............................................................................................................... 15-155
15-42-09 Push Rod ..................................................................................................................... 15-157
15-42-21 Tappet ........................................................................................................................... 15-159
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-165
15-45-09 Dipstick ......................................................................................................................... 15-168
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-171
15-51-03 Crankshaft Gear ........................................................................................................... 15-175
15-51-06 Camshaft Gear ............................................................................................................. 15-176
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-177
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-178
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-181
15-54-03 Housing ........................................................................................................................ 15-184
15-54-09 Gear Ring ..................................................................................................................... 15-186
15-54-12 Drive Plate .................................................................................................................... 15-187
15-57 Oil Filler
15-57-00 General ......................................................................................................................... 15-191
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-193
15-60-06 Pressure Relief Valve ................................................................................................... 15-197
15-63 Mount
15-63-00 General ......................................................................................................................... 15-201
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-205
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-209
15-72-03 Pulley ............................................................................................................................ 15-215
15-72-06 Voltage Regulator ......................................................................................................... 15-216
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-219
15-75-03 Solenoid ....................................................................................................................... 15-227
15-75-06 Brush Gear ................................................................................................................... 15-228
15-80 Glow Plug
15-80-00 General ......................................................................................................................... 15-231
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-235
15-84-03 Crankshaft Position ...................................................................................................... 15-245
15-84-06 Camshaft Position ........................................................................................................ 15-249
15-84-13 Mass Air Flow (MAF) ................................................................................................... 15-254
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-256
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-259
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-262
15-84-24 Fuel Temperature ......................................................................................................... 15-265
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-268
15-84-33 Coolant Temperature .................................................................................................... 15-271
15-84-43 Engine Oil Level ........................................................................................................... 15-274
15-87 Switch
15-87-03 Engine Oil Pressure ..................................................................................................... 15-279
15-90 Air Intake
9813/9100-1
2017-11-24
15-90-00 General ......................................................................................................................... 15-283
9813/9100-1
2017-11-24
Acronyms Glossary
ABDC After Bottom Dead Centre

ATDC After Top Dead Centre
BBDC Before Bottom Dead Centre
BTDC Before Top Dead Centre
CAN Controller Area Network
CCV Crankcase Ventilation
DC Direct Current
DTI Dial Test Indicator
ECM Engine Control Module
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
HLA Hydraulic Lash Adjuster
IMV Inlet Metering Valve
LMS Loadall Monitoring System
MAF Mass Air Flow
PRV Pressure Relief Valve
PTO Power Take-Off
TCV Turbocharger Control Valve
TDC Top Dead Centre
TMAP Temperature Manifold Air Pressure
9813/9100-1
2017-11-24
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/9100-1 15 - 1
Notes:
15 - 2 9813/9100-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-4 engine assembly. For specific engine technical
Technical Data ................................................. 15-6 information refer to the technical data section.
Component Identification ................................. 15-7
Make sure that the correct engine service tools,
Operation ....................................................... 15-12 consumables and torque figures are used when you
Diagram ......................................................... 15-16 perform service procedures.
Fault-Finding .................................................. 15-17
Drain and Fill ................................................. 15-27 Renewal of oil seals, gaskets, and any component
showing obvious signs of wear or damage is
Clean ............................................................. 15-27 expected as a matter of course.
Check (Condition) .......................................... 15-28
Check (Leaks) ............................................... 15-29 It is expected that components will be cleaned and
Check (Pressure) .......................................... 15-29 lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
Remove and Install ....................................... 15-31 excessive loss of hydraulic fluid, engine oil, coolant
Store and Recommission .............................. 15-35 and ingress of dirt.
Basic Description
The JCB engine is a 4 cylinder diesel engine in
which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle. Cylinder
number one is at the front or crankshaft pulley end
of the engine.
Figure 248.
B
C
A
1 2 3 4
D
A Front of engine (viewed from crankshaft pulley
end)
B Exhaust manifold side of engine
C Rear of engine (Flywheel end of engine)
D Inlet manifold side of engine
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 15-75-00.
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.
15 - 3 9813/9100-1 15 - 3
15 - Engine
00 - Engine
00 - General
The camshaft drives a high pressure fuel pump Health and Safety
via gears. The pump is part of the electronically
controlled common rail fuel injection system. Refer
Hot Components
to: PIL 18-18-15.
Touching hot surfaces can burn skin. The engine and
Air is drawn into the engine, via the inlet manifold machine components will be hot after the unit has
and exhaust gases exit via the exhaust manifold. The been running. Allow the engine and components to
engine uses a turbocharger which pressurises the air cool before servicing the unit.
at the inlet manifold. Refer to: PIL 18-35-00.
Turning the Engine
A mechanical lubrication oil pump is driven by the Do not try to turn the engine by pulling the fan or fan
camshaft via gears. The pump pressurises and belt. This could cause injury or premature component
circulates oil for engine lubrication and cooling failure.
purposes. Refer to: PIL 15-60-00.
Notice: The engine and other components could
A drive belt driven by the crankshaft, drives a be damaged by high pressure washing systems.
coolant circulation pump, alternator, radiator cooling Special precautions must be taken if the machine is
fan and other ancillaries such as an air conditioning to be washed using a high pressure system.Make
compressor.Refer to: PIL 15-18-00. 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 correct level of engine
oil in the sump. If there is too much engine oil,
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 - 4 9813/9100-1 15 - 4
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00 - General
accordance with local regulations. Use authorised

waste disposal sites.
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Technical Data
Table 73.
Description FL Engine
Engine Variants Turbocharged with Intercooler
Emission compliance US-EPA Tier 4, EU Stage IV
Rated speed 2200 RPM (Revolutions Per Minute)
Weight (Dry) (Dry weight-No cooling fan drive) 345kg
Number of cylinders 4
Nominal bore size 92mm
Stroke 112mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.98L
Compression ratio 16.5: 1
Engine Compression Compression variance between each cylinder should
be no greater than 3.5bar (50.7psi)
Direction of rotation (viewed from front {crankshaft Clockwise
pulley} end)
Valves 4 per cylinder
Lubricating oil pressure (Dependent on engine tem- 1.6–4.5bar (23.2–65.2psi)
perature and speed)
Filter type Screw-on canister (with drain facility)
Pressure to open filter by-pass valve 1.6bar (23.2psi)
Oil pressure relief valve
(1)
Remote recirculation valve with gallery sensing
Oil pressure relief valve setting
(1)
3.5bar (50.7psi)
Oil pressure switch setting
(1)
0.6bar (8.7psi) falling
Oil pump
(1)
6/7 gerotor pump with safety valve
Combustion system Common rail direct Injection
High pressure fuel pump High pressure with electronically controlled fuel me-
tering
(1) The oil pump and PRV (Pressure Relief Valve) are non-serviceable parts
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The following identifies the main components of a

typical engine assembly. Some variants may differ in
detail.
Figure 249.
U
A
T
A
S A
R
B
P
C
M
E
L
K
F
J G
H
A EGR (Exhaust Gas Recirculation) valve B EGR cooler

C High pressure fuel pump D Engine oil filler cap (side)
E Engine oil dipstick F Oil cooler
G Fuel filter H Oil drain plug (sump)
J Lubrication oil sump K Crankshaft pulley
L Oil filter housing drain plug M FEAD (Front End Accessory Drive) belt auto
tensioner
N Coolant pump P Alternator
Q Engine oil filter R Thermostat housing
S Rocker cover T Engine oil filler cap (top)
U ECM (Engine Control Module)
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00 - General
Figure 250.
V
U
AD
X
Y
AC
P
AB
Z
AA
U ECM V CCV (Crankcase Ventilation) System

W Turbocharger X Turbocharger oil feed pipe
Y Turbocharger oil drain pipe P Alternator
Z Coolant inlet connector AA Starter motor
H Oil drain plug (sump) AB Flywheel
AC Exhaust Manifold AD Injector cover
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00 - General
Figure 251.
AE
AB
AK
AJ
AH
AF
AG
AB Flywheel AE PTO (Power Take-Off) idler gear (optional)

AF Crankshaft drive gear AG Oil pump
AH Camshaft drive gear AJ High pressure fuel pump drive gear
AK Camshaft
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00 - General
Figure 252.
AQ
AP
AN
AM
AL
K Crankshaft pulley AL Connecting rod

AM Crankshaft AN Main bearing
AP Glow plug AQ Fuel injector
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Figure 253.
AR
AS
BD
AT
BC
AU
BB
AV
BA
AZ
AY
AX
AW
AR Rocker arm
AS Rocker shaft
AT Exhaust valve spring
AU Exhaust valve
AV Push rod
AW Hydraulic tappet
AX Piston
AY Piston ring - oil control
AZ Piston ring - compression No.2
BA Piston ring - compression No.1
BB Inlet valve
BC Inlet valve spring
BD Valve bridge piece
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Operation
The Four Stroke Cycle - 4 Cylinder It is important to note that number 1 cylinder is firing
Engine and about to start its power stroke. Rotating the
crankshaft a further full rotation would position the
This section describes the cycle sequence, for the 4 pistons as described but the engine would be at a
cylinder engine. different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons
in numbers 1 and 4 cylinders are at top dead centre The stages in the four stroke cycle for each cylinder
and pistons in numbers 2 and 3 cylinders are at are as follows:
bottom dead centre.
Table 74. 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.
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Figure 254.
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
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Four Stroke Cycle revolution of the crankshaft, thus, in one cycle of a

four stroke engine, the crankshaft revolves twice.
Induction
Figure 255.
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 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 energy. 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 (Top Dead Centre)
In a running engine these four phases are
continuously repeated. Each stroke is half a
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Figure 256.
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
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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 257.
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
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Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 75. Page 15-17
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 76. Page 15-18
Engine - Will Not Crank or Cranks Slowly Table 77. Page 15-18
Engine - Starts Then Stops Table 78. Page 15-19
Engine- Poor Running Table 79. Page 15-19
Engine - Poor Running at Idle Table 80. Page 15-20
Engine - Noise Excessive Table 81. Page 15-21
Engine - Compression Knocks Table 82. Page 15-21
Engine - Reduced Power Output Table 83. Page 15-22
Engine - Will Not Reach Maximum RPM Table 84. Page 15-22
Engine - RPM Surges Table 85. Page 15-23
Engine - Vibration Excessive Table 86. Page 15-23
Engine - Exhaust Smoke Excessive (Black Smoke) Table 87. Page 15-24
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 88. Page 15-24
Engine - Will Not Shut Off Table 89. Page 15-25
Lubricating Oil - Consumption Excessive Table 90. Page 15-25
Lubricating Oil - Contaminated Table 91. Page 15-25
Lubricating Oil - Pressure Low Table 92. Page 15-26
Lubricating Oil - Pressure High Table 93. Page 15-26
Table 75. 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 the specified amount:
Pressure: 0.133bar (1.9psi)
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.
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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 76. 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 100 mm Hg
Engine compression low in one or more cylinders. Check the engine compression.
Cranking speed too slow. See Also: Table 77. 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.
Table 77. 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.
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Cause Remedy
Crankshaft rotation restricted. 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 78. 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.
Table 79. Engine- Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 80. 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.
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Cause Remedy
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.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 80. 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.
restriction.
pump and injectors.
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Table 81. 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 87. Engine - Exhaust Smoke
Excessive (Black Smoke)
pump and injectors.
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.
Table 82. 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.
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Table 83. 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.
high pressure fuel pump
Engine in reduced torque or limp home mode. Check the electronic fault codes.
Table 84. 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.
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Cause Remedy
system.
inadequate). fuel to the injection pump. Check fuses.
pump and injectors.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 85. 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.
system.
Table 86. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 80. 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.
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Cause Remedy
Alternator bearing worn or damaged. Check/replace the alternator.
Transmission misaligned. Check/repair Transmission 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 87. 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.
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.
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
Table 88. 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.
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Cause Remedy
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 89. 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.
Lubrication oil is being burned in the cylinders See Also: Table 90. Lubricating Oil - Consumption
Excessive
Table 90. 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.
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.
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 91. 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.
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Table 92. 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 93. 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.
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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
be damaged by high pressure washing systems.
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.
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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 - 28 9813/9100-1 15 - 28
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 (0-70 892/00346 1
Bar)
2. Get access to the engine compartment (if
applicable) This test is used to diagnose suspected poor
compression in one or more of the engine cylinders.
3. Check the engine and the area below for oil Use ServiceMaster to control the test.
leaks.
4. Close the engine cover (if applicable).
Engine Oil Pressure
5. If necessary, contact your JCB dealer. Use the following procedures to measure the engine
oil pressure. Several factors can influence the engine
oil pressure, the following conditions are assumed:
• The correct engine oil has been used. Refer to:

PIL 15-21-00.
• The engine oil level is correct. Refer to: PIL
75-03-03.
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.
4. Install a suitable adaptor into the vacant pressure
switch port (M10 x 1.5mm thread) and a pressure
test gauge. Make sure that the gauge has a
sealing washer as shown.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
15 - 29 9813/9100-1 15 - 29
15 - Engine
00 - Engine
00 - General
Figure 258. • 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,
A 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
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, piston ring wear, lift pump
diaphragm damage or injector leakage if fuel is
B evident in the oil.
• 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
5. Start the engine and allow a few seconds to
gain oil pressure, increase the engine revs to
the rated speed. Record the pressure gauge
reading. Check that the pressure is within the
specified tolerance.
6. Remove the pressure gauge and install the
pressure switch.
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 pressure relief valve is at fault.
Low Lubrication Oil Pressure

Several factors can be the cause of low lubricating
oil pressure:
15 - 30 9813/9100-1 15 - 30
15 - Engine
00 - Engine
00 - General
Remove and Install Figure 259.
Special Tools
Description Part No. Qty. Q P
Fuel Injector equipment 320/B9321 1 B
Cap Kit (430 Engine)
Lifting Brackets (430 320/B9421 1 M
Engine)
Engine Lifting Spreader 892/01382 1
Bar
J G
Lifting Equipment
equipment is in good condition and complies with all H
local regulations.
N
The lifting equipment used must be an approved
type and capable of lifting the engine safely. The
recommended lifting equipment is shown. Use a A
A
spreader bar when lifting the engine. Never attempt
to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
an assistant. Inspect the lifting brackets for signs Figure 260.
of damage. The brackets must be correctly torqued
to the crankcase. Make sure the lifting equipment F F
does not damage any of the engine dressing and the R
rocker cover.
The following component identification is for a typical
engine installation. There will be some component
differences depending on the machine variant.
Before attempting to remove the engine ensure that
all the necessary components have either been
removed, or safely disconnected from the engine. D
E
A
A
15 - 31 9813/9100-1 15 - 31
15 - Engine
00 - Engine
00 - General
Figure 261. 4. Get access to the engine.
Remove
S 1. Disconnect and remove the battery.
2. Drain the engine oil.
K
3. Drain the engine coolant.
C
4. Remove the cooling pack.
5. Disconnect the air inlet hose.
L 6. Disconnect the turbocharger outlet hose.
7. Disconnect the charge air hose.
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine
block connectors. Release the hose clips and
disconnect the hoses.
10. Disconnect the top coolant hose.
11. Disconnect the bottom coolant hose.
12. Disconnect the wiring connections from the
A Engine mounting bolts starter motor.
B Front lifting bracket - front Refer to: PIL 15-75-00.
C Lifting bracket fixing bolts
D Fuel pipe - return to tank 13. Disconnect the wiring connections from the
E Fuel pipe - feed from lift pump alternator.
F Electrical connector - ECM (Engine Control
Module)
G Electrical connections - alternator 14. Disconnect the fuel supply and return pipes.
H Hose connection - cab heater Plug all the open ports and hoses to prevent
J Electrical connections - starter motor contamination.
K Rear lifting bracket
L Gearbox/hydraulic pump to engine mounting Special Tool: Fuel Injector equipment Cap Kit
bolts (430 Engine) (Qty.: 1)
M Top coolant hose
15. Disconnect the electrical harness at the ECM
N Bottom coolant hose
machine side connector. Important: Do not touch
P Air inlet hose
the connector pins on the ECM or harness
Q Turbocharger outlet hose
connectors. Cover the connectors to prevent
R Charge air inlet hose
contamination.
S Exhaust pipe
16. Make sure that all relevant harnesses and hoses
Before Removal are unclipped from the engine and tied out of the
way.
the engine has been running, let it cool before 17. If necessary, drain the hydraulic tank. Disconnect
you start the service work. and plug the hydraulic suction and delivery lines
at the transmission pump and gear pump. Label
2. Position the machine on firm level ground. Make the hoses to aid installation.
the machine safe.
18. Remove the gearbox/hydraulic pump to engine
retaining bolts and pull the gearbox/hydraulic
3. Discharge the hydraulic pressure. pump clear of the engine.
15 - 32 9813/9100-1 15 - 32
15 - Engine
00 - Engine
00 - General
18.1. Make sure that the torque converter stays Figure 262.
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Special Tool: Lifting Brackets (430 Engine) (Qty.: T
1)
Special Tool: Engine Lifting Spreader Bar (Qty.:
1)
20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
21. Raise the engine and lift it clear of the machine.
22. Lower the engine into a suitable stand that is
capable of supporting the weight of the engine.
U
A
A
A Lifting brackets
T Lifting equipment
U Spreader bar
Install
step.
2. It is vitally important that the torque converter
is installed at the gearbox and engine flywheel
correctly. Failure to locate the torque converter
correctly will result in damage to the gearbox oil
pump on engine start up.
15 - 33 9813/9100-1 15 - 33
15 - Engine
00 - Engine
00 - General
3. Fill the cooling system.

3.1. When you fill the cooling system make
sure you use the correct water/antifreeze
mixture. A 50% mixture should be
maintained even if frost protection is not
required.
4. Fill and check the hydraulic fluid level.
5. Fill and check the engine oil level. Make sure the
correct oil is used.
6. Check the hydraulic, fuel and cooling systems for
leaks.
7. Check the operation of all drive and hydraulic
services.
15 - 34 9813/9100-1 15 - 34
15 - Engine
00 - Engine
00 - General
Store and Recommission
Engines should be stored in the original shipping If an engine is to be placed into storage, all external
packaging. Damaged or disturbed packaging should signs of surface coating damage or corrosion should
be made weatherproof immediately. be cleaned and re-coated. Electrical connectors and
components should be coated with a protective
If an engine is shipped with oil, it should be stored in spray.
the correct (upright) position.
Capping Engine Openings
If an engine is shipped dry of oil, after 6 months it
should be filled with oil to the correct level and re- All openings on the engine must be suitably capped
inhibited, refer to hot test description. to prevent ingress of water and contamination by
foreign particles.
All floor stock engines should be stored under cover
in dry conditions and not subjected to extreme
variations in temperature or humidity.
15 - 35 9813/9100-1 15 - 35
15 - Engine
00 - Engine
00 - General
Figure 263.
A ECM (Engine Control Module) machine harness B Machine harness interconnect connector cap
connector cap
C Fuel pipe – return to tank cap D Fuel pipe – feed from lift pump cap
E Coolant circuit bleed pipe cap F Air intake cap
15 - 36 9813/9100-1 15 - 36
15 - Engine
00 - Engine
00 - General
Figure 264.
G Turbocharger intake cap H Coolant top hose cap

J Turbocharger compressor outlet cap K Coolant bottom hose cap
L Cab heater feed and return spigots M Heavy duty PTO (Power Take-Off)
15 - 37 9813/9100-1 15 - 37
15 - Engine
00 - Engine
00 - General
Figure 265. 2.9. Place in storage, under cover on level

ground or shelving.
2.10. Record details of work as required.
2.11. Do not expose to extremes of temperature
or humidity.
Notice: Do not operate the starter motor for more
than 20s at one time. Let the starter motor cool for
at least 2min.
Table 94. Oil Pressure Switch Set Points

Oil pressure switch >0.6bar (8.7psi)
N closed
Oil pressure switch open <0.6bar (8.7psi)
OEM Commissioning Check on Engine

Installation After More Than 12 Months
N Turbocharger exhaust outlet (tape over)
1. Flush the coolant system with proprietary
12 Month Revalidation Procedure flushing solution.
1. Pre-inspection: 2. Refill the coolant system with 50/50 mix of long

life antifreeze mixture.
1.1. Inspect packaging for signs of damage.
3. Hot test engine according to the hot test profile.
1.2. Inspect the caps for signs of damage. Refer to Table 95.
1.3. Inspect openings for signs of water or dirt 4. Drain engine oil and replace engine oil filter.
ingress.
1.4. Inspect the engine for signs of external 5. Refill with the correct oil and inhibit the cooling
corrosion. system using the correct product.
1.5. Inspect the engine for signs of fluid leaks. 6. Record details of work as required.
2. From storage: Hot Test Description

2.1. Remove the air intake caps. WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
2.2. Make sure the engine oil level is correct. the manufacturer's instructions and safety
2.3. Using a suitable power supply at the correct precautions.
voltage, crank the engine over for the
specified time period. All engines despatched from JCB will have been
Duration: 20s subjected to a hot test (checking items such as oil
pressure, engines speeds, torque values etc.) and
2.4. During cranking, check that the oil pressure therefore the interior surfaces will have been coated
switch opens using a multimeter. The switch with engine oil.
is closed when there is no or low oil
pressure and opens when oil pressure All coolant galleries are coated with CRODAFLUID
reaches a set point. After three separate PA75 corrosion inhibitor.
cranking periods, If the oil pressure switch
does not open (indicating no, or low oil Stored engines will require re-inhibiting every 12
pressure), contact your JCB engine dealer. months, this will include hot testing the engine using
2.5. Recap all engine openings. a dynamometer. The hot test profile is:
2.6. Coat any exposed bare metal with a Table 95. Hot Test Profile
suitable product.
Stage Mode Speed Torque Time
2.7. Electrical connectors and components (rpm) (Nm) (secs)
should be coated with a protective spray if 1 Speed/ 830 0 50
exposed. Torque
2.8. Cover in weatherproof packaging. 2 Speed/ 1300 50 60
Torque
15 - 38 9813/9100-1 15 - 38
15 - Engine
00 - Engine
00 - General
Stage Mode Speed Torque Time

(rpm) (Nm) (secs)
3 Speed/ 2500 0 60
Torque
4 Speed/ 1300 0 25
Torque
5 Speed/ 800 0 35
Torque
15 - 39 9813/9100-1 15 - 39
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-41
15 - 40 9813/9100-1 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 266.
A
A Crankcase
B Crankshaft
15 - 41 9813/9100-1 15 - 41
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 96. Crankcase and Bedplate Data

Cylinder bore
(1)
92–92.02mm
Main bearing (bedplate) bolts torque
(2)
First stage 30N·m

Second stage 50N·m
Third stage Slacken and tighten to 50N·m
Final stage Turn a further 180°
Surface finish for cylinder head joint
(3)
Rz < 15m, Rmax < 20
Diameter of first oversize bore 92.5–92.52mm
Diameter of second oversize bore 93–93.02mm
Main bearing bore (without bearings)
Numbers 1 to 4 76.02–76.039mm
Number 5 84.02–84.039mm
Camshaft bore
Numbers 1 to 4 50.04–50.07mm
Number 5 (bush) 60.04–60.07mm
Permissible wave profile wt < 10m (2.5mm 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 9813/9100-1 15 - 42
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-45
15 - 43 9813/9100-1 15 - 43
Notes:
15 - 44 9813/9100-1 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 9813/9100-1 15 - 45
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 97. Cylinder Head Data

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

- Side to side 0.03mm
Valve recess depth
- Inlet 0.95mm
- Exhaust 0.95mm
Valve seat angle
- Inlet 120° (inclusive)
- Exhaust 90° (inclusive)
Cylinder head bolts torque
(2)
- First stage 50
- Second stage 115
- Final stage Torque angle + 180°
Surface finish for cylinder head joint Rz < 15 Rmax < 20m
Permissible wave profile wt < 10m (2.5mm 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 9813/9100-1 15 - 46
15 - Engine
06 - Cylinder Head
00 - General
Figure 267.
A Cylinder head bolts

B Cylinder head
C Cylinder head gasket
15 - 47 9813/9100-1 15 - 47
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 9. Remove the fuel injector cover.

Description Part No. Qty. Refer to: PIL 18-18-04.
Torque Wrench 993/70111 1
(10-100Nm) 10. Remove the high pressure fuel pipes.
Consumables
Description Part No. Size 11. Remove the injector leak-off, leak-off pipe to fuel
Cleaner/Degreaser 4104/1557 0.4L filter, and return to tank low pressure fuel pipes.
- General purpose Refer to: PIL 18-96-06.
solvent based parts
cleaner 12. Remove the fuel injectors.
Before Removal
13. Remove the fuel rail.
This procedure requires service parts. Make sure Refer to: PIL 18-18-12.
you have obtained the correct parts before you start.
Refer to the Parts Catalogue. 14. Remove the EGR (Exhaust Gas Recirculation)
system.
15. Remove the exhaust manifold pressure sensor
2. Make sure that the engine is safe to work on. If assembly.
you start the service work. Refer to: PIL 15-84-16.
3. Get access to the engine. 16. Remove the exhaust manifold and turbocharger
assembly.
4. Drain the coolant. Refer to: PIL 18-24-04.
17. Remove the glow plugs.
5. Remove the engine wiring harness. Refer to: PIL 15-80-00.
6. Remove the ECM (Engine Control Module). 18. Disconnect the charge air inlet hose.
19. Remove the rocker cover.
7. Remove the thermostat. Refer to: PIL 15-42-06.
20. Remove the rocker assembly.
8. Disconnect the CCV (Crankcase Ventilation) Refer to: PIL 15-42-00.
pipes.
15 - 48 9813/9100-1 15 - 48
15 - Engine
06 - Cylinder Head
00 - General
Figure 268.
12
12
13 X
11
10 6 2 3 7
9 5 1 4 8
0° +180°
1-10 Cylinder head fixing bolts (x10) 11 Cylinder head

12 Location dowels (x2) 13 Cylinder head gasket
X Cylinder head gasket identification holes Y Matchmarks
21. Remove the push rods. Make a note of the 3. Using a suitable cleaning agent, carefully remove
order to make sure that they are installed in their all traces of the head gasket material from the
original positions. cylinder head and crankcase mating faces.
Consumable: Cleaner/Degreaser - General
Remove purpose solvent based parts cleaner
1. Progressively remove the cylinder head bolts in 4. Check the cylinder head and crankcase mating
reverse order, starting at bolt 10. The bolts MUST faces for signs of damage and distortion.
NOT be re-used. Discard the bolts.
2. Carefully lift the cylinder head from the
crankcase. If necessary use a soft face hammer. Before Install
DO NOT use a lever to separate the cylinder
head from the crankcase. Discard the head 1. Obtain the correct new cylinder head bolts. The
gasket. original bolts MUST NOT be re-used.
15 - 49 9813/9100-1 15 - 49
15 - Engine
06 - Cylinder Head
00 - General
2. Obtain the correct replacement head gasket.

Note the number of cylinder head gasket
identification holes.
3. Make sure that all items are clean and free from
Install
steps.
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 three stages, use the
torque and angle method.
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-10) to the 1st stage pre-torque.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
4.2. Tighten the bolts, starting with the middle
pair and working outwards (in sequence 1-
10) to the 2nd stage pre-torque.
4.3. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-10) to
the final stage torque. As a visual check,
matchmark the bolts to the cylinder head
before you start. When the bolts have
been angle tightened, the matchmarks will
appear as shown at Y.
Table 98. Torque Table

Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
1-10 (Final Stage) 180°
15 - 50 9813/9100-1 15 - 50
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-53
15 - 51 9813/9100-1 15 - 51
Notes:
15 - 52 9813/9100-1 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 269.
1
1 Bedplate
2 Crankcase
15 - 53 9813/9100-1 15 - 53
15 - Engine
09 - Bedplate
00 - General
Remove and Install

15 - 54 9813/9100-1 15 - 54
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-57

15-12-03 Main Bearing .................................................................................................................. 15-69
15-12-06 Front Oil Seal ................................................................................................................. 15-71
15-12-09 Rear Oil Seal ................................................................................................................. 15-74
15-12-12 Pulley .............................................................................................................................. 15-76
15 - 55 9813/9100-1 15 - 55
Notes:
15 - 56 9813/9100-1 15 - 56
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-57 The crankshaft is housed inside the crankcase. It is
Technical Data ............................................... 15-58 connected to the piston via a connecting rod, they
Component Identification ............................... 15-59 form a simple mechanism that converts reciprocating
Operation ....................................................... 15-60 motion into rotating motion. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-61
15 - 57 9813/9100-1 15 - 57
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 99.
Main bearing journal diameter (x4)
- min 71.98mm
- max 72mm
Main rear bearing journal diameter (x1)
- min 79.98mm
- max 80mm
Connecting rod bearing journal diameter
- min 64.98mm
- max 65mm
Maximum wear and ovality on journals No visible damage/wear or marks
Crankshaft induction hardness 55 HRc min on surface
Thrust washer width
- min 2.44mm
- max 3.04mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
Crankshaft gear
(1)
49 teeth
(1) The crankshaft gear is not available as a separate item. The gear must be heated on to the crankshaft in the
correct timed position. Specialist fixtures are used during the production process to achieve the correct timing.
15 - 58 9813/9100-1 15 - 58
15 - Engine
12 - Crankshaft
00 - General
Figure 270.
B
A Crankcase
B Crankshaft
C Crankshaft position sensor target wheel
15 - 59 9813/9100-1 15 - 59
15 - Engine
12 - Crankshaft
00 - General
Operation
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
diameter of the upper main bearing shell allows oil engine.
Figure 271.
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 - 60 9813/9100-1 15 - 60
15 - Engine
12 - Crankshaft
00 - General
Check (Condition) Blocked or restricted oilways will cause oil

starvation at the big end bearings.
1. Measure the crankshaft journal diameters to 4. Check that the piston cooling saddle jets are
confirm they are within service limits. clear. If the saddle jets cannot be cleared, replace
the saddle jets.
Figure 274.
Figure 272.
B
A Crankcase
B Crankshaft
C Crankshaft position sensor target wheel
2. Check the main bearing surfaces for damage and
excessive wear.
Figure 273.
E Saddle jets
D Main bearing shells

3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
15 - 61 9813/9100-1 15 - 61
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Special Tools Refer to: PIL 15-45-09.

12. Remove the bolts (x2) and disconnect the
Template for Sealant 320/02333 1 turbocharger oil drain pipe.
Bedplate to Crankcase
(430 Engine) 13. Remove the oil sump.
Crankshaft Turning Tool 320/A3170 1 Refer to: PIL 15-45-00.
(Major Repair) (430
Engine) 14. It is not necessary to remove the cylinder head
Torque Wrench 993/70111 1 assembly to remove the crankshaft. If however
(10-100Nm) the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
Consumables for example) remove it now.
Description Part No. Size Refer to: PIL 15-06-00.
Cleaner/Degreaser 4104/1557 0.4L
- General purpose 15. Remove the starter motor.
solvent based parts Refer to: PIL 15-75-00.
cleaner
16. Remove the flywheel.
method and device. 17. Remove the rear crankshaft oil seal.
Before Removal
18. Remove the flywheel housing.
1. This procedure requires service parts. Make Refer to: PIL 15-54-03.
sure you have obtained the correct service parts
before you start, refer to the Parts Catalogue. 19. Remove the oil pump.
2. Make sure that the engine is safe to work on. If Refer to: PIL 15-60-00.
you start the service work. 20. Remove the bolt securing the fuel hose to the
bedplate.
Figure 275.
4. Remove the engine.
5. Remove the fuel filter.
6. Remove the drive belt.
Refer to: PIL 15-18-03. E
7. Remove the crankshaft pulley.

8. Remove the front crankshaft oil seal.
E Fuel pipe retaining bolt
21. Remove the main bearing caps.
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase. Refer to: PIL 15-12-03.
10. Remove the dipstick. 22. Set the engine to TDC (Top Dead Centre).
11. Remove the dipstick tube.
15 - 62 9813/9100-1 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Special Tool: Crankshaft Turning Tool (Major Remove

Repair) (430 Engine) (Qty.: 1)
1. Remove the bedplate peripheral bolts.
Figure 276.
O
O
O
9 5 1 4 8
10 6 2 3 7
O
O O
O
P
N
O
1-10 Main bearing bolts (x10) N Bedplate

O Bedplate peripheral bolts (x12) P O-ring
2. Progressively remove the main bearing bolts in Figure 277.

reverse order starting at bolt 10. The bolts MUST R
NOT be re-used. Discard the bolts. N
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate. R
N Bedplate
R Lifting bolts (obtain locally)
4. Remove the bedplate.
15 - 63 9813/9100-1 15 - 63
15 - Engine
12 - Crankshaft
00 - General
5. Use suitable lifting equipment to carefully lift the Figure 279.

crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
6. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
Figure 278.
A
B
A Thrust washers
B Crankshaft D Main bearing shells
C Rear main bearing
9. It is recommended that the bearing shells are
7. Put labels on the thrust washers to make sure replaced. If however they are to be used again,
that they are installed in the correct positions put labels on the shells to make sure that they
during assembly. are installed in their original positions during
assembly.
8. Carefully lift out the bearing shells.
10. Inspect the crankshaft and main bearings for
damage and excessive wear.
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
purpose solvent based parts cleaner
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.
15 - 64 9813/9100-1 15 - 64
15 - Engine
12 - Crankshaft
00 - General
2. Make sure that all items are clean and free from 4. Use suitable lifting equipment (if the crankshaft
damage and corrosion. is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
3. Install the upper bearing shells as follows: DO NOT rotate the crankshaft, the bearing shells
can become dislodged. Make sure that the
Figure 280. connecting rods are located onto the crankshaft
journals.
G
4.1. Make sure that the connecting rods are
located onto the crankshaft journals.
4.2. Make sure that the crankshaft is installed
so that the engine timing is correct. The
single mark on the crankshaft drive gear
must locate between the two marks on the
camshaft drive gear.
Figure 281.
J
L
K
D M
Y J Camshaft drive gear timing marks

K Crankshaft drive gear timing mark
L Camshaft drive gear
M Crankshaft drive gear
D Main bearing shells
G Bearing location tab 5. Install the thrust washers as follows:
Y Oil-way holes
3.1. Use a suitable degreasing agent to make
sure that the surfaces of the upper bearing
shells are clean.
3.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
3.3. Make sure that the oil-way holes in the
bearing saddles align with the holes in the
bearing shell. If the holes are even partially
misaligned the piston cooling oil jet will be
restricted, causing the engine to fail.
3.4. Lubricate the upper bearing shells with
clean engine oil.
15 - 65 9813/9100-1 15 - 65
15 - Engine
12 - Crankshaft
00 - General
Figure 282. 5.2. Make sure that they are installed in the
correct positions, with the two oil slots
A facing outwards from the bearing saddle.
5.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
5.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged.
H 6. Check that the crankshaft end float is within
service limits.
7. Install the four lifting bolts to the bedplate as
shown.
A 8. Lubricate the lower bearing shells with clean

engine oil. If the bearings have been removed,
make sure that the location tab engages in the
slot as shown.
9. The sealant template is used on the crankcase,
NOT the bedplate.
Special Tool: Template for Sealant Bedplate to
Crankcase (430 Engine) (Qty.: 1)
B
C 10. Locate the location tabs on the template using
a location dowel and a fixing bolt. Use the
A Thrust washer templates as a guide apply a bead of sealant
B Crankshaft around the crankcase/bedplate mating face as
C Rear main bearing shown to the dimension specified.
H Oil slot - thrust washers Length/Dimension/Distance: 1.5mm
5.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
15 - 66 9813/9100-1 15 - 66
15 - Engine
12 - Crankshaft
00 - General
Figure 283.
V S
S
T
X
S Location dowels T Template location tab

U Sealant template V Sealant bead
W Crankcase X Sealant join
11. Remove the fixing bolt. Remove the sealant 13. The bedplate is heavy. Two people will be
template, make sure you do not smudge the required to lift and rotate the bedplate safely
sealant. Discard the templates. on to the crankcase. Install new main bearing
bolts 1-10. Tighten the bolts to the correct
12. Add a bead of sealant around the location dowel torque value, starting in the centre and working
and the bolt holes so as to join the sealant beads. outwards (in sequence 1-10) to the 1st stage pre-
torque.
15 - 67 9813/9100-1 15 - 67
15 - Engine
12 - Crankshaft
00 - General
Special Tool: Torque Wrench (10-100Nm) (Qty.:

1)
14. Install the bedplate peripheral bolts. Tighten the
bolts to the correct torque value.
15. After installation and tightening the bedplate
peripheral bolts, further tighten the main bearing
bolts, starting in the centre and working outwards
(in sequence 1-10) to the 2nd stage pre-torque.
16. Loosen and then tighten the main bearing bolts,
starting in the centre and working outwards (in
sequence 1-10) to the 3rd stage pre-torque.
17. Angle tighten the main bearing bolts in pairs,
starting in the centre and working outwards (in
sequence 1-10) for the final stage torque. Use
the torque and angle method.
18. Check that the crankshaft can be freely rotated
by hand. Remove the bedplate lifting bolts.
If the parts have not been tightened to the correct

torque value within the maximum 15min time period,
then the parts must be separated, thoroughly
cleaned and fresh sealant applied.
After Installation
1. The after installation procedure is the opposite of
the before removal procedure.

Item Torque Value
1-10 (2nd Stage) 50N·m
1-10 (3rd Stage) Loosen then tighten to
50N·m
1-10 (Final Stage) 180
E 10 ± 1N·m
O 47 ± 2N·m
15 - 68 9813/9100-1 15 - 68
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-69 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-70 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 284.
A Main bearing
B Crankshaft
15 - 69 9813/9100-1 15 - 69
15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition) Remove and Install

1. Check the bearing shell surfaces for signs of
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 - 70 9813/9100-1 15 - 70
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 285.

Crankshaft Front Oil 320/A3126 1
Seal Installation Tool
(430 Engine)
A
This procedure requires service parts. Make sure
you have obtained the correct service parts before B
you start. Refer to Parts Catalogue.
Remove C
D
2. Make sure that the engine is safe to work on. If A Crankshaft oil seal
the engine has been running, let it cool before B Crankcase
you start the service work. C Bedplate
D Crankshaft
4. Remove the drive belt. Install
Refer to: PIL 15-18-03. 1. Make sure that the counterbore and the
crankshaft hub are clean and free from damage
5. Remove the crankshaft pulley. and corrosion. Use a suitable degreasing agent
Refer to: PIL 15-12-12. to clean all traces of oil and grease from the
counterbore. The oil seal has a special coating
6. Use a suitable lever behind the lip of the and MUST be installed dry without lubricant.
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not 2. Install the crankshaft oil seal guide to the
to scratch or damage the counterbore or the crankshaft hub, using the bolts 1 (x3).
crankshaft hub. Damaged or dirty sealing faces Special Tool: Crankshaft Front Oil Seal
will cause the oil seal to fail. The crankshaft oil Installation Tool (430 Engine) (Qty.: 1)
seal must not be reused. Discard the crankshaft
oil seal.
15 - 71 9813/9100-1 15 - 71
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 286.
D Crankshaft E Crankshaft oil seal guide

F Bolts 1 (x3) G Crankshaft oil seal cup
H Spacer J Bolt 2
3. Install the oil seal on to the crankshaft oil seal

guide. Make sure that the seal is installed the
correct way around. Install the crankshaft oil seal
cup on to the oil seal guide and install the spacer
and the bolt 2.
4. Tighten the bolt 2 to push the seal squarely
into the counterbore until the oil seal cup comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore.
15 - 72 9813/9100-1 15 - 72
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 287.
B
F E D
G
A C
A Crankshaft oil seal
B Crankcase
C Bedplate
D Crankshaft
E Crankshaft oil seal guide
F Bolts 1 (x3)
G Crankshaft oil seal cup
H Spacer
J Bolt 2
5. Remove the crankshaft seal installation tool.
6. Install the crankshaft pulley.
7. Install the drive belt.
15 - 73 9813/9100-1 15 - 73
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install

Crankshaft Rear Oil 320/A3125 1
Seal Installation Tool
(430 Engine) A

you have obtained the correct service parts before
B C
Remove
the engine has been running, let it cool before A Crankshaft oil seal
you start the service work. B Crankshaft
C Flywheel housing
3. Get access to the engine. If necessary, remove
the engine. Install
1. Make sure that the counterbore and the
4. Remove the flywheel. crankshaft hub are clean and free from damage
and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
5. Use a suitable lever behind the lip of the counterbore. The oil seal has a special coating
seal, carefully prise out the oil seal from the and MUST be installed dry without lubricant.
counterbore in the flywheel housing. Take care
2. Install the crankshaft oil seal guide to the
not to scratch or damage the counterbore or the
crankshaft hub, using the bolts 1 (x2).
crankshaft hub. Damaged or dirty sealing faces
will cause the oil seal to fail. The crankshaft oil Special Tool: Crankshaft Rear Oil Seal
seal must not be reused. Discard the crankshaft Installation Tool (430 Engine) (Qty.: 1)
oil seal.
Figure 289.
F
E D
G
H
15 - 74 9813/9100-1 15 - 74
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
D Crankshaft oil seal guide E Bolts 1 (x2)

F Crankshaft oil seal cup G Spacer
H Bolt 2
3. Install the oil seal on to the crankshaft oil seal

guide. Make sure that the seal is installed the
correct way around. Install the crankshaft oil seal
cup on to the oil seal guide and install the spacer
and the bolt 2.
4. Tighten the bolt 2 to push the seal squarely
into the counterbore until the oil seal cup comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore.
Figure 290.
F E D B
H G
A
E C
A Crankshaft oil seal
B Crankshaft
C Flywheel housing
D Crankshaft oil seal guide
E Bolts 1 (x3)
F Crankshaft oil seal cup
G Spacer
H Bolt 2
5. Remove the crankshaft seal installation tool.
6. Install the flywheel.
7. If necessary, install the engine.
15 - 75 9813/9100-1 15 - 75
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Special Tool: Torque Wrench (10-100Nm) (Qty.:

1)
Remove and Install 4. The bolts are tightened using a torque and angle
method.
Special Tools
Torque Wrench 993/70111 1 Figure 292.
(10-100Nm)
Before Removal
you start, refer to the Parts Catalogue.
C
3. Get access to the engine. C Angle gauge (obtain locally)
4. Remove the drive belt. After Replacement
1. Install the drive belt.
Remove Refer to: PIL 15-18-03.
1. Remove the fixing bolts and withdraw the pulley Table 101.
from the crankshaft.
Item Torque Value Torque Angle
Figure 291. (Nm) (Degrees)
B (1st stage) 75N·m
B (Final stage) 90°
A
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
Install
steps.
3. Replace the fixing bolts. Tighten the bolts in two
stages to the correct torque value.
15 - 76 9813/9100-1 15 - 76
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-79
15 - 77 9813/9100-1 15 - 77
Notes:
15 - 78 9813/9100-1 15 - 78
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-79 The camshaft is an important component in an
Technical Data ............................................... 15-80 internal combustion engine.
Component Identification ............................... 15-80
Operation ....................................................... 15-81 The relationship between the rotation of the camshaft
and the rotation of the crankshaft is of critical
Check (Condition) .......................................... 15-83 importance. Since the valves control the flow of the
Remove and Install ....................................... 15-83 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.
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. Refer to: PIL 15-00-00.
15 - 79 9813/9100-1 15 - 79
15 - Engine
15 - Camshaft
00 - General
Technical Data Component Identification
Table 102. Camshaft Data Figure 293.

Camshaft journal diame-
ter
- 4 off 49.99–49.97mm
- 1 off 59.99–59.97mm
Camshaft lobe wear lim-
its A
Inlet lift 7.161–7.271mm E C D
Exhaust lift 7.2–7.31mm B
Camshaft bore diameter
- 4 off 50.07–50.04mm A Camshaft
B Camshaft drive gear
- 1 off 60.07–60.04mm C Exhaust lobe
Camshaft gear
(1)
98 teeth D Inlet lobe
(1) The camshaft gear is not available as a separate E Camshaft position sensor target wheel
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 - 80 9813/9100-1 15 - 80
15 - Engine
15 - Camshaft
00 - General
Operation
As the crankshaft rotates the camshaft also rotates, during the cycle it follows that the camshaft is driven
driven by a gear on the crankshaft. The inlet and at half crankshaft (engine) speed.
exhaust valves are opened by lobes on the camshaft
in time with the cycle. Lubrication
The diagrams show the position of the camshaft Oil is fed from the main gallery via a drilling to the
at each part of the four stroke cycle. Refer to: PIL camshaft bearing. A groove around the diameter of
15-00-00. the bearing and connecting the cross drilling ensures
that oil is always fed to the centre drilling. Oil is then
It can be seen that for a complete cycle the camshaft transferred to the remaining camshaft bearings by
revolves once. Since the crankshaft revolves twice further cross drillings in the shaft. The cam lobes and
tappets are 'splash' lubricated.
Figure 294.
A
B D
A
D B
A Main gallery B Camshaft bearing
15 - 81 9813/9100-1 15 - 81
15 - Engine
15 - Camshaft
00 - General
C Groove D Centre drilling
15 - 82 9813/9100-1 15 - 82
15 - Engine
15 - Camshaft
00 - General

Special Tools
1. Inspect the camshaft gear teeth for signs of Description Part No. Qty.
damage or excessive wear.
Crankshaft Turning Tool 320/A3160 1
2. Inspect the cam lobes for signs of excessive (430 Engine)
wear, scoring or pitting.
Before Removal
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the This procedure requires service parts. Make sure
dimensions are within service limits. you have obtained the correct parts before you start,
4. Inspect the cam bearing surfaces inside the refer to the Parts Catalogue.
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits. Refer to: PIL 01-03.
5. Inspect the bearing surfaces of the tappets for 2. Make sure that the engine is safe to work on. If
signs of excessive wear or damage. Check that the engine has been running, let it cool before
the dimensions are within service limits. you start the service work.
6. Inspect the tappet bores inside the crankcase for 3. Drain the engine oil.
signs of excessive wear or damage. Check that Refer to: PIL 15-21-00.
the dimensions are within service limits.
4. Remove the engine from the machine.
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries Refer to: PIL 15-00-00.
in the crankcase and camshaft may be blocked.
Make sure all oil ways are clear and free from 5. Set the engine to TDC (Top Dead Centre).
debris. Special Tool: Crankshaft Turning Tool (430
Engine) (Qty.: 1)
6. Remove the starter motor.
Remove
The engine must be inverted. Do not attempt to
remove the camshaft with the engine upright. The
tappets and push rods will fall into the engine and
further dismantling will be required to retrieve them.
1. Invert the engine.

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure 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.
15 - 83 9813/9100-1 15 - 83
15 - Engine
15 - Camshaft
00 - General
Figure 295. After Installation

1. The after installation procedure is the opposite
of the before removal procedure. Additionally do
the following step.
2. Replace the rear crankshaft oil seal.
A Camshaft and drive gear assembly
Install
1. Lubricate the camshaft with clean engine oil.
2. Insert the camshaft into the crankcase. Make
sure 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.
2.1. Make sure that the camshaft is installed
so that the engine timing is correct. The
single mark on the crankshaft drive gear
must locate between the two marks on the
camshaft drive gear.
Figure 296.
J
L
K
J Camshaft drive gear timing marks

K Crankshaft drive gear timing mark
L Camshaft drive gear
M Crankshaft drive gear
15 - 84 9813/9100-1 15 - 84
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-87

15-18-03 Drive Belt ....................................................................................................................... 15-89
15-18-21 Tensioner ........................................................................................................................ 15-94
15-18-24 Idler Pulley ..................................................................................................................... 15-95
15 - 85 9813/9100-1 15 - 85
Notes:
15 - 86 9813/9100-1 15 - 86
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-87 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-88 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-88 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 - 87 9813/9100-1 15 - 87
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 297.
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
WARNING! The engine has exposed rotating parts. F
engine cover open.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
C
G
B
E
D
A H
A Crankshaft drive pulley
B Coolant pump drive pulley
C Alternator drive pulley
D Idler pulley
E Tensioner
F Idler pulley/ cooling fan drive pulley
G Idler pulley/ air conditioning compressor drive
pulley
H Drive belt
15 - 88 9813/9100-1 15 - 88
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-89 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-90 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-90 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-91 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 - 89 9813/9100-1 15 - 89
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 298.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 90 9813/9100-1 15 - 90
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust
Adjustment is not possible with this drive belt. A

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct
tension.
15 - 91 9813/9100-1 15 - 91
15 - Engine
18 - Engine Belt
03 - Drive Belt
Remove and Install
Remove 2. Using a 1/2 inch square drive inserted into the

tensioner square drive socket, carefully rotate
1. Make sure that the engine is safe to work on. If the tensioner fully anticlockwise.
Figure 299.
A
D
C
A Drive belt B Example of frayed drive belt (refer to Check

Condition)
C Tensioner D Tensioner square drive socket
3. Remove the drive belt. Install

4. Slowly release the spring force by rotating the 1. The installation procedure is the opposite of the
tensioner unit in the opposite direction. removal procedure. Additionally do the following
step.
15 - 92 9813/9100-1 15 - 92
15 - Engine
18 - Engine Belt
03 - Drive Belt
2. Before you install the new belt, check that the

tensioner roller and the pulleys rotate smoothly
and that there is no play in the bearings.
15 - 93 9813/9100-1 15 - 93
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner
Remove and Install
Remove
2. Using a 1/2 inch square drive inserted into the
tensioner square drive socket, carefully rotate
the tensioner fully anticlockwise.
3. Remove the belt from the tensioner pulley.
Figure 300.
D
C E
A
B
A Tensioner
B Bolt 1
C Bolt 2
D Drive belt
E Tensioner square drive socket
4. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
5. Remove the bolts (x2) and remove the tensioner.
Install
step.
2. Tighten the bolts to the correct torque value.

Item Description Nm
B M8 bolt 22–24
C M10 bolt 55 ± 5
15 - 94 9813/9100-1 15 - 94
15 - Engine
18 - Engine Belt
24 - Idler Pulley
24 - Idler Pulley Install

step.
Remove 2. Tighten the bolt to the correct torque value.
1. Make the machine safe. Table 104. Torque Values

Refer to: PIL 01-03. Item Nm
C 55 ± 5
3. Remove the dust cover.
Figure 301.
A Idler pulley
B Dust cover
4. Remove the bolt.
Figure 302.
A Idler pulley
C Bolt
5. Remove the idler pulley.
15 - 95 9813/9100-1 15 - 95
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-97
15 - 96 9813/9100-1 15 - 96
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-97 The oil filter is a spin on type which screws on and
Health and Safety .......................................... 15-98 off the oil filter head.
Operation ..................................................... 15-100
Check (Level) .............................................. 15-100
15 - 97 9813/9100-1 15 - 97
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.
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 - 98 9813/9100-1 15 - 98
15 - Engine
21 - Oil Filter
00 - General
Figure 303.
C
1
C
G
F
J
A K
C
2
H A
D B
F
A
1 Oil filter state - engine running 2 Oil filter state - engine stopped
A Oil filter housing B Oil filter drain down plug
C Oil filter D Filter element
E Anti-drain seal F O-ring
G Anti-drain pipe H Spring
J Oil gallery - from cooler to filter head K Oil gallery - from filter head to main oil gallery
15 - 99 9813/9100-1 15 - 99
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. Refer to: PIL 78-24.
oil enters the inner part filter before leaving the filter
head via a port. 1. Make the machine safe.
At Engine Stopped
With the engine stopped oil pressure in the galleries 3. Check that the oil level is between the two marks
and filter decays. The anti-drain seal falls on on the dipstick.
its seat and oil is prevented from draining from
the filter assembly. The anti-drain pipe prevents Figure 304.
approximately half the filters oil capacity from A
draining. These features help protect the engine from
oil starvation on start up.
A Dipstick
C Marks
4. If necessary, add recommended oil through one
of the filler points.
15 - 100 9813/9100-1 15 - 100

15 - Engine
21 - Oil Filter
00 - General
Figure 305.
B
B
A Dipstick
B Oil filler point
15 - 101 9813/9100-1 15 - 101

15 - Engine
21 - Oil Filter
00 - General
Remove and Install
CAUTION Oil will gush from the hole when the accordance with local regulations. Use authorised
drain plug is removed. Keep to one side when you waste disposal sites.
remove the plug.
CAUTION It is illegal to pollute drains, sewers Drain the oil when the engine is warm as
or the ground. Clean up all spilt fluids and/or contaminants held in suspension will then be drained
lubricants. with the oil.
Used fluids and/or lubricants, filters and
Figure 306.
1 2 3
H
D
A
F
C G E
A Dipstick B Filler point

C Drain plug D O-ring
E Drain plug F Filter canister
G Filter head H Seal
1. Make the machine safe. 6. Loosen and remove the filter housing drain plug.
Drain the oil.
2. Get access to the engine compartment.
7. Install the filter housing drain plug. Tighten the
3. Place a suitable container below the sump drain filter housing drain plug to the correct torque
plug. value.
4. Remove the sump drain plug and O-ring. Drain Torque: 24–28N·m
the oil in to a suitable container.
8. Remove the filter canister.
5. Clean the sump drain plug. Install the sump drain
plug with a new O-ring. Tighten the sump drain 8.1. Use a chain wrench if necessary.
plug to the correct torque value. 9. Clean the seal face of the filter head.
Torque: 45–55N·m
15 - 102 9813/9100-1 15 - 102

15 - Engine
21 - Oil Filter
00 - General
10. Fit a seal on the new filter canister with clean

engine oil.
11. Install and tighten the new filter canister with your
hand.
12. Tighten the new filter canister to the correct
torque value.
Torque: 17–21N·m
13. Add the correct specification and quantity of oil
through one of the filler points to the maximum
mark on the dipstick.
13.1. Clean the spilt oil.
14. Fit the filler cap and make sure to secure the filler
cap.
15. Operate the engine at idle speed until the oil
pressure low warning light has extinguished and
the new filter primed before the engine speed is
increased above idle speed.
16. Check for leaks.
17. Check the oil level when the oil has cooled.
17.1. Fill with clean engine oil, if necessary.
15 - 103 9813/9100-1 15 - 103

15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ......................................................................................................................... 15-105

15-24-09 Dust Valve .................................................................................................................... 15-108
15 - 104 9813/9100-1 15 - 104

15 - Engine
24 - Air Filter
00 - General
Introduction .................................................. 15-105 Engine performance and durability will be severely
Health and Safety ........................................ 15-106 affected if the quality of the air intake is poor.
Check (Condition) ........................................ 15-106
Remove and Install ..................................... 15-107 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 - 105 9813/9100-1 15 - 105

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 - 106 9813/9100-1 15 - 106

15 - Engine
24 - Air Filter
00 - General
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 - 107 9813/9100-1 15 - 107

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 - 108 9813/9100-1 15 - 108

15 - Engine
28 - Crankcase Breather
Contents Page No.
15-28-00 General ......................................................................................................................... 15-111
15 - 109 9813/9100-1 15 - 109

Notes:
15 - 110 9813/9100-1 15 - 110

15 - Engine
00 - General
Introduction .................................................. 15-111 The crankcase breather allows excess combustion
Remove and Install ..................................... 15-112 gasses and vapours to leave the engine preventing
excessive pressure build up inside the crankcase.
The gasses and vapours leave the engine through
the rocker cover before passing through an oil
separator. A small amount of charge air pressure
is used to extract the clean gasses once they have
been through the oil separator.
Figure 308.
A
D B
C
A Crankcase breather
B Air inlet
C Rocker cover
D Crankcase breather vent pipe
15 - 111 9813/9100-1 15 - 111

15 - Engine
00 - General
G
Remove
you have obtained the correct service parts before J
you start, refer to the Parts Catalogue. H

G
G Bolts 2 (x10)
2. Make sure that the engine is safe to work on. If H Crankcase breather oil separator
the engine has been running, let it cool before J Turbo control valve
10. If installed remove the clamping plates (x2).
3. Disconnect and remove the crankcase breather
to air intake pipe. Figure 311.
Figure 309.
C K
B
K Clamping plates x2
A
E 11. Remove the crankcase breather oil separator.
Remove and discard the gasket. Do not reuse
the gasket.
D
A Crankcase breather to air intake pipe

Install
B Crankcase breather vent pipe 1. The installation procedure is the opposite of the
C Electrical connectors removal procedure. Additionally do the following
D Turbo control valve hoses steps.
E Bolts 1 (x2)
F Harness support bracket 2. Replace the gasket.
4. Disconnect the crankcase breather vent pipe. 3. Tighten the bolts to the correct torque value.
5. Disconnect the electrical connectors from the 4. Make sure that the rubber grommet is correctly
turbo control valve and the exhaust manifold seated on the spigot when the crankcase
temperature sensor. breather vent pipe is installed.
6. Remove the cable ties securing the wiring 5. Replace the cable ties.
harness to the crankcase breather oil separator.
7. Disconnect the hoses from the turbo control
valve. Item Nm
F 10 ± 1
8. Remove the bolts 1 (x2) and remove the harness G 10 ± 1
support bracket.
9. Remove the bolts 2 (x10) and remove the turbo
control valve and bracket.
15 - 112 9813/9100-1 15 - 112

15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ......................................................................................................................... 15-115

15-30-12 Valve Spring ................................................................................................................. 15-120
15-30-24 Stem Seal .................................................................................................................... 15-121
15 - 113 9813/9100-1 15 - 113

Notes:
15 - 114 9813/9100-1 15 - 114

15 - Engine
30 - Valve
00 - General
Introduction .................................................. 15-115 The valve train system opens and closes the
Technical Data ............................................. 15-116 valves with correct timing in relation to the piston
Component Identification ............................. 15-117 movements.
Each push rod has one end in a hydraulic tappet and
the other end under a rocker arm.
The hydraulic tappet automatically adjusts the

clearance between the rocker and push rods.
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 - 115 9813/9100-1 15 - 115

15 - Engine
30 - Valve
00 - General
Technical Data
Table 106. Inlet and Exhaust Valve Data

Max lift Inlet 7.56mm @ 101°ATDC
(After Top Dead Centre)
Max lift Exhaust 7.32mm @ 109 BTDC
(Before Top Dead Cen-
tre)
Inlet opens (top of ramp) 4.4°BTDC
Inlet closes 50.6°ABDC (After Bot-
tom Dead Centre)
Exhaust opens 48.4°BBDC (Before Bot-
tom Dead Centre)
Exhaust closes 34.6°ATDC
Valve stem diameter
- Inlet 5.94–5.955mm
- Exhaust 5.93–5.945mm
Valve spring free 47.2mm
length
(1)
Valve guide bore diame-

ter
- min 5.992mm
- max 6.008mm
Valve face angle
- Inlet 60.5°
- Exhaust 45.1°
Valve length 111.05–111.55mm
Valve sealing Stem seal with garter
spring
Valve head depth (below
cylinder head surface)
- Inlet 0.624–1.024mm
- Exhaust 0.6–1mm
Valve timing -0.1mm lash (compen-
sated)
(1) The valve spring is an asymmetric coil pitch
spring. The spring is assembled with a particular
orientation.
15 - 116 9813/9100-1 15 - 116

15 - Engine
30 - Valve
00 - General
Figure 312.
F
G
E
K J
D
C
B
A Camshaft gear B Crankshaft gear

C Camshaft D HLA (Hydraulic Lash Adjuster) (x8)
E Push rods (x8) F Rocker - exhaust (x4)
G Rocker - inlet (x4) H Rocker shaft
J Valve - inlet (x8) K Valve - exhaust (x8)
L Bridge piece (x8) M Valve spring (x16)
N HLA Guide (x4)
15 - 117 9813/9100-1 15 - 117

15 - Engine
30 - Valve
00 - General
Remove and Install
Special Tools 4. Remove the cylinder head assembly.

Description Part No. Qty. Refer to: PIL 15-06-00.
Valve Stem Seal 320/03890 1
Installation Tool (430 5. Measure the valve recession with a suitable DTI
Engine) (Dial Test Indicator). Clean the carbon deposits
from a small area of the valve heads for location
of the DTI probe. If the valve recession is outside
Before Removal the serviceable limits, it is advisable to obtain a
1. This procedure requires service parts. Make new or reconditioned cylinder head assembly.
sure you have obtained the correct service parts Refer to: PIL 15-06-00.
before you start. Refer to Parts Catalogue.
6. To aid removal and Installation, use a wooden
2. Make sure that the engine is safe to work on. If valve stand to retain the valves after removal.
the engine has been running, let it cool before Add labels to make sure that the valves are
you start the service work. correctly replaced.
Figure 313. Valve Stand

EXHAUST
EXHAUST
EXHAUST
INLET
INLET
INLET
CYL. 1 CYL. 2 CYL. 3
Remove 2. Remove the spring compressor tool and lift off

the retainer and valve spring.
1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure Figure 315.
that the springs are compressed squarely. C
Figure 314.
D
B
A
C Retainer
D Valve spring
3. Turn the cylinder head on its side and withdraw
the inlet valves and exhaust valves as shown.
A Spring compressor tool
B Collets
15 - 118 9813/9100-1 15 - 118

15 - Engine
30 - Valve
00 - General
Figure 316. 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. The exhaust valves have the installation tool to avoid damaging the seals.
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 317. Special Tool: Valve Stem Seal Installation Tool
(430 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.
4.1. Make sure that the valve springs are
orientated correctly, the white painted end
of the valve spring must go at the top.
5. Use the spring compressor tool to compress
H Valve stem seals each valve spring and insert the collets. Make
J Punch tool sure that the collets are correctly seated in the
valve stem grooves before you remove the spring
Inspection compressor tool.
1. Carefully clean the carbon deposits from the After Installation

valves, take care not to damage the valve seats.
1. Pop the valves by tapping the valve stems in turn
2. Check that the valves and valve seats are not using a rubber mallet.
cracked, burnt or damaged.
3. Check the valve stems and valve guides for wear.
15 - 119 9813/9100-1 15 - 119

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

15 - 120 9813/9100-1 15 - 120

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

15 - 121 9813/9100-1 15 - 121

15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ......................................................................................................................... 15-123

15-33-06 Big-End Bearing ........................................................................................................... 15-127
15 - 122 9813/9100-1 15 - 122

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-123 The connecting rod connects the piston to the
Technical Data ............................................. 15-124 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-124 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-125
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-125 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-126 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 - 123 9813/9100-1 15 - 123

15 - Engine
33 - Connecting Rod
00 - General
Table 107. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 69.02–69.039mm
ameter
Connecting rod side
clearance
min 0.07mm
max 0.42mm
Big end bearings
Width 25–25.25mm
Thickness (at centre) 1.991–1.997mm
Small end bearings
Inside diameter 36.02–36.034mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 124 9813/9100-1 15 - 124

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 - 125 9813/9100-1 15 - 125

15 - Engine
33 - Connecting Rod
00 - General

15 - 126 9813/9100-1 15 - 126

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

Introduction .................................................. 15-127 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-128 bearings at the big-end of the connecting rod.
15 - 127 9813/9100-1 15 - 127

15 - Engine
33 - Connecting Rod

Special Tools
1. Check the bearing shell surfaces for signs of Description Part No. Qty.
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. 1. This procedure requires service parts. Make
sure you have obtained the correct service parts
3. Renew any parts that are worn or not within the before you start. Refer to Parts Catalogue.
specified tolerances.
4. Disconnect and remove the fuel pipes from the
injectors. Refer to (PIL 18-96).
5. Remove the rocker cover. Refer to (PIL 15-42).
6. Remove the fuel injectors. Refer to (PIL 18-18).
7. Drain the oil from the engine. Refer to (PIL
15-21).
8. Remove the oil sump. Refer to (PIL 15-45).
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 - 128 9813/9100-1 15 - 128

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. Refer to Check Condition
(PIL 15-12).
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
15 - 129 9813/9100-1 15 - 129

15 - Engine
33 - Connecting Rod
4. Install the lower bearing shell to the big-end

bearing cap. Lubricate the bearing shell with
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 fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
1)
Figure 320.
T3
T3 Angle gauge (obtain locally)

5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
6. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
Figure 321.
0° +90°
After Installation
1. Carry out the procedures listed in Before
Removal in reverse order.
Table 108.
Item Torque Value
2 - 1st Stage 35N·m
2 - 2nd Stage 65N·m
2 - Final Stage 90°
15 - 130 9813/9100-1 15 - 130

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-133

15-36-03 Piston Ring ................................................................................................................... 15-144
15 - 131 9813/9100-1 15 - 131

Notes:
15 - 132 9813/9100-1 15 - 132

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-133 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-134 expanding combustion gases in the combustion
Component Identification ............................. 15-135 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-136 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-137
Calibrate ...................................................... 15-137 The pistons are cast from aluminium alloys for
Remove and Install ..................................... 15-139 increased strength and improved fatigue life.
Disassemble and Assemble ........................ 15-142
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 - 133 9813/9100-1 15 - 133

15 - Engine
36 - Piston
00 - General
Technical Data
Table 109. Piston Data

Gudgeon pin bore diam-
eter
- min. 36.01mm
- max. 36.015mm
Piston ring clearance
- Top ring 0.155–0.12mm
- Middle ring 0.13–0.09mm
- Bottom (oil) ring 0.08–0.02mm
Piston ring gap
- Top ring 0.25–0.35mm
Piston height above 0.239–0.558mm
(1)
crankcase (cold)
Piston groove width
- Top ring 1.952mm
(2)

Piston skirt 91.861–91.879mm
Piston pin 35.994–36mm
(1) Nominal measurement is 0.426mm
(2) Measure at gauge diameter 88.01 ± 0.38mm
15 - 134 9813/9100-1 15 - 134

15 - Engine
36 - Piston
00 - General
Figure 322.
TOP
B
C B
TOP
C
D
F
Da G
TOP
H
E
D
A Piston B Piston ring - compression No.1

C Piston ring - compression No.2 D Piston ring - oil control ring
Da Spiral wire - oil control ring E Connecting rod
F Piston pin G Retaining circlip (x2)
H Piston orientation cut out J Main bearing cap orientation mark
15 - 135 9813/9100-1 15 - 135

15 - Engine
36 - Piston
00 - General
Operation
The groove around the diameter of the upper main The jets spray oil directly to the under side of the
bearing shells allows oil transfer to an oil jet located pistons effectively transferring heat away from the
in the crankcase bearing saddle. Jets are installed at top of the pistons. Oil spray also enters the small end
the main bearing positions. bearing bushes via a feed hole on the top of each
connecting rod.
Figure 323.
2
3
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft
15 - 136 9813/9100-1 15 - 136

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 - 137 9813/9100-1 15 - 137

15 - Engine
36 - Piston
00 - General
Figure 324. 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 325. 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 - 138 9813/9100-1 15 - 138

15 - Engine
36 - Piston
00 - General
Remove and Install
Before Removal 3. Remove the ECM (Engine Control Module).

you have obtained the correct service parts before 4. Remove the fuel injector cover.
The following procedure is for one piston and 5. Remove the fuel injectors.
connecting rod assembly. Each assembly must be
replaced in the same cylinder bore. Label each piston Refer to: PIL 18-18-03.
and connecting rod assembly to make sure it is
installed in the correct position on assembly. 6. Remove the rocker cover.
the engine has been running, let it cool before 7. Remove the cylinder head assembly.
2. Remove the engine from the machine. 8. Remove the oil sump.
Refer to: PIL 15-00-00. Refer to: PIL 15-45-00.
15 - 139 9813/9100-1 15 - 139

15 - Engine
36 - Piston
00 - General
Figure 326.
H G
E
C
D
F
F
J
A Piston B Piston rings

C Connecting rod D Big end bearing cap
E Piston cut out - intake side of crankcase F Big end bearing cap orientation marks
G Shortest side of connecting rod - intake side of H Longest side of connecting rod - exhaust side of
crankcase crankcase
J Big end bearing cap bolts
15 - 140 9813/9100-1 15 - 140

15 - Engine
36 - Piston
00 - General
Remove Table 110. Torque Table

Item Torque Value Angle (de-
The piston and connecting rod assemblies are (Nm) grees)
removed through the top of the crankcase.
J (1st Stage) 35
1. Remove the big end bearing caps. J (2nd Stage) 65
J (Final Stage) 90
2. 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.
3. 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.
Before Installation
1. Check the big end bearings and the crank shaft
for signs of wear.
Install
2. Make sure that the big end bearing shells are
installed correctly.
3. Lubricate the cylinder bore with clean engine oil.
4. Lubricate the big end bearings 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 and the piston cut-out is
on the intake side of the engine. Take care not
to damage the cooling jets when you guide the
connecting rod down the cylinder bore and over
the crank pin diameter.
7. Install the big end bearing cap. Make sure that
it is orientated correctly, the orientation mark
should be on the same side as the orientation
mark on the connecting rod.
8. Install new big end bearing cap bolts. Tighten the
bolts in three stages to the correct torque value.
After Installation
15 - 141 9813/9100-1 15 - 141

15 - Engine
36 - Piston
00 - General
Disassemble and Assemble side of the connecting rod is on the same side as
the cut out in the piston.
4. Install new circlips. Make sure that they are
Dismantle installed correctly in the groove in the piston.
1. Clamp the connecting rod in a vice. Take care not 5. Lubricate the piston with clean engine oil. Install
to damage the connecting rod. the piston rings to the piston in sequence as
2. It is recommended that the piston rings are follows:
renewed. If they are to be reused, label the 5.1. Install the spiral wire for the oil control ring
rings to ensure they are installed in the correct in the bottom groove and locate the locking
positions and the correct way up on assembly. wire inside both ends of the spiral as shown.
Carefully remove the piston rings from the piston. Using a piston ring expander tool to install
To avoid damage or distortion to the rings, use a the oil control ring in the bottom groove and
suitable piston ring expander tool. Note that the locate the locking wire inside both ends of
oil control ring is installed with a spiral wire. Pull the spiral as shown. Make sure that the
the wire apart and remove it. ring gap is positioned 180° to the locking
3. Remove the circlips and push out the piston pin. wire. The correct ring orientation can also
be determined from the profile shape of the
Figure 327. ring.
5.2. Install the No.2 compression ring into the
middle groove. New rings have a reference
number etched on one face. Make sure
that this face is installed uppermost in the
piston groove. The correct ring orientation
can also be determined from the profile
shape of the ring.
A 5.3. Install the No.1 compression ring into the
B top groove. New rings have a reference
number etched on one face. Make sure
that this face is installed uppermost in the
C piston groove. The correct ring orientation
can also be determined from the profile
B shape of the ring.
A Piston Refer to: PIL 15-36-00.
B Circlip (x2)
C Piston pin 6. Rotate the piston rings so that the ring gaps are
120° apart as shown.
4. Use a suitable cleaning agent, clean the carbon
deposits from the piston.
Inspect
1. Inspect the pistons for signs of wear or damage.
Assemble
1. The assembly procedure is the opposite of
the disassembly 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 short
15 - 142 9813/9100-1 15 - 142

15 - Engine
36 - Piston
00 - General
Figure 328.
0°
12
12
0°
120°
15 - 143 9813/9100-1 15 - 143

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 - 144 9813/9100-1 15 - 144

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-147
15 - 145 9813/9100-1 15 - 145

Notes:
15 - 146 9813/9100-1 15 - 146

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 147 9813/9100-1 15 - 147

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-149

15-42-06 Rocker Cover ............................................................................................................... 15-155
15-42-09 Push Rod ..................................................................................................................... 15-157
15-42-21 Tappet ........................................................................................................................... 15-159
15 - 148 9813/9100-1 15 - 148

15 - Engine
00 - General
Introduction .................................................. 15-149 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-150 system consisting of rocker arms and a shaft.
Operation ..................................................... 15-152 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-152 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-153 raised and lowered by a rotating lobe of the camshaft
via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 149 9813/9100-1 15 - 149

15 - Engine
00 - General
Technical Data
Table 111. Rocker Levers, Rocker Shafts and Hydraulic Lash Adjuster Data
Rocker lever bore diameter
- min 21mm
- max 21.021mm
Rocker shaft diameter
- min 20.959mm
- max 20.98mm
HLA (Hydraulic Lash Adjuster) stem diameter
- min 21.387mm
- max 21.405mm
HLA bore diameter
- min 21.444mm
- max 21.473mm
Tappet height (maximum) 55.25mm
15 - 150 9813/9100-1 15 - 150

15 - Engine
00 - General
Figure 329.
B
A
D B
E
D B
E
D
E
D
A Rocker shaft assembly B Rocker shaft fixing bolts (x4)

C Rocker shaft oil feed Pedestal D Pedestal clamps (x4)
E Bridge pieces (x8)
15 - 151 9813/9100-1 15 - 151

15 - Engine
00 - General
Operation Check (Condition)
When the camshaft lobe raises the outside of the 1. Check the rocker shaft and rocker bushings for
rocker arm, the inside presses down on the valve signs of damage and excessive wear. Measure
stem to open the valve. When the outside of the the rocker shaft diameter and rocker bearing
rocker arm is permitted to return due to the camshafts bushes to confirm they are within service limits.
rotation, the inside rises to allow the valve spring to Refer to Technical Data. Note: The rocker
close the valve. bearing bushes are not renewable. If a rocker
bearing bush is damaged or worn the rocker
Lubrication must be renewed as a complete assembly.
Oil is fed from the main gallery via a drilling which
passes up through the crankcase and the cylinder 2. Make sure that all oil-ways and cross drillings in
head to a small transfer gallery under the rocker shaft the rocker shaft, rocker arms and pedestals are
pedestal. The oversize rocker shaft fixing bolt hole clear and free from debris. Use an air line to blow
allows oil to pass into a drilling in the centre of the through cross drillings.
rocker shaft. Further cross drilling’s transfer oil to
each of the rocker pivot bushes. Two cross drillings
in each rocker transfer oil to the end insert providing
an oil pressure feed to the valve bridge and push rod
end.
15 - 152 9813/9100-1 15 - 152

15 - Engine
00 - General
Special Tools
Description Part No. Qty. B B B B
Crankshaft Turning Tool 320/A3160 1
(430 Engine)
Remove
you start the service work. C C C C

B Bridge pieces
4. Loosen the bolts (x4) and remove the rocker C Push rods
shaft assembly. Do not remove the bolts from the
6. Remove the push rods from the crankcase, keep
rocker assembly.
the push rods in order so that they can be
Figure 330. installed in their original positions.
Before Installation
damage and corrosion. If components within the
rocker assembly are damaged or worn, they
must be replaced.
A
2. Make sure that all oilways and cross drillings in
the cylinder head, rocker shaft, rocker arms and
pedestals are clear and free from debris. Use an
3 1 2 4 air line to blow through the cross drillings.
Install
1-4 Bolts (x4) removal procedure. Additionally do the following
A Rocker shaft assembly steps.
5. Remove the bridge pieces from the valves, keep 2. Use a suitable degreasing agent to clean the top
the bridge pieces in order so that they can be of the cylinder head.
installed in their original positions.
3. Make sure that the push rods engage correctly
with the camshaft tappets.
4. Make sure that the valve bridges engage
correctly with the valve tips.
5. Tighten the bolts (x4) (in sequence 1-4) to the first
stage torque. Refer to Figure 330.
6. Tighten the bolts (x4) (in sequence 1-4) to the
second stage torque. Refer to Figure 330.
7. The hydraulic tappets take time to leak down and
settle in to their working positions. Make sure that
the engine is not started for the specified time
15 - 153 9813/9100-1 15 - 153

15 - Engine
00 - General
period. After the specified time period turn the

engine by hand to make sure that it is not locked
and is free to rotate
Duration: 1h
Special Tool: Crankshaft Turning Tool (430
Engine) (Qty.: 1)
8. After turning the engine by hand, check the
security of the rocker shaft bolts. If necessary,
tighten the bolts (x4) (in sequence 1-4) to the
second stage torque.

Item Description Nm
1-4 Stage 1 12
1-4 Stage 2 24 ± 2
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15 - Engine
06 - Rocker Cover
06 - Rocker Cover 11.1. Plug all the open ports and hoses to
prevent contamination.
Remove and Install Special Tool: Fuel Injector equipment Cap

Kit (430 Engine) (Qty.: 1)
Special Tools
12. Remove the fuel injectors.
Fuel Injector equipment 320/B9321 1 Refer to: PIL 18-18-03.
13. Remove the EGR (Exhaust Gas Recirculation)
assembly.
Remove
This procedure requires service parts. Make sure 14. Remove the EGR diffuser.
you start, refer to the Parts Catalogue. Refer to: PIL 18-27-15.
1. Make the machine safe. 15. Remove the cable ties (x5) securing the wiring
harness to the rocker cover.
Figure 332.
you start the service work. A A A
A
3. Disconnect the charge air hose.
4. Remove the air intake adaptor.
TMAP (Temperature Manifold Air Pressure) A Cable ties (x5)
sensor.
16. Remove the bolts 1 (x2) that secure the wiring
5.1. If necessary remove the TMAP sensor. harness to the rocker cover.
Refer to: PIL 15-84-17. Figure 333.
6. Remove the TCV (Turbocharger Control Valve)
assembly.
7. Remove the crankcase breather system.
B
8. Remove the ECM (Engine Control Module) and B
the ECM mounting bracket.
B Bolts 1 (x2)
9. Remove the injector cover.
17. Loosen the bolts 2 (x18). The bolts are captive
Refer to: PIL 18-18-04. and will remain in the rocker cover.
10. Remove the injector leak-off pipes.
10.1. Plug all the open ports and hoses to
Special Tool: Fuel Injector equipment Cap
11. Remove the injector high pressure fuel pipes.
15 - 155 9813/9100-1 15 - 155

15 - Engine
06 - Rocker Cover

C
C
F
C
G
G
E
C
C Bolts 2 (x18) G
D
19. If the rocker cover is being reused, remove and H
discard the injector seals and the gaskets. Do not
reuse the injector seals or gaskets. D Rocker cover
E Gasket - Inlet manifold to cylinder head
Install F Gasket - Rocker cover to cylinder head
G Injector seals (x4)
1. The installation procedure is the opposite of the H Gasket - Air intake to inlet manifold
3. Replace the injector seals if the rocker cover is
steps.
being reused. Replacement rocker covers are
2. Replace the gaskets if the rocker cover is being supplied with the injector seals installed.
reused. Replacement rocker covers are supplied Refer to: PIL 18-18-07.
with the gaskets installed.
2.1. Make sure that the gaskets are correctly
installed in the grooves on the housing. The 5. Replace the cable ties (x5).
location tabs must locate correctly in the
cut-outs. 6. Tighten the bolts to the correct torque value.

Item Nm
C 9±1
15 - 156 9813/9100-1 15 - 156

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

Introduction .................................................. 15-157 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-158 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 - 157 9813/9100-1 15 - 157

15 - Engine
09 - Push Rod
Remove and Install

15 - 158 9813/9100-1 15 - 158

15 - Engine
21 - Tappet
21 - Tappet Introduction
Introduction .................................................. 15-159
Hydraulic Tappet
Operation ..................................................... 15-160 A hydraulic tappet is a device for maintaining zero
Remove and Install ..................................... 15-161 valve clearance in an internal combustion engine.
The zero tolerance allows the valve train to operate
with zero clearance leading to quieter operation,
longer engine life, and eliminating the need for
periodic adjustment of valve clearance.
15 - 159 9813/9100-1 15 - 159

15 - Engine
21 - Tappet
Component Identification Operation

Figure 336. The operating principle of the hydraulic tappet is
J based on the incompressibility of the liquids and on
controlled leakage.
The pressurised oil flows from an opening in the

main gallery into a feed hole in the tappet body
which is connected to the low pressure chamber.
This maintains a constant flow of oil in the low
and high pressure chambers. The oil can enter the
high pressure chamber only through the non return
valve and leaves through the clearance between the
plunger and the tappet body (controlled leakage).
Figure 337.
A
B
K F
E
C
D
C
D
B E
A
A Roller assembly
B Roller axle
C Axle retaining clip
D Tappet body
E Spring
F High pressure chamber
G Piston A Rocker shaft
H Low pressure chamber B Rocker arm
J Piston retainer clip C Push rod
K Non-return valve D Tappet
E Tappet oil feed hole
The high pressure chamber is refilled when the

tappet is on the bottom of the cam base and the
spring keeps the plunger pressed. This eliminates
the clearance in the entire valve-rocker arm-push
rod-tappet-cam system.
15 - 160 9813/9100-1 15 - 160

15 - Engine
21 - Tappet
The tappet body moves away from the plunger Remove and Install
creating a slight vacuum in the high pressure
chamber and causes the valve to open, thus allowing
the oil in the low pressure chamber to flow into Before Removal
the high pressure chamber. This re-establishes the
quantity of oil required for optimal running conditions. 1. This procedure requires service parts. Make sure
you have obtained the correct parts before you
Difficult operating conditions start, refer to the Parts Catalogue.
For correct functioning of the hydraulic tappets, the 2. Make the machine safe.
pressure chamber of the plunger must always be Refer to: PIL 01-03.
filled with oil. But, this is not possible when the engine
is not running and oil leakages may cause partial 3. Make sure that the engine is safe to work on. If
emptying of the tappets. This situation will cause the engine has been running, let it cool before
too much clearance which will make itself apparent you start the service work.
through an unusual ticking sound that is not to be
confused with the normal ticking of the injectors. 4. Drain the engine coolant.
1. Starting from cold: The engine has not been
used for some time and the oil may have leaked 5. Remove the rocker cover.
out of the pressure chamber of the tappets. Refer to: PIL 15-42-06.
Moreover, lubricant flows with greater difficulty
at low temperatures, and hence several seconds 6. Remove the rocker assembly and push rods.
may go by before the tappets are once again
supplied with oil. Refer to: PIL 15-42-00.
2. Engine very hot: At minimum speed, the oil 7. Remove the cylinder head.
pressure is low and tiny air bubbles may form Refer to: PIL 15-06-00.
inside it (more than 5% of its volume). This
causes the lubricant to become compressible Remove
and the tappet is squeezed slightly creating
clearance and, thus making a noise. 1. Remove the tappet guides (x4).
3. Starting and stopping the engine repeatedly Figure 338.
(very rare): In this situation, the tappets may
empty temporarily. A
4. An oil with a viscosity not adequate to the B

environmental conditions of the engine, may
affect the proper functioning of the hydraulic
tappets.
In all four cases the ticking must not last too long.
If this is not the case, the problem is definitely due
to a manufacturing fault, wear and tear or dirt, which
can be drawn in by the oil and get between the non-
return valve and its seat inside the plunger, thus
compromising the functioning of the tappets. In this
case, replace the hydraulic tappets.
A Crankcase
B Tappet guide
2. Use a magnetic probe to remove the tappets (x8).
Make a note of the tappet order so that they are
installed in their original positions.
15 - 161 9813/9100-1 15 - 161

15 - Engine
21 - Tappet
Figure 339. After Installation

2. The tappets will be pushed down and out of the
tappet guide and onto the camshaft lobes when
C the rocker assembly and push rods are installed.
C Tappet
D Magnetic probe
Install
1. Lubricate the tappets with clean engine oil.
2. Install the tappets into the bottom of the tappet
guide. the tappets should be a snug fit in the
tappet guide. Make sure that they are orientated
correctly with the rollers facing down
Figure 340.
C
C
E E
B Tappet guide
C Tappet
E Roller assembly
3. Install the tappet guide and tappets assembly.
15 - 162 9813/9100-1 15 - 162

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-165

15-45-09 Dipstick ......................................................................................................................... 15-168
15 - 163 9813/9100-1 15 - 163

Notes:
15 - 164 9813/9100-1 15 - 164

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-165 The lubrication system distributes oil around the
Remove and Install ..................................... 15-166 engine by a system of galleries and drillings in the
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 in to

the crankcase and through a relief valve which limits
the maximum oil pressure by venting oil back to the
inlet side of the pump. Refer to (PIL 15-60). The oil
pump also has an emergency pressure relief valve
which vents oil directly to the sump if the pressure
exceeds the safe limit.
From the oil pressure relief valve, 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, turbocharger 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.
15 - 165 9813/9100-1 15 - 165

15 - Engine
45 - Oil Sump
00 - General
Special Tools
Description Part No. Qty. E D
Template for Sealant 320/B4120 1
Oil Sump - Pressed
(430 Engine)
Oil Sump Location 892/01150 2
Dowel
Consumables
Clear Silicone Sealant 4102/0901 0.31L
Remove
1. Make the machine safe. D Oil pick up seal
E Bedplate
7. Use a gasket removal compound, carefully
2. Make sure that the engine is safe to work on. remove all traces of sealing compound from the
If the engine has been running, make sure the oil sump and engine mating faces. Do not allow
engine has cooled sufficiently before you start. the sealing compound to enter the engine.
3. Drain the engine oil. 8. Use a suitable degreasing agent to thoroughly
Refer to: PIL 15-21-00. clean the oil sump.
4. If installed, disconnect the oil level sensor. Install

Figure 341. 1. Lightly smear the inside of the new oil pick up
seal with clean engine oil and install into the
bedplate. DO NOT install the seal on to the
oil sump as this may damage the oil pick up
seal. Damage to the seal could cause a drop
B in oil pressure and subsequently damage to the
C engine.
A 2. Install the oil sump location dowels into the

positions shown.
Special Tool: Oil Sump Location Dowel (Qty.: 2)
Figure 343.
A Oil sump
B Bolts (x19)
C Oil level sensor
5. Remove the bolts (x19) and remove the oil sump
from the engine. The oil sump may be difficult to
remove due to adhesion of sealing compound.
If necessary, carefully lever the mating flanges
apart. Do not use excessive force, the oil sump F
could be damaged. Make sure that you do not F
damage the sealing face on the bedplate or the
oil sump.
F Oil sump location dowels position
6. Remove the oil pick up seal. The oil pick up seal
MUST NOT be re-used. Discard the oil pickup 3. Use the fixing bolts to locate the template to
seal. the oil sump mating face. Make sure that the
15 - 166 9813/9100-1 15 - 166

15 - Engine
45 - Oil Sump
00 - General
template is the correct way round (note that holes

are on different centres).
Special Tool: Template for Sealant Oil Sump -
Pressed (430 Engine) (Qty.: 1)
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the
template as a guide as shown. Note the beads
around holes.
Consumable: Clear Silicone Sealant
5. Carefully remove the template without smudging
the sealant beads.
6. Apply a bead of sealant so as to join the sealant
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 the specified time period.
Duration: 5min
8. Position the oil sump with the oil suction tube
outlet aligned with the oil pump inlet port on the
engine. Take care not to damage the oil pick up
seal when you install the oil sump. Damage to
the seal could cause a drop in oil pressure and
subsequently damage to the engine.
9. Locate the oil sump on the location dowels on the
engine. Avoid smudging the sealant beads. DO
NOT remove the location dowels until sufficient
bolts have been installed to secure the oil sump.
10. Remove the oil sump location dowels
11. Install the remaining bolts and tighten the bolts to
the correct torque value.
After Installation.
1. Allow the sealant to cure for the specified time
period.
Duration: 20min
2. Fill the engine with the recommended engine oil.
3. Start the engine and check for oil leaks.

Item Nm
B 24 ± 2
15 - 167 9813/9100-1 15 - 167

15 - Engine
45 - Oil Sump
09 - Dipstick
09 - Dipstick
Remove and Install
Remove
you start, refer to Parts Catalogue.

3. Remove the bolt 1 and bolt 2.
4. Remove the dipstick assembly through the EGR
(Exhaust Gas Recirculation) coolant hoses.
Figure 344.
A Bolt 1
B Bolt 2
Install
steps.
2. Make sure that all sealing faces are clean and
the sealing hole in the bedplate (for the dipstick
tube) is free from debris.

Item Nm
A 24 ± 2
B 24 ± 2
15 - 168 9813/9100-1 15 - 168

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-171

15-51-03 Crankshaft Gear ........................................................................................................... 15-175
15-51-06 Camshaft Gear ............................................................................................................. 15-176
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-177
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-178
15 - 169 9813/9100-1 15 - 169

Notes:
15 - 170 9813/9100-1 15 - 170

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-171 The timing gears are located inside a case at the
Component Identification ............................. 15-172 flywheel end of the engine.
Operation ..................................................... 15-173
Check (Condition) ........................................ 15-174 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 - 171 9813/9100-1 15 - 171

15 - Engine
51 - Timing Gear
00 - General
Figure 345.
C E
D A
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO (Power Take-Off) idler gear
15 - 172 9813/9100-1 15 - 172

15 - Engine
51 - Timing Gear
00 - General
Operation
All the gears are driven via the crankshaft gear as • Oil pump gear - The oil pump is driven via the
follows: camshaft gear.
• Heavy duty PTO (Power Take-Off) idler gear -
• Camshaft gear - The camshaft is driven at half The heavy duty PTO idler gear is driven via the
crankshaft speed. camshaft gear.
• High pressure fuel pump gear - The high
pressure fuel pump is driven via the camshaft
gear.
Figure 346.
E
B
D
A
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO idler gear
15 - 173 9813/9100-1 15 - 173

15 - Engine
51 - Timing Gear
00 - General
Check (Condition)
1. Inspect the gears for wear or damage. If one or
more of the gears are worn or damaged, replace
them.
15 - 174 9813/9100-1 15 - 174

15 - Engine
51 - Timing Gear
03 - Crankshaft Gear
03 - Crankshaft Gear
Remove and Install
The crankshaft drive gear is an interference fit on

the end of the crankshaft and cannot be removed
individually. If the gear is damaged or worn the
complete crankshaft and gear assembly must be
replaced. Refer to Crankshaft- Remove and Install
(PIL 15-12).
15 - 175 9813/9100-1 15 - 175

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 - 176 9813/9100-1 15 - 176

15 - Engine
51 - Timing Gear
09 - Fuel Injection Pump Gear
09 - Fuel Injection Pump Gear 3. Install the flywheel. Refer to (PIL 15-54-00).
4. Fully install the high pressure fuel injection pump.
Remove and Install Refer to (PIL 18-18-15).
If the drive gear components are being removed prior

to crankshaft or camshaft removal the engine must
be inverted. If the gear components only are being
removed (for inspection/renewal) then the engine
need not be inverted.
Remove
2. Remove the high pressure fuel injection pump.
3. Loosely install the high pressure fuel pump and
fixing nut to retain the gear.
4. Remove the flywheel. Refer to (PIL 15-54-00).
5. Remove the flywheel housing. Refer to (PIL
15-54-03).
6. Remove the fixing nut and remove the high
pressure fuel pump drive gear.
Figure 347.
A Fixing nut
B High pressure fuel pump drive gear
Install
1. Use the fixing nut to loosely install the high
pressure fuel pump and the drive gear. DO NOT
lock the gear to the taper on the fuel pump drive
shaft.
2. Install the flywheel housing. Refer to (PIL
15-54-03).
15 - 177 9813/9100-1 15 - 177

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
15 - Heavy Duty PTO Gear
Remove and Install
Remove
2. Remove the starter motor. Refer to (PIL 15-75).
3. Remove the flywheel. Refer to (PIL 15-54).
4. Remove the flywheel housing. Refer to (PIL
15-54).
5. Remove the bolts (x3).
Figure 348.
B
A
A Bolts (x3)
B Heavy duty PTO (Power Take-Off) idler gear
6. Remove the heavy duty PTO idler gear.
Install
steps.
2. Make sure that the idler gear is orientated so that
the part number is visible.

Item Nm
A 65 ± 5
15 - 178 9813/9100-1 15 - 178

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-181

15-54-03 Housing ........................................................................................................................ 15-184
15-54-09 Gear Ring ..................................................................................................................... 15-186
15-54-12 Drive Plate .................................................................................................................... 15-187
15 - 179 9813/9100-1 15 - 179

Notes:
15 - 180 9813/9100-1 15 - 180

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-181 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-182 systems, where the energy source is not continuous.
Remove and Install ..................................... 15-182 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 - 181 9813/9100-1 15 - 181

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

Figure 349.
Remove
2 This procedure requires service parts. Make sure

1
3. Remove the engine fro the machine.
5. Remove the bolts (x10) and withdraw the
flywheel from the crankshaft hub. The bolts
MUST NOT be reused. Discard the bolts.
1 Flywheel
2 Flywheel gear ring Figure 350.
A Bolts (x10)
B Flywheel
Install
step.
2. Replace the bolts (x10).
The bolts are tightened using a torque and angle
method.
15 - 182 9813/9100-1 15 - 182

15 - Engine
54 - Flywheel
00 - General

Figure 351.
C Angle gauge (obtain locally)

Item Torque Value Angle (de-
(Nm) grees)
A (1st Stage) 40
A (2nd Stage) 120
15 - 183 9813/9100-1 15 - 183

15 - Engine
54 - Flywheel
03 - Housing
03 - Housing 6. If required, undo the bolts and remove the access

cover.

Special Tools
Template for Sealant 320/05400 1
Flywheel Housing G
to Gear Case (430
Engine)
Removal
H
G Access cover
Refer to: PIL 01-03. H Bolts (x2)
2. Make sure that the engine is safe to work on. If 7. Remove and discard the crankshaft rear oil seal.
the engine has been running, let it cool before Take care not to damage the seal bore in the
you start the service work. housing.
Before Installation
1. Carefully remove all traces of the old sealant
4. Remove the flywheel. compound from the flywheel housing mating
Refer to: PIL 15-54-00. faces.
5. Remove the flywheel housing fixing bolts 1 (x13) 2. Use a suitable degreasing agent to clean the
and the flywheel housing fixing bolts 2 (x7) and inside of the flywheel housing.
then separate the flywheel housing from the
crankcase. 3. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
Figure 352. or damage is evident, the components must be
E renewed.
B Installation
C 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
B together) it will immediately start to harden. Make
B sure that all the necessary tools, bolts etc. are readily
F available prior to assembling the components. The
parts must be installed and torque tightened within
B
5min with a maximum permissible time of 15min
B
C removal procedure. Additionally do the following
D steps.
B
A
3. Make sure that the dowels (x2) are installed to
the mating face of the flywheel housing.
A Flywheel housing
B Flywheel housing fixing bolts 1 (x13) 4. Install the sealant template on the housing.
C Flywheel housing fixing bolts 2 (x7)
D CCV (Crankcase Ventilation) hose Special Tool: Template for Sealant Flywheel
E CCV hose fixing bolt Housing to Gear Case (430 Engine) (Qty.: 1)
F Crankshaft rear oil seal 5. Locate the holes in the template onto the two
dowels in the flywheel housing.
15 - 184 9813/9100-1 15 - 184

15 - Engine
54 - Flywheel
03 - Housing
Figure 354. 10. Install the flywheel housing on to the crankcase

K and install the bolts 1 (x13) and the bolts 2 (x7).
Tighten the bolts to the correct torque value.
10.1. The parts must be separated, thoroughly
cleaned and fresh sealant applied if the
parts have not been torque tightened
within the maximum time period.
Duration: 15min
11. Install the access cover. Tighten the bolts to the
J correct torque value.
After Installation
K
1. Install a new crankshaft rear oil seal.
J Sealant template 2. Install the flywheel.

K Fixing points Refer to: PIL 15-54-00.
6. Use the template as a guide, apply a continuous 3. Install the starter motor.
bead of sealant around the flywheel housing
mating face Refer to: PIL 15-75-00.
Length/Dimension/Distance: 1.5mm Table 118. Torque Values

7. Remove the fixing bolts and remove the Item Nm
template. Make sure that you do not smudge the B 47
sealant. Discard the template. C 47
8. Apply a continuous bead of sealant around H 24 ± 2
location A on the flywheel housing.
Length/Dimension/Distance: 1.5mm
Figure 355.
M
L Location A
M Location B
9. Spread the sealant at locations A and B on the
flywheel housing to the specified length. Do not
add or remove any sealant.
15 - 185 9813/9100-1 15 - 185

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 oven
Before Removal to make sure that the heat is applied evenly
around the circumference. Do not heat the gear
1. This procedure requires service parts. Make ring above
sure you have obtained the correct service parts Temperature: 200°C (391.7°F)
before you start.
3. When sufficiently heated, install the gear ring into
2. Remove the flywheel from the crankshaft hub. position over the flywheel. Make sure that the
gear ring is installed the correct way around.
Figure 356.
X 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 - 186 9813/9100-1 15 - 186

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

Introduction .................................................. 15-187 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-188 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 357.
B
A Drive plate
B Coupling (PIL 2731)
15 - 187 9813/9100-1 15 - 187

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 119. 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
correct torque value.
(Medium Strength)
Figure 358.
A Drive plate
C Bolts
E Boss
15 - 188 9813/9100-1 15 - 188

15 - Engine
57 - Oil Filler
57 - Oil Filler
Contents Page No.
15-57-00 General ......................................................................................................................... 15-191
15 - 189 9813/9100-1 15 - 189

Notes:
15 - 190 9813/9100-1 15 - 190

15 - Engine
57 - Oil Filler
00 - General
00 - General
Remove and Install
Depending on the engine variant, an oil filler neck or 2. Make sure that the engine is safe to work on. If
an oil filler blanking plate may be installed. the engine has been running, let it cool before
Remove 3. Get access to the engine.
5. Remove the oil filler neck or blanking plate and
the track seal.
Figure 359.
A
B
C
D
C
E
B
D
E
A
A Oil filter neck/blanking plate B Bolts (x3)

C Track seal D Location tab
E Cut out
Install Table 120. Torque Values

Item Nm
removal procedure. Additionally do the following B 24 ± 2
steps.
2. Make sure that the track seal is not damaged. If
necessary install a new seal.
2.1. Make sure that the seal is correctly installed
in its groove on the oil filler neck or blanking
plate. The location tab must locate correctly
in the cut out.
4. Start the engine and check for leaks.
15 - 191 9813/9100-1 15 - 191

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-193

15 - 192 9813/9100-1 15 - 192

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-193 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-194 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-195 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 safety 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 oil sump. The spool is set to
activate at 9.5–11.5bar (137.7–166.7psi).
15 - 193 9813/9100-1 15 - 193

15 - Engine
60 - Oil Pump
00 - General
Figure 360.
C B
K E
G H
D
A Oil pump B Inner rotor
C Outer rotor D Inlet port
E Outlet port F Engine oil pressure relief valve port - return to
inlet port
G Safety valve assembly H Oil pump pressure safety valve port - return to
oil sump
J Safety valve spring K Oil pump pressure safety valve pressure port
15 - 194 9813/9100-1 15 - 194

15 - Engine
60 - Oil Pump
00 - General

1. Check the oil pump internal parts for signs of
Remove
2. Use feeler gauges to measure the inner and
outer rotor clearance, and the rotor end float to Refer to: PIL 01-03.
confirm they are within service limits.
Refer to: PIL 15-12-00. the engine has been running, let it cool before
3. Remove the engine from the machine.
Figure 361.
A
B
A Oil pump
B Bolts (x4)
8. Remove the oil pump.
Install
steps.
2. Lubricate the pump rotor with clean engine oil.
15 - 195 9813/9100-1 15 - 195

15 - Engine
60 - Oil Pump
00 - General

Item Nm
B 24 ± 2
15 - 196 9813/9100-1 15 - 196

15 - Engine
60 - Oil Pump
06 - Pressure Relief Valve
06 - Pressure Relief Valve Introduction

Introduction .................................................. 15-197 The oil pressure relief valve is located in the
Remove and Install ..................................... 15-198 crankcase next to the oil pump.
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 to
flow directly back to the oil pump outlet port. Oil from
the oil pump acts of the rear of the spool to reseat it
when the oil pressure reduces enough for the spring
to close the spool. The oil pressure relief valve is not
adjustable.
15 - 197 9813/9100-1 15 - 197

15 - Engine
60 - Oil Pump
Remove and Install
Remove
1. Make the machine safe
3. Clean the area around the oil pressure relief
valve assembly.
4. Remove the oil pressure relief valve assembly.
Make sure that no dirt or debris is allowed to enter
the engine.
Figure 362.
A
A Oil pressure relief valve
Install
steps.
2. Make sure that there is no debris or
contamination in the pressure relief valve port.
3. Tighten the oil pressure relief valve to the correct
torque value.

Item Nm
A 24 ± 4
15 - 198 9813/9100-1 15 - 198

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-201
15 - 199 9813/9100-1 15 - 199

Notes:
15 - 200 9813/9100-1 15 - 200

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-201 Engine mounts support the engine and in some
Remove and Install ..................................... 15-202 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 - 201 9813/9100-1 15 - 201

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 - 202 9813/9100-1 15 - 202

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-205
15 - 203 9813/9100-1 15 - 203

Notes:
15 - 204 9813/9100-1 15 - 204

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-205 The oil cooler allows the transfer of heat from the
Component Identification ............................. 15-206 engine oil to the engine coolant. It is located on the
Check (Condition) ........................................ 15-206 side of the crankcase. It is a non-serviceable part
Remove and Install ..................................... 15-207 and must be replaced if it is faulty. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 205 9813/9100-1 15 - 205

15 - Engine
69 - Oil Cooler
00 - General
Component Identification Check (Condition)

Figure 363. 1. Inspect the sealing faces on the oil cooler matrix,
oil cooler housing and the crankcase. Make sure
that the faces are clean and free from scale or
C2 damage.
2. Inspect the sealing gasket and o-rings for signs
C1 of damage. If in doubt, renew the gasket or O-
rings.
O2
O1
C1 Coolant inlet
C2 Coolant outlet
O1 Oil inlet
O2 Oil outlet
15 - 206 9813/9100-1 15 - 206

15 - Engine
69 - Oil Cooler
00 - General
Remove
C
2. Make sure that the engine is safe to work on. If E
the engine has been running, let it cool before D
3. Drain the coolant.
C
C Bolts 2 (x6)
4. Clean the area around the oil cooler. D Oil cooler
E Fuel pipe
8. Remove the bolts 2 (x6).
5. Remove the bolts 1 (x2) that secure the harness
bracket to the engine. 9. Remove the oil cooler and gasket from the
engine. Make sure any residual oil or coolant
Figure 364. is cleaned up. The gasket must not be reused,
discard the gasket.
Install
steps.
A 2. Clean the mating faces of the engine and the oil

cooler.
3. Replace the gasket.
4. Install the oil cooler.
B
5. Install the bolts 2 (x6) and loosely tighten to
locate the oil cooler and gasket on to the engine.
A Bolts 1 (x2)
B Harness bracket Table 123. Torque Values
6. Move the harness to gain access to the oil cooler. Item Nm
A 10 ± 1
7. Remove the fuel pipe from the mounting clip. C 24 ± 2
15 - 207 9813/9100-1 15 - 207

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-209

15-72-03 Pulley ............................................................................................................................ 15-215
15-72-06 Voltage Regulator ......................................................................................................... 15-216
15 - 208 9813/9100-1 15 - 208

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-209 The alternator is a three phase generator having a
Health and Safety ........................................ 15-210 rotating field winding and static power windings.
Technical Data ............................................. 15-210
Component Identification ............................. 15-211 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) ........................................ 15-211 warning light to the field winding. This creates
Remove and Install ..................................... 15-213 a magnetic field which supplements the residual
Disassemble and Assemble ........................ 15-214 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 - 209 9813/9100-1 15 - 209

15 - Engine
72 - Alternator
00 - General

• 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 - 210 9813/9100-1 15 - 210

15 - Engine
72 - Alternator
00 - General

Figure 366.
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. Make sure that the battery is fully 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
lubrication system.
A Alternator Check 1
B Regulator and brush assembly
C Drive pulley With the ignition switch ON, check that the heater
D Tie bolts 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.
Check 2
1. Stop the engine and turn the ignition switch to
OFF.
2. Check the battery voltage at the battery.
2.1. If the battery voltage is not within the
specified amount, charge or replace the
battery.
Voltage: 12.5–12.7V
3. Check the condition of the battery terminals.
Clean off any dirt or corrosion.
4. If applicable, check the battery specific gravity.
Do not attempt to check the specific gravity of a
sealed maintenance free battery. If the specific
gravity is not within the specified tolerance,
charge or replace the battery. 1.23 - 1.26
5. Check the voltage between terminal B+ on the
alternator and earth.
5.1. The multimeter should show battery
voltage.
15 - 211 9813/9100-1 15 - 211

15 - Engine
72 - Alternator
00 - General
5.2. If the reading is zero, check the cables 8.1. Red lead to amps socket (A) on the
for continuity, particularly at the starter multimeter.
terminals.
8.2. Black lead to negative on multimeter.
6. If the voltage is correct, check the alternator. 8.3. Right side slider to DC voltage
Alternator Charging Test 8.4. Left side slider to 200 Shunt
Figure 367. 9. FLUKE 85

9.1. Red lead to volts socket (V ) on multimeter.
9.2. Black lead to COM socket on multimeter.
9.3. Set dial to mV.
10. Start the engine and run at maximum speed.
Multimeter should show maximum alternator
output in Amps (Refer to Technical Data). The
multimeter reading should be taken as soon as
possible after starting the engine, as the charging
current will fall rapidly.
11. A zero reading indicates failure of the alternator
and may be caused by one of the following
conditions. These are listed in the order of
probability.
1. Make sure that all battery and alternator 11.1. Defective suppression capacitor.
connections are in place, secure and making 11.2. Dirty slip rings or worn brushes.
good metal to metal contact, especially the earth
connections to chassis and engine. 11.3. Defective regulator.
2. If the battery is in a fully charged condition, before 11.4. Defective rectifier.

commencing the test switch on the working lights 11.5. Open or short circuited field (rotor)
for windings.
Duration: 3min 11.6. Open or short circuited power (stator)
windings.
3. Alternatively, operate the starter for a few
moments with the ESOS (Engine Shut-Off 12. If any fault is found, replace the complete
Solenoid) fuse removed. alternator.
4. Install an open type shunt between the battery
positive lead and the battery positive terminal.
Current: 100A
5. Connect a Multimeter positive lead to machine
side of the shunt and negative lead to battery side
of the shunt.
6. Connect the leads to the multimeter and set the
multimeter to the relevant range as follows.
7. AVO 2002
7.1. Red lead to volts (middle) socket on
multimeter.
7.2. Black lead to negative on multimeter.
7.3. Right side slider to DC (Direct Current)
voltage.
7.4. Left side slider,Refer to Figure 367.
8. AVO 2003
15 - 212 9813/9100-1 15 - 212

15 - Engine
72 - Alternator
00 - General
Remove
B
2. Disconnect the battery.
A
3. Remove the FEAD (Front End Accessory Drive)
belt.
4. Disconnect the electrical leads from the
alternator terminals. Label the leads to assist with
installation. B
Figure 368. A Alternator

B Bolts (x2)
D+
Install
steps.
2. Make sure that you connect the electrical leads
to the alternator in the correct positions.
3. Tighten the electrical connections to the correct
torque value.
B+
Item Nm
B 47 ± 4
W D+ 3.8
B+ 16
W 3.8
D+ Terminal D+
B+ Terminal B+
W Terminal W
5. Remove the bolts (x2) and remove the alternator
from the engine.
15 - 213 9813/9100-1 15 - 213

15 - Engine
72 - Alternator
00 - General
Voltage Regulator and Brushes

1. The voltage regulator and brush set is a
combined assembly. Refer to (PIL 15-72-06).
Drive Pulley
1. Refer to (PIL 15-72-03).
15 - 214 9813/9100-1 15 - 214

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 - 215 9813/9100-1 15 - 215

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 - 216 9813/9100-1 15 - 216

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-219

15-75-03 Solenoid ....................................................................................................................... 15-227
15-75-06 Brush Gear ................................................................................................................... 15-228
15 - 217 9813/9100-1 15 - 217

Notes:
15 - 218 9813/9100-1 15 - 218

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-219 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-220 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-220 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-221 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-221 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-223 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-225 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 30 seconds before
overheating.
15 - 219 9813/9100-1 15 - 219

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 - 220 9813/9100-1 15 - 220

15 - Engine
75 - Starter Motor
00 - General

Figure 370. 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
12V and 24V systems. The highest values are for
machines with 24V systems. Identify the applicable
3 system before carrying out the tests.
1 Solenoid Do not operate the starter motor for more than 20s at
2 Brush gear one time. Let the starter motor cool for at least 2min
3 Tie bolts between starts.
1. Connect the multimeter across the battery

terminals.
Figure 371.
1.1. Reading in start position approximately

Voltage: 10V
Voltage: 20V
1.2. Minimum permissible reading in start
position
Voltage: 9.5V
Voltage: 18V
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: 0.5V
Voltage: 1V
15 - 221 9813/9100-1 15 - 221

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: 9V
Voltage: 17V 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: 8V
Voltage: 16V
Voltage: 8V
Voltage: 16V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 373. or in the wiring between the solenoid, starter
switch, and the start relay, if the reading
between terminal and earth is less than
Voltage: 8V
Voltage: 16V
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: 0.25V
Figure 375.
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: 8V
Voltage: 16V
B Starter earth connection
15 - 222 9813/9100-1 15 - 222

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 378.
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: 0.25V
Figure 376.
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 377. 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 - 223 9813/9100-1 15 - 223

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 - 224 9813/9100-1 15 - 224

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: 8mm 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 - 225 9813/9100-1 15 - 225

15 - Engine
75 - Starter Motor
00 - General
Figure 379.
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 - 226 9813/9100-1 15 - 226

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 - 227 9813/9100-1 15 - 227

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 - 228 9813/9100-1 15 - 228

15 - Engine
80 - Glow Plug
80 - Glow Plug
Contents Page No.
15-80-00 General ......................................................................................................................... 15-231
15 - 229 9813/9100-1 15 - 229

Notes:
15 - 230 9813/9100-1 15 - 230

15 - Engine
80 - Glow Plug
00 - General
Introduction .................................................. 15-231 A glow plug is a heating device used to help
Operation ..................................................... 15-232 start diesel engines. In cold weather, diesel engines
Remove and Install ..................................... 15-232 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 - 231 9813/9100-1 15 - 231

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.
Figure 380.
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 - 232 9813/9100-1 15 - 232

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-235

15-84-03 Crankshaft Position ...................................................................................................... 15-245
15-84-06 Camshaft Position ........................................................................................................ 15-249
15-84-13 Mass Air Flow (MAF) ................................................................................................... 15-254
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-256
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-259
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-262
15-84-24 Fuel Temperature ......................................................................................................... 15-265
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-268
15-84-33 Coolant Temperature .................................................................................................... 15-271
15-84-43 Engine Oil Level ........................................................................................................... 15-274
15 - 233 9813/9100-1 15 - 233

Notes:
15 - 234 9813/9100-1 15 - 234

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-235 The engine sensors continually send signals to the
Technical Data ............................................. 15-236 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-238 control the smooth running of the engine and related
Fault-Finding ................................................ 15-240 components.
Check (Operation) ....................................... 15-244 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 - 235 9813/9100-1 15 - 235

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

Sensor (TMAP)
Atmospheric Output voltage +/- V
Table 127. pressure bar V
Crankshaft Position Sensor (psi)
Type Hall effect 0.98 -0.025/ 1.84 0.05
Tightening torque 7.5 ± 0.75N·m +0.025
(14.2 -0.4/+0.4)
Table 128.
Table 131.
Camshaft Position Sensor
Rail Pressure Sensor
Type Hall effect
Type The rail pressure sensor
Tightening torque 8 ± 2N·m
is integral with the com-
mon rail.
Table 129.
Coolant Temperature Sensor Table 132.
Type Temperature dependent resis- MAF (Mass Air Flow) Sensor
tance
Type Air flow sensor
Tightening 22 ± 4N·m
torque Tightening torque 10 ± 1N·m
Thread diame- M12 x 1.5.
ter Table 133.
Temperature v Resistance Table Fuel Temperature Sensor
Temperature °C Resistance Ω +/- % Type Temperature dependent resis-
(°F) tance. Integral with the low pres-
25 (77.0) 2,062 5.7 sure fuel circuit.
50 (121.9) 833 4.3 Tightening 10 ± 1N·m
torque
100 (211.9) 187 2
Temperature v Resistance Table
110 (229.8) 144 2.4
Temperature °C Resistance Ω +/- %
Table 130. (°F)
-40 (-39.9) 47,000 15
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) 0 (32.0) 5,700 10
Fixing screw 7 ± 1.4N·m 25 (77.0) 2,000 5
tightening 40 (103.9) 1,150 6
torque 60 (139.9) 581 7
Fixing screw M6 80 (175.9) 316 8
thread diameter 100 (211.9) 182 10
Supply voltage 5V 120 (247.8) 110 15
Temperature Sensor
Type Temperature dependent resis- Table 134.
tance Intercooler Outlet Temperature Sensor
Temperature v Resistance Table Type Temperature dependent resis-
Temperature °C Resistance Ω +/- % tance.
(°F) Tightening 10 ± 1N·m
5 (41.0) 4,707 4.66 torque
10 (50.0) 3,791 4.55 Temperature v Resistance Table
15 (59.0) 3,075 4.44 Temperature °C Resistance Ω +/- %
20 (68.0) 2,510 4.33 (°F)
25 (77.0) 2,062 4.22 -40 (-39.9) 47,000 15
30 (86.0) 1,715 4.12 0 (32.0) 5,700 10
Pressure Sensor 25 (77.0) 2,000 5
Type Piezo-resistive 40 (103.9) 1,150 6
Atmospheric Pressure v Voltage 60 (139.9) 581 7
15 - 236 9813/9100-1 15 - 236

15 - Engine
84 - Sensor
00 - General
Intercooler Outlet Temperature Sensor

80 (175.9) 316 8
100 (211.9) 182 10
120 (247.8) 110 15
Table 135.
Exhaust Manifold Pressure Sensor
Type Pressure transducer
Tightening torque 15–18N·m
Table 136.
Exhaust Manifold Temperature Sensor
Type Temperature dependent resis-
tance.
Tightening 45 ± 5N·m
torque
Temperature v Resistance Table
Temperature °C Resistance Ω +/- %
(°F)
25 (77.0) 4,000,000 5
Table 137.
Oil Pressure Switch
Set pressure 0.6bar (8.7psi) falling.
Switch mode Normally open.
Maximum pressure 27.5bar (398.5psi)
Maximum working pres- 13.8bar (200.0psi)
sure
Tightening torque 14 ± 2N·m
Thread diameter M10 x 1.5.
15 - 237 9813/9100-1 15 - 237

15 - Engine
84 - Sensor
00 - General
Figure 381.
G
H
F
D E
A High pressure rail fuel pressure sensor B Crankshaft position sensor

C Camshaft position sensor D Oil level sensor
E Oil pressure switch F Fuel temperature sensor
15 - 238 9813/9100-1 15 - 238

15 - Engine
84 - Sensor
00 - General
G TMAP (Temperature Manifold Air Pressure) H Intercooler outlet temperature sensor

sensor
Figure 382.
J Exhaust manifold pressure sensor K Coolant temperature sensor

L Exhaust temperature sensor M MAF (Mass Air Flow) sensor
15 - 239 9813/9100-1 15 - 239

15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 138. Page 15-240
Water in Fuel Sensor Fault Table 139. Page 15-240
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 140. Page 15-241
Crankshaft Position Sensor Table 141. Page 15-242
Camshaft Position Sensor Table 142. Page 15-242
MAF (Mass Air Flow) Sensor Table 143. Page 15-243
Table 138. 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 139. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
If no faults is found, proceed to ECM connection
fault'.
15 - 240 9813/9100-1 15 - 240

15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
Wiring fault Check the harness continuity and machine and
engine earth contacts. Repair/ replace as necessary.
Table 140. 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 integrity of the air inlet circuit:–
Before turbo, air filter, turbo to charge air cooler,
charge air cooler to intake.
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.
15 - 241 9813/9100-1 15 - 241

15 - Engine
84 - Sensor
00 - General
Table 141. 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'.
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 142. 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.
15 - 242 9813/9100-1 15 - 242

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 Cam target wheel if damaged, replace
with new camshaft.
Table 143. MAF (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 - 243 9813/9100-1 15 - 243

15 - Engine
84 - Sensor
00 - General
Check (Operation)
1. Check the applicable fuse. Refer to (PIL 33-09).
2. Check the display for related fault codes. Refer
to (PIL 33-57).
3. Using Servicemaster perform the required
diagnostic tests. Refer to (PIL 33-57).
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 resistance. 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 - 244 9813/9100-1 15 - 244

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

Introduction .................................................. 15-245 The crankshaft position sensor is a device used
Operation ..................................................... 15-246 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-247 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-247 (Engine Control Module) to control the ignition
system timing and other engine parameters.
15 - 245 9813/9100-1 15 - 245

15 - Engine
84 - Sensor
Operation
A signal is generated by the crankshaft mounted processed by the ECM (Engine Control Module) to
target wheel and crankshaft position sensor. It is determine the timing of fuel injection.
Figure 383.
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 - 246 9813/9100-1 15 - 246

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

1. Carefully inspect the sensor. If it is found to be The crankshaft position sensor is a non-serviceable
defective, replace the sensor. item. If the sensor is defective it must be replaced.
2. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the Before Removal
sensor and cannot be replaced. 1. Make sure that the engine is safe to work on. If
3. Remove the HVAC (Heating Ventilation Air
Conditioning) compressor (if installed) or the idler
pulley bracket.
4. Clean the sensor and the adjacent area of the
crankcase.
Figure 384.
A
A
B B
CC
A Crankshaft position sensor

B Electrical connector
C Bolt
D O-ring
Remove
1. Remove the cable ties that secure the electrical
wires to the crankcase.
2. Remove the electrical connector from the
mounting clip on the crankcase.
4. Remove the bolt.
15 - 247 9813/9100-1 15 - 247

15 - Engine
84 - Sensor
5. Remove the sensor from the crankcase together

with the O-ring.
Install
steps.
2. Replace the cable ties.
3. Make sure that the sealing O-ring is correctly
installed.
4. Carefully push the sensor into the location bore
in the crankcase. Do not use excessive force.
5. Tighten the bolt to the correct torque value.

Item Nm
C 7.5 ± .75
15 - 248 9813/9100-1 15 - 248

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

Introduction .................................................. 15-249 The camshaft position sensor is a device that detects
Operation ..................................................... 15-250 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-251 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-252 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
15 - 249 9813/9100-1 15 - 249

15 - Engine
84 - Sensor
Operation
A signal is generated by the camshaft mounted target The ECM will select the correct cylinder for fuel
wheel and camshaft position sensor. This information injection.
is used by the ECM (Engine Control Module) to
process the signal to determine the engine phase
(which cylinder is firing).
Figure 385.
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 - 250 9813/9100-1 15 - 250

15 - Engine
84 - Sensor
Check (Operation)
1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
15 - 251 9813/9100-1 15 - 251

15 - Engine
84 - Sensor
Remove and Install
Before Removal 2. Clean the sensor and the adjacent area of the
crankcase.
Figure 386.
B
A
A Camshaft position sensor B Bolt

C Electrical connector D O-ring seal
15 - 252 9813/9100-1 15 - 252

15 - Engine
84 - Sensor
Remove
2. Disconnect the electrical connector at the sensor.
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.
Install
steps.
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.
5. Tighten the bolt to the correct torque value.

Item Nm
B 8±2
15 - 253 9813/9100-1 15 - 253

15 - Engine
84 - Sensor
13 - Mass Air Flow (MAF)
13 - Mass Air Flow (MAF) Introduction

Introduction .................................................. 15-254 The MAF (Mass Air Flow) sensor measures the
Operation ..................................................... 15-255 amount of air coming into the engine. It is integrated
Remove and Install ..................................... 15-255 into the turbocharger compressor housing.
Figure 387.
A MAF sensor
15 - 254 9813/9100-1 15 - 254

15 - Engine
84 - Sensor
13 - Mass Air Flow (MAF)
The MAF (Mass Air Flow) sensor produces a digital Remove

signal measuring air flow.
Figure 388.
C
B
A MAF (Mass Air Flow) sensor

C Bolts (x2)
5. Remove the MAF sensor.
Install
step.

Item Nm
C 10 ± 1
15 - 255 9813/9100-1 15 - 255

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

Introduction .................................................. 15-256 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-257 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-257 cylinders 1 and 2 exhaust outlet ports.
Figure 389.
A Exhaust manifold temperature sensor
15 - 256 9813/9100-1 15 - 256

15 - Engine
84 - Sensor
Operation Check (Operation)
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 1–4.5V.
15 - 257 9813/9100-1 15 - 257

15 - Engine
84 - Sensor
Remove and Install
The exhaust manifold temperature sensor is a non-

serviceable item. If the sensor is faulty or damaged
it must be replaced.
Before Removal
2. Get access to the exhaust manifold temperature
sensor.
Remove
Figure 390.
A Exhaust manifold temperature sensor

B Retaining nut
2. Undo the retaining nut.
3. Remove the sensor from the exhaust, take care
not to damage the sensor probe.
Install
steps.
2. Tighten the retaining screw to the correct torque
value.

Item Nm
B 45 ± 5
15 - 258 9813/9100-1 15 - 258

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

Introduction .................................................. 15-259 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-260 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-260 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-261 (Engine Control Module) controlled engine.
The sensor is mounted on a manifold on top of the

cylinder head.
Figure 391.
A Exhaust manifold pressure sensor
15 - 259 9813/9100-1 15 - 259

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 0.5–4.5V.
15 - 260 9813/9100-1 15 - 260

15 - Engine
84 - Sensor
Before Removal
Remove
C
Figure 392.
G F C
C Banjo bolt
F Exhaust pressure pipe
B
G Harness support clip
D
A 3. Remove the exhaust pressure pipe.
4. Remove the bolt and remove the exhaust
C manifold pressure sensor manifold.
E
Install
A Exhaust manifold pressure sensor
steps.
C Banjo bolt 2. Replace the sealing washers.
D Bolt
E Exhaust manifold pressure sensor manifold 3. Tighten the exhaust manifold pressure sensor
and the bolts to the correct torque value.
Sensor
Item Nm
2. Disconnect the electrical connector at the A 15–18
exhaust manifold pressure sensor. C 7–9
3. Remove the sensor from the exhaust pressure D 22–26
sensor manifold. The exhaust manifold pressure
sensor is a non-serviceable item. If the sensor is
faulty or damaged it must be replaced.
Manifold pressure take off pipe

1. Remove the glow plug wiring harness support
clip from the exhaust pressure pipe.
2. Remove the banjo bolts securing the exhaust
pressure pipe to the exhaust manifold and the
sensor manifold. Discard the sealing washers.
15 - 261 9813/9100-1 15 - 261

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 .................................................. 15-262 sensor is located in a port on top of the air inlet part
Operation ..................................................... 15-263 of the rocker cover. It measures the inlet manifold
Check (Operation) ....................................... 15-263 boost air pressure and temperature. The sensor
incorporates a piezo-resistive element and resistor.
Figure 394.
A
A TMAP Sensor
15 - 262 9813/9100-1 15 - 262

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.
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
15 - 263 9813/9100-1 15 - 263

15 - Engine
84 - Sensor
Remove and Install 3. Carefully push the sensor into its location bore in
the rocker cover. Do not use excessive force.
The TMAP (Temperature Manifold Air Pressure) 4. Tighten the bolt to the correct torque value.
sensor is a non-serviceable item. If the sensor is
defective, it must be replaced. Table 149. Torque Values
Item Nm
Before Removal C 7 ± 1.4
2. Clean the sensor and the adjacent area of the
engine.
Figure 395.
B
C
A TMAP
C Bolt
D O-ring seal
Remove
2. Remove the bolt.
3. Remove the sensor from the inlet manifold. Make
sure that you recover the O-ring.
Install
steps.
installed.
15 - 264 9813/9100-1 15 - 264

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

Introduction .................................................. 15-265 The fuel temperature sensor is located on the
Operation ..................................................... 15-266 crankcase above the oil cooler.
Check (Operation) ....................................... 15-266
Remove and Install ..................................... 15-267 Figure 396.
A Fuel temperature sensor
15 - 265 9813/9100-1 15 - 265

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 - 266 9813/9100-1 15 - 266

15 - Engine
84 - Sensor
Remove and Install
The fuel temperature sensor is incorporated into the

fuel filter to fuel injection pump low pressure fuel
pipe. If it is defective, the complete assembly must
be replaced. Refer to: PIL 18-96-06.
15 - 267 9813/9100-1 15 - 267

15 - Engine
84 - Sensor
27 - Fuel Rail Pressure
27 - Fuel Rail Pressure Introduction

Introduction .................................................. 15-268 The fuel rail pressure sensor measures the fuel
Operation ..................................................... 15-269 pressure in the common rail.
Check (Operation) ....................................... 15-269
A Fuel rail pressure sensor
15 - 268 9813/9100-1 15 - 268

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 - 269 9813/9100-1 15 - 269

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 - 270 9813/9100-1 15 - 270

15 - Engine
84 - Sensor
33 - Coolant Temperature
33 - Coolant Temperature Introduction

Introduction .................................................. 15-271 The coolant temperature sensor is located on the
Operation ..................................................... 15-272 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-272
A Coolant temperature sensor
15 - 271 9813/9100-1 15 - 271

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 - 272 9813/9100-1 15 - 272

15 - Engine
84 - Sensor
Remove and Install The coolant temperature sensor unit is a non-

serviceable item. If the sensor is faulty or damaged
it must be replaced.
Before Removal
Install
2. Make sure that the engine is safe to work on. If steps.
2. Tighten the coolant temperature sensor to the
3. Fill the cooling system with the recommended
Refer to: PIL 21-00-00. coolant mixture.
Figure 399. Refer to: PIL 21-00-00.
4. Start the engine and check for coolant leaks.

Item Nm
A 22 ± 4
B
A Coolant temperature sensor

C Encapsulated washer
Remove
3. Remove the sensor from the cylinder head.
4. Plug all the open ports to prevent contamination.
15 - 273 9813/9100-1 15 - 273

15 - Engine
84 - Sensor
43 - Engine Oil Level
43 - Engine Oil Level Introduction

Introduction .................................................. 15-274 The engine oil level sensor is used to warn the
Operation ..................................................... 15-275 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-275 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-276 mounted on the engine oil sump.
15 - 274 9813/9100-1 15 - 274

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 - 275 9813/9100-1 15 - 275

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 400.
A
C
B
D
E
A Engine oil level sensor B Oil level sensor float

C Bolts (x2) D Clip
E Oil Sump
Remove
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 - 276 9813/9100-1 15 - 276

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-03 Engine Oil Pressure ..................................................................................................... 15-279
15 - 277 9813/9100-1 15 - 277

Notes:
15 - 278 9813/9100-1 15 - 278

15 - Engine
87 - Switch
03 - Engine Oil Pressure
03 - Engine Oil Pressure Introduction

Introduction .................................................. 15-279 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-280 crankcase.
Check (Operation) ....................................... 15-280
A Engine oil pressure switch
15 - 279 9813/9100-1 15 - 279

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 - 280 9813/9100-1 15 - 280

15 - Engine
87 - Switch
Remove and Install
The engine oil pressure switch is a non-serviceable

item. If the switch is faulty or damaged it must be
replaced.
Remove
3. Clean the area around the oil pressure sensor.
4. Disconnect the electrical connector at the engine
oil pressure switch.
5. Remove the switch from the crankcase.
6. Discard the sealing washer. Plug all the open
ports and hoses to prevent contamination.
Figure 402.
A Engine oil pressure switch
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the

Item Nm
A 14 ± 2
15 - 281 9813/9100-1 15 - 281

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-283
15 - 282 9813/9100-1 15 - 282

15 - Engine
90 - Air Intake
00 - General

Check (Condition) ........................................ 15-283 Refer to: PIL 15-24-00.
15 - 283 9813/9100-1 15 - 283

15 - Engine
90 - Air Intake
00 - General
Depending on the engine variant, an air intake

adaptor or a throttle valve may be installed.
Remove
H
J
4. Disconnect the air intake pipe.
5. Disconnect the quick connectors (x2) from the H Track seal ring
sides of the adaptor housing. J Track seal location tab
Figure 403.
Install
E F G 1. The installation procedure is the opposite of the
B steps.
C 2. Make sure that the track seal ring is not
damaged. If necessary install a new seal.
A in its groove on the housing. The location
tab must locate correctly in the cut out.
D Figure 405.
B
A Air intake adapter

B Bolt 2 (x4)
C Quick connectors - CCV (Crankcase Ventilation)
to air intake adapter
D Quick connectors - TCV (Turbocharger Control
Valve) to air intake adapter
E Bolt 1 (x1)
F Inlet air temperature sensor J
G Electrical connector
7. Remove the bolt 1 (x1).
8. Remove the sensor from the top of the adaptor J Track seal location tab
housing.
9. Remove the bolt 2 (x4).
4. Start the engine and make sure that there are no
10. Remove the track seal and the adaptor housing. air leaks.
15 - 284 9813/9100-1 15 - 284

15 - Engine
90 - Air Intake
00 - General

Item Nm
B 10 ± 1
E 10 ± 1
15 - 285 9813/9100-1 15 - 285

Notes:
15 - 286 9813/9100-1 15 - 286

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-13
18-06 Level Sender
18-06-00 General ........................................................................................................................... 18-19
18-09 Filter
18-09-00 General ........................................................................................................................... 18-23
18-09-03 Filter Element ................................................................................................................. 18-26
18-09-09 Pre-Filter Element .......................................................................................................... 18-27
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-31
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-35
18-18 Injection
18-18-00 General ........................................................................................................................... 18-39
18-18-03 Injector ............................................................................................................................ 18-50
18-18-04 Injector Cover ................................................................................................................. 18-55
18-18-07 Injector Seal ................................................................................................................... 18-57
18-18-12 Rail ................................................................................................................................. 18-58
18-18-15 Pump .............................................................................................................................. 18-60
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-67
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-75
18-24-04 Outlet Manifold ............................................................................................................... 18-77
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-83
18-27-03 Actuator .......................................................................................................................... 18-89
18-27-15 Diffuser ........................................................................................................................... 18-91
18-35 Turbocharger
18-35-00 General ........................................................................................................................... 18-93
18-35-06 Wastegate Valve ............................................................................................................ 18-96
18-39 Fuel Cooler
18-39-00 General ........................................................................................................................... 18-99
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-103
18-96-03 High Pressure Pipe ...................................................................................................... 18-104
18-96-06 Low Pressure Pipe ....................................................................................................... 18-107
9813/9100-1
2017-11-23
Acronyms Glossary

DLA Data Link Adaptor
IMV Inlet Metering Valve
MAF Mass Air Flow
NOx Nitrogen Oxide
TCV Turbocharger Control Valve
WIF Water in Fuel
9813/9100-1
2017-11-23
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/9100-1 18 - 1
Notes:
18 - 2 9813/9100-1 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
Fault-Finding .................................................... 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Discharge and Pressurise ............................... 18-7 and cleanliness requirements, refer to Consumable
Clean ............................................................... 18-7 Products Refer to: PIL 75-00-00. Technical Data,
Check (Pressure) ............................................ 18-9 Fuel, Acceptable and Unacceptable Fuels and
Bleed ............................................................. 18-11 Cleanliness Requirements.
For information about the fuel injection system. Refer

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 9813/9100-1 18 - 3
00 - General

Fuel Table 154. Fuel System Data
Fuel is flammable, keep naked flames away from the
High pressure pump Delphi DFP 6.2.0
fuel system. Stop the engine immediately if a fuel
type
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Direction of rotation from Anticlockwise
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 9 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 -
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Pre-filter 0.2bar (2.9psi)
leaks and then examine the cardboard for signs of Main filter 0.7bar (10.1psi)
fluid. If fluid penetrates your skin, get medical help
immediately. Fuel return restriction - 0.3bar (4.3psi)
maximum
WARNING! Do not open the high pressure fuel Injector information Electronically controlled
system with the engine running. Engine operation solenoid actuated in-
causes high fuel pressure. High pressure fuel spray jectors. Each injector is
can cause serious injury or death. marked with a unique
Notice: Do not allow dirt to enter the fuel system. calibration code.
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.
18 - 4 9813/9100-1 18 - 4
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 155. Page 18-5
Fuel/Oil- Leaking from Exhaust Manifold Table 156. Page 18-5
General Fuel System Faults Table 157. Page 18-5
Exhaust Gas Recirculation Table 158. Page 18-6
Table 155. 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
Table 156. 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
Table 157. 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
18 - 5 9813/9100-1 18 - 5
00 - General
Cause Remedy
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 pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 158. 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 - 6 9813/9100-1 18 - 6
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 - 7 9813/9100-1 18 - 7
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 406.
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 - 8 9813/9100-1 18 - 8
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 machine, 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 159.
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 pressure lim-
then move it to the workshop. iting 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 high pressure fuel 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 the
pressure limiting valve.
18 - 9 9813/9100-1 18 - 9
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 408. Reduction in HP Pump Capacity
• Mechanical wear in the injector.
• Pressure limiting valve 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 407. 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 - 10 9813/9100-1 18 - 10
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: 30s
Figure 409.
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: 30s
4. Do the step 3 for two more times before you start
the engine.
18 - 11 9813/9100-1 18 - 11
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-13
18 - 12 9813/9100-1 18 - 12
03 - Tank
00 - General
Introduction .................................................... 18-13 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-14 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 - 13 9813/9100-1 18 - 13
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: 10min
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 - 14 9813/9100-1 18 - 14
03 - Tank
00 - General
Remove and Install
Remove 9. Support the fuel tank and remove the holding

strap fastenings.
10. Carefully lower the fuel tank from the machine
2. Make sure there is sufficient clearance under the making sure not to put strain on the fuel hoses.
machine to remove the fuel tank before you begin
work. 11. Put a label on the fuel feed and return hoses
before disconnecting to aid identification when
3. Remove the battery or batteries. Refer to (PIL replacing.
33-03-00).
12. Disconnect the fuel feed and return hoses.
4. Remove the fuel tank drain plug and drain the
fuel tank. 13. Put a label on the hoses to the fuel sender to help
installation.
5. Install a new seal and install the drain plug and
tighten to the correct torque value. 14. Plug all the open ports and hoses to prevent
contamination.
6. Remove the access panel in the cab floor (if
installed). Refer to (PIL 06-06-39). 15. Disconnect the fuel sender electrical connector.
7. Remove the side step. Refer to (PIL 06-49). 16. Remove the fuel tank from machine.
8. Disconnect the fuel filler neck and breather pipe

from the fuel tank. Take precautions to prevent
the ingress of debris.
18 - 15 9813/9100-1 18 - 15
03 - Tank
00 - General
Figure 410. Fuel Tank
C D
G
B A
F
C H
J
C098100-C1.eps
A Steps B Battery cover

C Fuel hoses D Electrical connections
E Clip F Nuts 1
G Bolts 1 H Holding straps
J Tank belly guard K Securing bolts and washers
X Drain plug
Install 1.2. Tighten the fuel tank support bracket nuts to

the correct torque value. Refer to (PIL 72).
1.3. Reinstall all pipework, electrical connectors,
brackets, cable ties and the filler neck.
steps.
Make sure that no hoses are twisted or
1.1. Make sure that all foam and rubber mats trapped.
and seals on the tank are in good condition 1.4. Make sure that all connections are tight and
(if installed). Install new parts if they are correctly connected and secured.
defective.
18 - 16 9813/9100-1 18 - 16
03 - Tank
00 - General
1.5. Fill the fuel tank with clean fuel. Refer to (PIL
75-00-00).
1.6. Bleed the fuel system. Refer to (PIL 18-00).
1.7. Check for leaks. Refer to (PIL 18-00).
18 - 17 9813/9100-1 18 - 17
06 - Level Sender
06 - Level Sender
Contents Page No.
18-06-00 General ........................................................................................................................... 18-19
18 - 18 9813/9100-1 18 - 18
06 - Level Sender
00 - General
00 - General
Remove and Install
Notice: Do not allow dirt to enter the fuel system. 2. Isolate the battery. Refer to (PIL 33-03-03).
thoroughly clean around the connection. When a 3. Carefully lower the fuel tank from the machine
component has been disconnected, for example making sure not to put strain on the fuel hoses.
a fuel pipe, always install protective caps and Refer to (PIL 18-03).
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the 4. Make sure that the area around the sender unit
fuel system. Dirt in the fuel system will seriously is clean. Make sure that no debris can enter the
damage the fuel injection equipment and could be fuel tank.
expensive to repair. 5. Disconnect the fuel sender electrical connector.
6. Disconnect the fuel feed and return hoses and
Remove plug the ends. Mark each hose before you
1. Make the machine safe. Refer to (PIL 01-03). disconnect them to make sure they are correctly
replaced.
Figure 411. Diesel Fuel Tank

D
D
C
C
B
B
FF
A
A
E
E
G
G
C098110
A Fuel connection B Electrical connection

C Fuel connection D Sender unit
E Bolts F O-ring
G Float X Installation orientation (pipe connections to point
towards the front of the machine)
18 - 19 9813/9100-1 18 - 19
06 - Level Sender
00 - General
7. Remove the bolts from the annular ring that

secures the sender unit to the fuel tank.
8. Manoeuvre the fuel sender to remove it from the
tank.
Install
steps.
1.1. Renew the sender unit O-ring seal.
1.2. Before replacing the fuel level sender unit
the float must be reset. Move the float to the
top of its travel and then let it to fall down to
the lowest point of travel.
1.3. Make sure to install the fuel level sender unit
with the pipe connections A and C pointing
to the front of the machine as shown at X.
1.4. Make sure that no debris enter the fuel tank
or fuel system.
1.5. Tighten all fasteners to the correct torque
value. Make sure you do not overtighten the
tanks sender bolts.
1.6. Bleed the fuel system. Refer to (PIL
18-00-00).
1.7. Make sure there are no leaks. Refer to (PIL
18-00-00).

Item Nm
E 5
18 - 20 9813/9100-1 18 - 20
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-23

18-09-03 Filter Element ................................................................................................................. 18-26
18-09-09 Pre-Filter Element .......................................................................................................... 18-27
18 - 21 9813/9100-1 18 - 21
Notes:
18 - 22 9813/9100-1 18 - 22
09 - Filter
00 - General
Introduction .................................................... 18-23 The fuel filter consists of a paper element folded in
Component Identification ............................... 18-24 such a way as to give a very large surface area. It is
Operation ....................................................... 18-25 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-25 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 23 9813/9100-1 18 - 23
09 - Filter
00 - General
Figure 412.
1F
1E
A B
1D
2A
2B
2C
1A
1C
1B
A From tank B To fuel injection pump

1 Fuel pre-filter/water separator 1A Water bowl
1B Fuel pre-filter drain screw 1C Water level probe
1D Fuel pre-filter element 1E Electric lift pump
1F Lift pump controller 2 Main fuel filter
2A Main fuel filter element 2B Sediment bowl
2C Main fuel filter drain screw
18 - 24 9813/9100-1 18 - 24
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 - 25 9813/9100-1 18 - 25
09 - Filter
03 - Filter Element
03 - Filter Element 2. Tighten the filter element to the correct torque

value.
Remove and Install Special Tool: Final fuel filter removal tool - engine
mounted (430 Engine) (Qty.: 1)
Special Tools
3. Make sure that the drain valve is closed.
Final fuel filter removal 320/A7126 1 4. Bleed the fuel system.
tool - engine mounted
(430 Engine) Table 161. Torque Values
Item Nm
Remove B 35 ± 5
3. Get access to the filter.
4. Thoroughly clean the outside of the filter housing
and around the filter head.
5. Loosen the drain tap and allow the fuel to drain
into a suitable container.
5.1. Drained fuel must be disposed of in
accordance with local regulations. Do not
reuse the drained fuel.
Figure 413.
A Filter head
B Filter element
C Drain valve
6. Remove the filter element.
Special Tool: Final fuel filter removal tool - engine
mounted (430 Engine) (Qty.: 1)
Install
1. Install the filter element.
18 - 26 9813/9100-1 18 - 26
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-27 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-28 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 27 9813/9100-1 18 - 27
09 - Filter
09 - Pre-Filter Element
Remove and Install 5.1. Any fuel and water mix drained must
be disposed of in accordance with local
Special Tools regulations. Do not reuse the drained fuel.
6. Disconnect the water in fuel sensor electrical
Fuel pre-filter removal 320/A7127 1 connector.
tool - machine mounted
(430 Engine) 7. Unscrew the locking ring and remove the water
separator bowl.
Remove
8. If there is sediment in the water separator bowl,
1. Make the machine safe. Remove the water separator drain valve and
clean the bowl in clean fuel.
2. Get access to the filter assembly.
9. Unscrew the locking ring and remove the filter
3. Thoroughly clean the outside of the filter housing element. Discard the element. Do not reuse a
and around the filter head. filter element once it has been removed.
4. On machines with a fuel shut-off valve, set the Special Tool: Fuel pre-filter removal tool -
valve to isolate the fuel supply. machine mounted (430 Engine) (Qty.: 1)
5. Drain the water separator bowl into a suitable Install

container.
1. Install a new filter element and secure in position
Figure 414. with the locking ring.
2. Tighten the filter element locking ring to the
3. Install the water separator bowl and secure in
position with the locking ring.
4. Tighten the water separator bowl locking ring to
5. Make sure that the water separator drain valve
B is closed.
6. Connect the water in fuel sensor electrical
connector.
A
Item Nm
B 35 ± 5
C 27 ± 5
F
A Filter Element
B Filter Element locking ring
C Water separator bowl locking ring
D Water separator bowl
E Water separator drain valve
F Water in fuel sensor electrical connector
18 - 28 9813/9100-1 18 - 28
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-31

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-35
18 - 29 9813/9100-1 18 - 29
Notes:
18 - 30 9813/9100-1 18 - 30
00 - General
Introduction .................................................... 18-31 The water separator is integral with the fuel pre-filter
Drain and Fill ................................................. 18-32 and water separator.
Clean ............................................................. 18-33
Remove and Install ....................................... 18-34 Figure 415.
A Fuel lift pump

B Fuel pre-filter
C Water separator
The fuel 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
18 - 31 9813/9100-1 18 - 31
00 - General
screw installed in the base of the bowl. It is essential Drain and Fill
that the water trap is drained regularly. Water must
be drained and disposed of in accordance with
local regulations immediately if the probe signals an 1. Obey all fuel system health and safety
alarm. information. Refer to (PIL 18-00).
3. Position a suitable container under the drain tap.
4. Drain off any water in the water separator bowl
by turning the tap. Do not disconnect the water
in fuel electrical connector (if installed).
4.1. If there is sediment in the bowl after
draining, Remove the bowl and wash in
clean fuel. Refer to PIL 18-12-00).
4.2. Any fuel and water mix drained must
5. Tighten the drain tap to the correct torque value.
6. Make sure that the water in fuel electrical
connector is correctly installed.
Figure 416. Typical Engine
A Water separator
B Drain tap
18 - 32 9813/9100-1 18 - 32
00 - General
Table 163. Torque Values Clean

Item Nm
A 7 ± .7
Draining the Water Separator
2. Get access to the filter.
3. If there is water but no sediment, open the tap
to drain the water. If there is any sediment in
the bowl replace the fuel filter element. Do not
disconnect the electrical connector (if installed).
4. Tighten the drain tap when all the water is
drained.
Figure 417.
A Tap
B Bowl
18 - 33 9813/9100-1 18 - 33
00 - General
Remove and Install
Refer to Fuel and Exhaust system - Filter - Pre-Filter

Element. Refer to: PIL 18-09.
18 - 34 9813/9100-1 18 - 34
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-35 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-36 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 - 35 9813/9100-1 18 - 35
04 - Water in Fuel Sensor
Remove and Install
Remove
3. Get access to the fuel pre-filter.
Figure 418.
B
A WIF (Water in Fuel) sensor/water separator
drain tap
5. Position a suitable container under the WIF
sensor/water separator drain tap.
5.1. Any fuel and water mix drained must
6. Remove the WIF sensor/water separator drain
tap.
Install
removal procedure.
18 - 36 9813/9100-1 18 - 36
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-39

18-18-03 Injector ............................................................................................................................ 18-50
18-18-04 Injector Cover ................................................................................................................. 18-55
18-18-07 Injector Seal ................................................................................................................... 18-57
18-18-12 Rail ................................................................................................................................. 18-58
18-18-15 Pump .............................................................................................................................. 18-60
18 - 37 9813/9100-1 18 - 37
Notes:
18 - 38 9813/9100-1 18 - 38
18 - Injection
00 - General
Introduction .................................................... 18-39 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-40 injectors via high pressure fuel pipes.
Operation ....................................................... 18-41
Fault-Finding .................................................. 18-44 The high pressure fuel injector fuel 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 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 - 39 9813/9100-1 18 - 39
18 - Injection
00 - General
Figure 419.
J C H
D D D D
B
N
T
P
Q
E
F G
S
A ECM (Engine Control Module) B Fuel injection pump

C Fuel rail D Fuel injectors
E Fuel filter (2 micron) F Fuel lift pump with pre-filter and water separator
(5 micron)
G Fuel tank H IMV (Inlet Metering Valve)
J Fuel rail pressure sensor K TMAP (Temperature Manifold Air Pressure)
sensor
L Camshaft position sensor M Crankshaft position sensor
N Coolant temperature sensor P Exhaust manifold temperature sensor
Q Exhaust manifold pressure sensor R MAF (Mass Air Flow) sensor
S Throttle position sensor T Fuel temperature sensor
18 - 40 9813/9100-1 18 - 40
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 420.
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 - 41 9813/9100-1 18 - 41
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 422.
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 421. 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 - 42 9813/9100-1 18 - 42
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 - 43 9813/9100-1 18 - 43
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 164. Page 18-44
Injector Trim Codes Table 165. Page 18-44
Open Circuit Injector Table 166. Page 18-45
Injection Bank Table 167. Page 18-45
Short Circuit Injector Table 168. Page 18-46
Engine Low on Power Table 169. Page 18-46
Injector Calibration Table 170. Page 18-47
Open Circuit Injector Table 171. Page 18-47
High Pressure Injection Diagnostics Table 172. Page 18-48
Fuel Rail Pressure Calibration Table 173. Page 18-48
IMV Table 174. Page 18-49
Table 164. 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 fuel injector connection and repair as
necessary.
If fault is found, raise a Techweb Helpdesk call.
Table 165. Injector Trim Codes

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Coolant 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 - 44 9813/9100-1 18 - 44
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.
Wiring fault Check the harness continuity and electrical
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.
If no fault is found raise a Techweb Helpdesk call.
Table 166. 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.
installation, repair/replace as necessary.
Table 167. 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 - 45 9813/9100-1 18 - 45
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 168. 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 169. 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 - 46 9813/9100-1 18 - 46
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 170. 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 171. 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 - 47 9813/9100-1 18 - 47
18 - Injection
00 - General
Table 172. High Pressure Injection Diagnostics

Cause Remedy
Pressure diagnostics fault Check the fault of type IMV (Inlet Metering Valve) 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 a Techweb
Helpdesk Call.
Table 173. 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 - 48 9813/9100-1 18 - 48
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 a Techweb
Helpdesk call.
Table 174. 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 a Techweb Helpdesk call.
18 - 49 9813/9100-1 18 - 49
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-50 The fuel Injectors are electronically controlled and
Component Identification ............................... 18-51 incorporate a small solenoid valve. The injectors are
Check (Operation) ......................................... 18-51 supplied with pressurised fuel by the high pressure
Remove and Install ....................................... 18-53 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 425.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 50 9813/9100-1 18 - 50
18 - Injection
03 - Injector
Component Identification Check (Operation)

Special Tools
Figure 426. Description Part No. Qty.
Injector Leak-off Test 320/A7166 1
N Kit (430 Engine)
H
Data Link Adaptor 892/01174 1
(DLA) Kit
G
Injector Leak-off Test 892/12350 1
D F Kit ((Electronic Engine))
M
The injectors can be tested using Servicemaster
E diagnostics and by means of a leak-off test. To test
for a defective injector first use Servicemaster to
C diagnose the problems with the high pressure fuel
injection equipment, specifically when the engine
J does not start.
Set-up
The leak off test kit must be installed on the engine
and ServiceMaster used to test the engine.

B Refer to: PIL 01-03.
A 2. Remove the injector cover.

2.1. If possible, do not disconnect the ECM
(Engine Control Module).
2.2. Install the oil filler blanking cap from the
L injector leak-off test kit.
Special Tool: Injector Leak-off Test Kit (430
Engine) (Qty.: 1)
A Multi-point injector nozzle 3. Mount the ECM so that the engine can be run
B Needle safely without risk of damage. Make sure that
C Spacer the harness or connectors are not excessively
D Nut stressed.
E Valve
F Solenoid coil 4. Operate the engine until it is within the specified
G Valve spring temperature.
H Calibration dowel
J Injector spring Temperature: 25–95°C (77.0–202.9°F)
L Electrical connector 5. Stop the engine.
M Return port (bleed off)
N High pressure port and filter element 6. Disconnect the bleed off pipe at each injector.
Cap the open connectors on the pipes with the
caps in the injector leak-off test kit.
Special Tool: Injector Leak-off Test Kit
((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Leak-off Test Kit (430
Engine) (Qty.: 1)
18 - 51 9813/9100-1 18 - 51
18 - Injection
03 - Injector
Figure 427. specified amount of fuel, a fault with the injector

or fuel injection system is indicated.
Volume: 0.037L
Figure 429.
C
A
A Injector
B Leak of test kit pipe
C Leak of pipe connector Cranking Bottle Leak off Test
Figure 428. 1. Use the engine diagnostic tool in Servicemaster
to run the test. Follow the on screen instructions.
2. At the end of the test there should not be more
that the specified amount of fuel in the test pipes.
If any of the pipes has more that the specified
amount of fuel a fault with the injector or fuel
injection system is indicated.
D C Length/Dimension/Distance: 100mm
Figure 430.
C Leak of pipe connector

D Leak of pipe connector cap
100mm
7. Connect the test pipes to the leak-off ports on the 90mm
four injectors. 80mm
8. Position the four plastic bottles as upright as 70mm
possible. Keep the test equipment clear of 60mm
moving parts and components that get hot when 50mm
the engine is operated. 40mm
30mm
9. Make sure it is safe to start the engine.
20mm
10. Connect the DLA (Data Link Adaptor) to the 10mm
machine.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
1)
Injector Leak off Test

1. Use the engine diagnostic tool in Servicemaster
to run the test. Follow the on screen instructions.
2. At the end of the test there should not be more
that the specified amount of fuel in the test
bottles. If any of the bottles has more that the
18 - 52 9813/9100-1 18 - 52
18 - Injection
03 - Injector
Special Tools
Fuel Injector equipment 320/B9321 1
B
Remove
This procedure requires service parts. Make sure C A
you start. Refer to the Parts Catalogue. E
D
Refer to: PIL 01-03. 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
has been running, wait at for the specified time A Injector
period before you start work. B Fuel leak-off pipe
C High pressure fuel pipe
Duration: 1h D Electrical connector
3. Remove the injector cover. E Bolt
F Injector clamp
7. Disconnect the fuel leak-off pipes.
4. Remove the crankcase breather system.
9. Remove the bolt.
5. Record which injector is for which cylinder. The
injectors must be installed in the same positions. 10. Remove the injector clamp.
6. Remove the high pressure fuel pipes. The high 11. Carefully pull the injector up to remove it from the
pressure fuel pipes must not be reused, discard engine.
the high pressure fuel pipes.
Refer to: PIL 18-96-03. 12. Remove and discard the sealing washer. The
sealing washer must not be reused.
18 - 53 9813/9100-1 18 - 53
18 - Injection
03 - Injector
D
A
G
A Correction factor (20 characters)
B Injector serial number
C JCB part number
D Manufacturers reference
H steps.
2. Install a new copper sealing washer and O-ring.
A Injector
G O-ring 3. Make sure that the injector is installed in the
H Copper sealing washer correct orientation, with the leak-off port facing
the front (FEAD (Front End Accessory Drive)
13. Remove and discard the O-ring. The O-ring must belt) of the engine. Make sure the injector is
not be reused. pushed fully into the cylinder head.
14. Install a clean protective cap over the nozzle of 4. Tighten the bolt to the correct torque value.
the injector.
5. Replace the high pressure fuel pipes.
Special Tool: Fuel Injector equipment Cap Kit
(430 Engine) (Qty.: 1) Refer to: PIL 18-96-03.
6. If a new injector has been installed, program the
Install ECM with the new correction factor.
The fuel injectors are not interchangeable between Refer to: PIL 33-57-03.
cylinders or other engines. Make sure you install the
injectors in the same positions. If a new injector is Table 175. Torque Values
installed, the ECM (Engine Control Module) must be Item Nm
re-programmed.
E 33 ± 2
When new injectors are installed, record the
correction factor code and which cylinder the injector
is installed into.
18 - 54 9813/9100-1 18 - 54
18 - Injection
04 - Injector Cover
04 - Injector Cover Figure 435.
Remove and Install C

B
Remove
This procedure requires service parts. Make sure C
you have obtained the correct service parts before C

C
2. Make sure that the engine is safe to work on.
If the engine has been running, let it cool down B Injector cover
before you start service work. C Captive bolts (x11)
3. Remove the ECM (Engine Control Module) and 6. Remove and discard the track seal. Do not reuse
the ECM mounting bracket. the track seal.
Install
4. Remove the cable ties that secure the harness to
the injector cover. 1. The installation procedure is the opposite of the
Figure 434. steps.
2. Install a new track seal. Make sure that the seal
is correctly located in the groove on the housing
with the locating tab in the cut-out.
Figure 436.
A
A
D E
A Cable ties
5. Loosen the bolts (x11) and remove the injector
cover. The bolts are captive to the injector cover,
do not attempt to remove them.
D Track seal
E Location tab
4. Replace the cable ties.
5. Check the condition of the oil cap O-ring. Replace
the O-ring if necessary.
18 - 55 9813/9100-1 18 - 55
18 - Injection
04 - Injector Cover

Item Nm
C 9±1
18 - 56 9813/9100-1 18 - 56
18 - Injection
07 - Injector Seal
07 - Injector Seal 2. Place supports under the rocker cover and tap in
the new seals using the special tool.
Remove and Install Special Tool: Injector Seal Installation Tool

(Electronic Engine) (Qty.: 1)
Special Tools
Figure 438.
Injector Seal 892/12346 1
E
Installation Tool
(Electronic Engine)
F
Remove
you start. Refer to the Parts Catalogue.
1. Make the machine safe. G

E Injector seal installation tool
Refer to: PIL 01-03. F Injector seals
2. Make sure that the engine is safe to work on. If G Wooden supports
the engine has been running, let it cool before 3. Install the rocker cover.
4. Install the fuel injectors.
4. Remove the fuel injectors.
5. Install the injector cover.
Refer to: PIL 15-42-06. After Installation
6. Put wooden supports under the rocker cover and 1. Start the engine and check for oil and fuel leaks.
tap out the injector seals using the special tool.
Discard the seals.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
Figure 437.
F E
G
E Injector seal installation tool
F Injector seals
G Wooden supports
Install
1. Remove all oil and sludge contamination from
inside the rocker cover.
18 - 57 9813/9100-1 18 - 57
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-58 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-59 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 a fuel rail pressure

sensor and a fuel pressure limiting valve. DO NOT
remove the fuel pressure limiting valve or the fuel rail
pressure sensor from the rail. If these components
are defective, replace the complete common rail
assembly.
Figure 439.
A Fuel rail assembly
18 - 58 9813/9100-1 18 - 58
18 - Injection
12 - Rail
Remove and Install Special Tool: Fuel Injector equipment Cap Kit
Special Tools
Description Part No. Qty. 8. Remove the fuel return pipe adaptor. The copper
sealing washer must not be reused, discard the
Fuel Injector equipment 320/B9321 1 copper sealing washer.
Figure 441.
Remove
you have obtained the correct parts before you start.
Refer to the Parts Catalogue. E

F
2. Obey all fuel system health and safety
information.
3. Make sure that the engine is safe to work on. The E Fuel return pipe adaptor
engine must cool and pressure in the fuel system F Copper sealing washer
must decay before you start work. If the engine
has been running, wait at least for the specified 9. Remove the bolts (x2)
time period before you start work.
10. Remove the fuel rail.
Duration: 1h
4. Clean the engine. Install
Refer to: PIL 15-00-00. 1. The installation procedure is the opposite of the
5. Remove the high pressure fuel pipes. The high steps.
pressure fuel pipes MUST NOT be reused.
Discard the high pressure fuel pipes. 2. Tighten the bolts to the correct torque value.
Special Tool: Fuel Injector equipment Cap Kit 3. Replace the fuel return pipe adaptor copper
(430 Engine) (Qty.: 1) sealing washer.
4. Tighten the fuel return pipe adaptor to the correct
6. Disconnect the fuel rail pressure sensor. torque value.
Figure 440. 5. Replace the high pressure fuel pipes.

C
Item Nm
B D 17 ± 2
E 25
A
D D
A Fuel rail
B Fuel rail pressure sensor
C Fuel return pipe
D Bolts (x2)
7. Disconnect the fuel return pipe from the fuel
pressure limiting valve.
18 - 59 9813/9100-1 18 - 59
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-60 The high pressure fuel injection pump is a rotary
Remove and Install ....................................... 18-61 type device that pumps fuel into the cylinders of
the engine. The pump is driven indirectly from the
crankshaft by gears.
18 - 60 9813/9100-1 18 - 60
18 - Injection
15 - Pump
Special Tools
FIP Gear Nut Catcher 320/A6603 1
(430 Engine)
Pump Gear Removal 892/01155 1 A
Tool
C-Shaped Ring 892/01179 1
C
Spanner
B
Remove
The following procedures include removal and
installation of high pressure fuel system components.
Before starting the procedures the engine assembly
must be cleaned.Refer to: PIL 15-00-00.
A IMV electrical connector
Service procedures on the high pressure fuel pump B Fuel tank return pipe
can only be carried out by specialist personnel with C Fuel inlet pipe
the relevant training and equipment.
4. Disconnect the fuel tank return pipe. Plug all the
This procedure requires service parts. Make sure open ports and hoses to prevent contamination.
1. Make the machine safe. 4.1. When removing components dirt and debris
Refer to: PIL 01-03. may become exposed or dislodged. Stop
the removal procedures and clean away the
2. Make sure that the engine is safe to work on. If exposed deposits.
3. Disconnect the electrical connector from the IMV 5. Disconnect the fuel inlet pipe. Plug all the open
(Inlet Metering Valve). ports and hoses to prevent contamination.
6. Remove the high pressure fuel pipe between
the fuel injection pump and the fuel rail. The
high pressure fuel pipe MUST NOT be reused.
Discard the high pressure fuel pipe. Plug all the
open ports and hoses to prevent contamination.
18 - 61 9813/9100-1 18 - 61
18 - Injection
15 - Pump
E Fuel injection pump gear cover

F O-ring
9. Insert the fuel injection pump nut catcher special
D High pressure fuel pipe tool.
7. Remove the fuel injection pump gear cover. Special Tool: FIP Gear Nut Catcher (430 Engine)
(Qty.: 1)
Figure 444.
10. Remove the nut securing the fuel injection pump
gear to the drive shaft. Remove the fuel injection
pump nut catcher special tool.
Figure 446.
E Fuel injection pump gear cover

8. Remove the O-ring from the fuel injection pump
gear cover. The O-ring MUST NOT be reused. G Fuel injection pump drive gear retaining nut
Discard the O-ring.
11. Remove the bolts (x3) securing the fuel injection
pump to the engine. When the bolts are removed
the pump will be held in place only by the taper
between the drive gear and the drive shaft.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
18 - 62 9813/9100-1 18 - 62
18 - Injection
15 - Pump
Figure 447. P Gear removal tool body

Q Gear removal tool bolt
R Fuel injection pump drive shaft
13. The fuel injection pump drive gear is located on
a taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel injection pump. Tap the end of the gear
removal tool bolt with a soft faced hammer. When
the taper breaks there will be an audible sound.
The pump drive gear connects to the injection
pump drive shaft by means of taper lock alone,
there is no mechanical locking key.
J
14. Remove the service tools and remove the fuel
J injection pump.
Install
H
1. Make sure that the taper surfaces on the fuel
injection pump drive shaft and gear are clean and
H Fuel injection pump free from oil and damage.
J Bolts (x3)
2. Make sure that the O-ring is correctly located on
12. Install the reaction cap over the fuel injection the fuel injection pump mounting face.
pump drive shaft. Screw the body to the housing.
Use a suitable ratchet drive and socket to screw Figure 449.
the bolt in until you feel a slight resistance.
Special Tool: Pump Gear Removal Tool (Qty.: 1)
Figure 448.
H
K L
M
N
S
P
S O-ring
3. Locate the pump on to the engine. Make sure that
H Fuel injection pump you locate the fuel injection pump drive gear on
K Crankcase to the drive shaft.
L Flywheel housing
M Fuel injection pump drive gear 4. Install the bolts (x3).
N Reaction cap
18 - 63 9813/9100-1 18 - 63
18 - Injection
15 - Pump

6. Install the fuel injection pump drive gear nut and
tighten to the correct torque value.
6.1. If a washer is supplied with a replacement
pump, Do not install the washer. Secure the
gear with the gear pump nut only.
7. Tighten the nut to the correct torque value.
8. Install a new O-ring on to the fuel injection pump
gear cover.
9. Install the fuel injection pump gear cover.
10. Tighten the cover to the correct torque value.
11. Install a new high pressure fuel pipe. Do not
reuse the high pressure fuel pipes. Tighten the
fuel pipe to the correct torque value.
12. Connect the fuel inlet pipe.
13. Connect the fuel tank return pipe.
14. Connect the electrical connector to the IMV.
15. Replace the fuel filters.
16. Start the engine and check for fuel leaks.

Item Nm
D 27 ± 2.7
E 35–40
G 65
J 24
18 - 64 9813/9100-1 18 - 64
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-67
18 - 65 9813/9100-1 18 - 65
Notes:
18 - 66 9813/9100-1 18 - 66
21 - Fuel Pump
00 - General
00 - General Technical Data

Technical Data ............................................... 18-67
Operation ....................................................... 18-71
Check (Pressure) .......................................... 18-71
Table 179. Pressure

Operating pressure 5.75 ± 0.5bar (83.3 ± 7.2psi)
Free flow delivery 4.3L/min at 0bar (0.0psi)
Table 180. Pump Electrical

Machine Minimum Maximum Minimum Maximum Minimum Maximum
Voltage V Voltage Voltage Resistance Resistance Current Draw Current Draw
(ohms) (ohms) (A) (A)
12 8 16 0.8 1.5 4 8
Table 181. Sensor

Item Resistance
WIF (Water in Fuel) sensor 220,000Ω

Pre-filter to pump body 35 ± 5N·m
Drain bowl to pre-filter body 27 ± 5N·m
WIF sensor 7 ± 0.7N·m
Filter assembly mounting flange bolts (8.8) (X2) 45 ± 3N·m
18 - 67 9813/9100-1 18 - 67
21 - Fuel Pump
00 - General
The fuel lift pump is a sealed electrical unit integral The fuel lift pump is a non-serviceable component.
with the fuel pre-filter and water separator. If any part is defective, replace the complete pump,
filter and separator assembly.
18 - 68 9813/9100-1 18 - 68
21 - Fuel Pump
00 - General
Figure 450.
K
K
D E
H
400/D7339-4
C
A Fuel lift pump B Fuel pre-filter

C Water separator D Bleed port (if installed)
E Electrical connector F Fuel outlet
G Fuel inlet H Water in fuel sensor
18 - 69 9813/9100-1 18 - 69
21 - Fuel Pump
00 - General
J Electrical connector K Pump and filter assembly securing bolt (X2)
18 - 70 9813/9100-1 18 - 70
21 - Fuel Pump
00 - General
Operation Check (Pressure)

Special Tools
The pump draws fuel from the tank, through the water Description Part No. Qty.
separator, pumping it through the fuel filter and into LP Fuel Pressure 320/A7138 1
the fuel injection pump. The pump has a built in Gauge Hose (430
protection against running dry and will shut down Engine)
after 2min if no fuel is present.
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 24s.
Alternatively use the JCB engine diagnostic tool

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5s delay the pump runs for a
period of 24s.

2. Clean the fuel lift pump and the surrounding area
reduce the risk of contamination. Refer to (PIL
18-00-00).
3. Connect a pressure gauge between the fuel lift
pump and the outlet fuel pipe. Make sure it is
located securely away from hot or moving parts.
Special Tool: LP Fuel Pressure Gauge Hose (430
Engine) (Qty.: 1)
4. Switch the ignition on.
5. Record the pressure on the gauge. If the
pressure is not within the specified tolerance,
a fuel restriction or a faulty fuel lift pump is
indicated. Refer (PIL 18-21-00).
18 - 71 9813/9100-1 18 - 71
21 - Fuel Pump
00 - General
Remove and Install
Remove
2. See fuel and exhaust system, general,
component identification (PIL 18-00-00).
4. Disconnect the fuel lift pump electrical connector.
5. Disconnect the WIF (Water in Fuel) sensor
electrical connector.
6. Label the fuel pipes to aid installation.
7. Disconnect the fuel pipes at the fuel lift pump
using the quick release connectors on the pipes.
8. Support the fuel lift pump and remove the bolts
(x2).
9. Remove the fuel lift pump and pre-filter/separator
assembly from the machine.
Install
removal procedure.
Refer to: PIL 72.
3. Bleed the fuel system.
18 - 72 9813/9100-1 18 - 72
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-75

18-24-04 Outlet Manifold ............................................................................................................... 18-77
18 - 73 9813/9100-1 18 - 73
Notes:
18 - 74 9813/9100-1 18 - 74
24 - Exhaust
00 - General
Introduction .................................................... 18-75 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-76 away from the controlled combustion inside the
Check (Condition) .......................................... 18-76 engine by means of an exhaust pipe. Depending on
the machine design, the exhaust gas will flow through
the following components:
• Cylinder head and exhaust manifold.

• EGR (Exhaust Gas Recirculation) system to
reduce air pollution (nitrous oxides).
• Turbocharger to increase the engine power.
• 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 - 75 9813/9100-1 18 - 75
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
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
WARNING! The engine has exposed rotating parts.
engine cover open.
18 - 76 9813/9100-1 18 - 76
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-77 The exhaust outlet manifold collects the exhaust
Component Identification ............................... 18-78 gases from the multiple cylinders and delivers it to
Check (Condition) .......................................... 18-79 the turbocharger or the exhaust pipe.
18 - 77 9813/9100-1 18 - 77
24 - Exhaust
Figure 451.
E
A F
A Exhaust manifold B Bolts (x10)

C Exhaust manifold to cylinder head gasket D Exhaust manifold to turbocharger gasket
E Exhaust manifold temperature sensor boss F Exhaust manifold pressure sensor boss
18 - 78 9813/9100-1 18 - 78
24 - Exhaust

Special Tools
1. Check the manifold mating faces for signs of Description Part No. Qty.
damage and distortion.
2. Check the manifold casting for signs of cracks. (10-100Nm)
3. Renew the manifold if there are any signs of Remove

defect.
4. Visually inspect for leaks at the exhaust manifold. This procedure requires service parts. Make sure
Make sure all gaskets are in good condition, you have obtained the correct service parts before
replace as required. you start. Refer to the Parts Catalogue.

3. Disconnect the air inlet and outlet hoses from the
turbocharger.
4. Disconnect the exhaust from the turbocharger.
5. Remove the oil pipes support clip.
6. Remove the bolts (x2) and remove the
turbocharger oil pipes. Make sure you do not
bend or damage the pipe. Discard the gasket.
Figure 452.
E
G
D
C
F
B
A
A Turbocharger oil drain bolts (x2)
B Turbocharger oil drain
C Turbocharger oil pipes support clip
D Turbocharger oil feed pipe
E Turbocharger oil feed banjo bolt - turbocharger
F Turbocharger oil feed banjo bolt - crankcase
G Actuator hose
7. Remove the turbocharger oil feed banjo bolts
(x2) and remove the turbocharger oil feed pipe.
Discard the sealing washers.
18 - 79 9813/9100-1 18 - 79
24 - Exhaust
8. Disconnect the turbocharger actuator hose. 2. Tighten the nuts (x4) to the correct torque value.
9. Remove the MAF (Mass Air Flow) sensor. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
3. Install the exhaust manifold and turbocharger
Figure 453. assembly to the engine. Make sure that you
replace the gasket.
H
4. Tighten the bolts (x10) (in sequence 1-10) to the
first stage torque.
K Special Tool: Torque Wrench (10-100Nm) (Qty.:
J 1)
Figure 455.
9 5 1 2 6
10 8 4 3 7
H MAF sensor 1-10 Exhaust manifold bolts tightening sequence

J Exhaust manifold temperature sensor 5. Tighten the bolts (x10) (in sequence 1-10) to
K Banjo bolt the final stage torque. Use the torque and angle
10. Remove the exhaust manifold temperature method.
sensor. Special Tool: Torque Wrench (10-100Nm) (Qty.:
Refer to: PIL 15-84-14. 1)
11. Remove the banjo bolt securing the exhaust
manifold pressure pipe to the exhaust manifold. 6. Install the exhaust manifold temperature sensor.
Discard the sealing washers. Refer to: PIL 15-84-14.
Refer to: PIL 15-84-16. 7. Install the MAF sensor.
12. Remove the bolts (x10) and remove the exhaust Refer to: PIL 15-84-13.
manifold and turbocharger assembly. Discard the
gasket. 8. Install the banjo bolt that secures the exhaust
manifold pressure pipe to the exhaust manifold.
13. Remove the nuts (x4) and remove the Make sure that you replace the sealing washers.
turbocharger from the exhaust manifold. Discard
the gasket.
9. Connect the actuator hose to the turbocharger.
Figure 454.
L 10. Install the turbocharger oil drain pipe. Make sure
N that you replace the gasket. Tighten the bolts to
11. Prime the top of the turbocharger with the
specified amount of fresh, clean engine oil. It is
Important not to run the turbocharger dry.
Volume: 0.2L
M
N
12. Install the oil feed pipe. Make sure that you
L Turbocharger replace the sealing washers.
M Exhaust manifold
N Nuts (x4) 13. Tighten the banjo bolts to the correct torque
value.
Install
14. Install the oil pipes support clip.
1. Install the turbocharger to the exhaust manifold.
Make sure that you replace the gasket. 15. Connect the exhaust pipe to the turbocharger.
18 - 80 9813/9100-1 18 - 80
24 - Exhaust
16. Connect the air inlet and outlet hoses to the

turbocharger.

Item Torque Value
1-10 (Final stage) 90
A 24 ± 2N·m
E 21 ± 1N·m
F 34–37N·m
N 24 ± 2N·m
18 - 81 9813/9100-1 18 - 81
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-83

18-27-03 Actuator .......................................................................................................................... 18-89
18-27-15 Diffuser ........................................................................................................................... 18-91
18 - 82 9813/9100-1 18 - 82
00 - General
Introduction .................................................... 18-83 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................... 18-84 a technique that re-circulates a portion of the
Check (Condition) .......................................... 18-85 exhaust gases back into the combustion chamber.
Remove and Install ....................................... 18-85 The system cools and controls the quantity of re-
circulated exhaust gas.
Disassemble and Assemble .......................... 18-87
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 - 83 9813/9100-1 18 - 83
00 - General
Figure 456.
A
E
B
A Exhaust gas intake pipe B EGR (Exhaust Gas Recirculation) valve

C EGR actuator D EGR cooler
E EGR cooler coolant hoses F EGR actuator coolant hoses
G Diffuser
18 - 84 9813/9100-1 18 - 84
00 - General

1. Check that the EGR (Exhaust Gas Recirculation)
for excessive carbon build up. Visually inspect for
Remove
leaks at the EGR. Make sure all gaskets are in This procedure requires service parts. Make sure
good condition, replace as required. you have obtained the correct service parts before

EGR (Exhaust Gas Recirculation) actuator.
Figure 457.
A Electrical connector
B Coolant hoses
5. Disconnect the coolant hoses.
6. Remove the bolts 1 (x2) that secure the exhaust
gas intake pipe to the cylinder head.
18 - 85 9813/9100-1 18 - 85
00 - General
Figure 458. Install

D steps.
2. Replace the gaskets and seals.
E 3. Tighten the bolts to the correct torque value.

4. When you fill the cooling system, make sure that
you use the correct water/antifreeze mixture. A
D C 50% mixture should be maintained even if frost
C Bolts 1 (x2) protection is not required.
D Bolts 2 (x2) Refer to: PIL 75-09-03.
E Bolt 3 (x1)
7. Remove the bolts 2 and the bolt 3. Remove the
EGR system from the engine. Item Nm
C 24 ± 2
8. Discard the exhaust gas inlet pipe gasket and the D 24 ± 2
exhaust gas inlet lobe seal.
E 24 ± 2
Figure 459. H 24 ± 2
F
F Exhaust gas inlet pipe gasket
G Exhaust gas inlet lobe seal
9. Remove the bolts 4 (x6) and remove the EGR
system mounting brackets.
Figure 460.
J J
H H
H Bolts 4 (x6)
J EGR system mounting brackets
18 - 86 9813/9100-1 18 - 86
00 - General
Disassemble and Assemble Figure 463.
Disassemble

system assembly from the engine.
2. Remove the cable tie. F
Figure 461. E
A
E EGR valve
A B F EGR cooler
7. Remove the studs (x3).
Figure 464.
A EGR valve coolant hoses

B Cable tie
3. Remove the EGR valve coolant hoses.
4. Remove the nuts (x3).
Figure 462. G
C D
F EGR cooler
G Studs (x3)
C
Install
C Nuts (x3) removal procedure. Additionally do the following
D Exhaust gas intake pipe steps.
5. Remove the exhaust gas intake pipe. Discard the 2. Make sure that all sealing faces are clean and
gasket. free from corrosion.
6. Remove the EGR valve. Discard the gasket. 3. Replace the gaskets and seals.
4. Replace the cable tie.
5. Tighten the bolts, nuts and studs to the correct
torque value.
18 - 87 9813/9100-1 18 - 87
00 - General

Item Nm
C 23–27
G 6±2
18 - 88 9813/9100-1 18 - 88
03 - Actuator
03 - Actuator Introduction
Introduction .................................................... 18-89 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ....................................... 18-90 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 - 89 9813/9100-1 18 - 89
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 - 90 9813/9100-1 18 - 90
15 - Diffuser
15 - Diffuser Figure 466.
Remove and Install
Remove
you start, refer to the Parts Catalogue. A
2. Make sure that the engine is safe to work on. If C
cooler assembly. Refer to (PIL 18-27-00). A EGR diffuser
C O-ring
Figure 465. Install
steps.
B
2. Replace the O-ring.
A 3. Tighten the bolts to the correct torque value.

Item Nm
B 10
A EGR diffuser
B Bolts (x2)
5. Remove the EGR diffuser.
6. Remove and discard the O-ring. The O-ring must
not be reused.
18 - 91 9813/9100-1 18 - 91
35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ........................................................................................................................... 18-93

18-35-06 Wastegate Valve ............................................................................................................ 18-96
18 - 92 9813/9100-1 18 - 92
35 - Turbocharger
00 - General
Introduction .................................................... 18-93 The turbocharger (turbo) is a turbine driven forced
Check (Condition) .......................................... 18-94 induction device that makes an engine more efficient
Check (Operation) ......................................... 18-95 and helps to produce more power for its size.
Engine exhaust gasses drive a turbine, which in turn
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.
Boost pressure control is achieved using a

mechanical wastegate valve in the turbine housing
allowing exhaust gasses to bypass the turbine when
opened. The control of this valve is via an electronic
TCV (Turbocharger Control Valve).
18 - 93 9813/9100-1 18 - 93
35 - Turbocharger
00 - General
Check (Condition) Figure 468.
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 467. 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 - 94 9813/9100-1 18 - 94
35 - Turbocharger
00 - General
Check (Operation) Remove and Install

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 - 95 9813/9100-1 18 - 95
35 - Turbocharger
06 - Wastegate Valve
06 - Wastegate Valve Introduction

Introduction .................................................... 18-96 The TCV (Turbocharger Control Valve) is a solenoid
Operation ....................................................... 18-97 valve that controls the opening and closing of the
Remove and Install ....................................... 18-97 turbocharger wastegate. It is controlled by the ECM
(Engine Control Module).
Figure 469.
A TCV
18 - 96 9813/9100-1 18 - 96
35 - Turbocharger
06 - Wastegate Valve
The TCV (Turbocharger Control Valve) is supplied Remove

with a small amount of charge air from the air
intake. When the valve is closed, charge air is 1. Make the machine safe.
prevented from entering the wastegate actuator and
opening the wastegate. When the valve is open Refer to: PIL 01-03.
the charge air pressure moves the turbocharger 2. Make sure that the engine is safe to work on. If
wastegate actuator to open the wastegate. When the the engine has been running, let it cool before
TCV moves from open to closed in order to close the you start the service work.
wastegate, the pressure in the wastegate actuator
and pipework is vented to atmosphere. 3. Disconnect the MAF (Mass Air Flow) sensor
The ECM (Engine Control Module) uses signals
from the MAF (Mass Air Flow) sensor, TMAP Figure 470.
(Temperature Manifold Air Pressure) sensor, exhaust
manifold temperature sensor and throttle to control
the opening and closing of the TCV. This maintains C
optimum boost pressure in the engine depending on
the engine load and operating conditions.
The TCV is configured to maintain a maximum

compressor outlet pressure of above barometric B
pressure independently of the engines operating
state. This design offers significant improvements A
over a pneumatically controlled wastegate allowing
for improved engine response while protecting high
temperature and high altitude operation with respect F
to shaft speed and turbo charger outlet temperature.
D E
A TCV (Turbocharger Control Valve)
B MAF sensor
C TCV electrical connector
D TCV to turbocharger hose
E TCV to intake hose
F Bolts (x2)
4. Disconnect the TCV electrical connector.
5. Disconnect the TCV to turbocharger hose.
6. Disconnect the TCV to intake hose.
8. Remove the TCV.
Install
step.

Item Nm
F 24 ± 2
18 - 97 9813/9100-1 18 - 97
39 - Fuel Cooler
39 - Fuel Cooler
Contents Page No.
18-39-00 General ........................................................................................................................... 18-99
18 - 98 9813/9100-1 18 - 98
39 - Fuel Cooler
00 - General
00 - General
Remove and Install
Remove 5. Open the engine compartment cover. Refer to

(PIL 06-06).
6. Disconnect the fuel hoses from the matrix at the
2. Follow the general health and safety procedures. quick release couplings.
7. Support the matrix.
3. Switch off the engine before working in the
engine compartment. Remove ignition key or 8. Remove the nuts.
isolate battery to prevent the engine from being
started. Refer to (PIL 33-03). 9. Remove the fuel cooler matrix from the machine.
4. If the engine is hot let it cool for one hour.
Figure 471.
A
C
B
A Quick release couplings B Nuts

C Matrix
18 - 99 9813/9100-1 18 - 99
39 - Fuel Cooler
00 - General
Install
steps also.
1.1. Bleed the fuel system. Refer to fuel system-
general, refer to (PIL 18-00).
1.2. After installation, start the engine and check
for fuel leaks.
18 - 100 9813/9100-1 18 - 100

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-103

18-96-03 High Pressure Pipe ...................................................................................................... 18-104
18-96-06 Low Pressure Pipe ....................................................................................................... 18-107
18 - 101 9813/9100-1 18 - 101

Notes:
18 - 102 9813/9100-1 18 - 102

96 - Fuel Pipe
00 - General
00 - General
Health and Safety

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.
Notice: Do not allow dirt to enter 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.
18 - 103 9813/9100-1 18 - 103

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe Figure 472.
Remove and Install

Special Tools
Socket 17MM Offset - 331/27987 1
(HP Fuel pipes)
(10-100Nm)
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts Injector Fuel Pipes
before you start. Refer to the Parts Catalogue.
Remove
1.1. The high pressure fuel pipes MUST BE
REPLACED with new ones. 1. Remove the EGR (Exhaust Gas Recirculation)
1.2. The new fuel pipes must remain sealed system.
inside their bags before use. If a bag is open Refer to: PIL 18-27-00.
DO NOT USE the fuel pipe.
2. Remove the fuel injector cover.
3. Remove the fuel pipes one at a time as follows:
3. Obey all fuel system health and safety
information. 3.1. Remove the retaining clips.
Refer to: PIL 18-00-00. 3.2. Loosen the nut 2 at the fuel rail. Do not
remove the nut at this step.
4. Clean the engine. Additional cleaning must be
carried out prior to working on the high pressure Special Tool: Socket 17MM Offset - (HP
fuel system. Fuel pipes) (Qty.: 1)
Refer to: PIL 18-00-00. (Qty.: 1)
5. Make sure that the engine is safe to work on. Figure 473.
The engine must cool and pressure in the fuel B
system must decay before you start work. If the
engine has been running, wait for the specified
time period before you start work.
Duration: 1h
C
6. Always use a spanner at the top of the fuel pipe
nut (this will prevent damage to the nut). A
E
A Fuel pipe
B Nut 1
C Fuel injector
D Fuel rail
E Nut 2
18 - 104 9813/9100-1 18 - 104

96 - Fuel Pipe
3.3. Push the fuel pipe against the injector cone Figure 474.
and at the same time remove the nut 1.
3.4. Push the fuel pipe against the fuel rail cone
3.5. Make sure that there is no dirt or debris on
the fuel pipe or the connectors. D
3.6. Remove the fuel pipe.
contamination.
Special Tool: Fuel Injector equipment Cap E
4. Discard the old fuel pipes. A
Install
1. Install the fuel pipes one at a time as follows: B
1.1. locate the injector end of the fuel pipe C
against the correct injector cone.
A Fuel pipe
1.2. Tighten the nut 1 by hand. B Nut 1
1.3. locate the fuel rail end of the fuel pipe C Fuel injection pump
against the correct fuel rail cone. D Fuel rail
E Nut 2
1.4. Tighten the nut 2 by hand.
1.2. Push the fuel pipe against the fuel injection
1.5. Tighten the nut 1 to the correct torque value.
pump cone and at the same time remove
Special Tool: Socket 17MM Offset - (HP the nut 1.
Fuel pipes) (Qty.: 1)
1.3. Push the fuel pipe against the fuel rail cone
(Qty.: 1)
1.4. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1) 1.5. Remove the fuel pipe.
Special Tool: Torque Wrench (10-100Nm) 1.6. Plug all the open ports and hoses to prevent
(Qty.: 1) contamination.
1.7. Install the retaining clips. Special Tool: Fuel Injector equipment Cap
2. Install the fuel injector cover.
Refer to: PIL 18-18-04. 2. Discard the old fuel pipe.
3. Install the EGR system. Install

Refer to: PIL 18-27-00. 1. Install the fuel pipe as follows:
Fuel Injection Pump to Fuel Rail Pipe 1.1. locate the injector end of the fuel pipe
against the correct injector cone.
Remove 1.2. Tighten the nut 1 by hand.
1. Remove the fuel pipe as follows: 1.3. locate the fuel rail end of the fuel pipe
against the correct fuel rail cone.
1.1. Loosen the nut 2 at the fuel rail. Do not
remove the nut at this step. 1.4. Tighten the nut 2 by hand.
Special Tool: Socket 17MM Offset - (HP 1.5. Tighten the nut 1 to the correct torque value.
Fuel pipes) (Qty.: 1) Special Tool: Socket 17MM Offset - (HP
18 - 105 9813/9100-1 18 - 105

96 - Fuel Pipe

(Qty.: 1)
Special Tool: Socket 17MM Offset - (HP
(Qty.: 1)
After Installation
1. Make sure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced.

Item Nm
B 27 ± 2.7
E 27 ± 2.7
18 - 106 9813/9100-1 18 - 106

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 475.
Remove and Install

Special Tools
Fuel Injector equipment 320/B9321 1 A
Cap Kit (430 Engine) B
Before Removal
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 has been running, wait for the specified A Injector leak-off pipe connector - injectors
time period before you start work. B Injector leak-off pipe connector outer sheath
Duration: 1h 3.2. Pull the connector to disconnect it from the
injector. Make sure you do not overstress
3. Clean the engine. the leak-off pipe.
4. Disconnect the leak-off pipes from the fuel filter
4. Plug all the open ports and hoses to prevent return pipe.
contamination whenever a fuel pipe is removed
or disconnected. Figure 476.

Injector leak-off Pipes

Remove
2. Remove the EGR system.
C
3. Disconnect the leak-off pipes from the injectors
as follows: C Injector leak-off pipe connector - fuel filter return
3.1. Pull the outer sheath of the connector up. 5. Disconnect the retaining clips.
6. Remove the injector leak-off pipes.
Install
removal procedure.
Leak-off Pipe To Fuel Filter Low Pressure

Pipe
Remove
1. Remove the EGR system.
18 - 107 9813/9100-1 18 - 107

96 - Fuel Pipe
2. Disconnect the fuel supply connector. Figure 478.

3. Remove the retaining clips securing the pipe to
the engine.
M
Figure 477.
C
A L
K J
D
A J Return to tank pipe machine connector
K Retaining clip
L Fuel injection pump connector
M Fuel rail connector
N Fuel pipe
H
A 2. Remove the retaining clip.
D
A 3. Disconnect the fuel injection pump connector.
4. Disconnect the fuel rail connector.
5. Remove the fuel pipe.
F Install
E 1. The installation procedure is the opposite of the
G removal procedure.
C Injector leak-off pipe connector Fuel Filter To Fuel Injection Pump Pipe
D Retaining clips (x2)
E 3 way connector Remove
F Bolt 1
G Fuel filter connector 1. Make sure that the engine is fully clean. The fuel
H Fuel pipe filter to fuel injection pump pipe is on the 'clean'
side of the fuel filter. Any contamination will go
4. Remove the bolt 1 securing the three way directly into the high pressure fuel system.
connector to the engine.
5. Disconnect injector leak off pipes.
2. Disconnect the electrical connector from the fuel
6. Disconnect the fuel pipe from the fuel filter. temperature sensor.
Install
step.
2. Tighten the bolt 1 to the correct torque value.
Return To Tank Fuel Pipe

Remove
1. Disconnect the return to tank pipe from the
machine.
18 - 108 9813/9100-1 18 - 108

96 - Fuel Pipe
Figure 479. Table 189. Torque Values

Item Nm
F 10 ± 1
U 10 ± 1
R
U
S
Q
T
P Fuel filter connector

Q Electrical connector
R Fuel injection pump connector
S Fuel pipe
T Fuel temperature sensor
U Bolt 2
3. Remove the retaining clips securing the fuel pipe
to the engine.
4. Disconnect the fuel injection pump connector.
5. Disconnect the fuel filter connector
Install
step.
2. Tighten the bolt 2 to the correct torque value.
After Installation
1. Make sure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced.
18 - 109 9813/9100-1 18 - 109

Notes:
18 - 110 9813/9100-1 18 - 110

21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ............................................................................................................................. 21-9
21-03-03 Radiator .......................................................................................................................... 21-15
21-03-09 Transmission Oil Cooler ................................................................................................. 21-16
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-21
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-29
21-09 Pump
21-09-00 General ........................................................................................................................... 21-35
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-39
21-15 Heater
21-15-00 General ........................................................................................................................... 21-45
21-21 Inlet
21-21-00 General ........................................................................................................................... 21-47
21-42 Manifold
21-42-00 General ........................................................................................................................... 21-49
21-93 Hose
21-93-00 General ........................................................................................................................... 21-51
9813/9100-1
2017-11-23
Acronyms Glossary
CAC Charge Air Cooler

9813/9100-1
2017-11-23
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/9100-1 21 - 1
Notes:
21 - 2 9813/9100-1 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
Drain and Fill ................................................... 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Check (Condition) ............................................ 21-5 quickly and then maintain it.
Check (Leaks) ................................................. 21-6
Check (Level) .................................................. 21-6
21 - 3 9813/9100-1 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 190.
cap, hot coolant can spray out and burn you. Radiator cap pressure 1bar (14.5psi)
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) 9mm
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 9813/9100-1 21 - 4
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 20L 1.1. Leaks.
Concentrate 4006/1103 200L 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.

2. Stop the engine and let it cool down.
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 480.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 5 9813/9100-1 21 - 5
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 - 6 9813/9100-1 21 - 6
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ............................................................................................................................. 21-9

21-03-03 Radiator .......................................................................................................................... 21-15
21-03-09 Transmission Oil Cooler ................................................................................................. 21-16
21 - 7 9813/9100-1 21 - 7
Notes:
21 - 8 9813/9100-1 21 - 8
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction ...................................................... 21-9 The cooling pack contains the following major
Component Identification ............................... 21-10 components:
Clean ............................................................. 21-12
Check (Condition) .......................................... 21-12 • Radiator.
• Cooling fan.
Remove and Install ....................................... 21-13 • CAC (Charge Air Cooler).
Disassemble and Assemble .......................... 21-14 • Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 9 9813/9100-1 21 - 9
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 481.
F
E
B G
A
E
H
21 - 10 9813/9100-1 21 - 10
21 - Cooling System
03 - Cooling Pack
00 - General
Table 191.
Item Description
A Air to air inter cooler ma-
trix
B Hydraulic oil cooler ma-
trix
C Fuel lift pump and pre-
filter and water trap
D Fuel cooler matrix
E Hose to top of hydraulic
oil cooler
F Hose to bottom of hy-
draulic oil cooler
G Hose to motor P port
H Check valve
J Hose from motor T port
K Hose from motor D port
L Fan speed sensor
M Variable Speed Cooling
fan and hydraulic motor
assembly
N Proportional pressure
relief cartridge
P Cooling pack assembly
21 - 11 9813/9100-1 21 - 11
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 - 12 9813/9100-1 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install 1.1. Tighten the pipe clamps to the correct
torque value.
Although it is possible to remove individual 1.2. Fill the engine cooling system with the
components it is quicker and easier to remove correct type of coolant. Refer to (PIL 21-00).
the complete sub assembly, particularly if access 1.3. Operate the engine and check the fan motor
is necessary for engine overhaul or removal speed.
and replacement for example. See component
identification, Refer to: PIL 21-00-00. 1.4. Check the hydraulic fluid level. Refer to (PIL
30-00-00).
Disassembly 1.5. Check the transmission oil level and top up
as necessary.
2. Make sure that the engine and hydraulic systems
are cool before you start the removal procedure.
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.
7. Disconnect the radiator top hose.
8. Disconnect the fan motor electrical connections
(if installed).
control solenoid and the speed sensor
10. Disconnect the transmission cooler hoses from
the chassis.
contamination.
12. Disconnect the hydraulic hoses from the chassis.
contamination.
14. Disconnect the intercooler inlet and outlet hoses.
15. Support the cooling pack assembly, remove the
fusebox bolts and the fixing bolts.
16. Carefully lift and move the assembly away from
the machine.
Install
steps.
21 - 13 9813/9100-1 21 - 13
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 - 14 9813/9100-1 21 - 14
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 - 15 9813/9100-1 21 - 15
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Check (Condition)

Check (Condition) .......................................... 21-16 The liquid to liquid cooler is a possible source of
Remove and Install ....................................... 21-17 water contamination. It should be tested for possible
failure as follows:
1. Drain any remaining oil/water from the cooler.

2. Fit 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: 6bar (87.0psi)
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, refer to (PIL 21-03).
7. If the cooler is not damaged, clean and make it
dry before you assemble it to the machine. Refer
to (PIL 21-03).
21 - 16 9813/9100-1 21 - 16
21 - Cooling System
03 - Cooling Pack
Remove and Install
Remove 4. Drain the engine coolant. Refer to (PIL 21-00).
1. Make the machine safe. Refer to (PIL 01-03). 5. Disconnect the electrical oil temperature sensor.
2. Follow the general health and safety procedures. 6. Carefully disconnect the oil feed and return
Refer to (PIL 01-03). hoses. The oil may be hot.
3. Remove the engine cover base for easy access 7. Remove the water hose clips and the retaining
to the transmission oil cooler. Refer to (PIL clips. Take out the cooler.
06-06).
Figure 482.
A
C D C C C
A Electrical oil temperature sensor B Oil feed and return hoses

C Retaining clips D Cooler
21 - 17 9813/9100-1 21 - 17
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 - 18 9813/9100-1 21 - 18
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-21
21 - 19 9813/9100-1 21 - 19
Notes:
21 - 20 9813/9100-1 21 - 20
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-21 The product is equipped with a hydraulically driven
Technical Data ............................................... 21-22 fan motor to provide air flow though the cooling pack.
Remove and Install ....................................... 21-24 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 - 21 9813/9100-1 21 - 21
21 - Cooling System
05 - Fan Motor
00 - General
Technical Data
Variable Speed Fan Motor (JCB 430 Engines)

Table 192.
Type: Uni- directional gear motor
Direction of rotation: Clockwise (viewed from motor shaft end)
Motor displacement: 11 cc/rev
Fan speed (at maximum RPM (Revolutions Per Variable
Minute)):
Maximum pressure setting: 230bar (3,333.3psi)
Colour code (see sticker): Green
Solenoid current draw 1.4A
Solenoid to motor body tightening torque 40N·m
Weight (bare unit, no fan) 5kg
21 - 22 9813/9100-1 21 - 22
21 - Cooling System
05 - Fan Motor
00 - General
Figure 483.
B
A Cooling pack B Fan supply hydraulic pump section (Variflow

pump shown for illustration purposes, the fan
system operation is identical for gearpump
machines).
C Right hand cluster ECU (Electronic Control Unit) D Fan speed sensor
E Hydraulic cooling fan motor F Fan speed proportional solenoid
21 - 23 9813/9100-1 21 - 23
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Variable Speed Fan If the performance is below that specified, the

motor should be renewed. Renewal of individual
Your machine is installed with a variable speed fan. components such as gears, bearings and housings
will not result in a permanent cure. If the motor
Before you remove the fan motor, check its performance is satisfactory, but there is external
performance. leakage, it should be dismantled for re-sealing
purposes only.
Figure 484.
B C E
G
D
F
E
A Fan retaining nut B Lock washer

C Drive key D Cooling fan motor tapered shaft
E Cooling fan motor F Fan
G Cooling pack
Remove 5. Disconnect the harness form the solenoid

6. Disconnect the harness from the speed sensor
Refer to: PIL 01-03. electrical connector.
2. Install the safety strut. Refer to (PIL 06-69). 7. Disconnect the harness from the direction
Refer to: PIL 06-69. solenoid (if installed).
3. Discharge the hydraulic pressure. 8. Disconnect and plug the feed and return hoses.
Refer to: PIL 30-00. 9. Disconnect and plug the case drain hose.
4. Mark the hydraulic feed and return hoses to help 10. Support the motor and fan assembly.
identification when you install.
21 - 24 9813/9100-1 21 - 24
21 - Cooling System
05 - Fan Motor
00 - General
11. Undo the fan bracket securing bolts (x4) and lift
the fan and motor assembly from the machine.
12. Prevent the fan from turning, release the tab
washer and then undo the fan retaining nut.
13. Withdraw the fan from the motor shaft. Retain the
drive key.
14. Undo the motor retaining bolts and remove the
motor.
Install
steps.
1.1. Install a new lock washer.
1.2. Tighten all the fastening nuts and bolts to
Refer to: PIL 72.
1.3. Make sure all hoses are attached to the
correct ports. The case drain hose (if
installed) must be fed in to a tank line
otherwise damage to the motor will occur.
1.4. Check and adjust the hydraulic fluid level.
Table 193. Torque Settings

Item Value
A 36N·m
21 - 25 9813/9100-1 21 - 25
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 26 9813/9100-1 21 - 26
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-29
21 - 27 9813/9100-1 21 - 27
Notes:
21 - 28 9813/9100-1 21 - 28
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-29 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-30 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 - 29 9813/9100-1 21 - 29
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 0.01L 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 - 30 9813/9100-1 21 - 30
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 485.
D A
E F E E
A Hose clips B Hoses

C Tank cover D Expansion tank
E Bolts F Bracket
21 - 31 9813/9100-1 21 - 31
21 - Cooling System
06 - Expansion Tank
00 - General
Install
steps.
1.1. Apply sealant to the bolts.
(Medium Strength)
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 - 32 9813/9100-1 21 - 32
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-35
21 - 33 9813/9100-1 21 - 33
Notes:
21 - 34 9813/9100-1 21 - 34
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-35 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-36 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-36
Remove and Install ....................................... 21-37 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 35 9813/9100-1 21 - 35
21 - Cooling System
09 - Pump
00 - General

Figure 486. The coolant pump is driven via a pulley and front end
A 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 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.
D
C
A Coolant pump
B Drive pulley
C Track seal
D Impeller
21 - 36 9813/9100-1 21 - 36
21 - Cooling System
09 - Pump
00 - General
Remove
A
2. If the engine has been running, let it cool before
D
5. Remove the FEAD (Front End Accessory Drive)
belt.
Refer to: PIL 15-18-03. C
6. Remove the fixing screws.
Figure 487.
A Coolant pump
C Track seal
D Track seal location tab
B
The pump is a non-serviceable item. If the pump is
faulty or damaged it must be replaced.
Install
A removal procedure. Additionally do the following
steps.
2. Make sure that the mating face on the crankcase
is clean and free from damage or corrosion.
3. Install a new track seal.
B
A Coolant pump in its groove on the housing. The location
B Fixing screws tab must locate correctly in the cut-out.
7. Remove the coolant pump. 4. Tighten the screws to the correct torque value.
8. Remove and discard the track seal. 5. When you fill the cooling system, make sure that
you use the correct water/antifreeze mixture. A
50% mixture should be maintained even if frost
protection is not required.

Item Nm
B 24 ± 2
21 - 37 9813/9100-1 21 - 37
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-39
21 - 38 9813/9100-1 21 - 38
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-39 The thermostat is located between the engine and
Operation ....................................................... 21-40 the radiator. The function of the thermostat is to block
Check (Condition) .......................................... 21-41 the flow of coolant to the radiator until the engine has
Check (Operation) ......................................... 21-41 warmed up to a sufficient temperature.
Remove and Install ....................................... 21-42 When the engine is cold, no coolant flows through
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 - 39 9813/9100-1 21 - 39
21 - Cooling System
12 - Thermostat
00 - General
Operation diameter orifice allows trapped air to be expelled

from the system.
The thermostat is a wax element type and is Figure 490.

configured for by-pass blanking. The thermostat 7 3
functions as follows:
8 11
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
plate up against its seat, closing the outlet port to the 9
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 1
housing inlet port into the bypass gallery.
Figure 489. 2
7 3
6
8 10
11 5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
9 5 Wax pellet
1 6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
2 9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
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 1mm 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 1mm
21 - 40 9813/9100-1 21 - 40
21 - Cooling System
12 - Thermostat
00 - General
Check (Condition) Check (Operation)

1. If the thermostat is suspected of being faulty, A period of 3–5min before the thermostat valve starts
perform a thermostat test, refer to Thermostat to operate is normal because of the time required to
- Check Operation to confirm its serviceability. heat soak the thermostat.
Note that the thermostat is a non-serviceable
item. If the thermostat is faulty or damaged it 1. Make sure that the engine is safe to work on. If
must be renewed. the engine has been running, let it cool before
2. Inspect the seal for damage or splits. If necessary
renew the seal. Make sure that the seal is 2. Remove the thermostat housing and the
correctly located. thermostat. Refer to (PIL 21-12).
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 491.
Figure 491.
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.
6. Record the start to open temperature, the fully
open temperature and the amount of valve lift
travel when fully open. Compare this with the
data in Technical Data (PIL 21-00).
21 - 41 9813/9100-1 21 - 41
21 - Cooling System
12 - Thermostat
00 - General

Remove removal procedure. Additionally do the following
step.
2. Replace the seal.
the engine has been running, let it cool before 4. When you fill the cooling system, make sure that
you start the service work. you use the correct water/antifreeze mixture. A
50% mixture should be maintained even if frost
3. Drain the coolant. protection is not required.
4. Disconnect the hose from the thermostat Table 196. Torque Values
housing.
Item Nm
5. Remove the bolts (x3). A 24 ± 2
Figure 492.
B
A
A Bolts (x3)
B Thermostat housing
6. Remove the thermostat housing.
7. Remove the thermostat.
Figure 493.
C Thermostat
D Seal
8. Remove the seal. The seal must not be reused,
discard the seal.
21 - 42 9813/9100-1 21 - 42
21 - Cooling System
15 - Heater
15 - Heater
Contents Page No.
21-15-00 General ........................................................................................................................... 21-45
21 - 43 9813/9100-1 21 - 43
Notes:
21 - 44 9813/9100-1 21 - 44
21 - Cooling System
15 - Heater
00 - General
00 - General Install
steps.
Before Removal 2. Install new track seals. Make sure that the seals
are correctly located in the groove on the housing
This procedure requires service parts. Make sure with the locating tab in the cut out.
you start. Refer to the Parts Catalogue. Figure 495.

3. Get access to the engine. C
D
4. Drain the coolant. D
Refer to: PIL 21-00-00. C Track seals (x2)
D Locating tab
The housing may be orientated differently to that
shown in the illustration, depending on the engine 3. Tighten the bolts to the correct torque value.
installation.
4. Connect the cab heater hoses.
Remove
After Installation
1. Disconnect the hoses from the cab heater spigot.
1. Fill the engine with the recommended coolant
2. Remove the bolts (x3). mixture.
3. Remove the cab heater spigot and the track seals Refer to: PIL 21-00-00.
(x2). The track seals must not be reused. Discard 2. Start the engine and check for coolant leaks.
the track seals.
Item Nm
A 24 ± 2
A
B
A Bolts (x3)
B Cab heater spigot
21 - 45 9813/9100-1 21 - 45
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-47
21 - 46 9813/9100-1 21 - 46
21 - Cooling System
21 - Inlet
00 - General
steps.
Before Removal 2. Install a new track seal. Make sure that the seal
This procedure requires service parts. Make sure with the locating tab in the cut-out.
you start, refer to the Parts Catalogue. Figure 497.

D
The housing may be orientated differently to that

shown in the illustration, depending on the engine
installation. C
C Track seal
Remove D Locating tab
1. Disconnect the radiator hose from the inlet elbow. 3. Tighten the bolts to the correct torque value.
2. Remove the bolts (x4). 4. Connect the radiator hose to the housing.
3. Remove the inlet elbow and the track seal. The
track seal must not be reused. Discard the track After Installation
seal. 1. Fill the engine with the recommended coolant
Figure 496. mixture.
A Table 198. Torque Values

Item Nm
A 24 ± 2
A
A Bolts (x4)
B Inlet elbow
21 - 47 9813/9100-1 21 - 47
21 - Cooling System
42 - Manifold
42 - Manifold
Contents Page No.
21-42-00 General ........................................................................................................................... 21-49
21 - 48 9813/9100-1 21 - 48
21 - Cooling System
42 - Manifold
00 - General
steps.
Before Removal 2. Install a new track seal. Make sure that the seal
This procedure requires service parts. Make sure with the locating tab in the cut-out.
you start, refer to the Parts Catalogue. Figure 499.

E
3. Get access to the engine. C
Refer to: PIL 21-00-00. D
Remove
1. Remove the oil filter.
2. Disconnect the coolant hoses (x2).
Figure 498.
B C Coolant manifold
D Track seal
E Locating tab
A
C 4. Fill the engine with the recommended coolant
mixture.
B
5. Start the engine and check for coolant leaks

Item Nm
B 24 ± 2
A Coolant hoses (x2)
B Bolts (x3)
C Coolant manifold
4. Remove the coolant manifold and the track seal.
The track seal must not be reused. Discard the
track seal.
21 - 49 9813/9100-1 21 - 49
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-51
21 - 50 9813/9100-1 21 - 50
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-51 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-52 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-52 between the engine and the radiator/cooling pack.
21 - 51 9813/9100-1 21 - 51
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 - 52 9813/9100-1 21 - 52
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ........................................................................................................................... 24-13
24-03-01 Master Cylinder .............................................................................................................. 24-23
24-03-03 Tank ................................................................................................................................ 24-26
24-03-39 Piston ............................................................................................................................. 24-27
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-31
24-03-46 Vacuum Pump ................................................................................................................ 24-34
24-03-50 Light Switch .................................................................................................................... 24-39
24-03-57 Pressure Sensor ............................................................................................................ 24-43
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-45
24-18-03 Switch ............................................................................................................................. 24-57
24-18-06 Cable .............................................................................................................................. 24-59
24-18-15 Pad ................................................................................................................................. 24-69
24-18-18 Caliper ............................................................................................................................ 24-70
24-18-21 Disc ................................................................................................................................ 24-77
24-18-48 Actuator .......................................................................................................................... 24-87
9813/9100-1
2017-08-02
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
9813/9100-1
2017-08-02
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/9100-1 24 - 1
Notes:
24 - 2 9813/9100-1 24 - 2
24 - Brake System
00 - Brake System
00 - General

Health and Safety ........................................... 24-3 Brake Fluid
Technical Data ................................................. 24-5 Use of incorrect brake fluid will cause serious
Fault-Finding .................................................... 24-8 damage to the seals of the braking system. This will
Check (Level) ................................................ 24-11 result in brake failure.
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.
Working Under the Machine
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
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
24 - 3 9813/9100-1 24 - 3
24 - Brake System
00 - Brake System
00 - General
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 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 9813/9100-1 24 - 4
24 - Brake System
00 - Brake System
00 - General
Technical Data
For: 533-105 [T4F] ...................... Page 24-5

For: 535-v125 [T4F], 540-v180 [T4F]
..................................................... Page 24-5
For: 540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 550-140 [T4F], 550-170 [T4F]
..................................................... Page 24-6
(For: 533-105 [T4F])
Single axle service brakes system
Table 200. Service brake

Type Single circuit, oil immersed multi-plate disc.
Actuation Hydraulic.
Hydraulic, servo assisted.
(1)
Location Front axle, centre mounted (2 brake packs).

(1) Machines with turbo inter-cooled engines.
Table 201. Master cylinder

Type Master cylinder.
Master cylinder with remote servo unit.
(1)
No. of Cylinders 1
Diameter 31.75mm
Stroke 39mm
Displacement Minimum- 2835 cc.
(1) Machines with turbo inter-cooled engines.
Table 202. Servo unit

Type Vacuum assisted hydraulic valve.
Vacuum cylinder diameter 175mm
Hydraulic cylinder diameter 22.2mm
Brake vacuum pressure 0.8–1bar (11.6–14.5psi)
Minimum oil displacement 23.6 cc
Stroke 61mm
Table 203. Park brake

Type Independent disc (with manually adjusted calliper)
park brake in the drive to the front axle.
Actuation Cable operated.
Location Mounted on the gearbox.
Disc diameter 279.4mm
(For: 535-v125 [T4F], 540-v180 [T4F])
Twin axle service brake system (S1)
Table 204. Service brakes

Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic, servo assisted.
(1)
24 - 5 9813/9100-1 24 - 5
24 - Brake System
00 - Brake System
00 - General

Rear axle, centre mounted (2 brake packs).
(1) Machines installed with turbo inter-cooled engines.
Table 205. Master Cylinder

Type Master cylinder with remote servo unit.
(1)
No. of Cylinders 1
Diameter 38.1mm
Stroke 35mm
Displacement 39.5 cc/min
Table 206. Servo unit

Oil displacement 32 cc
Stroke TBA
Table 207. Park brake

Type Independent disc (with manually adjusted caliper)
(For: 540-140 [T4F], 540-170 [T4F], 540-200 [T4F], 550-140 [T4F], 550-170 [T4F])
Twin Axle Service Brake System
Table 208. Service Brakes

Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic, servo assisted.
(1)

Rear axle, hub mounted (2 brake packs).
Table 209. Master Cylinder

Type Master cylinder with remote servo unit.
(1)
No. of cylinders 1
Diameter 41.28mm
Stroke 35mm
Displacement 42.81 cc/min
Table 210. Servo Unit

24 - 6 9813/9100-1 24 - 6
24 - Brake System
00 - Brake System
00 - General
Oil displacement 32 cc
Stroke TBA
Table 211. Park Brake- PS750 Gearbox (if installed)

Type Independent disc (with manually adjusted caliper)
Table 212. Park Brake- PS760 Gearbox (if installed)

Type Operates on the drive to the front axle via an oil im-
mersed, multi-plate brake pack housed inside the
gearbox.
Location Mounted in the gearbox.
Friction pack thickness (new) 38.9mm
Friction pack minimum thickness 37.1mm
24 - 7 9813/9100-1 24 - 7
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 213. Page 24-8
pulling to one side)
Pedal travel excessive (but not touching floor) Table 214. Page 24-8
Pedal hard to operate Table 215. Page 24-8
Pedal touches floor under constant pressure- no fluid loss Table 216. Page 24-9
Pedal touches floor under constant pressure and fluid loss Table 217. Page 24-9
Poor braking (not pulling to one side) Table 218. Page 24-9
Brakes not releasing Table 219. Page 24-9
Poor braking when hot Table 220. Page 24-10
Excessive brake noise in operation (Due to the metal to metal contact of oil Table 221. Page 24-10
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 222. Page 24-10
the fault is as indicated by checking that the brake pedal does not touch the
floor when it is operated under constant pressure).
Table 213. 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 214. 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 215. 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 - 8 9813/9100-1 24 - 8
24 - Brake System
00 - Brake System
00 - General
Table 216. 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 217. 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 218. 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 219. 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: 0.5mm
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 - 9 9813/9100-1 24 - 9
24 - Brake System
00 - Brake System
00 - General
Table 220. 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 221. 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 222. 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 - 10 9813/9100-1 24 - 10
24 - Brake System
00 - Brake System
00 - General
Check (Level) Figure 501.

A
(For: 533-105 [T4F], 535-v125 [T4F],
540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F])
WARNING Faulty brakes can kill. If you have
to top up the brake reservoir frequently, get the B
brake system checked by your JCB Dealer. Do
not use the machine until the fault has been put
right.
the correct fluid. The fluid can harm your skin.
Wear rubber gloves. Cover cuts or grazes.
A Tank cap
The brake fluid tank is in the panel in front of the cab. B Tank
Pull the release knob to open the panel.
3.1. Remove the tank cap.
Figure 500. 3.2. Add the recommended fluid slowly.
3.3. Replace the tank cap.
3.4. Clean any spilt fluid.
A Knob
2. Check the brake fluid level. The correct fluid level
is marked on the tank.
3. If necessary, add more fluid:
24 - 11 9813/9100-1 24 - 11
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ........................................................................................................................... 24-13

24-03-01 Master Cylinder .............................................................................................................. 24-23
24-03-03 Tank ................................................................................................................................ 24-26
24-03-39 Piston ............................................................................................................................. 24-27
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-31
24-03-46 Vacuum Pump ................................................................................................................ 24-34
24-03-50 Light Switch .................................................................................................................... 24-39
24-03-57 Pressure Sensor ............................................................................................................ 24-43
24 - 12 9813/9100-1 24 - 12
24 - Brake System
03 - Service Brake
00 - General
Introduction .................................................... 24-13 The service brake is used to stop the machine when
Component Identification ............................... 24-14 it is in motion.
Diagram ......................................................... 24-17
Bleed ............................................................. 24-20 The service brake is a hydraulic system. The
machine operator applies pressure to the brake
Disassemble and Assemble .......................... 24-22 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 - 13 9813/9100-1 24 - 13
24 - Brake System
03 - Service Brake
00 - General
For: 533-105 [T4F] .................... Page 24-14 vacuum pump and remotely mounted servo unit
For: 535-v125 [T4F], 540-140 [T4F], 540-170 which is located on the front of the cab.
[T4F], 540-200 [T4F], 540-v180 [T4F],
550-170 [T4F] ........................... Page 24-15 The brake hydraulic fluid tank is situated outside the
For: 535-v125 [T4F], 540-v140 [T4F], cab, below the front windscreen.
550-140 [T4F] ........................... Page 24-16
An electrical switch is fitted to the pedal assembly for
operation of the rear facing brake lights.
(For: 533-105 [T4F])
Auto 4-wheel braking
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
the brake pedal is released.
Figure 502.
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)
24 - 14 9813/9100-1 24 - 14
24 - Brake System
03 - Service Brake
00 - General
E Servo unit F Brake fluid tank

G Brake light electrical switch
(For: 535-v125 [T4F], 540-140 [T4F], hydraulically by a single foot pedal and master
540-170 [T4F], 540-200 [T4F], 540-v180 cylinder. An exhauster (vacuum) unit is fitted on the
engine to power the servo unit.
[T4F], 550-170 [T4F])
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 223. Component Location Table

Braking system 507-42, 509-42, 510-56, 512-56, 514-56, 540-170,
540-140, 540-200
Servo unit Located under the RH rear of the chassis
Figure 503.
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 Exhauster (vacuum) unit (the location of the
between machine models, refer to the exhauster on the engine depends on the engine
component location table). installed)
C Brake fluid tank D Master cylinder
E Pedal
24 - 15 9813/9100-1 24 - 15
24 - Brake System
03 - Service Brake
00 - General
(For: 535-v125 [T4F], 540-v140 [T4F], hydraulically by a single foot pedal and master
550-140 [T4F]) cylinder. An exhauster (vacuum) unit is fitted on the
engine to power the servo unit.
Twin axle service brakes system The brake hydraulic fluid tank is situated outside the
cab, below the front windscreen.
The service brakes act on the front and rear axle
half shafts of the machine. The multi-disc brakes are The location of servo unit varies between machine
immersed in oil. The brake packs and are operated models. Refer to component location table.
Table 224. Component Location Table

Braking system 535-125, 540-v140, 550-140
Servo unit Located under the centre front of the chassis
Figure 504.
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 - 16 9813/9100-1 24 - 16
24 - Brake System
03 - Service Brake
00 - General
Diagram
For: 533-105 [T4F] .................... Page 24-17

For: 535-v125 [T4F], 540-140 [T4F], 540-170
[T4F], 540-v180 [T4F], 550-170 [T4F]
................................................... Page 24-19
(For: 533-105 [T4F])

Hose and pipework- Machines with trailer brakes
Figure 505.
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 - 17 9813/9100-1 24 - 17
24 - Brake System
03 - Service Brake
00 - General
Hose and pipework- Machines without trailer brakes
Figure 506.
D
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
24 - 18 9813/9100-1 24 - 18
24 - Brake System
03 - Service Brake
00 - General
(For: 535-v125 [T4F], 540-140 [T4F], 540-170 [T4F], 540-v180 [T4F], 550-170 [T4F])
Twin axle service brakes system

Hydraulic operation and schematics
Figure 507.
A Fluid tank B Master cylinder

C Master cylinder (servo unit) D Servo unit
E Front brake packs F Rear brake packs
24 - 19 9813/9100-1 24 - 19
24 - Brake System
03 - Service Brake
00 - General
Bleed Figure 509. Servo unit
For: 533-105 [T4F] .................... Page 24-20

For: 535-v125 [T4F], 540-140 [T4F], 540-170
[T4F], 540-200 [T4F], 540-v140 [T4F], 540-
v180 [T4F], 550-140 [T4F], 550-170 [T4F]
................................................... Page 24-20
(For: 533-105 [T4F])
Single axle service brake system

WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn
cause brake failure.

B
2. Follow all the care and safety procedures. Refer
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
B Bleed point on servo unit
the point on the front axle.
6. Attach a tube to the applicable bleed screw.
Figure 508. Front axle
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
A 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.
10. Top up the tank to the full mark.
A Bleed point on front axle
(For: 535-v125 [T4F], 540-140 [T4F],
5.2. Machines with servo brakes- Bleed at the 540-170 [T4F], 540-200 [T4F], 540-v140
point on the servo unit and the point on the [T4F], 540-v180 [T4F], 550-140 [T4F],
front axle. 550-170 [T4F])
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 - 20 9813/9100-1 24 - 20
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 510. Servo unit
B Bleed point on servo unit

Figure 511. 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 - 21 9813/9100-1 24 - 21
24 - Brake System
03 - Service Brake
00 - General
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F])
Refer to driveline, axle, general, dissasemble and
assemble, (PIL 27-20-00).
24 - 22 9813/9100-1 24 - 22
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Remove and Install

Remove and Install ....................................... 24-23 The master cylinder is a non-serviceable part. If it is
Disassemble and Assemble .......................... 24-25 defective, it must be replaced with a new one.
Remove
30-00).
4. For machines with power brake system,
Discharge the brake system pressure. Refer to
(PIL 24-00).
5. Remove the retaining clip.
Figure 512. Single axle brak-
ing system- Master cylinder
A C
B
E
F G E
A Retaining clip
B Clevis pin
C Brake pedal lever bracket
D Operating rod
E Nut
F Bolt
G Master cylinder
6. Remove the clevis pin to disconnect the master
cylinder operating rod from the brake pedal lever
bracket.
24 - 23 9813/9100-1 24 - 23
24 - Brake System
03 - Service Brake
Figure 513. Twin axle brak- Figure 514.

ing system- Master cylinder
A C
D F
H
F
E
G
J
K
A Retaining clip
B Clevis pin
C Brake pedal lever bracket
D Operating rod
E Nut H Cab front cover
F Bolt J Plastic feed pipe
G Master cylinder K Master cylinder output hose
7. Get access to the master cylinder hydraulic 10. Plug the cylinder port and blank off the hose (or
connections which are located behind the cab pipe) to prevent ingress of dirt.
front cover.
11. Machines with twin axle service brakes have
8. Disconnect the plastic feed pipe from the brake three master cylinder securing bolts. Machines
fluid tank and then either blank off the pipe or with single axle service brakes have two securing
drain the tank. bolts.
9. Disconnect the master cylinder output hose (or 12. Support the master cylinder.
pipe as applicable).
13. Remove the nuts and the bolts.
14. 'Remove the master cylinder from the machine.
Install
steps.
1.1. Once the master cylinder is installed and
the pipework connected make sure the
brake fluid tank level is correct. Refer to (PIL
24-00).
1.2. Bleed the brake system. Refer to (PIL
24-00).
1.3. Check the operation of the brake light
switch and adjust if necessary. Refer to (PIL
24-03-50).
24 - 24 9813/9100-1 24 - 24
24 - Brake System
03 - Service Brake
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 25 9813/9100-1 24 - 25
24 - Brake System
03 - Service Brake
03 - Tank
03 - Tank Figure 515.
Remove and Install
(For: 535-v125 [T4F], 540-140 [T4F],

540-170 [T4F], 540-200 [T4F], 540-v140
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F]) A
D
Remove
2. Make sure that the engine cannot be started.
3. Remove the cover at the front of the cab. Refer
to (PIL 24-00).
4. Clean the tank and the tube.
5. Seal off the tube with a clamp. C
B
6. Remove and discard the clip.
7. When the tube is removed from the tank, there
will be brake fluid leakage. Put a container below
the tube to collect the fluid.
8. Remove the tube from the tank. A Tank
B Tube
9. Put a cap on the pipe on the bottom of the tank. C Clip
D Bolts
10. Support the tank and remove the bolts.
11. Remove the tank. Keep the tank vertical. Install
steps.
1.1. Examine the tube. If it is defective, replace
it with a new one.
1.2. Use a new clip.
value.
1.4. Bleed the brakes. Refer to (PIL 24-03).

Item Description Nm
D Bolts 5.5
24 - 26 9813/9100-1 24 - 26
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-27
Technical Data ............................................... 24-28
Brake Piston Seal Leakage
Check (Leaks) ............................................... 24-28 The most common reason for internal piston seal
Disassemble and Assemble .......................... 24-30 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 - 27 9813/9100-1 24 - 27
24 - Brake System
03 - Service Brake
39 - Piston
Technical Data Check (Leaks)
Refer to brakes- general, refer to (PIL 24-00). (For: 533-105 [T4F], 540-200 [T4F], 540-
v140 [T4F], 540-v180 [T4F], 550-140
[T4F], 550-170 [T4F])
Special Tools
Bar)
Consumables
JCB Hydraulic Fluid HP 4002/0501 1L
15 4002/0503 5L
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.
The most common reason for internal piston seal

leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service
periods.
Two types of internal leakage can occur within the

axle or hub:
1. Low Pressure Leaks- Seal damage, or scoring to

seal component surfaces, caused by a build-up
of metal particles.
2. High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
The low pressure leak test should be performed

first. Low pressure leaks are difficult to find using a
high pressure test- seals and other components can
distort and form a seal under pressure.
The following procedures explain how to check for

low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.

2. Disconnect the brake piston feed pipe (or hose,
as applicable) at port 1.
contamination.
24 - 28 9813/9100-1 24 - 28
24 - Brake System
03 - Service Brake
39 - Piston
4. Completely remove the pipe and install a plug at Figure 517.

port 2.
5. Fill both brake piston housings with JCB Light
Hydraulic Fluid through the port 1 and port 3.
X
Consumable: JCB Hydraulic Fluid HP 15
Figure 516.
D
A
E
B C
F
E Port 4
A Port 1 F Brake piston port
B Pipe X Brake fluid level line
C Port 2
D Port 3 7. Test for a high pressure leak as follows:
6. Test for a low pressure leak as follows: 7.1. Install a hand pump installed with a
pressure gauge of the specified value to the
6.1. Install an adaptor with a piece of clear tube brake piston port.
to the brake piston port. Special Tool: Pressure Gauge (0-40 Bar)
6.2. Make sure you keep the tube vertical during (Qty.: 1)
the test. Use tape to attach the tube to the 7.2. Fill the hand pump with the correct
side of the machine. Hydraulic Fluid.
6.3. Fill the tube until approximately three 7.3. Use the hand pump to generate a pressure
quarters full with the correct Hydraulic Fluid. in the brake piston housing. Do not exceed
6.4. Use a suitable pen to mark the level line of the specified value.
the brake fluid on the tube. Pressure: 69bar (1,000.0psi)
6.5. After approximately 30 minutes, check if 7.4. If the pressure falls off rapidly, or if no
the level has dropped below the original pressure reading can be obtained, the
marked line. If it has, check the brake piston piston seal is severely damaged. Install a
seal for slight nicks, cuts or generally for new seal.
wear.
7.5. Repeat the 7.1 to step 7.4 at port 4.
6.6. Repeat the step 6.1 to step 6.5 at port 4.
24 - 29 9813/9100-1 24 - 29
24 - Brake System
03 - Service Brake
39 - Piston
Figure 518. Disassemble and Assemble
Refer to driveline- front axle, refer to (PIL 27-20).

X
E Port 4
F Brake piston port
X Brake fluid level line
8. Put the brake system back to the original
condition as follows:
8.1. Connect all the brake pipes and bleed
the brake system. Refer to brakes- service
brake. Refer to (PIL 24-03).
For twin axle brake systems, do this procedure on

the other axle, if applicable.
24 - 30 9813/9100-1 24 - 30
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit Check (Leaks)

Check (Leaks) ............................................... 24-31 Refer to (PIL 24-03-46).
24 - 31 9813/9100-1 24 - 31
24 - Brake System
03 - Service Brake
Remove and Install
For: 533-105 [T4F] .................... Page 24-32 3. Disconnect the servo vacuum hose.
For: 535-v125 [T4F], 540-140 [T4F],
540-170 [T4F], 540-200 [T4F], 540-v140 4. Disconnect and install a plug on the master
[T4F], 550-140 [T4F], 550-170 [T4F] cylinder output pipe. Install a plug on the cylinder
................................................... Page 24-33 port.
5. Disconnect and install a plug on the cylinder
(For: 533-105 [T4F]) output hose. Install a plug on the cylinder port.
Servo unit- Single axle brakes 6. Loosen the securing bolts (x3) and slide the
servo unit out of its mounting bracket.
Remove 7. Make sure you carefully keep the washers (if
1. Make the machine safe. Refer to (PIL 01-03). installed).

Figure 519.
D A B
D D
D
E
G F
A Servo vacuum hose B Master cylinder output pipe

C Cylinder output hose D Bolts (x3)
E Bracket F Washers
G Servo unit
24 - 32 9813/9100-1 24 - 32
24 - Brake System
03 - Service Brake
Install Figure 520.
1. The installation procedure is the opposite of the E B

steps.
1.1. Check the brake fluid level. Refer to (PIL
24-00).
1.2. Make sure to install the washers, if installed.
24-03). D
(For: 535-v125 [T4F], 540-140 [T4F],

540-170 [T4F], 540-200 [T4F], 540-v140
[T4F], 550-140 [T4F], 550-170 [T4F])
Servo Unit- Twin axle brakes C
Remove
E A
1. Make the machine safe. Refer to (PIL 01-03). F E
Refer to (PIL 01-03). A Servo vacuum hose
B Master cylinder hose
3. Disconnect the servo vacuum hose. C Cylinder output hose
D Servo breather hose
4. Disconnect and install a plug on the master E Securing nuts (x3)
cylinder hose. Install a plug on the cylinder port. F Mounting bracket
5. Disconnect and install a plug on the cylinder Install
output hose. Install a plug on the cylinder port.
6. Disconnect the servo breather hose. removal procedure. Additionally do the following
7. Remove the securing nuts (x3) and lift the servo steps.
unit complete with the rear mounting bracket 1.1. Check the brake fluid level. Refer to (PIL
from the front mounting bracket. 24-00).
24-03).
24 - 33 9813/9100-1 24 - 33
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump Introduction

Introduction .................................................... 24-34 The service brake system requires vacuum
Component Identification ............................... 24-35 assistance to operate.
Check (Leaks) ............................................... 24-35
Remove and Install ....................................... 24-37 On machines with standard hydraulic service brakes
the vacuum assistance is provided by a vacuum
pump mounted on the engine.
24 - 34 9813/9100-1 24 - 34
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Component Identification Check (Leaks)

Figure 521. JCB 430 Engine The procedure explains how to determine if the brake
servo vacuum system is functioning correctly.
The following test equipment is used to carry out this

A test:
• Vacuum gauge (range up to 1 bar).

• T-adaptor.
• Vacuum hose- 2 lengths x 75 mm (3 inch) long.
• Clips- worm drive.
Brake Vacuum Test (if applicable)

2. Open the engine compartment cover. Refer to
(PIL 06-06).
A Brake Exhauster (Vacuum) 3. Disconnect the brake vacuum line at the brake
vacuum pump and connect a vacuum gauge
directly to the pump.
3.1. The location of the vacuum pump may
differ depending on the specification of your
machine.
4. Run the engine at 1500 RPM (Revolutions Per
Minute) and note the reading on the vacuum
gauge:
4.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
4.2. If there is little or no vacuum, renew the
vacuum pump.
5. Remove the vacuum gauge from the pump port
and connect it again into the brake vacuum line
using a T-adaptor.
6. Run the engine at 1500 RPM and note the
reading on the vacuum gauge:
6.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
6.2. If there is little or no vacuum, check the
vacuum hose connections for leaks.
6.3. Check the security of the clips and then do
step 7.
7. Switch OFF the engine and monitor the vacuum
gauge reading:
7.1. Make sure that the mercury (Hg) level stays
above the specified value after 60 seconds.
24 - 35 9813/9100-1 24 - 35
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
7.2. Check that the vacuum is sufficient for 3 or 4

pedal operations. The vacuum must decay
slowly with each pedal operation.
8. The brake vacuum pump and brake servo unit
are non-serviceable parts. If they are suspected
as being faulty, install new parts.
Figure 522. Typical Vacuum Pump Installation
A Brake vacuum line

B T-adaptor
24 - 36 9813/9100-1 24 - 36
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Remove and Install
If the brake performance is poor and the brake servo 7. Install a cap on the open ends of the hoses to
vacuum is suspected, do the brake vacuum test prevent the ingress of dirt. Tie the hoses out of
before you install a new servo exhauster unit. Refer the way.
to brakes- service brake. Refer to (PIL 24-03).
8. Remove the screws and carefully take out the
servo exhauster unit from the engine. Discard the
Remove gasket.
1. Make the machine safe. Refer to (PIL 01-03)
Install
Refer to (PIL 01-03). The servo exhauster unit is a non-serviceable part. If
it is suspected as being faulty it must be renewed as
3. Disconnect the battery. Refer to (PIL 33-03). a complete assembly.
4. Open the engine compartment cover. Refer to
The special adaptor is installed with an oil feed
(PIL 06-06).
restrictor orifice (3 mm diameter). Check to make
5. Remove the clip and release the brake vacuum sure that the orifice is not blocked before installing
hose from the pipe stub. the servo exhauster unit.
6. Disconnect the oil feed hose. 1. The installation procedure is the opposite of the
steps.
Figure 523. JCB 430 Engine

B C
D
24 - 37 9813/9100-1 24 - 37
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
A Gasket (not shown) B Screw (X2)

C Vacuum pipe stub D Lubrication pipe and restrictor
E Drive gear F O-ring seal
1.1. Make sure that the servo exhauster unit

flange and the engine mating face is clean.
Install a new seal.
1.2. Carefully align the gear so that the gear
teeth engages with the drive gear in the
engine.
1.3. Tighten the screws to the specified torque
value.
1.4. On completion, make sure the brakes work
correctly.

Item Nm
B 47
24 - 38 9813/9100-1 24 - 38
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-39 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-40 harness.
Figure 524.
3 2 1 3 2 1
24 - 39 9813/9100-1 24 - 39
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 526.
Brake Light Switch- Proximity Type
Figure 525.
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.
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 - 40 9813/9100-1 24 - 40
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 527.
A Electrical connector B Bracket

C Screw D Switch
24 - 41 9813/9100-1 24 - 41
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 42 9813/9100-1 24 - 42
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 - 43 9813/9100-1 24 - 43
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-45

24-18-03 Switch ............................................................................................................................. 24-57
24-18-06 Cable .............................................................................................................................. 24-59
24-18-15 Pad ................................................................................................................................. 24-69
24-18-18 Caliper ............................................................................................................................ 24-70
24-18-21 Disc ................................................................................................................................ 24-77
24-18-48 Actuator .......................................................................................................................... 24-87
24 - 44 9813/9100-1 24 - 44
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-45 The park brake also called the hand brake is a
Technical Data ............................................... 24-46 latching brake usually used to keep the vehicle
Operation ....................................................... 24-46 stationary. It is also used to prevent a vehicle from
Check (Condition) .......................................... 24-47 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Check (Operation) ......................................... 24-48
Adjust ............................................................ 24-49 The park brake usually consists of a cable directly
Disassemble and Assemble .......................... 24-52 connected to the brake mechanism on one end, and
to a hand-operated lever, on the floor at the side of
the driver.
24 - 45 9813/9100-1 24 - 45
24 - Brake System
18 - Park Brake
00 - General
Technical Data Operation

For: PS764, PS766 ................... Page 24-46 For: PS750 MK4 ....................... Page 24-46
For: PS750 MK4 ....................... Page 24-46 For: PS764, PS766 ................... Page 24-46
(For: PS764, PS766) (For: PS750 MK4)

Table 228. 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 528.
Table 229. Park Brake B
Description Acceptable Tolerances
Disc minimum thickness 8.9mm
Pad minimum thickness 1mm
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.
The lever has a simple system for adjustment of the

cable when necessary.
24 - 46 9813/9100-1 24 - 46
24 - Brake System
18 - Park Brake
00 - General
Figure 529. Check (Condition)

For: PS764, PS766 ................... Page 24-47
For: PS750 MK4 ....................... Page 24-48
A
(For: PS764, PS766)
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
A Multi-plate brake pack plates. If any of the plates show signs of damage
or distortion, renew the complete plate pack.
An electrical switch senses if the park brake lever
is set to the brake on or brake off position. The Figure 530.
switch controls operator warnings and transmission
interlocks. 1
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 531.
X Friction pack assembly thickness

2.1. If the friction pack is outside these limits,
the complete friction pack assembly must
be renewed.
24 - 47 9813/9100-1 24 - 47
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
WARNING Oil on the brake disc will reduce sure the area around the machine is clear of
brake effectiveness. Keep oil away from the people.
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the 1. Park the machine and make it safe.
solvent manufacturer's safety instructions. If the
pads are oily, install with the new pads. 2. Follow the care and safety procedures. Refer to
(PIL 01-03).
1. Follow the brake pad removal instructions. refer
to (PIL 24-03). 3. Apply the park brake fully.
2. Make sure that the minimum thickness of the 4. Start the engine and raise the attachments to the
friction material on either pad is 1mm (0.04 in), appropriate travelling position.
but it is recommended to install new pads as it 5. Select the fourth gear.
may not be possible to adjust pads worn to this
limit. 6. Push down hard on foot brake pedal.
3. Check the condition of the disc surface. Install a 7. Select forward drive on the left hand column
new disc if the surface is badly warped, pitted or switch.
worn.
WARNING! If the machine starts to move during
4. Make sure the actuator is adjusted correctly. the park brake test, immediately apply the foot
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: 20s
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 - 48 9813/9100-1 24 - 48
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 24-49
For: PS764, PS766 ................... Page 24-50
Figure 532.
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
has been used in an emergency the brake pack

0 25
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
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

emergency stop, remove and install new brake
A
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 - 49 9813/9100-1 24 - 49
24 - Brake System
18 - Park Brake
00 - General
Figure 533. forward and reverse lever away from neutral (starter
switch at IGN).
A
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.
Figure 534.
B
A Handle grip
B Pin D
(For: PS764, PS766)

Consumables
C
JCB Multi-Gasket 4102/1212 0.05L
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.
A Screws
WARNING Do not use a machine with a faulty B Bolts 1
park brake. 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 535.
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
F Pin
Adjustment at the park brake lever should only
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
should illuminate when the brake is engaged with the
24 - 50 9813/9100-1 24 - 50
24 - Brake System
18 - Park Brake
00 - General
7. After adjusting the park brake lever, do Figure 537.

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 536.
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 230. 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 - 51 9813/9100-1 24 - 51
24 - Brake System
18 - Park Brake
00 - General
(For: PS764, PS766)

Consumables
24 - 52 9813/9100-1 24 - 52
24 - Brake System
18 - Park Brake
00 - General
Disassemble
Figure 538.
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 - 53 9813/9100-1 24 - 53
24 - Brake System
18 - Park Brake
00 - General
1. Position the output yoke as shown. Refer to 5.3. Friction plates.

Figure 539.
5.4. Counter plates.
Figure 539.
6. If the brake assembly is being removed before
you disassemble the gearbox, then remove the
reaction pins. Refer to Figure 538.
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 540.
Figure 540.
M
K
K Output yoke
2. Remove the cover plate as follows: Refer to
Figure 538.
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 538.
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 538. M Circlip
N Clevis pin
5. Remove the following: Refer to Figure 538.
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 - 54 9813/9100-1 24 - 54
24 - Brake System
18 - Park Brake
00 - General
Assemble
Figure 541.
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 - 55 9813/9100-1 24 - 55
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 541.
2. Assemble the reaction pins and then install the
friction pack in the gearbox case. Refer to Figure Consumable: JCB Multi-Gasket
541. 6. Attach the cover with the bolts (x4). Refer to
2.1. Note that a counter plate is installed first Figure 541.
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 542. Refer to Figure 541.
Figure 542. 8. Apply a bead of sealant to the mating face on the

cover. Refer to Figure 541.
L R Consumable: JCB Multi-Gasket
M 9. Attach the cover plate with screws (x5) and the

bolts (x2). Refer to Figure 541.
10. Tighten the screws and bolts to the correct torque
value. Refer to Figure 541.
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 - 56 9813/9100-1 24 - 56
24 - Brake System
18 - Park Brake
03 - Switch
03 - Switch Adjust
Adjust ............................................................ 24-57
(For: 540-140 [T4F], 540-170 [T4F], 540-
v180 [T4F], 550-170 [T4F])
The park brake switch is reed type. It operates when
the metal vane moves between the switch faces. The
switch is not adjustable.
If switch failure is suspected, then check all the

related wires and connectors for damage. Make sure
that the vane moves between the switch faces when
the park brake is operated. If the switch fails, then
install a new switch.
Figure 543.
C
A
C
A Park brake switch

B Vane
C Switch faces
24 - 57 9813/9100-1 24 - 57
24 - Brake System
18 - Park Brake
03 - Switch

Remove removal procedure.
1. Park the machine and make it safe. Follow all 2. When installing do the following steps also:
safety precautions. Please see (PIL 01-03). 2.1. To align the switch correctly, engage the
2. Put chocks on both sides of the wheels to prevent switch location dowel with the hole in the
the machine rolling. Release the park brake. mounting bracket.
3. Remove the rubber gaiter.

switch connector.
5. Hold the switch and remove the screw.
6. Remove the switch.
Figure 544.
B G D
F
C
A Rubber gaiter
B Switch
D Switch connector
E Screw
F Dowel
G Mounting bracket
24 - 58 9813/9100-1 24 - 58
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-59 For: PS750 Mk4, PS750 MK4
................................................... Page 24-59
For: PS764, PS766 ................... Page 24-60
(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: 0.5–0.75mm
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 - 59 9813/9100-1 24 - 59
24 - Brake System
18 - Park Brake
06 - Cable
Figure 545.
C
A Hand grip
B Pin
C Locknuts
Figure 546.
D
D Operating lever
(For: PS764, PS766) The park brake should be fully engaged when
the lever is vertical. The park brake indicator light
During normal operation little or no adjustment of should illuminate when the brake is engaged with the
the brake cable at the lever is required. In the forward and reverse lever away from neutral (starter
event of poor brake performance it is likely that switch at IGN).
components have failed or, after extended service,
friction material is worn away. Dismantle, inspect and 1. Before attempting to adjust the park brake
install components as required. after an emergency stop remove and inspect
24 - 60 9813/9100-1 24 - 60
24 - Brake System
18 - Park Brake
06 - Cable
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)
4. Turn the hand grip clockwise, half a turn.
Figure 547.
A Screws (x5) B Bolts (x2)

C Housing cut out D Cover plate
Figure 548. 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 - 61 9813/9100-1 24 - 61
24 - Brake System
18 - Park Brake
06 - Cable
Figure 549.
H J
G Clevis pin hexagon H Bolt

J Cover plate
6.1. Remove (x5) screws and (x2) bolts. Using a Figure 550.
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 - 62 9813/9100-1 24 - 62
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 - 63 9813/9100-1 24 - 63
24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
For: PS750 Mk4, PS750 MK4 Remove

................................................... Page 24-64
For: PS764, PS766 ................... Page 24-66 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 551.
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 - 64 9813/9100-1 24 - 64
24 - Brake System
18 - Park Brake
06 - Cable
Figure 552.
K
K
N L
M
P
Install
Table 233. 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 - 65 9813/9100-1 24 - 65
24 - Brake System
18 - Park Brake
06 - Cable
7. Adjust the sleeve and the locknut 2 until you get Figure 553.
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: 15mm 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 234. Torque Values B Bolts (x2)
C Screws (x5)
Item Description Nm D Cover plate
K Bracket fixing bolts 3 E Clevis screw
F Circlip
(For: PS764, PS766) G Cable assembly
Y O-ring
Consumables
Description Part No. Size 3. Clean off all dirt from the gearbox brake housing.
JCB Multi-Gasket 4102/1212 0.05L Make sure there is no dirt or debris trapped in the
housing at the cable entry.
and Sealer (Medium 4101/0251 0.05L 4. Remove the screws and the bolts securing the
Strength) cover plate. Remove the cover plate.
Park Brake Maintenance 5. Remove the clevis screw and the circlip. Remove
the cable assembly from the housing.
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels 6. Working at the park brake lever, remove the
to prevent the machine rolling. Stop the engine and gaiter fixings and pull up the gaiter (not shown).
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the 7. Disconnect the park brake switch electrical
machine could run over you. connector.
Internal park brake cable 8. Remove the lever fixing bolts and then remove
the lever assembly together with the cable.
Remove 9. Measure and record the dimension between the
sleeve and the locknut.
1. Make the machine safe. Obey all care and safety
procedures. Refer to (PIL 01-03). 10. Remove the two buffer bracket fixing bolts.
2. Release the park brake lever (lever horizontal). 11. Remove the cable sideways from the lever,
disengaging the cable nipple from the clevis
screw.
12. Remove the buffer assembly from the cable.
24 - 66 9813/9100-1 24 - 66
24 - Brake System
18 - Park Brake
06 - Cable
Figure 554.
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 - 67 9813/9100-1 24 - 67
24 - Brake System
18 - Park Brake
06 - Cable
11. Feel the edge of the brake pack plates. When the Table 235. Torque Values
brake is released free play between the plates
Item Nm
should be easily detectable.
B 56
Figure 555. 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 556.
T JCB Multigasket
15. Install the cover plate and secure it with the bolts.
24 - 68 9813/9100-1 24 - 68
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 - 69 9813/9100-1 24 - 69
24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Component Identification

Check (Condition) .......................................... 24-71
Figure 557.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
Table 236. 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 - 70 9813/9100-1 24 - 70
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 - 71 9813/9100-1 24 - 71
24 - Brake System
18 - Park Brake
18 - Caliper
Remove and Install
(For: PS750 Mk4, PS750 MK4) 2. Release the park brake lever (horizontal).
Safety Critical Installation 3. Remove the pin and disconnect the clevis joint,
This is a safety critical installation. Do not attempt note which of the three holes on the lever is used.
to do this procedure unless you are skilled and 4. Remove the clip and disconnect the cable from
competent to do so. the bracket.
Installation and mounting of the park brake caliper
requires tightening of the mounting bolts to a specific 5. Support the caliper and remove the two mounting
torque figure. Do not attempt to do this job unless you bolts and hardened washers.
have the correct tools available. 6. Lift the caliper clear of the brake disc.
Remove 7. Do not remove transmission mounting bracket,
unless it is necessary to be replaced.
Figure 558.
A B C D
E
B
A Clip B Mounting bolts

C Clevis joint D Pin
E Operating lever F Transmission mounting bracket
24 - 72 9813/9100-1 24 - 72
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 - 73 9813/9100-1 24 - 73
24 - Brake System
18 - Park Brake
18 - Caliper
(For: PS750 Mk4, PS750 MK4) 7. Push out the rotor the remove the ball spacer and
the ball bearings.
Safety Critical Installation
This is a safety critical installation. Do not attempt 8. Make sure you keep the ball bearings properly in
to do this procedure unless you are skilled and a container.
competent to do so. 9. Push out the mounting bushes and then remove
Installation and mounting of the park brake caliper the dust seals.
requires tightening of the mounting bolts to a specific
torque figure. Do not attempt to do this job unless you 10. Remove the O-rings.
have the correct tools available. 11. Remove the rotor seal and then the bearing ring.
Disassembly 12. Note that the rotor seal may be located on the
rotor shaft or may have been left in the calliper
1. Remove the caliper and the brake pads. Refer to housing.
remove and install (PIL 24-18-18).
13. It is not necessary to replace the shaft seal
2. Hold the lever against the tension of the spring. unless it is excessively worn or damaged.
3. Remove the screw and both the washer 1, 13.1. If removal is necessary, use a suitable
washer 2. spacer block and a bench press to push
the seal out from inside the housing.
4. Note the position of the lever with respect to the
splines of the rotor shaft. 13.2. Clean out any remains of the seal after
removal.
5. Mark the end of the shaft and lever to assist in
assembly. Before assembly make sure all parts are clean
and serviceable. Refer to park brake caliper-check
6. Remove the lever and the spring. condition (PIL 24-18-18).
24 - 74 9813/9100-1 24 - 74
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 559.
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 238. 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 560.
Q Bearing ring
R Housing
S Shaft seal
Assembly
Before assembly make sure all parts are clean and
serviceable.
24 - 75 9813/9100-1 24 - 75
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 560.
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 560.
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 239. Torque table

Item Torque value
Screw 13–16N·m
24 - 76 9813/9100-1 24 - 76
24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................... 24-77 A disc brake is a wheel brake that slows the rotation
Check (Condition) .......................................... 24-78 of the wheel by the friction caused by pushing brake
Remove and Install ....................................... 24-79 pads against a brake disc with a set of calipers.
24 - 77 9813/9100-1 24 - 77
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 - 78 9813/9100-1 24 - 78
24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
(For: PS750 MK4) 7. Do not use a steel hammer, damage can occur
to the output shaft bearing.
Special Tools
Description Part No. Qty. 8. If necessary remove the oil seal. Do not damage
Flange Spanner 992/04800 1 the seal housing.
Remove Install
1. If installed remove the park brake caliper. 1. Make sure that the oil seal interface on the brake
disc is clean and free from wear or damage.
2. Bend back the stake nut locking ring.
2. If necessary install a new oil seal. Lubricate the
3. Clean the brake disc and the gearbox around the lips of the seal.
brake disc. Make sure no contamination enters
the gearbox when the brake disc is removed. 3. Install the brake disc onto the output shaft.
4. Hold the brake disc with the service tool and 4. Install the washer.
remove the output shaft stake nut. Discard the 5. Hold the brake disc with the service tool.
stake nut.
Special Tool: Flange Spanner (Qty.: 1) 6. Install a new stake nut.
5. Remove the washer. 7. Progressively tighten the nut to the correct torque
value.
6. Lift off the brake disc. If necessary use a soft
faced mallet to remove the brake disc. 8. Stake the nut to the shaft with a square ended
staking tool.
24 - 79 9813/9100-1 24 - 79
24 - Brake System
18 - Park Brake
21 - Disc
Figure 561.
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 - 80 9813/9100-1 24 - 80
24 - Brake System
18 - Park Brake
21 - Disc
(For: PS764, PS766) A separate disassembly procedure is given for each

sub-assembly.
The internal park brake consists of a wet multi plate
friction pack and a mechanical actuator assembly.
24 - 81 9813/9100-1 24 - 81
24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the multi-plate brake pack
Figure 562.
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 - 82 9813/9100-1 24 - 82
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 563. 6. Use a flat bladed screwdriver at the cover cutout
to remove the cover plate.
Figure 563.
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 564.
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 - 83 9813/9100-1 24 - 83
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 565.
G
D
E
A X
C
Z
24 - 84 9813/9100-1 24 - 84
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 566.
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 - 85 9813/9100-1 24 - 85
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 - 86 9813/9100-1 24 - 86
24 - Brake System
18 - Park Brake
48 - Actuator
48 - Actuator Check (Condition)

Check (Condition) .......................................... 24-87
(For: PS764, PS766)
Before you check the brake components use a
suitable degreaser to clean the brake components.
Check the following components for signs of

excessive wear or damage:
• Ball bearings and their tapered locating slots.

• Needle roller thrust bearing and the
corresponding bearing surfaces.
Note: Some discolouration of the needle rollers is

acceptable providing the surface of the rollers is
otherwise undamaged.
Figure 567.
4
1 Tapered locating slots
2 Ball bearings
3 Tapered locating slots
4 Needle roller thrust bearing
• Make sure that the park brake cable is smooth
and free in operation. Check the cable outer
for signs of damage. Replace the cable if it is
damaged or hard to operate.
24 - 87 9813/9100-1 24 - 87
24 - Brake System
18 - Park Brake
48 - Actuator
(For: PS764, PS766) 2. Remove the washer 1 and washer 2.

3. Remove the spring 1 and spring 2.
Disassembly
4. Remove the brake actuator plate then the ball
1. Carefully remove the screw. bearings.
1.1. Be careful the screw is under tension from
spring 1 and spring 2.
Figure 568.
Item Description
Table 242. F Actuator plate
Item Description G Ball bearings (x5)
A Screw H Brake actuator cover
B Spring 1
C Spring 2 Assembly
D Washer 1 1. Locate the ball bearings in their slots in the cover.
E Washer 2
24 - 88 9813/9100-1 24 - 88
24 - Brake System
18 - Park Brake
48 - Actuator
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 - 89 9813/9100-1 24 - 89
Notes:
24 - 90 9813/9100-1 24 - 90
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-00-03 Manual Steer Mode System .......................................................................................... 25-23
25-00-06 Auto Steer Mode System ............................................................................................... 25-29
25-01 Pump
25-01-00 General ........................................................................................................................... 25-41
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-43
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-49
25-09 Mode Valve
25-09-03 Manual Mode Valve ....................................................................................................... 25-59
25-09-06 Auto Mode Valve ............................................................................................................ 25-67
25-12 Column
25-12-00 General ........................................................................................................................... 25-75
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-79
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-85
25-33 Link Arm
25-33-00 General ........................................................................................................................... 25-95
9813/9100-1
2017-09-30
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
LS Load Sense
9813/9100-1
2017-09-30
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3

25-00-03 Manual Steer Mode System .......................................................................................... 25-23
25-00-06 Auto Steer Mode System ............................................................................................... 25-29
25 - 1 9813/9100-1 25 - 1
Notes:
25 - 2 9813/9100-1 25 - 2
00 - General
Introduction ...................................................... 25-3 Your machine may be installed with either manual
Health and Safety ........................................... 25-4 or auto steer mode systems depending on the
Technical Data ................................................. 25-4 specification of the machine.
Component Identification ................................. 25-6
Operation ....................................................... 25-10 Manual Steer Mode System
Diagram ......................................................... 25-12 In a manual steer system, there are three steering
Fault-Finding .................................................. 25-15 modes available:
Check (Leaks) ............................................... 25-18
Check (Pressure) .......................................... 25-19 1. 2WS (Two Wheel Steer) (front axle only)- only
the front wheels are steered.
Adjust ............................................................ 25-20
Bleed ............................................................. 25-21 2. 4WS (Four Wheel Steer) both axles are steered,
giving a smaller turning circle
3. Crab steer- allows the machine to be driven
diagonally
Auto Steer Mode System

In an auto steer system, there are three steering
modes available:
1. 2WS (front axle only)- only the front wheels are

steered.
2. 4WS both axles are steered, giving a smaller
turning circle
3. Crab steer- allows the machine to be driven
diagonally
The operation of the steer mode switch, solenoids

and proximity switches is controlled by an ECU
(Electronic Control Unit).
On some machines a separate Steer Mode Control

ECU is used - refer to (PIL 33-45-18).
Other machines the steer modes are controlled by

either the hydraulic control ECU or the transmission
control ECU. For details of the ECU operation refer
to (PIL 33-45).
25 - 3 9813/9100-1 25 - 3
00 - General

Engine/Steering Failure For: 533-105 [T4F] ...................... Page 25-4
For: 535-v125 [T4F], 540-v140 [T4F]
If the engine or steering fails, stop the machine as ..................................................... Page 25-4
quickly as possible. Do not operate the machine until
the fault has been corrected. For: 540-140 [T4F] ...................... Page 25-4
For: 540-170 [T4F], 550-170 [T4F]
Working Under the Machine ..................................................... Page 25-5
Make the machine safe before getting beneath it. For: 540-v180 [T4F] .................... Page 25-5
Make sure that any attachments on the machine are For: 540-200 [T4F] ...................... Page 25-5
has wheels use blocks to prevent unintentional (For: 533-105 [T4F])
movement.
Fluid Under Pressure Table 244.
Fine jets of fluid at high pressure can penetrate the Model Rexroth Bosch Eaton 160cc
skin. Keep face and hands well clear of fluid under LAGC 160
pressure and wear personal protective equipment. Volumetric 160 cc/rev 160 cc/rev
Hold a piece of cardboard close to suspected displacement
leaks and then examine the cardboard for signs of gerotor 1:
fluid. If fluid penetrates your skin, get medical help
Volumetric - -
immediately.
displacement
Hydraulic Pressure gerotor 2:
Hydraulic fluid at system pressure can injure you. Relief Valve Op- 195–200bar 175bar
Before connecting or removing any hydraulic hose, erating Pres- (2,826.1– (2,536.2psi)
residual hydraulic pressure trapped in the service sure (at 1500 2,898.5psi)
hose line must be vented. Make sure the hose RPM (Rev-
service line has been vented before connecting or olutions Per
removing hoses. Make sure the engine cannot be Minute))
started while the hoses are open. Shock valve op- 250bar 235bar
WARNING! When getting access for maintenance erating pres- (3,623.2psi) (3,405.8psi)
work, make sure no-one is in a position to be caught sure- if installed
and/or crushed by the wheels when the steering
wheel is turned. (For: 535-v125 [T4F], 540-v140 [T4F])
Table 245.
Model Eaton 403-7274-78
Volumetric displacement 160 cc/rev
gerotor 1:
Volumetric displacement -
gerotor 2:
Relief valve operating 190bar (2,753.6psi)
pressure (at 1500 RPM)
Shock valve operating 250bar (3,623.2psi)
pressure- if installed
(For: 540-140 [T4F])
Table 246.
gerotor 1:
gerotor 2:
25 - 4 9813/9100-1 25 - 4
00 - General

(For: 540-170 [T4F], 550-170 [T4F])

Table 247.
gerotor 1:
gerotor 2:
(For: 540-v180 [T4F])

Table 248.
gerotor 1:
gerotor 2:
(For: 540-200 [T4F])

Table 249.
gerotor 1:
gerotor 2:
25 - 5 9813/9100-1 25 - 5
00 - General
For: 533-105 [T4F], 535-v125 [T4F], 540-

v140 [T4F] ................................... Page 25-6
For: 540-140 [T4F], 540-170 [T4F], 550-140
[T4F], 550-170 [T4F] ................... Page 25-8
(For: 533-105 [T4F], 535-v125 [T4F], 540-v140 [T4F])
Manual Steer Mode System
Figure 569.
B
A
A Steer mode selection lever B Steer mode selection unit

C Steer mode unit cable D Steer mode valve
25 - 6 9813/9100-1 25 - 6
00 - General
Auto Steer Mode System
Figure 570.
A Steer mode switch B Front steer proximity switch

C Rear steer proximity switch
Figure 571. Auto Steer Mode Valve
C B
D A
1
25 - 7 9813/9100-1 25 - 7
00 - General
1 Located under the LH centre of the chassis
(For: 540-140 [T4F], 540-170 [T4F], 550-140 [T4F], 550-170 [T4F])
Figure 572.
B
A
A Steer mode selection lever B Steer mode selection unit

C Steer mode unit cable D Steer mode valve
25 - 8 9813/9100-1 25 - 8
00 - General
Auto Steer Mode System Figure 574. Auto Steer Valve
Figure 573.
3
A D
C
B
B C
A Steer mode switch

B Rear steer proximity switch
C Front steer proximity switch
3 Located under the centre rear of the chassis
25 - 9 9813/9100-1 25 - 9
00 - General
Operation
(For: 533-105 [T4F]) valve then directs oil from the hydraulic pump to the
steer unit, which in turn directs the flow to the steer
The main components of the steering system are the rams on the axles.
priority valve (PIL 25-03) , the load sensing steer
unit (PIL 25-06), the steer mode control valve (PIL When the steering lock is achieved, the pressure
25-09) (if installed) and the double acting steer rams signal in the load sense line ceases. The priority
or power track rods as applicable (PIL 25-18 and or valve then directs the oil from the hydraulic pump
19). into the main hydraulic system for operation of the
hydraulic services.
When the you turn the steering wheel, a pressure
signal (demand) is generated in the load sense line The maximum steering system pressure is set by a
from the steer unit to the priority valve. The priority relief valve housed inside the steer unit.
Figure 575. Machine with Power Track Rods
A,B
D
E
C
25 - 10 9813/9100-1 25 - 10
00 - General
Figure 576. Machine with Steer Rams
F
D
A, B
F
C
Table 250.
Item Description
A Hydraulic pump
B Priority valve
C Steer unit
D Control valve
E Power track rods
F Steer rams
25 - 11 9813/9100-1 25 - 11
00 - General
Diagram Figure 577.

C
(For: 535-v125 [T4F], 540-140 [T4F],
540-170 [T4F], 540-200 [T4F], 540-v140
[T4F])
D E
Gear Pump Machines
These diagrams are for illustration purposes, a
typical hydraulic circuit is shown. For specific details
of the circuit refer to the applicable hydraulic
schematic, refer to hydraulic system, general,
schematic circuit, (PIL 30-00-50).
Machines with Steer Rams

The diagram shows the complete steer circuit. There
are different steer modes. Refer to steering system- B
steer mode system, refer to (PIL 25-00).
B1 B2
A1
A Hydraulic pump
A1 Priority valve
B Steer unit
B1 Relief valve
B2 Non-return valve
C Steer mode control valve
D Steer rams- front axle
E Steer rams- rear axle
T Hydraulic tank
Machines with Power Track Rods

are different steer modes. Refer to steering system-
25 - 12 9813/9100-1 25 - 12
00 - General
Figure 578. Variflow Machines

C
are different steer modes. Refer to steering system-
D E Figure 579.
E F
B2
B
C2
C
B1
C1
M LS D
DLS
X
0.8
B
8 BAR
B1
X
X1
T
LIFT
A1
A
X
A Hydraulic pump G
A1 Priority valve
B Steer unit
B1 Steering system relief valve
B2 Shock valves
C Steer mode control valve A Hydraulic pump
D Power track rod- front axle B Control valve block- priority inlet section
E Power track rod- rear axle B1 Priority valve
F Hydraulic tank C Steer unit
X Steering pressure test point C1 Steering system relief valve
C2 Shock valves
25 - 13 9813/9100-1 25 - 13
00 - General
D Steer mode control valve

E Power track rod- front axle
F Power track rod- rear axle
G Hydraulic tank
X Pump output pressure test point
X1 Load sense pressure test point
25 - 14 9813/9100-1 25 - 14
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 251. Page 25-15
Steering wheel turns on its own. Table 252. Page 25-15
Machine will not turn when the steering wheel turned. Table 253. Page 25-15
Steering 'drifts' out of phase during operation. Table 254. Page 25-16
Steering fails to respond to selected mode (solenoid operated mode valve Table 255. Page 25-16
only).
Table 251. 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 252. 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 253. 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).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
25 - 15 9813/9100-1 25 - 15
00 - General
Cause Remedy
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 254. 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 255. 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 - 16 9813/9100-1 25 - 16
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 - 17 9813/9100-1 25 - 17
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 580.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 18 9813/9100-1 25 - 18
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: 5.9–8.7bar (85.5–126.1psi)
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.
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 581. 1)
G H Figure 582.
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 - 19 9813/9100-1 25 - 19
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 583.
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 584.
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 - 20 9813/9100-1 25 - 20
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 - 21 9813/9100-1 25 - 21
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 - 22 9813/9100-1 25 - 22
03 - Manual Steer Mode System
Operation
(For: 533-105 [T4F], 535-v125 [T4F], Figure 585. Right turn shown
540-170 [T4F], 540-200 [T4F], 540-v140
[T4F], 540-v180 [T4F], 550-140 [T4F],
A
550-170 [T4F])

Machines with power track rods L R
2-wheel steer selected
With the spool of the steer mode control valve in the

2-wheel steer position there is a hydraulic connection
between the steer unit and the front power track
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track P
rod is blocked by the spool assembly and the axle is
held in the straight ahead position by the locked-up B
E
hydraulic oil in the track rod ram. T
When the steering wheel is turned, the steering D

system only operates the front power track rod.
V
If the steering wheel is turned to the left, the oil flow
is reversed and the machine will turn in the opposite
direction.
Table 256.
Item Description
A Front power track rod
B Steer unit
C Rear axle power track rod
D Steer mode control valve port
E Steer mode control valve port
L Left side
P Steer mode control valve port
R Right side
T Steer mode control valve port
V Steer mode control valve
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 23 9813/9100-1 25 - 23
4-wheel steer selected Figure 586. Right turn shown
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection A
between the steer unit and the front and rear axle
power track rods. Steer mode control valve ports
are internally connected. When the steering wheel is
turned to the right, oil is fed to the rear power track rod
and the displaced oil is fed to the front power track L R
rod through the valve spool. The front power track
rod turns the wheels in the opposite direction to the
rear wheels and displaced oil returns to tank.

direction. P
E
B
D T
Table 257.
Item Description
B Steer unit
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
Crab steer selected axle power track rods. Steer mode valve ports are
internally connected. When the steering wheel is
With the spool of the steer mode valve in the turned to the right, oil is fed to the rear power track
crab steer position there is a hydraulic connection rod and the displaced oil is fed to the front power
between the steer unit and the front and rear
25 - 24 9813/9100-1 25 - 24
track rod through the valve spool. The front power Figure 587. Right turn shown
track rod turns the wheels in the same direction as
the rear wheels, causing the machine to crab to the
right. Displaced oil returns to tank. A

is reversed and the machine will crab in the opposite
direction.
L R
P
B
E
D V T
Table 258.
Item Description
B Steer unit
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 25 9813/9100-1 25 - 25
Machines with steer rams Figure 588.
2-wheel steer selected
With the spool of the steer mode control valve in the

2-wheel steer position there is a hydraulic connection
between the steer unit and the front steer rams. Steer
mode control valve ports are internally connected.
The oil feed to the rear axle steer rams is blocked by
the spool assembly and the axle is held in the straight L R
ahead position by the locked-up hydraulic oil in the F G
rams.
When the steering wheel is turned, only the front axle

rams are operated by the steering unit.
If the steering wheel is turned to the left, the oil flow P

direction. B
E
D T
H J
Table 259.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 26 9813/9100-1 25 - 26
4-wheel steer selected Figure 589.
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection
steer rams. Steer mode control valve ports are
internally connected. When the steering wheel is
turned to the right, oil is fed to the rear rams and
the displaced oil is fed to the front rams through the
spool assembly. The front rams turn the wheels in the L
opposite direction to the rear wheels and displaced F R
G
oil returns to tank.

direction. P
E T
B
D
H J
Table 260.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
25 - 27 9813/9100-1 25 - 27
Crab steer selected Figure 590.
With the spool of the steer mode valve in the

crab steer position there is a hydraulic connection
steer rams. Steer mode valve ports are internally
connected. When the steering wheel is turned to the
right, oil is fed to the rear rams through the spool
assembly. The front rams turn the wheels in the same
direction as the rear wheels, causing the machine to L R
crab to the right. Displaced oil returns to tank. F G

direction.
P
B
E
T
D
V
H J
Table 261.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 28 9813/9100-1 25 - 28
06 - Auto Steer Mode System
Operation
Auto Steer Mode System Figure 591.
There are 3 steering modes available:
• 2WS (Two Wheel Steer) (front axle only)

• 4WS (Four Wheel Steer) F
• Crab steer
In the 2WS mode, only the front wheels are steered.

In 4WS mode, both the axles are steered, giving a
smaller turning circle. The crab steer mode allows the
machine to be driven diagonally. L R
The system is prevented from changing mode until

all the wheels are in the straight ahead position. This
is detected by proximity sensors on the front and E.C.U.
rear axles. If the system is set in 4WS and 2WS

is selected, the system will stay in 4WS until the
rear wheels are turned to the straight ahead position.
The rear wheels are then hydraulically locked in the
straight ahead position.
S
The operation of the steer mode switch, solenoids
V
and proximity switches is controlled by the hydraulic
control ECU (Electronic Control Unit) and the
transmission control ECU. Refer to steering system-
general, refer to (PIL 25-00). T
Hydraulic Operation and Schematics A
Machines with power track rods

Operation- 2-wheel steer selected
The illustrations shown are for the purpose of circuit

explanation only. Actual installations may not be as
shown.
With the spools of steer mode control valve in B

the 2WS position (solenoid energised), there is a
hydraulic connection between the steer unit and the
front power track rod. The oil feed to the rear axle A Solenoid Energised
power track rod is blocked by the spool assembly and B Rear power track rod
the axle is held in the straight ahead position by the F Front power track rod
locked-up hydraulic oil in the track rod ram. L Left
R Right
When the steering wheel is turned, the steering unit S Steer unit
operates only the front power track rod. V Control valve
If the steering wheel is turned to the left, the oil flow Operation- 4-wheel steer selected
direction. The illustrations shown are for the purpose of circuit
shown.
25 - 29 9813/9100-1 25 - 29
With the spools of steer mode valve in the 4WS S Steer unit
position (solenoid 1 and solenoid 2 energised), there T Tank
is a hydraulic connection between the steer unit and V Steer mode valve
the front and rear axle power track rods. When the
steering wheel is turned (right turn shown), oil is fed Operation- Crab Steer Selected
to the rear power track rod and the displaced oil is fed
to the front power track rod via the valve spools. The The illustrations shown are for the purpose of circuit
front power track rod turns the wheels in the opposite explanation only. Actual installations may not be as
direction to the rear wheels and displaced oil returns shown.
to tank.
With the spools of steer mode valve in the crab
If the steering wheel is turned to the left, the oil flow steer position (solenoid 1 and solenoid 2 energised),
is reversed and the machine will turn in the opposite there is a hydraulic connection between the steer unit
direction. and the front and rear power track rods. When the
steering wheel is turned (right turn shown), oil is fed
Figure 592. to the rear power track rod and the displaced oil is fed
to the front power track rod via the valve spools. The
front power track rod turns the wheels in the same
direction as the rear wheels, causing the machine to
F crab to the right. Displaced oil returns to tank.

direction.
L R
E.C.U.
S
C
D T
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
R Right
25 - 30 9813/9100-1 25 - 30
Figure 593. R Right

S Steer unit
V Steer mode valve
F Schematics
The steer mode valve spools have mechanical

detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer mode
suddenly.
L R
E.C.U.
C
D
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
25 - 31 9813/9100-1 25 - 31
2- wheel steer
Figure 594.
R2 C B F2
F1
R1 D A
S
R2 F2
R L
B A FR
R1 F1
D C
R Oil flow direction- right

turn
Table 262. 2- wheel steer
L Oil flow direction- left
Steer Mode 2WS turn
Ports internally connect- F2 - F1 V Steer mode valve
(1)
ed FR Front axle
Ports internally blocked R1 - R2
(1) Refer to component location for variation of valve
Solenoids energised A orientation.
Key
S Steer unit
25 - 32 9813/9100-1 25 - 32
4- wheel steer
Figure 595.
R2 F2
C B
D A F1
R1
V
S
R2 F2
R L
B A FR
R1 F1
D C
S Steer unit
Table 263. 4- wheel steer
turn
Steer Mode 4WS L Oil flow direction- left
Ports internally connect- F1 - R2 turn
ed F2 - R1 V Steer mode valve
(1)
Ports internally blocked - FR Front axle

Solenoids energised B, D (1) Refer to component location for variation of valve
Key orientation.
25 - 33 9813/9100-1 25 - 33
Crab steer
Figure 596.
R2 F2
C B
D A F1
R1
V
S
R2 F2
R L
B A FR
R1 F1
D C
Machines With Steer Rams

Table 264. crab steer
Steer Mode Crab Steer
Ports internally connect- F1 - R1 The illustrations shown are for the purpose of circuit
ed explanation only. Actual installations may not be as
F2 - R2
shown.
Ports internally blocked -
Solenoids energised B, C With the spools of the steer mode control valve in
Key the 2WS position, there is a hydraulic connection
between the steer unit and the front steer ram 1 and
S Steer unit
front steer ram 2. The oil feed to the rear axle steer
R Oil flow direction- right ram 1 and the rear axle steer ram 2 is blocked by the
turn spool assembly and the axle is held in the straight
L Oil flow direction- left ahead position by the locked-up hydraulic oil in the
turn rams.
V Steer mode valve
(1)
When the steering wheel is turned, only the front axle

FR Front axle rams (or front power track rod) are operated by the
(1) Refer to component location for variation of valve steering unit.
orientation.
25 - 34 9813/9100-1 25 - 34
If the steering wheel is turned to the left, the oil flow With the spools of the steer mode valve in the 4WS
is reversed and the machine will turn in the opposite position, there is a hydraulic connection between the
direction. steer unit and the front and rear axle steer rams.
When the steering wheel is turned (right turn shown),
Figure 597. oil is fed to the rear rams and the displaced oil is fed
to the front rams via the spool assembly. The front
rams turn the wheels in the opposite direction to the
rear wheels and displaced oil returns to tank.

direction.
Figure 598.
L R
F1 F2
S
R
V L
F1 F2
H
S
V
T
F3 F4
F1 Front steer ram 1

F3 Rear steer ram 1
F4 Rear steer ram 2
L Left
R Right
S Steering unit
T Tank
F3 F4
The illustrations shown are for the purpose of circuit F3 Rear steer ram 1
explanation only. Actual installations may not be as F4 Rear steer ram 2
shown. L Left
R Right
25 - 35 9813/9100-1 25 - 35
S Steer unit Figure 599.

T Tank
V Steer mode valve
Operation- Crab Steer Selected

The illustrations shown are for the purpose of circuit
shown.
With the spools of steer mode valve in the crab steer R

position there is a hydraulic connection between the F1 L F2
steer unit and the front and rear axle steer rams.
When the steering wheel is turned (right turn shown),
oil is fed to the rear rams and the displaced oil is fed
to the front rams via the spool assembly. The front
rams turn the wheels in the same direction as the
rear wheels, causing the machine to crab to the right.
Displaced oil returns to tank.
If the steering wheel is turned to the left, the oil flow S

direction. V
F3 F4
F3 Rear steer ram 1
F4 Rear steer ram 2
L left
R Right
S Steering unit
T Tank
V Steer mode valve
Schematics
The steer mode valve spools have mechanical
detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer
mode suddenly. Faulty electrical connections to the
solenoid coils (energising the coil) could cause the
steer mode to change suddenly with no operator
input.
25 - 36 9813/9100-1 25 - 36
2- wheel steer
Figure 600.
F1 R1
A D
B C
F2 R2
C
F1 D
R1
A
FR B
S
F2 R2
R L
S Steer unit
Table 265.
turn
Steer Mode 2WS L Oil flow direction- left
Ports internally connect- F2 - F1 turn
ed V Steer mode valve
Ports internally blocked R1, R2 FR Front axle
Solenoids energised A
Key
25 - 37 9813/9100-1 25 - 37
4- wheel steer
Figure 601.
F1 A D R1
F2 B C R2
C D
F1 R1
A B
FR
S
F2 R2
R L
Key
S Steer unit
Table 266.
Steer Mode 4WS turn
Ports internally connect- F1 - R2 L Oil flow direction- left
ed F2 - R1 turn
Ports internally blocked - V Steer mode valve
Solenoids energised B, D FR Front axle
25 - 38 9813/9100-1 25 - 38
Crab steer
Figure 602.
V
F1 R1
A D
B C R2
F2
C
F1 D
R1
A B
FR
S
F2 R2
R L
V Steer mode valve

Table 267. FR Front axle
Steer Mode Crab Steer
Ports internally connect- F1 - R1
ed F2 - R2
Ports internally blocked -
Solenoids energised B, C
Key
S Steer unit
turn
L Oil flow direction- left
turn
25 - 39 9813/9100-1 25 - 39
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-41
25 - 40 9813/9100-1 25 - 40
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 41 9813/9100-1 25 - 41
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-43
25 - 42 9813/9100-1 25 - 42
03 - Priority Valve
00 - General

Operation ....................................................... 25-44
Gear pump machines
Clean ............................................................. 25-46 The priority valve is mounted on the side of the gear
pump.
Figure 603.
LS P EF
EF
LS
EF Return line
P Pressure port
LS Load sense
25 - 43 9813/9100-1 25 - 43
03 - Priority Valve
00 - General
Operation
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v140 [T4F], 540-v180 [T4F])
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 604. Gear pump type valve shown
LS P EF
LS
A
B
P EF
When the steering is not being operated, flow to the

steering circuit is dead ended by the closed centre
Table 268. steering unit, and no pressure signal (demand) is
Item Description generated in the load sense line. Pressure from the
pump outlet is directed through the orifice 1 and
A Pump outlet
orifice 2, onto the end of the priority valve spool. This
B Orifice 1 creates a large pressure difference across the spool,
C Priority valve spool causing it to move up against the force of the spring.
D Orifice 2 This allows the full pump flow to be directed through
E Steering unit port (EF) back to the tank or join with the main flow
to the control valve.
P Pressure line
LS Load sense line
EF Port
25 - 44 9813/9100-1 25 - 44
03 - Priority Valve
00 - General
Turning Pressure is then applied to the spring end of

the priority valve spool. This reduces the pressure
When the steering wheel is turned, a pressure signal difference across the spool, causing it to move down
is generated in the load sense line from the steering under spring force. This allows some of the pump
unit. outlet flow to be directed through the pressure port
to the steering unit, which in turn directs the flow to
the corresponding steer rams to turn the wheels.
Figure 605. Gear pump type valve shown
LS P EF
LS
A
B
P EF
difference across the spool. The spool moves back

Table 269. up and allow the pump full flow to be directed through
port (EF) back to the tank or joins with the main flow
Item Description to the control valve.
A Pump outlet
B Orifice 1 The maximum steering system pressure is set by a
relief valve located inside the steering unit.
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
25 - 45 9813/9100-1 25 - 45
03 - Priority Valve
00 - General
Clean 9. Install the blanking plug and tighten it to the

10. Reconnect the hose to the LS port, and bleed the
(For: 533-105 [T4F], 540-170 [T4F], LS line as described below.
540-200 [T4F], 540-v140 [T4F], 540-v180
[T4F], 550-140 [T4F], 550-170 [T4F]) 10.1. Start the engine.
10.2. Loosen the connection on the valve, then
The priority valve spool and spring may be removed turn and hold the steering wheel fully in
for cleaning with the pump in the machine. either direction.
1. Make the machine safe. Refer to (PIL 01-03). 10.3. When bubble free oil seeps from the joint,
tighten the connection.
2. Follow the general health and safety procedure.
Refer to (PIL 01-03). Table 270.
3. Discharge the hydraulic pressure. Refer to (PIL Item Description
30-00). B 100–105N·m
4. Turn the steering wheel to the left and to the right C 75–81N·m
several times to discharge system pressure.
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 606.
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.
25 - 46 9813/9100-1 25 - 46
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-49
25 - 47 9813/9100-1 25 - 47
Notes:
25 - 48 9813/9100-1 25 - 48
00 - General
Introduction .................................................... 25-49 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-50 fluid flow in the steering system.
25 - 49 9813/9100-1 25 - 49
00 - General
(For: 533-105 [T4F], 535-v125 [T4F], 540-140 [T4F], 540-170 [T4F], 540-200 [T4F],
550-140 [T4F], 550-170 [T4F])
Figure 607.
D E
C C
A
B
G D
G K J F
J
F E
Item Description
Table 271.
F Valve inlet
Item Description G Return line
A Hydraulic steer unit H Steer valve
B Shock Valves (if in- J Load sense port
stalled)
K Steering system relief
C Check valve valve
D Left feed/ return port
E Right feed/ return port
25 - 50 9813/9100-1 25 - 50
00 - General
Remove and Install
For: 533-105 [T4F] .................... Page 25-51 5. Make sure that the steering wheel is in the
For: 535-v125 [T4F], 540-v140 [T4F] straight ahead position.
................................................... Page 25-52
6. Get access to the steer unit. Remove the front
For: 540-140 [T4F], 550-140 [T4F] panel from the cab.
................................................... Page 25-54
For: 540-170 [T4F], 540-200 [T4F], 550-170 Refer to: PIL 06-06-12.
[T4F] .......................................... Page 25-55
(For: 533-105 [T4F]) 8. Disconnect the hydraulic hoses from the steering
unit.
Remove 9. Plug all the open ports and hoses to prevent
1. Make the machine safe. Refer to (PIL 01-03). contamination.
2. Follow all the general health and safety 10. Mark the orientation of steering unit to the splined
procedure. Refer to (PIL 01-03). shaft.
3. Discharge the hydraulic pressure. Refer to (PIL 11. Remove the bolts from inside the cab. At the
30-00). same time, get an assistant to support the
steering unit from under the machine.
several times to discharge the system pressure. 12. Remove the steering unit.
Figure 608.
C
B
B Steering unit C Bolts (x 4)

D Splined shaft
Install 1.2. Make sure that the hoses are connected in

the correct positions.
1.3. If the hydraulic adaptors are removed make
sure that they are tightened to the correct
steps.
torque value.
1.1. Tighten the bolts to the correct torque value.
25 - 51 9813/9100-1 25 - 51
00 - General
Figure 609.
E Hydraulic adaptor 1 F Hydraulic adaptor 2
1.4. The steering unit is spring loaded to the 5. Gain access to the steer unit. Remove the front
neutral position. Make sure that the steering panel from the cab (if installed).
wheel is in the straight ahead position when
you connect the splined shaft. 6. Remove the window washer tank (If installed in
this location).
1.5. Before you drive the machine, bleed the
system. Refer to (PIL 25-00). Figure 610.
1.6. If a new steering unit is installed then
the system relief valve must be tested for
correct pressure setting.
1.7. Check the hydraulic oil level and top up as

Item Nm
A
C 45
E 48 A Front panel (If installed)
F 14
(For: 535-v125 [T4F], 540-v140 [T4F]) 8. Disconnect the hydraulic hoses from the steering
unit.
Remove
9. Plug all the ports and hoses to prevent
1. Make the machine safe. Refer to (PIL 01-03). contamination.
2. Follow the general health and safety procedures. 10. Mark the orientation of steering unit to the splined
Refer to (PIL 01-03). shaft.
3. Turn the steering wheel to the left and to the right 11. Remove the bolts from inside the cab. At the
several times to discharge the system pressure. same time have an assistant to support the
4. Make sure that the steering wheel is in the
straight ahead position. 12. Remove the steering unit.
25 - 52 9813/9100-1 25 - 52
00 - General
Figure 611.
C
B
B Steering unit C Bolts (x4)

D Splined shaft

sure that they are tighten to the correct
steps.
torque value.
Figure 612. 535-v125 and 540-v140 Machines
E Hydraulic adaptor 1 F Hydraulic adaptor 2
1.4. The steering unit is spring loaded to the 1.7. Check the hydraulic fluid level. Refer to (PIL
neutral position. Make sure the steering 30-00).
you connect the splined shaft. Table 273. Torque Values
1.5. Before you drive the machine, bleed the Item Nm
system. Refer to (PIL 25-00). E 48
1.6. If a new steering unit is installed then F 14
25 - 53 9813/9100-1 25 - 53
00 - General
(For: 540-140 [T4F], 550-140 [T4F]) Figure 613.
Remove
several times to discharge the system pressure. A
4. Make sure that the steering wheel is in the A Front panel (If installed)
5. Gain access to the steer unit. Remove the front
panel from the cab (if installed). 8. Disconnect the hydraulic hoses from the steering
unit.
6. Remove the window washer tank (If installed in
this location). 9. Plug all the ports and hoses to prevent
contamination.
10. Mark the orientation of steering unit to the splined
shaft.
11. Remove the bolts from inside the cab. At the
same time have an assistant to support the
12. Remove the steering unit.
Figure 614.
C
B

D Splined shaft

steps.
torque value.
25 - 54 9813/9100-1 25 - 54
00 - General
Figure 615. 540-140, 550-140
H
G
G Hydraulic adaptor 3 H Hydraulic adaptor 4
1.4. The steering unit is spring loaded to the 4. Make sure that the steering wheel is in the
neutral position. Make sure the steering straight ahead position.
you connect the splined shaft. 5. Gain access to the steer unit. Remove the front
panel from the cab (if installed).
system. Refer to (PIL 25-00). 6. Remove the window washer tank (If installed in
this location).
the system relief valve must be tested for Figure 616.
30-00).

Item Nm
G 77
H 22
A
(For: 540-170 [T4F], 540-200 [T4F],
A Front panel (If installed)
550-170 [T4F])
Remove
8. Disconnect the hydraulic hoses from the steering
1. Make the machine safe. Refer to (PIL 01-03). unit.
2. Follow the general health and safety procedures. 9. Plug all the ports and hoses to prevent
Refer to (PIL 01-03). contamination.
3. Turn the steering wheel to the left and to the right 10. Mark the orientation of steering unit to the splined
several times to discharge the system pressure. shaft.
25 - 55 9813/9100-1 25 - 55
00 - General
11. Remove the bolts from inside the cab. At the 12. Remove the steering unit.
same time have an assistant to support the
Figure 617.
C
B

D Splined shaft

steps.
torque value.
Figure 618. 540-170, 550-170 and 540-200 machines
H
G
G Hydraulic adaptor 3 H Hydraulic adaptor 4
1.4. The steering unit is spring loaded to the wheel is in the straight ahead position when
neutral position. Make sure the steering you connect the splined shaft.
25 - 56 9813/9100-1 25 - 56
00 - General

system. Refer to (PIL 25-00).
30-00).

Item Nm
G 77
H 22
25 - 57 9813/9100-1 25 - 57
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-03 Manual Mode Valve ....................................................................................................... 25-59

25-09-06 Auto Mode Valve ............................................................................................................ 25-67
25 - 58 9813/9100-1 25 - 58
09 - Mode Valve
03 - Manual Mode Valve
03 - Manual Mode Valve Remove and Install

(For: 533-105 [T4F])
Remove
2. Install the safety strut. Refer to (PIL 06-69).
30-00).
several times to discharge the system pressure
fully.
6. Make sure that the steering wheel is in the
8. Disconnect the hydraulic hoses from the steer
mode valve.
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 - 59 9813/9100-1 25 - 59
09 - Mode Valve
Figure 619.
A C
A B
A
A Hoses B Bolts
C Steer mode valve
25 - 60 9813/9100-1 25 - 60
09 - Mode Valve
Figure 620.
D Steer mode selector control handle
25 - 61 9813/9100-1 25 - 61
09 - Mode Valve
Figure 621.
E E
E Nuts F Steer mode selector unit
Figure 622.
G A B
H C
A Spacer plates B Bolts

C Steer mode valve G Chassis side plate
H Washer
25 - 62 9813/9100-1 25 - 62
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.
25 - 63 9813/9100-1 25 - 63
09 - Mode Valve
(For: 533-105 [T4F]) travel away from the valve) until they disengage
the operating cable thread.
Consumables
Description Part No. Size 4. Remove the locknut 2 and disconnect the
JCB Threadlocker 4101/0250 0.01L operating cable from valve adaptor.
and Sealer (Medium 4101/0251 0.05L 5. Remove the screws 2 from the end cap 2.
Strength)
6. Remove the locknut 3. Rotate the locknut 3 and
Disassemble the end cap 2 counterclockwise (so that the parts
travel away from the valve) until they disengage
1. Remove the steer mode valve assembly from the the operating cable thread.
machine. Refer to (PIL 25-09).
7. Disengage the operating cable from the steer
2. Remove the screws 1 from the end cap 1. mode selector.
3. Remove the locknut 1. Rotate the locknut 1 and
the end cap 1 counterclockwise (so that the parts
Figure 623.
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
25 - 64 9813/9100-1 25 - 64
09 - Mode Valve
J Locknut 3 K Steer mode selector
25 - 65 9813/9100-1 25 - 65
09 - Mode Valve
Assemble
following steps.
Figure 624.
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 624. 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 - 66 9813/9100-1 25 - 66
09 - Mode Valve
06 - Auto Mode Valve
06 - Auto Mode Valve Check (Operation)

Check (Operation) ......................................... 25-67
(For: 533-105 [T4F], 535-v125 [T4F],
540-140 [T4F], 540-170 [T4F], 540-v180
[T4F], 550-140 [T4F], 550-170 [T4F])
Machines may be installed with different types of
steer mode solenoid valve.
The solenoids operate according to the selected

steer mode.
Figure 625.
A D
C
B
A Solenoid1
B Solenoid2
C Solenoid3
D Solenoid4
Table 276.
Mode Solenoid(s) energised
2 Wheel Steer A
4 Wheel Steer B, C
Crab Steer B, D
Operation (energisation) of a solenoid can be easily

identified by placing a steel object (e.g. screwdriver
blade) close to the outer case. magnetic attraction
of the steel object towards the solenoid indicates
energisation.
If a solenoid is not energising do the following

checks:
1. Check the appropriate fuse. If it has blown, make

sure the wiring is not damaged and then renew
the fuse. Check that all steer mode solenoid
combinations function correctly.
2. If the fuse is ok then, remove the electrical
connector from the malfunctioning solenoid(s)
and check that the 12V supply is available across
25 - 67 9813/9100-1 25 - 67
09 - Mode Valve
the connector pins. If not, check the supply Remove and Install
circuit.
For: 533-105 [T4F], 535-v125 [T4F], 540-
3. Check the solenoid coil resistance which should v180 [T4F], Hi-Viz ..................... Page 25-68
measure a few ohms (if you are not sure about
the value compare with a known good solenoid). For: 540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 550-140 [T4F], 550-170 [T4F]
3.1. Replace the solenoid, if the reading ................................................... Page 25-69
indicates a short circuit (zero ohms) or open
circuit (infinite resistance). If a reading is (For: 533-105 [T4F], 535-v125 [T4F], 540-
somewhere between the zero and infinite, v180 [T4F], Hi-Viz)
then reverse the two instrument probes and
repeat for a valid check. WARNING Make the machine safe before getting
The electrical connectors at the steer mode valve the machine are correctly attached. Engage the
solenoids are identical. Before you remove any of the park brake, remove the ignition key, disconnect
connectors, make sure you label them A, B, C or D the battery.
as applicable. If you think that the connectors have WARNING Hydraulic fluid at system pressure
been made to the wrong solenoids see the electrical can injure you. Before connecting or removing
connection data for wire number identification. any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented.
before connecting or removing hoses. Make sure
open.
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.
Remove
30-00).
Make sure that the steering wheel is in the
5. Disconnect the electrical solenoid connections.
6. Put a label on each connector before you remove
to help installation. Identify the wires as shown in
the figure. Refer to Figure 626.
8. Disconnect the hydraulic hoses from the steer
mode valve assembly.
contamination.
25 - 68 9813/9100-1 25 - 68
09 - Mode Valve
10. Support the steer mode valve assembly and Figure 627.
remove the screws. Remove the steer mode
valve from the machine.
F
11. Make sure you collect the two washers to the rear
of the valve block which may fall out when you
remove the screws. E
Figure 626.
G H
E Screws
F Chassis side plate
G Washer
H Valve block
D Install
A 1. The installation procedure is the opposite of the

E removal procedure. Additionally do the following
steps.
1.1. Make sure that the electrical solenoid
connections are installed in the correct
position.
1.2. Make sure that the two washers are
installed between the valve block and the
E chassis side plate.
1.3. Make sure that the hoses are correctly
installed.
B 25-00).
C
(For: 540-140 [T4F], 540-170 [T4F],
540-200 [T4F], 550-140 [T4F], 550-170
A-D Electrical solenoid connector wires [T4F])
E Screws WARNING Make the machine safe before getting
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
WARNING Hydraulic fluid at system pressure
can injure you. Before connecting or removing
any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented.
before connecting or removing hoses. Make sure
open.
25 - 69 9813/9100-1 25 - 69
09 - Mode Valve
close to suspected leaks and then examine the Figure 628.

Remove
30-00).
Make sure that the steering wheel is in the A
5. Disconnect the electrical solenoid connections. D
6. Put a label on each connector before you remove

to help installation. Identify the wires as shown in
the figure. Refer to Figure 628.
F
7. Put a label on the hoses to help installation. F
8. Disconnect all the hydraulic hoses from the steer B
mode valve assembly. C
9. Plug all the open ports and hoses to prevent E

contamination.
10. Support the steer mode valve assembly and E
remove the screws. Remove the steer mode
valve from the machine.
A-D Electrical connector solenoid wires

E Nuts
F Bolts
Install
steps.
1.1. Make sure that the electrical solenoid
connections are installed in the correct
position.
installed.
1.3. Tighten the nuts and bolts to the correct
torque value.
25-00).
25 - 70 9813/9100-1 25 - 70
09 - Mode Valve

Item Description Nm
E Nuts 35
25 - 71 9813/9100-1 25 - 71
09 - Mode Valve
(For: 533-105 [T4F], 535-v125 [T4F], Disassemble

540-140 [T4F], 540-200 [T4F], 550-140
1. Loosen and remove the knurled cap and pull off
[T4F], 550-170 [T4F], Hi-Viz) the solenoid coil.
The solenoid valves are non-serviceable parts. 2. Remove the O-ring 1 and the O-ring 2.
Replace the faulty valves. The following procedure
explains the removal and installation of a valve 3. Using the correct open ended spanner, loosen
installed at the manifold block. The procedure is the valve stem from the manifold block.
identical for all the valves (2 or 4 valve assemblies
depending on machine variant). The procedure 4. Remove the O-ring 3.
assumes that the complete valve and manifold block
assembly has been removed from the machine.
Figure 629.
F
E
C
B
A Manifold block B Knurled cap

C O-ring 1 D Solenoid coil
E O-ring 2 F Valve stem
G O-ring 3
25 - 72 9813/9100-1 25 - 72
09 - Mode Valve
Assemble
1. Make sure that all components are perfectly
clean. If contamination is suspected, make sure
that all the oilways in the manifold block are clear
of debris.
2. Install new O-rings.
3. Lubricate the parts with JCB special hydraulic
fluid before assembling.
25 - 73 9813/9100-1 25 - 73
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-75
25 - 74 9813/9100-1 25 - 74
12 - Column
00 - General
00 - General Figure 630.

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 - 75 9813/9100-1 25 - 75
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 - 76 9813/9100-1 25 - 76
15 - Proximity Switch
Contents Page No.
25-15-00 General ........................................................................................................................... 25-79
25 - 77 9813/9100-1 25 - 77
Notes:
25 - 78 9813/9100-1 25 - 78
00 - General
Introduction .................................................... 25-79 These are installed on machines with auto steer
Adjust ............................................................ 25-80 mode system or manual (indicated) mode system.
25 - 79 9813/9100-1 25 - 79
00 - General
Adjust Figure 632.
A
(For: 533-105 [T4F], 535-v125 [T4F],
540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F])
If the proximity switch is defective, replace it. Refer B
to steering system- proximity switch, refer to (PIL
25-15). Y
For electrical operation and testing, refer to electrical

system- electronic diagnostic, refer to (PIL 33-57). D
The proximity switch setting procedure is the same

for both the front and rear axles. D C
1. Align the wheels in the straight ahead position.

2. Check the alignment as shown in the figure. Set
the steering so that the dimension X is of the
specified value.
A Target disc
Figure 631. B Proximity switch
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
X 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 - 80 9813/9100-1 25 - 80
00 - General
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F], Remove

540-140 [T4F], 540-170 [T4F], 540-200
1. Make the machine safe. Follow all the general
[T4F], 540-v180 [T4F], 550-140 [T4F], safety procedures. Refer to (PIL 01-03).
550-170 [T4F])
2. Disconnect the harness electrical connector from
Working Under the Machine the switch electrical connector.
Make sure that any attachments on the machine are 3. Remove the proximity switch cover.
4. Remove the bolt and nut that secure the
proximity switch to the support bracket.
movement. 5. Remove the proximity switch from the support
bracket.
The following procedure applies to each of the steer
proximity switches on the front and rear axles.
Figure 633.
C B
A Proximity switch B Nut

C Support bracket D Proximity switch electrical connector
25 - 81 9813/9100-1 25 - 81
00 - General
Install
During the installation procedure do this below step
also.
1. Make sure to set the proximity switch air gap.
25 - 82 9813/9100-1 25 - 82
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-85
25 - 83 9813/9100-1 25 - 83
Notes:
25 - 84 9813/9100-1 25 - 84
00 - General

Check (Condition) .......................................... 25-85
Check Energiser Seals
Disassemble and Assemble .......................... 25-90 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 634.
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 635.
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 - 85 9813/9100-1 25 - 85
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 636.
25 - 86 9813/9100-1 25 - 86
00 - General
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F], 10.3. Remove the mounting screw 1.
540-140 [T4F], 540-170 [T4F], 540-200 10.4. Remove the pipe assembly.
[T4F], 540-v180 [T4F], 550-140 [T4F], 10.5. Remove the adaptor 2.
550-170 [T4F], Front, Rear)
10.6. Plug all the open ports and hoses to
Remove
11. At this point, if the power track rod is to be
dismantled, loosen the track rod link arms while
2. Follow the general health and safety procedures the track rod is still securely clamped. Refer to
for the hydraulic system. Refer to (PIL 30-00). steering system, Arm. Refer to (PIL 25-33).
3. Discharge the hydraulic pressure. Refer to (PIL 12. Remove the screw and the pin at each end
30-00). of the axle and separate the link arms from
their mounting points. Discard the two web seals
4. Turn the steering wheel to the left and to the right seated in the eye of each link arm.
Make sure that the steering wheel is in the 13. Make alignment marks on the cylinder flange,
straight ahead position. the end cover of the power track rod and on the
housing flange of the axle.
5. Before you start work, clean the area around the
axle and the power track rod. 14. Remove the mounting screws 2 (x4).
6. Raise the front or the rear wheels from the 15. If you work on the front axle, do the following
ground with suitable lifting equipment. steps:
7. Block the chassis. 15.1. Use suitable jacks to support both ends
of the axle and then remove the mounting
8. Remove the front left or the rear right wheel as nuts from both ends. Leave the bolts in
applicable. position.
9. If you work on the front axle, do the following 15.2. Lower the jack at the left end so that there
steps: is sufficient room for removal of the power
track rod.
9.1. Put a label on the hoses to help installation. 15.3. Use a soft-faced hammer to gently tap the
9.2. Disconnect hose 1 and hose 2 and then closed end of the track rod cylinder to the
remove the adaptor 1. left and out of its mounting.
9.3. Plug all the open ports and hoses to prevent 16. If you work on the rear axle, do the following
contamination. steps:
10. If you work on the rear axle, do the following 16.1. Use a suitable jack to raise the left end of
steps: the axle so as to swivel the right end down
to make room for removal of the power
10.1. Put a label on the hoses to help track rod.
installation.
16.2. Use a soft-faced hammer to gently tap the
10.2. Disconnect the pipe assembly from the closed end of the track rod cylinder to the
power track rod at the end point 1 and the right and out of its mounting.
end point 2.
25 - 87 9813/9100-1 25 - 87
00 - General
Figure 637.
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 - 88 9813/9100-1 25 - 88
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.
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 - 89 9813/9100-1 25 - 89
00 - General
(For: 533-105 [T4F], 535-v125 [T4F], 2. Remove the steering link arm 1 and the steering
540-140 [T4F], 540-170 [T4F], 540-200 link arm 2. Refer to steering system- track rod,
[T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F]) 3. Remove the end cap and then pull the piston rod
assembly from the cylinder.
Consumables
Description Part No. Size 4. Do not allow the piston rod to come into contact
Cleaner/Degreaser 4104/1557 0.4L with the cylinder bore. The cylinder bore may be
- General purpose damaged by careless dismantling.
solvent based parts
cleaner 5. Position the piston rod assembly on the bench in
place of the ram cylinder.
6. Remove and discard the wear rings and the seal/
Use the alphabetical sequence shown on the energising ring.
illustration as a guide to disassembly. Refer to Figure
638. 7. The piston head cannot be removed from the
rod, if there is damage to the rod or piston head,
Disassemble replace the complete assembly.
1. Fix the ram assembly on a locally manufactured 8. Carefully inspect the bore of the cylinder and the
strip/ rebuild bench. piston rod outer diameter for scoring, nicks and
burrs. If damaged, install a new component.
25 - 90 9813/9100-1 25 - 90
00 - General
Figure 638.
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 - 91 9813/9100-1 25 - 91
00 - General

F G E
H
E Wear ring 1
F Wear ring 2
G Seal
Figure 640. 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 640.
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 641.
25 - 92 9813/9100-1 25 - 92
33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ........................................................................................................................... 25-95
25 - 93 9813/9100-1 25 - 93
Notes:
25 - 94 9813/9100-1 25 - 94
33 - Link Arm
00 - General
00 - General
Remove and Install
Consumables Figure 642.

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 642. and point2 and turn against each other until one
ball joint unscrews as shown. Refer to Figure
643.
3. For this explanation, assume the ball joint at
point1 is now loose, do as follows:
25 - 95 9813/9100-1 25 - 95
33 - Link Arm
00 - General
Figure 643.
A
B
A Point1 B Point2
25 - 96 9813/9100-1 25 - 96
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 644.
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 - 97 9813/9100-1 25 - 97
33 - Link Arm
00 - General
Figure 645.
X Distance1 Y Distance2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 98 9813/9100-1 25 - 98
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-06 Semi-Automatic Gearbox
27-06-00 General ............................................................................................................................. 27-9
27-06-06 Clutch - Reverse ............................................................................................................ 27-87
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-91
27-06-08 Clutch - Layshaft .......................................................................................................... 27-120
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-139
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-152
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-160
27-06-15 Solenoid Control Valve ................................................................................................. 27-175
27-06-21 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 ............................................................................................................................. 27-208
27-06-40 Suction Strainer ............................................................................................................ 27-210
27-06-45 Piston Ring Seal .......................................................................................................... 27-212
27-06-47 Oil Seal ........................................................................................................................ 27-214
27-06-52 Driveshaft ..................................................................................................................... 27-216
27-06-54 Main Shaft .................................................................................................................... 27-219
27-06-56 Layshaft ........................................................................................................................ 27-222
27-06-57 Input Shaft .................................................................................................................... 27-223
27-06-58 Output Shaft ................................................................................................................. 27-224
27-06-81 Mount ........................................................................................................................... 27-234
27-06-85 Oil Feed Pipe ............................................................................................................... 27-235
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-236
27-06-90 Front Case ................................................................................................................... 27-237
27-06-91 Rear Case .................................................................................................................... 27-247
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-249
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-253
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-279
27-14-06 Control Valve ................................................................................................................ 27-287
27-14-09 Relief Valve .................................................................................................................. 27-289
27-20 Axle
27-20-00 General ......................................................................................................................... 27-293
27-20-15 Breather ........................................................................................................................ 27-326
9813/9100-1
2017-11-01
27-20-81 Mount ........................................................................................................................... 27-327
27-22 Drivehead
27-22-00 General ......................................................................................................................... 27-329
27-22-06 Crownwheel .................................................................................................................. 27-350
27-22-09 Pinion Gear .................................................................................................................. 27-352
27-24 Differential
27-24-00 General ......................................................................................................................... 27-355
27-27 Hub
27-27-00 General ......................................................................................................................... 27-367
27-27-66 Wheel Stud ................................................................................................................... 27-396
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-399
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-403
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-407
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-413
27-51-15 Shaft Hub Side ............................................................................................................. 27-417
9813/9100-1
2017-11-01
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
9813/9100-1
2017-11-01
Notes:
9813/9100-1
2017-11-01
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/9100-1 27 - 1
Notes:
27 - 2 9813/9100-1 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 ......................................................... 27-7 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 9813/9100-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
Table 280. 533-105

Item Feature
Transmission PS754
Front Axle SD 70 Pivot mount, 3 piece
Front drive head 80 series 3 piece
Rear Axle SD 55 Pivot mount, 1 piece
Rear drive head 55 series 1 piece
Front differential LSD or Maxtrac
(2)
Rear differential LSD or Maxtrac

(2)
Front hub 80 Series

Front swivels and drive shafts 55 Series
Front axle brakes 70 Series integral brakes
Rear swivels and drive shafts 55 Series
Rear axle brakes .
(1) Axle options.
(2) If the LSD differential option is not installed, a JCB Maxtrac differential is installed.
(3) PS764 transmissions are not installed on JCB 430 engine machines.
Table 281. 535-v125, 540-v140

Item Feature
Transmission PS754
Front Axle SD 80 Trunnion mount, sway 3 piece
SD 80 Pad mount, non sway 3 piece
(1)

Rear Axle SD 80 Trunnion mount, 3 piece
(2)
Rear differential Maxtrac

Front hub 80 Series
Front axle brakes 70 Series integral brakes centre mounted
Rear axle brakes 70 Series integral brakes centre mounted
(1) Axle options.
Table 282. 540-140, 550-140

Item Feature
Transmission PS754, PS764
(3)
Front Axle SD 80 Pivot mount, sway 3 piece

SD 80 Pad mount, non sway 3 piece
(1)

SD 80 Trunnion mount, 3 piece
(1)

(2)
27 - 4 9813/9100-1 27 - 4
27 - Driveline
00 - Driveline
00 - General
Item Feature
Front hub 80 Series
(1) Axle options.
Table 283. 540-170, 550-170

Item Feature
(3)

(2)

Front hub 80 Series
Rear axle brakes 70 Series integral brakes hub mounted
(1) Axle options.
Table 284. 540-v180

Item Feature
Transmission PS754
Front Axle SD 80 Trunnion mount, sway 3 piece
Rear Axle SD 80 Trunnion mount, 1 piece
(2)

Front hub 80 Series
(1) Axle options.
Table 285. 540-200

Item Feature
(3)
27 - 5 9813/9100-1 27 - 5
27 - Driveline
00 - Driveline
00 - General
Item Feature
(2)

Front hub 80 Series
Rear axle brakes 70 Series integral brakes hub mounted
(1) Axle options.
27 - 6 9813/9100-1 27 - 6
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 (526-56 Drive is taken from the bevel gearbox to the main
machines have the option of a Manually Controlled hydraulic pump via a short splined tube.
gearbox). Drive from the gearbox is transmitted to the
steer drive front axle and to the steer drive rear axle The engine has a vibration damper bolted to the
via the propshafts. flywheel.
Figure 646.
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 - 7 9813/9100-1 27 - 7
27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ............................................................................................................................. 27-9

27-06-06 Clutch - Reverse ............................................................................................................ 27-87
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-91
27-06-08 Clutch - Layshaft .......................................................................................................... 27-120
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-139
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-152
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-160
27-06-15 Solenoid Control Valve ................................................................................................. 27-175
27-06-21 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 ............................................................................................................................. 27-208
27-06-40 Suction Strainer ............................................................................................................ 27-210
27-06-45 Piston Ring Seal .......................................................................................................... 27-212
27-06-47 Oil Seal ........................................................................................................................ 27-214
27-06-52 Driveshaft ..................................................................................................................... 27-216
27-06-54 Main Shaft .................................................................................................................... 27-219
27-06-56 Layshaft ........................................................................................................................ 27-222
27-06-57 Input Shaft .................................................................................................................... 27-223
27-06-58 Output Shaft ................................................................................................................. 27-224
27-06-81 Mount ........................................................................................................................... 27-234
27-06-85 Oil Feed Pipe ............................................................................................................... 27-235
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-236
27-06-90 Front Case ................................................................................................................... 27-237
27-06-91 Rear Case .................................................................................................................... 27-247
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-249
27 - 8 9813/9100-1 27 - 8
27 - Driveline
00 - General
Introduction ...................................................... 27-9 Semi-automatic gearboxes are a hybrid form of
Technical Data ............................................... 27-10 transmission where an integrated control system
Component Identification ............................... 27-18 handles manipulation of the clutch automatically,
Operation ....................................................... 27-31 but the driver can still take manual control of gear
selection.
Fault-Finding .................................................. 27-58
Drain and Fill ................................................. 27-65 Many of these transmissions allow the driver to fully
Clean ............................................................. 27-66 delegate gear shifting choice to the control system,
Check (Condition) .......................................... 27-66 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
Check (Level) ................................................ 27-67 torque converter instead of a straight friction clutch
Check (Pressure) .......................................... 27-68 to manage the connection between the transmission
Remove and Install ....................................... 27-81 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 - 9 9813/9100-1 27 - 9
27 - Driveline
00 - General
Technical Data
For: PS750 MK4 ....................... Page 27-10

For: PS764 ................................ Page 27-12
For: PS766 ................................ Page 27-15
(For: PS750 MK4)

Table 286. 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 215kg
Permanent 4 wheel drive TBA
Clutch solenoid current draw 1.36A 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 287. 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 1bar (14.5psi)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
27 - 10 9813/9100-1 27 - 10
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00 - General
RPM (Revolutions Per Minute) from the figures given

in the table.
Table 288. 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 289. Oil Pressures
Pressure
Converter pressure (in neutral)
Converter In at 50°C (121.9°F) 1000 RPM 1.5–4bar (21.7–58.0psi)
2000 RPM 5–7bar (72.5–101.4psi)
Converter Out at 50°C (121.9°F) 1000 RPM TBA
2000 RPM TBA
Converter inlet relief pressure 6.5bar (94.2psi)
(max.)
Lubrication pressure (in neutral)
Oil at 50°C (121.9°F) 1000 RPM 0.14–0.28bar (2.0–4.1psi)
2000 RPM 0.28–0.55bar (4.1–8.0psi)
Main Line Pressure (in neutral)
Oil at 50°C (121.9°F) 1000 RPM 11–13bar (159.4–188.4psi)
2000 RPM 12–14.5bar (173.9–210.1psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7bar (10.1psi).
27 - 11 9813/9100-1 27 - 11
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Flow Rates (in Flow Rate

neutral)
Table 290. Oil Flow Rates
Pump oil flow at 1000 RPM 11–15
Flow Rates (in Flow Rate 50°C (121.9°F)
neutral) 2000 RPM 22.5–29.5
Cooler oil 1000 RPM 8–13
flow at 50°C For new gearboxes (i.e. under 100 hours service),
(121.9°F) or gearboxes that have been fully serviced, the
2000 RPM 19–25 pressures will be slightly higher than those shown
(approximately 0.7–1bar (10.1–14.5psi)).
(For: PS764)
Table 291. 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 242kg
Clutch ratio solenoid types 3 way, 2 position, normally closed, with integral pro-
portional solenoid.
Clutch ratio solenoid current draw 0.85A for clutch pressure of 12bar (173.9psi)
Clutch ratio solenoid coil resistance 7.25Ω (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 1.68A at 12V at 20°C (68.0°F)
Torque converter diameter 310mm
Torque converter identification W300
Torque multiplication at stall 2.02:1

Modes' (Powershift Electronic Control).
Table 292. 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. Only 1st, 2nd and 3rd If the ECU does not de-
gears available. tect any input from the
speed sensor it will pre-
vent selection of any
gear above 3rd.
27 - 12 9813/9100-1 27 - 12
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Mode Possible Reason pressure of 1bar (14.5psi)at sea level. The changes
Limp Mode 4 (Repeating Error reading transmis- in ambient temperature, pressure and humidity and
beeps until ECU power sion speed fuel grade will affect engine power and hence the stall
is reset) figures.
Machine holds a gear If the ECU detects and For example, at 10,000 ft the power reduction of a
error with the speed naturally aspirated engine could be 29% and for a
sensor while operating, turbo engine 8%.
it prevents autoshifting.
The figures apply to `bedded-in' engines, i.e. engines
Stall Speed Combinations that have done a minimum of 250 working hours.
Therefore they should not be used for pre-delivery
The tests carried out at the factory record the correct inspection (PDI) checks.
engine r.p.m. (stall speed) when under maximum
load from the transmission and hydraulic systems. All figures are recorded with the transmission oil
The figures relate to tests conducted at an ambient (130.9°F). Figures achieved should be within +/- 100
temperature of 25°C (77.0°F) and barometric RPM 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 - 13 9813/9100-1 27 - 13
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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 1.4–2.2bar (20.3–31.9psi)
2000 RPM 5.8–6.9bar (84.1–100.0psi)
Converter In at 100°C (211.9°F) 1000 RPM 0.5–1.3bar (7.2–18.8psi)
2000 RPM 2.5–3.5bar (36.2–50.7psi)
Converter Out at 50°C (121.9°F) 1000 RPM 0.6–1.6bar (8.7–23.2psi)
2000 RPM 2.8–3.8bar (40.6–55.1psi)
Converter Out at 100°C (211.9°F) 1000 RPM 0.2–1bar (2.9–14.5psi)
2000 RPM 1–1.9bar (14.5–27.5psi)
Converter inlet relief pressure 7.1bar (102.9psi)
(max.)
2000 RPM 1.1–2.1bar (15.9–30.4psi)
2000 RPM 0.4–1.4bar (5.8–20.3psi)
Oil at 50°C (121.9°F) 1000 RPM 11–13bar (159.4–188.4psi)
2000 RPM 13–15.2bar (188.4–220.3psi)
2000 RPM 11.4–14.5bar (165.2–210.1psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7bar (10.1psi) and 4WD clutch pressure to be within 1.4bar (20.3psi)
27 - 14 9813/9100-1 27 - 14
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neutral)
Pump oil flow at 1000 RPM 11.5–15.6L/min
Flow Rates (in Flow Rate 100°C (211.9°F)
neutral) 2000 RPM 24–33L/min
Cooler oil 1000 RPM 8.5–11L/min
flow at 50°C For new gearboxes (i.e. under 100 hours service),
(121.9°F) or gearboxes that have been fully serviced, the
2000 RPM 17–25.1L/min pressures will be slightly higher than those shown
Cooler oil 1000 RPM 6.2–9.5L/min (approximately 0.7–1bar (10.1–14.5psi)).
flow at 100°C
(211.9°F)
2000 RPM 15–19.5L/min
(For: PS766)
Table 298. 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 285kg
Clutch solenoid types 3 way, 2 position, normally closed, integral suppres-
sion diode
Coil resistance 7.5Ω maximum (at 20°C (68.0°F))
Torque converter diameter 310mm
Torque converter identification W300 Lock up torque converter (LUC)
Torque multiplication at stall 2.52:1

Modes' (Powershift Electronic Control).
Table 299. 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.
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Mode Possible Reason Table 301. 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:
load from the transmission and hydraulic systems.
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 1bar (14.5psi)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
hydraulic gearpump are performed with the crowd
service operated until the relief valve is lifted.
(130.9°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 2–4.95bar (29.0–71.7psi)
2000 RPM 4–6.8bar (58.0–98.6psi)
Converter Out at 50°C (121.9°F) 1000 RPM 0.6–2.25bar (8.7–32.6psi)
2000 RPM 1.25–2.5bar (18.1–36.2psi)
Lock up torque converter inlet relief valve pressure (Maximum) 8.5bar (123.2psi)
Oil at 50°C (121.9°F) 1000 RPM 0.25–1bar (3.6–14.5psi)
2000 RPM 0.5–1bar (7.2–14.5psi)
2000 RPM 12.4–17bar (179.7–246.4psi)
27 - 16 9813/9100-1 27 - 16
27 - Driveline
00 - General

neutral)
Cooler oil 1000 RPM 14L/min
flow at 50°C
(121.9°F)
2000 RPM 17L/min
Pump oil flow at 1000 RPM 16L/min
50°C (121.9°F)
2000 RPM 34L/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 0.7–1bar (10.1–14.5psi)).
27 - 17 9813/9100-1 27 - 17
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00 - General
For: PS750 MK4 ....................... Page 27-18 Figure 647.

For: PS764, PS766 ................... Page 27-24
(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
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Main Component Identification
Figure 648. External components
27 - 19 9813/9100-1 27 - 19
27 - Driveline
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Item Description
13 Oil pump
Table 304.
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 - 20 9813/9100-1 27 - 20
27 - Driveline
00 - General
Figure 649. 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 305.
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 - 21 9813/9100-1 27 - 21
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 - 22 9813/9100-1 27 - 22
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00 - General
Figure 650. Test Point
1 4
Test point Description

4 Forward high ratio clutch
Table 306.
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 - 23 9813/9100-1 27 - 23
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00 - General
Test point Description Clutch Control Solenoids

8 Layshaft clutch pressure
Figure 651.
9 2/4 wheel drive clutch
pressure
3022
3021
3033
3041
3029
3040
Table 307.
Gear Clutches engaged Solenoids energised Refer to
Figure 651.
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
(For: PS764, PS766) details on the unit identification plate. In the case of
gear replacements, always check the part number
Unit Identification stamped on the gear, and the number of teeth.
The gearbox serial number is stamped on the

unit identification plate as shown. When you make
an order for parts replacement, always quote the
27 - 24 9813/9100-1 27 - 24
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Figure 652.
27 - 25 9813/9100-1 27 - 25
27 - Driveline
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Main component identification
Figure 653.
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 308.
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 - 26 9813/9100-1 27 - 26
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Sectional Drawing
Figure 654.
1 2
23
22 3
21 4
17
18
20
12
16
14
15
13
11 5
10
9 19
7 6
8
27 - 27 9813/9100-1 27 - 27
27 - Driveline
00 - General
Item Description
13 Bearing end float control
Table 309.
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 655. PS764
A B C D
G F E
27 - 28 9813/9100-1 27 - 28
27 - Driveline
00 - General
Table 310.
Gear Clutches engaged Solenoids engaged Refer to Fig-
ure 655.
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 656. PS766
A B C D
G F E
Table 311.
ure 656.
1st gear forward 6 speed E
Layshaft F
2nd gear forward Forward low A
27 - 29 9813/9100-1 27 - 29
27 - Driveline
00 - General

ure 656.
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 - 30 9813/9100-1 27 - 30
27 - Driveline
00 - General
Operation
For: PS764 ................................ Page 27-31 A gearbox mounted ground speed sensor detects
For: PS750 MK4 ....................... Page 27-39 the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via
For: PS766 ................................ Page 27-47
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
Electrical interlocks prevent the engine being started,
Transmission dump
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,
forward, neutral or reverse. The switch is connected
Foot Brake Control
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
the joystick switch is enabled. A cab mounted switch controls 2 or 4 wheel
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 - 31 9813/9100-1 27 - 31
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00 - General
Limp Modes Figure 658. 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 657. 1st gear forward (4 wheel drive) S
T Table 313.
Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us)
Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring -
applied) (S)
Z Figure 659. 3rd gear forward (4 wheel drive)
Table 312.
Clutches engaged Solenoids energised T
Forward low ratio (T) 3022 (Ts) Y
applied) (S)
Table 314.
Forward low ratio (T) 3022 (Ts)
Mainshaft (Y) 3033 (Ys)
applied) (S)
27 - 32 9813/9100-1 27 - 32
27 - Driveline
00 - General
Figure 660. 4th gear forward (4 wheel drive) Figure 662. 2nd gear reverse
S S
Table 315. Table 317.

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 663. 3rd gear reverse
Figure 661. 1st gear reverse
W
W
S
S
Table 318.
Table 316.
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 - 33 9813/9100-1 27 - 33
27 - Driveline
00 - General
Figure 664. 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 319.
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 - 34 9813/9100-1 27 - 34
27 - Driveline
00 - General
Figure 665.
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 320.
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
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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 - 36 9813/9100-1 27 - 36
27 - Driveline
00 - General
Figure 666.
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 - 37 9813/9100-1 27 - 37
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 667.
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 - 38 9813/9100-1 27 - 38
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 668.
B C
A1
A
3 2
1
A2

C Piston D Springs
E Output yoke F Actuating sleeve
G Pressure plate
(For: PS750 MK4) 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
For ECU details refer to (PIL 33-45).
direction selection are controlled by engaging and
disengaging multi-disc clutch packs.
Start up
Electric solenoid valves divert pressurised oil
(provided by the gearbox oil pump) to the selected Electrical interlocks prevent the engine being started,
clutch packs. unless the transmission is set to neutral.
Drive direction and gear ratio are selected by means

of electrical control switches (typically a steering
27 - 39 9813/9100-1 27 - 39
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 669. 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 321.
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 - 40 9813/9100-1 27 - 40
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00 - General
Figure 670. 2nd gear forward Table 324.

B Forward high ratio (B) 3021
Mainshaft (F) 3033
Reverse
E Figure 673. 1st gear reverse
E
Table 322.
Forward high ratio (B) 3021
Layshaft (E) 3029
Figure 671. 3rd gear forward C
A
Table 325.
F
Reverse low ratio (C) 3041
Layshaft (E) 3029
Figure 674. 2nd gear reverse
Table 323.
Clutches engaged Solenoids energised E
Forward low ratio (A) 3022
Mainshaft (F) 3033
Figure 672. 4th gear forward

D
B
F Table 326.
Reverse high ratio (D) 3040
Layshaft (E) 3029
27 - 41 9813/9100-1 27 - 41
27 - Driveline
00 - General
Figure 675. 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 327. 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 676. 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 328. 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 - 42 9813/9100-1 27 - 42
27 - Driveline
00 - General
Figure 677.
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 329.
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 - 43 9813/9100-1 27 - 43
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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 - 44 9813/9100-1 27 - 44
27 - Driveline
00 - General
Figure 678.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q

G1 Gear 1 G2 Gear 2
27 - 45 9813/9100-1 27 - 45
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 679.
D B E
A A1
3 2
1
A2 C

C Piston D Springs
E Output yoke
27 - 46 9813/9100-1 27 - 46
27 - Driveline
00 - General
Figure 680.
D G B F E
A A1
3 2
1
A2

C Piston D Springs
G Pressure plate
(For: PS766) Direction Control

The gearbox system is controlled electronically. A column switch controls the direction control,
Inputs from control devices are connected to various forward, neutral or reverse. The switch is connected
ECUs. The ECU’s energise the applicable electrical to inputs on the ECU which in turn energise the
devices depending on the machine status. The applicable gearbox control solenoids.
ECU’s are connected to the machine CANbus which
enables integrated control of all the main machine Joystick Direction Control
systems.
Drive direction can also be controlled with the joystick
For details of the ECUs installed on the machine refer direction control switch. Inputs from the switch are
to (PIL 33-45). connected to the transmission ECU via the joystick
powerbase ECU and the CANbus. There is a logic
Start up control for drive direction selection. Selection of
Forward or Reverse with the column switch disables
Electrical interlocks prevent the engine being started, the joystick direction control switch. Both the joystick
unless the transmission is set to neutral. The and column switch must first be set to Neutral before
interlock is controlled by the ECU. the joystick switch is enabled.
27 - 47 9813/9100-1 27 - 47
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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 - 48 9813/9100-1 27 - 48
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00 - General
Drive paths Table 331.

Forward Forward low ratio (T) 3022 (Ts)
Figure 681. 1st gear forward (4 wheel drive) Layshaft (Z) 3029 (Zs)
X applied) (S)
Figure 683. 3rd gear forward (4 wheel drive)
U
Z
S
Table 330.
6 speed (X) 3004 (Xs)
2/4 wheel drive (spring - Table 332.
applied) (S) Clutches engaged Solenoids energised
Figure 682. 2nd gear forward (4 wheel drive) Layshaft (Z) 3029 (Zs)
applied) (S)
27 - 49 9813/9100-1 27 - 49
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00 - General
Figure 684. 4th gear forward (4 wheel drive) Table 334.

X
Forward low ratio (T) 3022 (Ts)
applied) (S)
Figure 686. 6th gear forward (4 wheel drive)
Z
U
S
Y
Table 333.
6 speed (X) 3004 (Xs)
S
applied) (S)
Figure 685. 5th gear forward (4 wheel drive) Table 335.

applied) (S)
27 - 50 9813/9100-1 27 - 50
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Reverse Table 337.
Figure 687. 1st gear reverse Clutches engaged Solenoids energised

Reverse high ratio (V) 3040 (Vs)
applied) (S)
W
Figure 689. 3rd gear reverse
S
Y
Table 336.
Clutches engaged Solenoids energised S
Reverse low ratio (W) 3041 (Ws)
applied) (S)
Table 338.
Figure 688. 2nd gear reverse Clutches engaged Solenoids energised

Reverse low ratio (W) 3041 (Ws)
applied) (S)
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Figure 690. 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 339. 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 - 52 9813/9100-1 27 - 52
27 - Driveline
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Figure 691.
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 340.
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
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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 - 54 9813/9100-1 27 - 54
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Figure 692.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q

G1 Gear 1 G2 Gear 2
27 - 55 9813/9100-1 27 - 55
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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 693.
B C
A1
3 2
1
A2

C Piston D Springs
E Output yoke
27 - 56 9813/9100-1 27 - 56
27 - Driveline
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Figure 694.
B C
A1
A
3 2
1
A2

C Piston D Springs
G Pressure plate
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Fault-Finding
Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 341. Page 27-58
overheating.
Machine does not drive in any gear. Table 342. Page 27-59
Some gears fail to engage or lack power. Table 343. Page 27-60
Gearbox oil overheating. Table 344. Page 27-60
Noisy operation. Table 345. Page 27-61
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 346. Page 27-61
Cannot engage 2WD (Spring ON clutch). Table 347. Page 27-61
Gearbox oil contaminated with water. Table 348. Page 27-62
Consequential Faults (Gearbox faults caused typically by water Table 349. Page 27-62
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 352. Page 27-63
(Lock-up torque converter variants only).
Gear shifts fail to function normally- Sychroshuttle gearboxes only. Table 353. Page 27-63
Gear shifts fail to function normally or shifts occur at the incorrect road Table 354. Page 27-63
speed.
The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and Table 355. Page 27-63
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 341. 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.
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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 342. 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.
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Table 343. 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 344. 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.
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Table 345. 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 346. 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 347. 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.
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Table 348. 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 349. 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).
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Table 352. 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 353. Gear shifts fail to function normally- Sychroshuttle gearboxes only.
Cause Remedy
Cable shift mechanism faulty Adjust or replace gear shift cables as necessary.
Table 354. 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 355. 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.
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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.)
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Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30min
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: 5s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5min
12. Repeat step 10.
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Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
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.
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00 - General
5.4. Re-assemble the pump. Check (Level)

Figure 695.
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: 4min
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.
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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)).
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 702. • 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 - 68 9813/9100-1 27 - 68
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Figure 696. Test points
A D
H
Item Description
F Reverse high ratio clutch
Table 356. 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
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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 697.
specified limit to the mainline pressure test point.
2.2. A high or low reading may indicate a
faulty pressure maintenance valve. Refer to
Pressure: 0–20bar (0.0–289.9psi) Figure 697.
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 697.
pressure gauge will show the main line pressure.
Refer to Figure 697. 4. Stop engine and remove the test gauge. Refer to
Figure 697.
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Figure 697. Pump flow test
A
L
X Y Z
P
Q
N
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Special Tool: Flowmeter (Qty.: 1)
Table 357. 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 697.
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 697.
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 697.
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 697.
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 697. 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 697. 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 698.
697.
Pressure: 0–20bar (0.0–289.9psi)
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 697. 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 698.
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 697. a pump flow test. Refer to Figure 698.
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 698.
to the correct torque value. Refer to Figure 2.3. Low pressure could be caused by a faulty
697. pump or internal leakage. Refer to Figure
3.4. Type 'z': With the component parts 698.
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 698.
to Figure 697.
3.5. Connect the flowmeter to the flow and
return adapters (shown with arrows). Refer
to Figure 697.
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Figure 698. Converter in, converter relief valve pressure tests

S
C Converter inlet and converter relief valve S Load valve

pressure test point
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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 698.
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°C higher than specified then the valve is faulty.
(121.9°F) and/or the engine is run at over 2000 RPM. Refer to Figure 698.
7. A low opening pressure indicates a leaking pump
In this event the relief valve opens and returns
to casing seal or a faulty converter relief valve.
oil directly to the transmission sump, bypassing
the torque converter, cooler and clutch lubrication
circuits, protecting against damage due to excessive 8. Stop engine, remove test gauges and the load
pressure. valve. Refer to Figure 698.
For this reason it is essential that the transmission oil 9. Install hoses to their original position. Refer to
should be more than 50°C (121.9°F) and the engine Figure 698.
should run between idle and 1000 RPM when you
test the relief valve. Bypassing the converter relief valve
1. Connect a pressure gauge of the specified limit
During some powershift pressure and oil flow tests
to the converter inlet and converter relief valve
it is advisable to temporarily bypass the converter
pressure test point. Refer to Figure 698.
relief valve. If the relief valve opens at the time of the
Pressure: 0–20bar (0.0–289.9psi) following tests it will cause false results.
• Converter out pressure/Oil cooler flow rate
2. Install a load valve into the converter out line. • Converter in pressure
Make sure the load valve is fully open before • Lubrication pressure
starting the test. Refer to Figure 698. • Torque converter stall test
3. Do not allow the pressure to exceed more than Before you bypass the torque converter relief valve
the specified value, or else it can damage the make sure that the mainline pressure is correct and
converter seals. Refer to Figure 698. that the transmission oil filter is fitted.
To temporarily bypass the relief valve (prevent the
4. Start the engine and run at 1000 RPM. With the valve from opening) proceed as follows:
transmission in neutral, slowly screw down the
load valve and monitor the gauge reading which 1. Stop the engine and remove the relief valve.
should increase to the converter relief (safety) Refer to Figure 699.
valve pressure setting. Refer to Figure 698.
2. Carefully remove the spring. Refer to Figure 699.
5. The gauge pressure will fall, once the valve has
opened. This is normal relief valve operation and 3. Obtain a suitable plug, drill and tap the centre
then install a locking bolt. Refer to Figure 699.
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Figure 699. 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 699. 699.
5. Do not damage the spool and its seat. Refer to Duration: 1min
Figure 699.
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 699. 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.
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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 700.
converter out line. Refer to Figure 700.
4.1. A high pressure together with low flow could
Pressure: 0–20bar (0.0–289.9psi) 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 700.
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 700.
Figure 700.
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 700.
in neutral. Refer to Figure 700.
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 700.
Figure 700. 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
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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 700. 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 700. record the pressure readings. Refer to Refer to
Table 358.
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 700. 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 358.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 701. high clutch is used for selection of both 2nd
Pressure: 0–20bar (0.0–289.9psi) 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 358.
Gear select Ratio clutch Mainshaft or layshaft Value (Examples Only)
clutch
1st Forward low Layshaft 9.65bar (139.9psi)
2nd Forward high Layshaft 8.62bar (124.9psi)
3rd Forward low Mainshaft 9.65bar (139.9psi)
4th Forward high Mainshaft 8.62bar (124.9psi)
27 - 77 9813/9100-1 27 - 77
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00 - General
Figure 701.
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 701.
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 701.
the specified to the mainline pressure test point.
Refer to Figure 701. 7. Start engine and run at 1000 RPM, select 2nd
Pressure: 0–20bar (0.0–289.9psi) 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 701.
to Figure 701.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 701.
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 701. the gauges is still greater than the specified
27 - 78 9813/9100-1 27 - 78
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00 - General
value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 701. readings are different than the value
mentioned in step 7 then calibrate the
gauges and again do the check. Refer to
Figure 701.
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Figure 702. Transmission Technical Data Checklist
27 - 80 9813/9100-1 27 - 80
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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 703.
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.
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Figure 704.
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 - 82 9813/9100-1 27 - 82
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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.
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For: PS750 MK4 ....................... Page 27-84 the correct machine service documentation. The
For: PS764, PS766 ................... Page 27-85 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 359. 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).
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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.
(For: PS764, PS766) Figure 705.

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
park brake the brake assembly must be removed B
A
before you disassemble the gearbox. Refer to (PIL
27-06). A Layshaft cover
B Bolt 1
Gearboxes compatible with a lock up torque
converter are installed with a control valve and 1.1. Remove the bolts.
interconnecting pipe. These components must be 1.2. Remove the cover.
removed before dismantling the gearbox.
1.3. Note: Unless the cases are to be replaced,
Disassemble or the gearbox oil has been contaminated it
is not necessary to remove the cover.
1. If installed, remove the layshaft cover. Refer to
Figure 705. 2. Separate the front and rear case and remove the
clutch shafts.
3. Do not attempt to disassemble the gearbox
further until it is safely positioned in a suitable
work cradle.
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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 706.
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
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27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse Introduction

Introduction .................................................... 27-87 A clutch is a mechanical device that engages and
Check (Condition) .......................................... 27-88 disengages drive, from driving shaft to driven shaft.
Check (Pressure) .......................................... 27-88
Remove and Install ....................................... 27-89 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.
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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: 8.6–9.3bar (124.6–134.8psi)
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.
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27 - Driveline
Figure 707. 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.
Refer to the mainshaft remove and install procedure.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 89 9813/9100-1 27 - 89
27 - Driveline

For: PS750 MK4 ....................... Page 27-90
For: PS764, PS766 ................... Page 27-90
(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 - 90 9813/9100-1 27 - 90
27 - Driveline
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Introduction

Introduction .................................................... 27-91 A clutch is a mechanical device that engages and
Component Identification ............................... 27-92 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-98
Check (Pressure) .......................................... 27-98 Each gear on the gearbox has an associated clutch
Disassemble and Assemble ........................ 27-103 When the solenoid is engaged fluid is applied to the
shaft.

27 - 91 9813/9100-1 27 - 91
27 - Driveline
For: PS750 MK4, PS764, PS766

................................................... Page 27-92
For: PS750 MK4, PS764, PS766
................................................... Page 27-93
For: PS764, PS766 ................... Page 27-95
(For: PS750 MK4, PS764, PS766)
Figure 708. 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 - 92 9813/9100-1 27 - 92
27 - Driveline
U O-ring 2 (Shaft)
(For: PS750 MK4, PS764, PS766)
Figure 709. 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 - 93 9813/9100-1 27 - 93
27 - Driveline
Figure 710. 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 - 94 9813/9100-1 27 - 94
27 - Driveline
(For: PS764, PS766)
Figure 711. 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 - 95 9813/9100-1 27 - 95
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 - 96 9813/9100-1 27 - 96
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 - 97 9813/9100-1 27 - 97
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: 8.6–9.3bar (124.6–134.8psi)
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 - 98 9813/9100-1 27 - 98
27 - Driveline
Figure 714. Remove and Install

For: PS764, PS766 ................... Page 27-99
For: PS750 MK4 ..................... Page 27-102
(For: PS764, PS766)

Special Tools
Drive Coupling 892/00812 1
Spanner
Remove
1. Remove the 4WD clutch assembly as follows:
Figure 715.
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 - 99 9813/9100-1 27 - 99
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 717.
not to damage the seal housing. Dimension: 3mm
1.8. Lift the 4WD clutch and shaft assembly from
the housing. Figure 717.
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 716.
Figure 716.
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 718.
Dimension: 3mm
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 719.
27 - 100 9813/9100-1 27 - 100

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: 0.01–0.16mm
3. Continue the installation of the 4WD clutch
assembly as follows:
27 - 101 9813/9100-1 27 - 101

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
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.
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 720.
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 - 102 9813/9100-1 27 - 102

27 - Driveline
For: PS750 MK4, PS764, PS766, Pressure

ON ........................................... Page 27-103
For: PS750 MK4, S1, Spring ON
................................................. Page 27-107
For: PS750 MK4, S2, Spring ON
................................................. Page 27-110
For: PS764, PS766 ................. Page 27-113
(For: PS750 MK4, PS764, PS766, Pressure ON)

Special Tools
Hand Pump Pressure 892/00223 1
Test
27 - 103 9813/9100-1 27 - 103

27 - Driveline
Disassemble
Figure 721.
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 - 104 9813/9100-1 27 - 104

27 - Driveline
3. With a puller or press, remove the 4WD gear and Figure 723.
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 722.
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 - 105 9813/9100-1 27 - 105

27 - Driveline
Figure 724. 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 - 106 9813/9100-1 27 - 106

27 - Driveline
(For: PS750 MK4, S1, Spring ON)
Disassemble
Figure 725.
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 - 107 9813/9100-1 27 - 107

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: 26,700N 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 726.
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 - 108 9813/9100-1 27 - 108

27 - Driveline
Figure 727. 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.
23. Before pushing the outer cup of bearing 1 into the
16.2. If necessary, install a new shim to get the housing cover make sure you install the spacer.
correct gap.
24. Do an operational test of the clutch assembly.
27 - 109 9813/9100-1 27 - 109

27 - Driveline
(For: PS750 MK4, S2, Spring ON)
Disassemble
Figure 728.
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 - 110 9813/9100-1 27 - 110

27 - Driveline

23 Shaft
1. Carefully remove the piston ring seal from the Figure 729.
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
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: 26,700N 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 730.
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 - 111 9813/9100-1 27 - 111

27 - Driveline
Figure 731. 5.7. The shaft will approximately drop to

the specified distance when the splines
engage.
Distance: 3mm
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 732.
Figure 734.
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 733. 7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
Figure 735.
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 - 112 9813/9100-1 27 - 112

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: 0.75–1.5mm
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 736. 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
Pressure Test Adaptor 993/59300 1
CAUTION! The spring (or springs) apply Adaptor Spanner 998/10738 1
avoid damage or injury. Consumables
12. Use a suitable press to compress the disc springs
1 and install the retaining circlip. JCB Threadlocker 4101/0250 0.01L
13. Use levers to remove the free play. Strength)
Figure 737. Gearboxes can be installed with one of three clutch

types 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.
2. Use a suitable puller or press to remove the 4WD
gear and splined hub together with its taper roller
27 - 113 9813/9100-1 27 - 113

27 - Driveline
bearing 1, needle roller bearing and the thrust 11.1. Match mark the piston and the clutch
washer 1. housing, to make sure that the piston is
assembled in the same orientation when
2.1. Remove the thick thrust washer. they are assembled again.
2.2. Note, the thick thrust washer and thrust
Figure 738.
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.
7. Turn the assembly over and remove the friction
and counter plates retaining circlip. 11.2. If the piston does not loosen, then hand
8. Remove the pressure end plate 1 and shims, if
installed. Special Tool: Hand Pump Pressure Test
(Qty.: 1)
plates. 12. Remove the piston.
9.1. Keep them together in sets, do not mix the 13. Remove and discard the O-ring 1 and O-ring 2
plates with those from other clutches. from the piston.
10. Remove the pressure end plate 2. 14. Remove and discard the O-ring 3 from the shaft.
11. Turn the assembly over and knock the clutch 15. If it is necessary to replace, remove the
shaft on a piece of aluminium (or wood) to loosen capscrews and the reaction pins.
the piston.
27 - 114 9813/9100-1 27 - 114

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 - 115 9813/9100-1 27 - 115

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 - 116 9813/9100-1 27 - 116

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 - 117 9813/9100-1 27 - 117

27 - Driveline
Assembly the retaining circlip and the pressure end

plate2.
1. Assemble the reaction pins.
Figure 742.
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.
Torque: 10–12N·m
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 washer1.
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: 4–5mm 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 and prevent it from rotation when torque is
a shim or an extra counter plate, between applied.
27 - 118 9813/9100-1 27 - 118

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: 13bar (188.4psi)
15. Apply gearbox oil to the taper roller bearing2 and
press the bearing onto the shaft.
16. Install the piston ring seal.

Item Description Nm
H Locknut 300
27 - 119 9813/9100-1 27 - 119

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08 - Clutch - Layshaft
08 - Clutch - Layshaft Introduction

Introduction .................................................. 27-120 A clutch is a mechanical device that engages and
Component Identification ............................. 27-121 disengages drive, from driving shaft to driven shaft.
Check (Condition) ........................................ 27-126
Calibrate ...................................................... 27-127 Each gear on the gearbox has an associated clutch
shaft.

27 - 120 9813/9100-1 27 - 120

27 - Driveline
For: PS750 MK4 ..................... Page 27-122

For: PS764, PS766 ................. Page 27-124
27 - 121 9813/9100-1 27 - 121

27 - Driveline
(For: PS750 MK4)
Figure 743.
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 - 122 9813/9100-1 27 - 122

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 - 123 9813/9100-1 27 - 123

27 - Driveline
(For: PS764, PS766)
Figure 744.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
Item Description
Table 363.
C Circlip 1
Item Description D 4 wheel drive transfer
A Piston ring seals gear
B Taper roller bearing 1
27 - 124 9813/9100-1 27 - 124

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
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 - 125 9813/9100-1 27 - 125

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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 - 126 9813/9100-1 27 - 126

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Calibrate
.............................................. Page 27- Later clutch assemblies feature an additional thin

For: PS764, PS766 ................. Page 27-127 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: 1.9–2.5mm applicable
Figure 745. 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
(For: PS764, PS766) assemble the components given in steps 1 to 6.
Special Tools Special Tool: Thrust Washer Kit (Qty.: 1)
Description Part No. Qty. 11. Measure the end float again and assemble the
Thrust Washer Kit 823/10420 1 clutch assembly.
End Float Setting - Plate Carrier and Gear 12. Make sure you install the correct thick thrust
washer on final assembly.
Note: The following procedure is only applicable to
clutch assemblies fitted with thin thrust washer3.
27 - 127 9813/9100-1 27 - 127

27 - Driveline
Figure 746.
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 - 128 9813/9100-1 27 - 128

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 - 129 9813/9100-1 27 - 129

27 - Driveline
Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

clutch and forward / input clutch are all part of the
mainshaft assembly.

27 - 130 9813/9100-1 27 - 130

27 - Driveline
For: PS750 MK4 ..................... Page 27-132

For: PS764, PS766 ................. Page 27-135
27 - 131 9813/9100-1 27 - 131

27 - Driveline
(For: PS750 MK4)
Disassemble
Figure 747.
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 - 132 9813/9100-1 27 - 132

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.
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 - 133 9813/9100-1 27 - 133

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 749.
Figure 748.
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 - 134 9813/9100-1 27 - 134

27 - Driveline
21.3. Use an air line to check the operation of 8. Remove the friction and counter plates retaining
the clutch. circlip.
22. Apply gearbox oil onto the taper roller bearing 1 9. Remove the pressure end plate and shim, if
and install the bearing onto the shaft. installed.
23. Install the new piston ring seals. 10. Remove the friction plates and the counter
plates.
(For: PS764, PS766) 10.1. Keep them together in sets, do not mix the
Special Tools plates with those from other clutches.
Test 11.1. With a cut away tube compress the piston
spring and then remove the circlip 2.
The illustration shows a main shaft assembly for a 6
speed gearbox. The main shaft assembly for 4 speed Figure 750.
gearboxes has some small differences. Procedures
are applicable for both 4 and 6 speed variants.
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.
12. Lift off the spring retaining plate.
3.1. Make a note in which orientation the gear is
installed for assembly. 13. Remove the spring and oil baffle.
3.2. The 2 wheel drive (2WD) machines have a 14. Turn the assembly over and knock the clutch
spacer installed instead of a gear. shaft on a piece of aluminium (or wood) to loosen
the piston.
4. Remove the gear and the splined hub together
with the thin thrust washer1 and thrust bearing1. 14.1. If the piston does not loosen, then hand
5. Remove the two needle roller bearing
assemblies.
(Qty.: 1)
5.1. 4-speed transmissions have only one
Figure 751.
needle roller bearing installed.
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
puller, although it can damage the bearing
cage which will require a new bearing.
27 - 135 9813/9100-1 27 - 135

27 - Driveline
15. Remove the piston. 17. Remove and discard the shaft O-ring 2.
16. Remove and discard the piston O-ring 1.
Figure 752.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
27 - 136 9813/9100-1 27 - 136

27 - Driveline
Figure 753.
Table 364.
Item Description
A Piston ring seals
C Circlip 1
D 4 wheel drive transfer
gear
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
K Thrust bearing 2 plate.
L Thick thrust washer
M Taper roller bearing 2 7.1. Continue to install alternate counter and
N Friction and counter
plates retaining circlip 8. Install the pressure end plate. Make sure that the
P Pressure end plate chamfered face of the pressure end plate faces
Q Shim the clutch pack.
R Friction plates 9. Make sure that the teeth are not aligned with the
S Counter plates lubrication slots in the housing.
T Circlip 2
10. A spring disc is not installed in this clutch pack.
U Spring retaining plate
V Spring 11. Do not install the shim at this stage.
W Oil baffle 12. Install the friction and counter plate retaining
X Piston circlip.
Y O-ring 1
Z O-ring 2
pressure end plate. The value should be within
the specified range.
Assembly
Figure 754.
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
installing a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip
and the pressure end plate.
27 - 137 9813/9100-1 27 - 137

27 - Driveline
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.
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 - 138 9813/9100-1 27 - 138

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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 - 139 9813/9100-1 27 - 139

27 - Driveline
For: PS750 MK4 ..................... Page 27-140

For: PS764, PS766 ................. Page 27-142
(For: PS750 MK4)
Figure 755.
M
N
P J
K
L
Q
G
B
A
27 - 140 9813/9100-1 27 - 140

27 - Driveline
Item Description
H Counter plates
Table 365.
J Circlip 2
Item Description
K Spring retaining plate
A Piston ring seals
L Spring
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 9813/9100-1 27 - 141

27 - Driveline
(For: PS764, PS766)
Figure 756.
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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 27 - 144

27 - Driveline
For: PS750 MK4 ..................... Page 27-145

For: PS764, PS766 ................. Page 27-148
(For: PS750 MK4)

Special Tools
Test
27 - 145 9813/9100-1 27 - 145

27 - Driveline
Disassemble
Figure 757.
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 9813/9100-1 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 759.
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 758. 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 9813/9100-1 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: 1.9–2.5mm clutch.
Figure 760. 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
are applicable for both 4 and 6 speed variants.
13. If it is necessary to adjust the end float to bring it
27 - 148 9813/9100-1 27 - 148

27 - Driveline
Disassemble
Figure 761.
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 9813/9100-1 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 763.

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.
avoid damage or injury.
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 762.
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 9813/9100-1 27 - 150

27 - Driveline

plate.
9. Install the pressure end plate. Make sure that the
the clutch pack.
lubrication slots in the housing.
12. Install the friction and counter plate retaining
circlip 1.
pressure end plate. The value should be within
the specified range.
Figure 764.

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 9813/9100-1 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 9813/9100-1 27 - 152

27 - Driveline
Figure 765.
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 9813/9100-1 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 9813/9100-1 27 - 154

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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 9813/9100-1 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.
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 9813/9100-1 27 - 156

27 - Driveline
Figure 766.
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 9813/9100-1 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 9813/9100-1 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
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 767.
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.
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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 9813/9100-1 27 - 160

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For: PS750 MK4 ..................... Page 27-161

For: PS764, PS766 ................. Page 27-163
(For: PS750 MK4)
Figure 768.
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 9813/9100-1 27 - 161

27 - Driveline
Table 366.
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 9813/9100-1 27 - 162

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(For: PS764, PS766)
Figure 769.
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 367. 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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 27 - 166

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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 9813/9100-1 27 - 167

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Disassemble
Figure 770.
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 9813/9100-1 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 771.

then check for burrs or damage on the shaft
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.
13. Turn the assembly over and knock the clutch
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)
27 - 169 9813/9100-1 27 - 169

27 - Driveline
Figure 772. 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: 1.9–2.5mm
17. To disassemble the opposite clutch, carefully Figure 773.

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
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 9813/9100-1 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
25. Install the thrust bearing 3, thick washer 2, and
thin washer 3. Figure 774.

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.
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 Special Tool: Hand Pump Pressure Test
then check for burrs or damage on the shaft (Qty.: 1)
fine grade abrasion paper and oil. Figure 775.
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.
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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 776.
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 9813/9100-1 27 - 172

27 - Driveline
7.1. Make sure that the disc spring is installed

Table 368. 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: 1.9–2.5mm
U Spring Figure 777.
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.
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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 9813/9100-1 27 - 174

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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 9813/9100-1 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 20L
4000/2603 200L
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
7. Remove the valve stem from the gearbox case.
27 - 176 9813/9100-1 27 - 176

27 - Driveline
Figure 778. 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 369.
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 369.
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 9813/9100-1 27 - 177

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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.
6. If any of the individual solenoid valve cartridges
N are to be removed, take care not to grip the unit
by its electrical connector block. The connector
N block is not designed as a leverage point.
N 7. Remove and discard the valve block sealing

gasket.
K Electrical harness connector
L Retaining bolts 7.1. The gasket may disintegrate on removal,
M Valve make sure that all traces are removed and
N O-ring seals 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 369.
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27 - Driveline
Figure 780. 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 370. 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 781.
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 9813/9100-1 27 - 179

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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.
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21 - Pressure Maintenance Valve (PMV)
21 - Pressure Maintenance Valve

(PMV)
Remove and Install
(For: PS750 MK4) 2. Do not allow particles of grit to fall into the
gearbox.
Remove 3. Remove the plug then the sealing washer, the
spring and the valve spool.
1. Clean the area around the valve and the gearbox
case.
Figure 782.
B
C
D
A Plug B Sealing washer

C Spring D Valve spool
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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
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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 783.
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.
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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 0.05L 7. Put some clean, new, oil into the pump at the
Strength) location shown.
Remove Table 372. Torque Values

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 784.
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 9813/9100-1 27 - 184

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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.
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27 - Speed Sensor
For: PS750 MK4 ..................... Page 27-186

For: PS764, PS766 ................. Page 27-187
(For: PS750 MK4)

Figure 785. Location
A
A Ground speed sensor
Wires and Connectors
Figure 786. 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)
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27 - Driveline
27 - Speed Sensor
5 Signal B- earth (brown) 6 Signal B - output (yellow)
(For: PS764, PS766)
A Ground speed sensor B Input speed sensor
Wires and Connectors
Figure 788. 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 9813/9100-1 27 - 187

27 - Driveline
27 - Speed Sensor
Figure 789. Input Speed Sensor
B A
A Earth B Power
C Signal output
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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.
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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 790. 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 791. 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 9813/9100-1 27 - 190

27 - Driveline
27 - Speed Sensor
(For: PS764, PS766) Figure 793. Input Speed

Figure 792. Ground Speed B
1 R
5 R
1 C
R
R R 3
A 6
2
R
A
B 2
4
A Sensor element A Earth

B Diagnostic element B Power
R Resistor C Signal output
1 Signal A - power (red) R Resistor
2 Signal A - earth (black) 1 Sensor element
3 Signal A - output (white) 2 Diagnostic element
4 Signal B - power (orange)
5 Signal B- earth (brown)
6 Signal B - output (yellow)
Figure 794. 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
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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.
4. Tighten the screw 1 to the correct torque value.
2. Clean the area around the speed sensor.
Figure 795.
B
A
G B
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27 - Speed Sensor
5. Install the screw 2.
Table 373. 6. Tighten the screw 2 to the correct torque value.

Item Description Table 374. 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
(For: PS764, PS766)
F O-ring 2
G Shims or spacers Speed sensors are installed depending on the
machine application. The gearbox has provision for
Speed sensor 2 two speed sensors.
Remove Speed sensor 1

1. If connected, disconnect the speed sensor Remove
1. If connected, disconnect the speed sensor
2. Clean the area around the speed sensor. electrical connector.
3. Do not allow particles of grit to fall into the 2. Clean the area around the speed sensor.
gearbox.
3. Do not allow particles of grit to fall into the
4. Remove the screw 2. 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 5. Remove the speed sensor 1 from the housing.
the sensor 2.
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 1 is damaged replace it with a new
2. If the O-ring 2 is damaged replace it with a new one.
one.
3. If the spacers or the shims were removed replace
them correctly. 4. Tighten the screw 1 to the correct torque value.
4. The speed sensor may be damaged or fail to

operate correctly if it is not at the correct distance
inside the housing.
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27 - Driveline
27 - Speed Sensor
Figure 796.
B
A
G B
3. Do not allow particles of grit to fall into the

Table 375. 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.
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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.
6. Tighten the screw 2 to the correct torque value.

Item Description Nm
C Screw 1 28
E Screw 2 12
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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.
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Component Identification (For: PS764, PS766)

For: PS750 MK4 ..................... Page 27-197 Figure 799. Location
For: PS764, PS766 ................. Page 27-197
A
(For: PS750 MK4)
A Transmission Oil Pressure Switch

Figure 798. 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 9813/9100-1 27 - 197

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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 3. Replace the sealing washer.
pressure switch. 4. Tighten the pressure switch to the correct torque
2. There must be no signs of debris, dirt or grit value.
inside the gearbox.
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 801.
A Pressure switch
B Sealing washer
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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 802.
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 378.

Item Nm
A 10

B Seal
C Transmission Oil Pressure harness electrical
connector
2. Clean off all debris, dirt and grit from around the
switch.
3. There must be no signs of debris, dirt or grit
inside the gearbox.
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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 ............................. 27-203 (Electronic Control Unit) to warn if the transmission
Remove and Install ..................................... 27-206 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 9813/9100-1 27 - 200

27 - Driveline
Technical Data
For: PS750 MK4 ..................... Page 27-201

For: PS764, PS766 ................. Page 27-201
(For: PS750 MK4)

Table 379. 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
100 183
27 - 201 9813/9100-1 27 - 201

27 - Driveline

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
145 205.5
150 182.6
27 - 202 9813/9100-1 27 - 202

27 - Driveline
For: PS750 MK4 ..................... Page 27-203

For: PS764, PS766 ................. Page 27-205
(For: PS750 MK4)
B A
A Transmission Oil Temperature Sender B Transmission Oil Cooler
27 - 203 9813/9100-1 27 - 203

27 - Driveline
2 1
1 2
Figure 805.
ECU
A Transmission ECU (Electronic Control Unit)

B Transmission Oil Temperature Sender
27 - 204 9813/9100-1 27 - 204

27 - Driveline
(For: PS764, PS766)

A Transmission Temperature Sender

1 2
ECU
2
1
1 Transmission ECU
2 Temperature Sender
27 - 205 9813/9100-1 27 - 205

27 - Driveline
Remove and Install
For: PS750 MK4 ..................... Page 27-206

For: PS764, PS766 ................. Page 27-207
(For: PS750 MK4)
Remove
Figure 808.
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 382.
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 - 206 9813/9100-1 27 - 206

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 809.
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 383.

Item Nm
A 16
A Temperature Switch
B Seal
C Temperature Switch harness electrical
connector
2. Clean off all debris, dirt and grit from around the
switch.
3. There must be no signs of debris, dirt or grit
inside the gearbox.
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39 - Filter
39 - Filter Introduction
Introduction .................................................. 27-208 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-209 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.
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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 20L
4000/2603 200L
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 810.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
27 - 209 9813/9100-1 27 - 209

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40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................. 27-210 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-211 large and coarse particles entering the transmission
system.
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27 - Driveline
Remove and Install Table 384. Torque Values

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 811.
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 - 211 9813/9100-1 27 - 211

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45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................. 27-212 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-213 the outer diameter of a piston
27 - 212 9813/9100-1 27 - 212

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 812.
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 813.
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 - 213 9813/9100-1 27 - 213

27 - Driveline
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................. 27-214 Oil seals close spaces between components in
Remove and Install ..................................... 27-215 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 - 214 9813/9100-1 27 - 214

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 814.
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 - 215 9813/9100-1 27 - 215

27 - Driveline
52 - Driveshaft
52 - Driveshaft Introduction
Introduction .................................................. 27-216 The driveshaft is a mechanical component for
Remove and Install ..................................... 27-217 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 - 216 9813/9100-1 27 - 216

27 - Driveline
52 - Driveshaft
Remove and Install
(For: PS764, PS766) 1.2. Draw the pump away from the gearbox,
disengage the drive shaft.
Remove 1.3. Lift the pump clear.
1. If the main hydraulic pump has not already been 2. Remove the circlip and the bearing.
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 815.
A
A
B E
F
C
A Bolts B Pump
C Circlip D Ball bearing
E Driveshaft F Sealing ring
27 - 217 9813/9100-1 27 - 217

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 - 218 9813/9100-1 27 - 218

27 - Driveline
54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-219 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-220 and transmits the power to other components in the
Remove and Install ..................................... 27-220 gearbox.
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 219 9813/9100-1 27 - 219

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 816.
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 - 220 9813/9100-1 27 - 220

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 817.
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 - 221 9813/9100-1 27 - 221

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 - 222 9813/9100-1 27 - 222

27 - Driveline
57 - Input Shaft
57 - Input Shaft
Introduction
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 223 9813/9100-1 27 - 223

27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-224 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-225 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-226 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 - 224 9813/9100-1 27 - 224

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 - 225 9813/9100-1 27 - 225

27 - Driveline
58 - Output Shaft
Remove and Install
For: PS750 MK4 ..................... Page 27-226 Figure 818.

For: PS764, PS766 ................. Page 27-230
B
(For: PS750 MK4) A
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 818.
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
819.
27 - 226 9813/9100-1 27 - 226

27 - Driveline
58 - Output Shaft
H E
M
J
L K
H Bolt1
J Park brake bracket
K Rear case
L 82mm
M 75mm
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: 12.5mm
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 820. 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 821.
Special Tool: Setting Tool Kit (Qty.: 1)
27 - 227 9813/9100-1 27 - 227

27 - Driveline
58 - Output Shaft
3.2. Tighten the service tool nut to the correct Figure 822.
torque value.
Torque: 50N·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 821.
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
386.
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: 50N·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 822. Torque: 1.5N·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: 35N·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 823.
27 - 228 9813/9100-1 27 - 228

27 - Driveline
58 - Output Shaft
Figure 823. 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: 2N·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 386. 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 - 229 9813/9100-1 27 - 229

27 - Driveline
58 - Output Shaft
Figure 824. 1.1. Remove the plug.

1.2. Remove the spring and valve spool from the
rear case.
C C 2. If required, remove the speed sensor as follows:

1
2.1. Remove the bolt 1.
2 2.2. Remove the sensor and its O-ring from the
rear case.
3. Hold the output yoke with the service tool.
Special Tool: Drive Coupling Spanner (Qty.: 1)
3
4. Remove the bolt 2 and the thick washer.
4.1. The bolt is very tight, the help of an assistant
will be required.
A
5. Remove the yoke.
6. Remove and discard the oil seal. Make sure that
you do not damage the seal housing.
B
1 Output shaft 7. Support the transfer gear shaft assembly and
2 Taper rollers remove the gear from inside the rear case.
3 Bearing outer cup
A Gear 8. The gear assembly will come down along with
B Position 1 the following components:
C Spacers 8.1. Inner taper roller bearing.
Note: If the output shaft is being removed after initial 8.2. Inner taper bearing outer cup.
assembly, typically to set the end float, take extreme 8.3. Solid spacer.
care to avoid damage to the bearing outer cup and
inner cup and taper rollers. Use only soft spacers 9. Remove the outer taper rolling bearing and the
such as aluminium, Do not use hardened steel items outer bearing outer cup.
such as screwdrivers.
9.1. Note: If the inner and outer taper roller
If the bearing is damaged a new bearing MUST be bearings are to be used again, keep the
installed. The tolerance difference between the new bearings together with their respective outer
bearings is expected to be less than the difference cups in their original relationships.
between the solid spacer sizes so changing a
bearing should not affect the end float. 9.2. Put tags on the bearings to make sure that
assembly of them in their original positions.
(For: PS764, PS766) 9.3. If any of the two bearings is worn or
damaged, both the bearings must be
Special Tools replaced and a new solid spacer be
Description Part No. Qty. selected and installed.
Spanner 10. Remove the layshaft bearing outer cup from the
rear case.
Transfer Gear 892/01083 1
Assembly Tool
Bearing Assembly Tool 892/01084 1
Before Removal
1. Remove the front case and the clutch shafts.
Remove
1. Remove the pressure maintenance valve as
follows:
27 - 230 9813/9100-1 27 - 230

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 - 231 9813/9100-1 27 - 231

27 - Driveline
58 - Output Shaft
Install 3. Measure the transfer gear output shaft assembly

end float as follows: Refer to Figure 828.
1. Install the layshaft outer bearing cup into the rear
case. Figure 828.
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: 13.7mm
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 827.
Special Tool: Transfer Gear Assembly Tool
(Qty.: 1) X
Figure 827.
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: 50N·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 - 232 9813/9100-1 27 - 232

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
388. 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: 2N·m
torque value.
Torque: 50N·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: 1.5N·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 827.
6.4. Tighten the plug to the correct torque value.
Table 388. Spacer Selection Example

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 - 233 9813/9100-1 27 - 233

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 - 234 9813/9100-1 27 - 234

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 829.
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 - 235 9813/9100-1 27 - 235

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 830.
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 - 236 9813/9100-1 27 - 236

27 - Driveline
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-237
Check (Condition) ........................................ 27-238
Remove and Install ..................................... 27-238 - 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 - 237 9813/9100-1 27 - 237

27 - Driveline
90 - Front Case

Consumables For: PS750 MK4 ..................... Page 27-238
Description Part No. Size For: PS764, PS766 ................. Page 27-241
and Sealer (Medium 4101/0251 0.05L (For: PS750 MK4)
Strength)
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 0.05L
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 - 238 9813/9100-1 27 - 238

27 - Driveline
90 - Front Case
Figure 831. 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 833.
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 832.
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
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27 - Driveline
90 - Front Case
Before installation Figure 835.

• 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 834.
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.
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27 - Driveline
90 - Front Case
Figure 836. 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 837.
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 837.
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
Special Tools further until it is safely positioned in a suitable
Description Part No. Qty. work cradle.
Gearbox Assembly 892/01082 1 5. Remove the torque converter housing as follows:
Cradle Refer to Figure 838.
Consumables
Strength)
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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 840.
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.
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90 - Front Case
Figure 840. 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 842.
Figure 842.
R
Q S
T
H Transfer pipes (x3)

9. Carefully remove the clutch shaft assemblies in
the sequence given below: Refer to Figure 841.
Figure 841.
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 843.
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.
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90 - Front Case
Figure 843. 5.1. Make sure that the O-rings are correctly
installed to the rear case. Refer to Figure
L M K 843.
N 5.2. Apply a thin bead of sealant to the rear case
mating face as shown in the figure. Refer to
P
Figure 845.
Figure 845.
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 846.
3.3. Forward/Input clutch shaft.
Figure 846.
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 844.
U
G
F Front case
G Bolt 2
U Sealing rings (x4)
5. Assemble the front and rear cases as follows:
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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 847. the specified range.
6.1. For 4x4 gearbox: Remove the plug 1. Length/Dimension/Distance: 0.02–0.16mm
6.2. For 6x4 gearbox: Remove plug 1 and plug 8. Provided components are assembled correctly
2. the end float will be within the limits given. Check
that the shafts can be rotated by hand (turn the
6.3. Install a bolt to the threaded hole in the end input shaft and output yoke). The shafts should
of the shaft. rotate smoothly. The end floats can be checked
6.4. Pull the bolt to detect excessive end float. to confirm correct assembly.
Remove the bolt.
9. Install the 4WD clutch assembly.
6.5. The end float of the shafts should be within
the specified range. 10. Install the gearbox oil pump.
Length/Dimension/Distance: 0.02–0.16mm 11. Install the torque converter housing as follows:
6.6. Apply sealant to the plug 1 and plug 2 (for Refer to Figure 848.
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 847. torque converter: Install the O-rings 2 (x3)
to the front case.
L W X K
M N Figure 848.
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: 3mm
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
849. or Refer to Figure 850.
7. Measure the end float of the input shaft as
follows: Refer to Figure 847.
7.1. Pull the input shaft to detect excessive end
float.
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90 - Front Case
Figure 849. 13 Bolts Configuration

C
B Bolt 1 (x13)
Figure 850. 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
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91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-247 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-248
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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).
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27 - Driveline
95 - Coupling Yoke 4WD
95 - Coupling Yoke 4WD Introduction

Introduction .................................................. 27-249 The drive yoke is an important component of a
Remove and Install ..................................... 27-250 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.
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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.
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.
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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
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12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-253
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00 - General
Introduction .................................................. 27-253 The transfer gearbox is a system of gears used in
Component Identification ............................. 27-254 4WD (Four Wheel Drive) vehicles, which transfers
Clean ........................................................... 27-257 torque from the transmission to the front and rear
Check (Condition) ........................................ 27-257 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Calibrate ...................................................... 27-258 wheels.
Disassemble and Assemble ........................ 27-267 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.
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00 - General
Unit Identification order for parts replacement, always give the details
mentioned on the unit identification plate. In the case
The gearbox serial number is stamped on the unit of gear replacements, always check the part number
identification plate as shown. When you make an stamped on the gear, and the number of teeth.
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Figure 852. 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
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00 - General
Table 395.
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
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00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
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.
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00 - General
Calibrate
Figure 853.
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
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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 855.
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 854.
AQ M,AD
AR
AR 75mm
8. Pull the spring balance until the pinion gear
housing stops to rotate and then record the
reading.
Weight/Force: 6.9–19.6N
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 396. 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.
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00 - General
Figure 856. Table 396. 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 857.
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 857.
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: 0.13–0.2mm
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.
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27 - Driveline
00 - General
2. With the gearbox under load, rotate the gears in Figure 859.
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
858. ) in mesh with the bevel gear do the
following:
Figure 858.
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 859. ) 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.
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00 - General
Method B
Figure 860.
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 397. 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 860.
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 Constant +40
this event start by installing 0.5mm 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.
397. and Refer to Table 398.. When you note down Table 398. 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 397. AK Pinion assembly deviation 17
AL Pinion gear deviation +60
AP
(1)
=77
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00 - General
Item Description Devia- Figure 861.

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: 0.33mm
1.2. Compare the old and new dimension
measured during assembly. Refer to Table
399.
Table 399.
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 400.
Table 400.
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 862.

deviations. Refer to Table 401.
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 401. - 27
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27 - Driveline
00 - General
Table 401.
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 862.
If the case deviation markings are not visible it will Figure 863.
not be possible to calculate shim stack adjustment.
In this event start by installing 0.5mm 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 402.
Old = 40.65
New = 40.32
Result = -0.33
Table 403.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Difference = +0.1
Add difference from Refer to Table = -0.33
402.
Result = -0.23
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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 864.
A Flywheel housing bolts
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27 - Driveline
00 - General
Install
removal procedure.

Item Nm
A 70
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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: 55mm
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 4003/2017 0.4kg pinion gear. Make sure you also remove the
4003/2006 12.5kg bearing 1 and spacer 2.
4003/2005 50kg 1.8. Remove the triple-lip seal 1 and the O-ring
2.
Machines (Before 2011) 1.9. Important: If the bearings or the gear
assembly is to be replaced, measure and
Earlier (before 2011) and later (after 2011) record the dimension as shown below.
procedures are shown. Make sure you refer to the Make sure you use suitable measuring
correct procedures for your machine. equipment with an accuracy of the specified
value.
Disassemble Dimension: 0.01mm
Remove the gearbox from the machine, place Figure 865.
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.
Disassemble the gear assembly as follows (For X

Machines before 2011).
1. Remove the pinion drive gear assembly. 1.10. Remove the bearing cups from the pinion
gear housing.
1.1. Remove the bolts 1 that attach the
pinion drive gear assembly to the gearbox 1.11. Put a suitable drift through the two holes
housing. in the pinion gear and then remove the
bearing2 from the gear.
1.2. If necessary, use a jacking bolt in the tapped
extraction holes on the pinion gear housing. 2. Remove the bevel gear assembly.
1.3. Remove the shim set 1 and put a label as 2.1. Remove the bolts 2 that attach the bevel
'for use with the pinion gear assembly.' gear assembly to the gearbox housing.
1.4. Use a reaction block to hold the gear 2.2. If necessary, use a jacking bolt in the tapped
assembly in a vice. extraction holes on the bevel gear housing.
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27 - Driveline
00 - General
2.3. Remove the shim set 2 and put a label as Figure 866.
'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: 46mm
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: 0.01mm
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27 - Driveline
00 - General
Figure 867. 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
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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
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27 - Driveline
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Assemble Figure 868.
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: 55mm
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: 0.5–2.5N·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 869.
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: 55mm
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 867.
Torque: 0.5–1.5N·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.
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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: 0.5–2.5N·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 867.
3.8. Tighten the nut 2 to the correct torque value
with a socket of the specified dimension. Table 405. Torques (Before 2011)
Dimension: 46mm 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: 0.5–1.5N·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 870.
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: 46mm
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27 - Driveline
00 - General
Figure 871. 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 872.
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.
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27 - Driveline
00 - General
Figure 872. 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
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27 - Driveline
00 - General
Figure 873. 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
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.
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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 872.
Figure 873. and Refer to Figure 872.
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 874. 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 873. and Refer to Figure 872.
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.
Figure 875.
1.12. If the seal drag is within limits, tighten the
setscrew to the specified torque value.
Torque: 395N·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: 395N·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.
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27 - Driveline
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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: 0.4–0.75N·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: 395N·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 876.
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.
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27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ......................................................................................................................... 27-279

27-14-06 Control Valve ................................................................................................................ 27-287
27-14-09 Relief Valve .................................................................................................................. 27-289
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27 - Driveline
00 - General
Introduction .................................................. 27-279 The torque converter is a type of fluid coupling that
Component Identification ............................. 27-280 is used to transfer rotating power from the engine to
Operation ..................................................... 27-280 a rotating driven load.
Check (Operation) ....................................... 27-281
The torque converter normally takes the place of
Remove and Install ..................................... 27-285 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.
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27 - Driveline
00 - General

Figure 877. 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).
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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 878.
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.
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27 - Driveline
00 - General
Figure 878.
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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 is 27-06).
above 50°C (121.9°F). Also make sure that the valve
block LSRV (Load Sense Relief Valve) pressure and Interpreting the Test Results
the variflow pump Delta P pressure are set correctly.
If all the engine speeds are below the stated figures
Before completing the following test, remove the either the engine is losing power and should be
transmission dipstick. If there is any sign of serviced/ overhauled or the torque converter reaction
smoke emitting from the dipstick tube stop the member clutch is slipping. To check the engine,
test immediately and dismantle the transmission for select neutral, open throttle fully and operate a
servicing. hydraulic service to 'blow off' the main relief valve.
Engine speed should fall to slightly below the
1. Check all engine fluid levels. Run the engine at maximum governed speed. Refer to (PIL 15-00). If
maximum speed and check the no load speed. engine speed is correct the torque converter reaction
Refer to Engine, General, General, Technical member clutch is slipping.
Data, (PIL 15-00-00).
If all the engine speeds are higher than the stated
2. Make sure that the engine and transmission are figures in all gears the torque converter safety relief
at normal working temperature (the transmission valve may be faulty. Alternatively there may be
oil must be above the specified temperature). internal oil leakage.
Run engine at maximum speed and check the
engine speed is correct (High Idle/ maximum If the engine speeds are higher than the stated
governed speed). Refer to engine- general, refer figures in some gears, check the transmission for
to (PIL 15-00). clutch slippage or internal leakage.
The example given below shows how the results can
3. Apply the park brake and foot brake firmly. be used to isolate a suspect clutch.
If necessary, set the machine against a fixed
obstruction.
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27 - Driveline
00 - General
Table 406.
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-
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27 - Driveline
00 - General
Remove and Install
Consumables 2. Remove the gearbox. Refer to (PIL 27-06).

3. Prise out the access panel from the bevel
JCB Threadlocker 4101/0250 0.01L gearbox torque converter housing.
Strength) 4. Rotate the engine so as to gain access to the
torque converter retaining bolts (x4).
Remove
5. Support the torque converter. Loosen and
1. Due to the configuration of the engine and the remove the bolts (x4). Remove the torque
transmission mounting system, we recommend converter.
to remove the engine and the transmission as a
full assembly.
Figure 879.
D
F
B
A Access panel B Retaining bolt

C Drive plate D Spigot
E Bolts F DTI (Dial Test Indicator)
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27 - Driveline
00 - General
Install
steps.
1.1. Make sure that the drive plate and the
torque converter mating faces are perfectly
clean.
1.2. If removed, make sure that the drive plate
mating faces are clean and free from burrs
before you install it over the spigot on the
drive flange.
1.3. Install the bolts with JCB Threadlocker and
Sealer. Tighten to the correct torque value.
(Medium Strength)
1.4. Make sure that there are no burrs on the
torque converter spigot or to any of the
mating faces adjacent to the drive plate.
1.5. Install the torque converter spigot on the
recess in the bevel box output shaft.
1.6. Install a DTI.
1.7. Rotate the torque converter and measure
the run out of the drive shaft. Make sure that
the run out does not exceed the specified
value.

Item Nm
B 46
E 28
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27 - Driveline
06 - Control Valve
06 - Control Valve Figure 880.

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 - 287 9813/9100-1 27 - 287

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 - 288 9813/9100-1 27 - 288

27 - Driveline
09 - Relief Valve
09 - Relief Valve
Remove and Install
(For: PS750 MK4) 2. Do not allow particles of grit to fall into the
gearbox.
Remove 3. Remove the plug, sealing washer, spring and the
poppet.
1. Clean the area around the valve and the gearbox
case.
Figure 881.
B
C
A Plug B Sealing washer

C Spring D Poppet
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27 - Driveline
09 - Relief Valve
Install
At the time of installation do the following step.

Item Description Nm
A Plug 56
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27 - Driveline
20 - Axle
20 - Axle
Contents Page No.
27-20-00 General ......................................................................................................................... 27-293

27-20-15 Breather ........................................................................................................................ 27-326
27-20-81 Mount ........................................................................................................................... 27-327
27 - 291 9813/9100-1 27 - 291

Notes:
27 - 292 9813/9100-1 27 - 292

27 - Driveline
20 - Axle
00 - General

Technical Data ............................................. 27-293
Drain and Fill ............................................... 27-299
Check (Level) .............................................. 27-302
27 - 293 9813/9100-1 27 - 293

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20 - Axle
00 - General
For: 70/80-Series, Front .......... Page 27-294 The axle consists of a centre casing (drivehead) and
For: 55-Series, 70-Series ........ Page 27-294 two axle arms and swivel wheel hubs.
For: 70/80-Series, Rear ........... Page 27-295 The drivehead houses the differential gearing and
For: 55-Series ......................... Page 27-298 two oil immersed disc brake units. The axle arms
house the driveshafts. Specially shaped spider gears
(For: 70/80-Series, Front) in the differential provide torque proportioning, which
make sure drive power will be kept on one wheel if
3 Piece Axle the other is slipping. The wheel hubs are connected
to the driveshafts through universal joints which drive
The illustration shows a typical 3 piece steer drive sun-and-planet gears inside the hubs.
front axle.
The drive yoke, pinion, crownwheel and differential
unit are all components of the drivehead.
Figure 882.
C D N
M L
E H F
A
B
A Yoke connection to propshaft (axle input) B Pinion

C Crownwheel D Differential unit
E Driveshaft F Universal coupling
G Reduction gear hub H Steer swivel trunnion bearings
L Inboard oil-immersed multi-plate disc brake M Brake actuating piston
pack
N Hydraulic brake lines
(For: 55-Series, 70-Series) SD55 1 Piece Steer Drive Axle
SD80 3 Piece Steer Drive Axle- Integral The illustration shows a typical steer drive rear axle.
Brakes The axle has a single piece case which houses the
differential and half shafts. The rear axle is pivot
For SD80 3 piece steer axle, refer to (PIL 20-00). mounted to the chassis.
27 - 294 9813/9100-1 27 - 294

27 - Driveline
20 - Axle
00 - General
Figure 883.
A B
E
F
G
J
K
C
D
L
A Yoke connection to propshaft B Pinion

E Drive shaft F Universal coupling
J Axle pivot K Oil fill and level plug
L Oil drain plug
(For: 70/80-Series, Rear) The axle has a single-piece casing which houses the
differential and driveshafts.
1 Piece Axle The axle is mounted to the chassis with a pivot pin to
allow the machine to sway.
The illustration shows a typical 1 piece steer drive
rear axle.
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20 - Axle
00 - General
Figure 884.
A B
F
G
J
K
C
D
E
H

J Axle pivot K Oil filler / level plug
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27 - Driveline
20 - Axle
00 - General
3 Piece Axle house the driveshafts. Specially shaped spider gears

in the differential provide torque proportioning, which
The illustration shows a typical 3 piece steer drive make sure drive power will be kept on one wheel if
rear axle. the other is slipping. The wheel hubs are connected
to the driveshafts through universal joints which drive
The axle consists of a centre casing (drivehead) and sun-and-planet gears inside the hubs.
two axle arms and swivel wheel hubs.
The drive yoke, pinion, crownwheel and differential
The drivehead houses the differential gearing and unit are all components of the drivehead.
two oil immersed disc brake units. The axle arms
Figure 885.
C D N
M L
E H F
A
B

L Inboard oil-immersed multi-plate disc brake M Brake actuating piston
pack
N Hydraulic brake lines
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20 - Axle
00 - General
(For: 55-Series)
Figure 886. SD55 1 Piece Steer Drive Axle
A B
F E
J
K
D
C
A Yoke connection to propshaft B Pinion

E Drive shaft F Universal coupling
J Axle pivot K Oil fill and level plug
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27 - Driveline
20 - Axle
00 - General
Drain and Fill
Notice: The oil level must be checked with the axle for your machine. Refer to Figure 887.
machine level, otherwise a false indication of the and Refer to Figure 888.
amount of oil will be given.
1.2. Then make sure you identify the correct
Notice: It is not recommended that the machine plug for your machine.
be driven with the axle partially filled with oil.
1.3. Then use the related torque information for
the drain plug. Refer to Table 410. and Refer
Remove to Table 411.
1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the hexagonal fill/level plug with its
sealing washer (if installed) or the tapered plug.
2. Get access to the axle drain plug.
3. Fill with the specified oil until oil is level with the
3. Clean the area around the drain plug. bottom of the hole. Refer to (PIL 75-00).
4. Drain the oil. 4. Clean the fill/level plug.
4.1. Place a container of suitable size beneath 5. Install the fill/level plug with its sealing washer (if
drain plug to catch the oil. installed) or the tapered plug.
4.2. Remove the hexagonal drain plug and its 6. Tighten the fill/level plug to the correct torque
washer (if installed) or the tapered plug. value.
Allow oil to drain out. Wipe it clean (metallic
particles should be carefully removed). 6.1. To Make sure you use the correct torque
tightening information, identify the correct
Install axle for your machine. Refer to Figure 887.
and Refer to Figure 888.
1. Install the drain plug (and sealing washer- if
6.2. Then make sure you identify the correct
installed), tighten to the correct torque.
plug for your machine.
1.1. To Make sure you use the correct torque 6.3. Then use the related torque information for
tightening information, identify the correct the fill/level plug. Refer to Table 410. and
Refer to Table 411.
Figure 887. JCB Axle (Inboard Brakes)
C
A
B
C
A Axle fill/level plug B Axle drain plug

C Hub drain plug
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20 - Axle
00 - General
Figure 888. JCB Axle (Braked Hubs)

F
D
E
D Axle fill/level plug E Axle drain plug

F Hub drain plug
Figure 889. Hexagonal Plug and Seal- Figure 890. Taper Plug (January 2011 Onwards)
ing Washer (Prior to January 2011)
Table 410. JCB Axles With Inboard Brakes

Function of Plug Installed Description Torque (Nm)
Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80
Table 411. Axles With Braked Hubs

Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
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27 - Driveline
20 - Axle
00 - General

Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80
Also refer to hub, general, drain and refill, (PIL

27-00).
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20 - Axle
00 - General
Check (Level)
Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
Notice: It is not recommended that the machine
be driven with the axle partially filled with oil.

2. Get access to the axle fill/level plug.
3. Clean the area around the fill/level plug.
4. Remove the plug with its sealing washer.
5. Make sure the oil is level with the bottom of the
hole.
6. If necessary add the correct new oil. Refer to (PIL
75-00).
7. Clean the fill/level plug.
8. Install the plug with its sealing washer.
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00 - General
Remove and Install
For: 70-Series, 80-Series, Front Remove

................................................. Page 27-303
For: 540-140 [T4F], 540-170 [T4F], 540-200 1. Make the machine safe. Refer to (PIL 01-03).
[T4F], 550-140 [T4F], 550-170 [T4F], 70/80-
Series, Front ........................... Page 27-305 2. Install the safety strut. Refer to (PIL 06-69).
For: 535-v125 [T4F], 70/80-Series, Front 3. Shims may have been installed on the axle
................................................. Page 27-309 mounts. Make sure to note the position and
For: 540-140 [T4F], 540-170 [T4F], 540-200 quantity of these shims before removal. There
[T4F], Rear .............................. Page 27-312 may be an uneven number of shims on each side
For: 535-v125 [T4F], Rear ....... Page 27-314 of the axle as they are used to adjust the machine
For: 55 Series (1 Piece Axle), 55-Series, height and make it level.
Rear ........................................ Page 27-316
4. Make sure to collect the shims and replace them
For: 80 Series (3 Piece Axle), 80-Series, in the correct position when you replace the axle.
Rear ........................................ Page 27-318
5. If installed, remove the front stabilisers. Refer to
(For: 70-Series, 80-Series, Front) (PIL 06-42-00).
Consumables 6. Remove the bolt 1 and disconnect the propshaft
Description Part No. Size coupling from the axle.
7. Disconnect the hydraulic feed hoses from the
4003/2006 12.5kg steer rams (one hose on each ram). Cap the
4003/2005 50kg open ports and hoses to prevent contamination.
Raised Machine 8. Loosen the front road wheel retaining nuts then
raise and support the front end of the machine
Never position yourself or any part of your body
on support stands or blocks positioned under the
under a raised machine which is not correctly
chassis. Refer to (PIL 27-29.
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be 9. Remove the front road wheels.
killed.
WARNING! A raised and badly supported machine 10. If installed, remove the front fenders. Refer to
(PIL 06-54).
surface before raising one end. Ensure the other 11. Disconnect the brake hose. Cap the open ports
end is securely chocked. Do not rely solely on the and hoses to prevent contamination.
machine hydraulics or jacks to support the machine
when working under it. Disconnect the battery, to 12. Remove the bolt 2 and then remove the pivot pin
prevent the machine being started while you are 1.
beneath it.
13. Support the axle on a trolley jack.
WARNING! Before disconnecting any propshaft,
make sure you block both sides of all wheels to 14. Remove the bolt 3 and then remove the pivot pin
prevent machine movement. The park brake will 2.
become ineffective or may only operate on 2 wheels
(depending on machine specification). 15. Remove the axle from the machine.
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20 - Axle
00 - General
Figure 891. SD80 Pivot sway axle
A B
F
C
Install
Table 412. 1. The installation procedure is the opposite of the
Item Description removal procedure. Additionally do the following
steps.
A Bolt 1
B Hydraulic feed hoses 1.1. Install the road wheels. Refer to (PIL 27-29).
C Brake hose 1.2. Tighten the bolt 2 and bolt 3 to the correct
D Bolt 2 torque value.
E Pivot pin 1 1.3. Make sure that you bleed the brake system.
F Bolt 3 Refer to (PIL 24-00).
G Pivot pin 2, Axle pivot 1.4. Make sure that you bleed the steering
1.5. Make sure that you re-phase the steering
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20 - Axle
00 - General
1.6. Apply grease on the axle pivot. Refer to (PIL 5. Plug all the open ports and hoses to prevent
75-06-00). contamination.
Consumable: Special HP Grease 6. Slacken off the front road wheel retaining nuts
and then raise and support the front end of the
Table 413. Torque Values machine on axle stands or blocks positioned
Item Description Nm under the chassis.
G Pivot pin 2 118
7. Remove the front road wheels. Refer to (PIL
27-29).
(For: 540-140 [T4F], 540-170 [T4F],
540-200 [T4F], 550-140 [T4F], 550-170 8. Remove the front fenders (if installed). Refer to
(PIL 06-54).
[T4F], 70/80-Series, Front)
Special Tools 9. Disconnect the steer mode proximity switch
Description Part No. Qty. electrical connector.
Slide Hammer Kit 993/68100 1 10. Put a label on the hoses to help installation.
11. Disconnect the brake hose at the axle.
SD80 3 Piece Fixed Steer Drive Axle
1. Make the machine safe. Refer to (PIL 01-03). 13. Use suitable lifting equipment to support the axle.
2. Remove the propshaft bolts and disconnect the 14. Remove the axle securing bolts, nuts and
propshaft coupling from the axle. Refer to (PIL washers.
27-47).
15. Lower the axle away from the mounting yoke and
3. Put a label on the hoses to help installation. remove from the machine.
4. Disconnect the hydraulic feed hoses to the power
track rods.
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20 - Axle
00 - General
Figure 892.
A Fender support bracket B Axle securing bolts

C Propshaft securing bolts D Propshaft securing bolts
27 - 306 9813/9100-1 27 - 306

27 - Driveline
20 - Axle
00 - General
Install 5. Plug all the open ports and hoses to prevent

contamination.
removal procedure. Additionally do the following 6. Slacken off the front road wheel retaining nuts
steps. and then raise and support the front end of the
machine on axle stands or blocks positioned
1.1. Install the road wheels. Refer to (PIL 27-29). under the chassis.
2. Before you drive the machine do the following 7. Remove the front road wheels. Refer to (PIL
steps: 27-29).
2.1. Bleed the brake system. Refer to brakes- 8. Remove the front fenders (if installed), refer to
service brake (PIL 24-03). (PIL 06-54-00).
2.2. Bleed the steering system. Refer to steering 9. Disconnect the steer mode proximity switch
system- general (PIL 25-00). electrical connector.
2.3. Re-phase the steering system. Refer to
steering system- general (PIL 25-00). 10. Put a label on the hoses to help installation.
Table 414. Torques table 12. Plug all the open ports and hoses to prevent
Item Torque contamination.
A 98N·m 13. Remove the sway ram pivot pin securing bolt.
B
(1)
969N·m
600N·m 14. Use the slide hammer to remove the sway ram
B
(2)
pivot pin.
C 56N·m
D 78N·m
(1) Dry nuts 15. Remove the sway ram securing bracket bolts and
(2) Nuts with special dry lubricating film. remove the bracket.
SD80 3 Piece Steer Drive Pivot Sway Axle
17. Remove the axle pivot pin securing bolt.
Remove
18. Use the slide hammer to remove the axle pivot
1. Make the machine safe. Refer to (PIL 01-03). pin.
2. Remove the propshaft bolts and disconnect the Special Tool: Slide Hammer Kit (Qty.: 1)
propshaft coupling from the axle. Refer to (PIL
27-47).
remove from the machine.
4. Disconnect the hydraulic feed hoses to the power
track rods.
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27 - Driveline
20 - Axle
00 - General
Figure 893.
C
D
A
J
G
A Sway ram pivot pin securing bolt B Sway ram securing bracket
C Sway ram pivot pin D Sway ram securing bracket bolts
E Fender support bracket F Propshaft securing bolts
G Propshaft securing bolts H Axle pivot pin securing bolt
J Axle pivot pin
27 - 308 9813/9100-1 27 - 308

27 - Driveline
20 - Axle
00 - General
Install 3. Install the road wheels. Refer to (PIL 27-29).
1. The installation procedure is the opposite of the 4. Make sure that the axle oscillates freely before
removal procedure. Additionally do the following finally tightening the securing bolts.
steps.
5. Before you drive the machine, do the following
2. Adjust the sway sight rod so that the top of the steps:
rod is in line with the top of the tube when the
machine is horizontal. 5.1. Bleed the brake system. Refer to brakes-
service brake (PIL 24-03).
2.1. Slacken the locknuts and screw the sight 5.2. Bleed the steering system. Refer to steering
rod up or down to the correct position. system- general (PIL 25-00).
Tighten the locknuts when the position is
correct. 5.3. Re-phase the steering system. Refer to
steering system- general (PIL 25-00).
Figure 894.
5.4. Put grease in the axle pivot. Refer to (PIL
X
75-00).
Table 415. Torques table

Item Torque
D 969N·m
Y
E 98N·m
F 56N·m
G 78N·m
X Tube
Y Sight rod
Z Locknuts
(For: 535-v125 [T4F], 70/80-Series, Front)

Special Tools
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20 - Axle
00 - General
SD80 3 Piece Steer Drive Trunnion Sway Axle
Figure 895.
C C
B D
D
H
G
J
A Trunnion securing nuts B Trunnion securing bolts

C Hydraulic hoses D Dowels
E Fender support bracket F Propshaft bolts
G Pivot pin securing bolt H Pivot pin
27 - 310 9813/9100-1 27 - 310

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20 - Axle
00 - General
J Sway ram securing bracket bolts K Steer mode proximity switch
Figure 896. 12. Plug all the open ports and hoses to prevent
contamination.
13. Remove the pivot pin securing bolt.
L
14. Use the slide hammer to remove the pivot pin.
L
15. Remove the sway ram securing bracket bolts and
remove the bracket.
16. Remove the access plate screws and access
plate to get access to the top of the trunnion
securing bolts.
18. Remove the trunnion securing nuts.
M M
19.1. Make sure to retrieve the dowels.
N 19.2. If shims are installed record their positions.
19.3. Use some wire to tie the trunnions to the
L Trunnion securing bolts
axle.
M Access plate screws
N Access plate
Install
Remove 1. The installation procedure is the opposite of the
steps.
2. Remove the propshaft bolts and disconnect the
2. Adjust the sway sight rod so that the top of the
propshaft coupling from the axle. Refer to (PIL
rod is in line with the top of the tube when the
27-47).
machine is horizontal.
2.1. Slacken the locknuts and screw the sight
4. Disconnect the hydraulic feed hoses to the power rod up or down to the correct position.
track rods. Tighten the locknuts when the position is
correct.
contamination.
6. Slacken off the front road wheel retaining nuts
and then raise and support the front end of the
under the chassis.
7. Remove the front road wheels. Refer to (PIL
27-29).
8. Remove the front fenders (if installed). Refer to
(PIL 06-54-00).
9. Disconnect the steer mode proximity switch
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27 - Driveline
20 - Axle
00 - General
Figure 897. 3. Install the road wheels. Refer to (PIL 27-29).

X
4. Make sure that the dowels together with any
shims are installed in their original positions.
5. Make sure that the axle oscillates freely before
finally tightening the securing bolts.
Y 6. Before you drive the machine do the following
steps:
24-03).
25-00).
Z 6.3. Re-phase the steering system. Refer to (PIL
25-00).
6.4. Put grease in the axle pivot. Refer to (PIL
75-00).
Z
Item Nm
A 476
B 476
E 98
F 78
J 600
X Tube
Y Sight rod
Z Locknuts
(For: 540-140 [T4F], 540-170 [T4F], 540-200 [T4F], Rear)

Special Tools
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20 - Axle
00 - General
SD80 3 Piece Steer Drive Axle
Figure 898.
B
A
A Propshaft bolts B Transducer LLMI (Longitudinal Load Moment

Indicator)
C Pivot pin D Pivot pin securing bolt
27 - 313 9813/9100-1 27 - 313

27 - Driveline
20 - Axle
00 - General
E Fender support bracket
Remove 2.2. Bleed the steering system. Refer to steering

system- general (PIL 25-00).
2.3. Re-phase the steering system. Refer to
2. Remove the propshaft bolts and disconnect the steering system- general (PIL 25-00).
propshaft coupling from the axle. Refer to (PIL 2.4. Put grease in the axle pivot. Refer to (PIL
27-47). 75-00).
3. Put a label on the hoses to help installation. 2.5. Do the LLMI calibration procedure. Refer to
(PIL 33-66).
4. Disconnect the hydraulic feed hoses to the steer
rams. Table 417. Torque Values
5. Plug all the open ports and hoses to prevent Item Nm
contamination. A 78
6. Slacken off the rear road wheel retaining nuts D 118
and then raise and support the rear end of the E 98
under the chassis. Remove the rear road wheels. (For: 535-v125 [T4F], Rear)
7. Remove the rear fenders (if installed). Refer to SD80 3 Piece Steer Drive Axle
(PIL 06-54-00).
Remove
8. Disconnect the LLMI transducer electrical
connector. 1. Make the machine safe. Refer to (PIL 01-03).
9. Disconnect the steer mode proximity switch 2. Remove the propshaft bolts and disconnect the
electrical connector. propshaft coupling from the axle. Refer to (PIL
27-47).
10. Disconnect the brake hose at the axle (located
near the centre at the top). 3. Put a label on the hoses to help installation.
10.1. Put a label on the hoses to help 4. Disconnect the hydraulic feed hoses to the power
installation. track rods.
10.2. Plug all the open ports and hoses to 5. Plug all the open ports and hoses to prevent
prevent contamination. contamination.
11. Support the axle on a trolley jack. 6. Slacken off the rear road wheel retaining nuts
and then raise and support the rear end of the
12. Remove the bolt securing the axle pivot pin. machine on axle stands or blocks positioned
13. Using the slide hammer to remove the pivot pin. under the chassis.
Special Tool: Slide Hammer Kit (Qty.: 1) 7. Remove the rear road wheels. Refer to (PIL
27-29).
remove from the machine. 8. Remove the rear fenders (if installed). Refer to
(PIL 06-54-00).
Install
9. Disconnect the LLMI transducer electrical
1. The installation procedure is the opposite of the connector.
steps. 10. Disconnect the steer mode proximity switch
1.1. Install the road wheels. Refer to (PIL 27-29).
2. Before you drive the machine do the following
steps: 12. Disconnect the brake hose at the axle (located
near the centre at the top).
2.1. Bleed the brake system. Refer to brakes-
service brake (PIL 24-03). 13. Plug all the open ports and hoses to prevent
contamination.
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20 - Axle
00 - General
14. Support the axle on a trolley jack. 16.1. Make sure to collect the dowels.
15. Remove the trunnion securing nuts. 16.2. If shims are installed record their positions.
16.3. Tie the trunnions to the axle with wire.
Figure 899.
C C
B D
F
D
H G
A Trunnion securing nuts B Trunnion securing bolts

C Hydraulic hoses D Dowels
27 - 315 9813/9100-1 27 - 315

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20 - Axle
00 - General
E Fender support bracket F Transducer LLMI

G Propshaft bolts H Steer mode proximity switch
Install 2. Install the safety strut. Refer to (PIL 06-69).
1. The installation procedure is the opposite of the 3. Follow the general health and safety procedures.
removal procedure. Additionally do the following Refer to (PIL 01-03).
steps.
4. Remove the bolts 1 and disconnect the propshaft
1.1. Install the road wheels. Refer to (PIL 27-29). coupling from the axle. Refer to (PIL 27-48).
1.2. Make sure the dowels together with 5. Disconnect and install caps on the hydraulic feed
any shims are installed in their original hoses to the steer rams (one hose on each ram).
positions.
6. Remove the rear fenders (if installed).
1.3. Make sure that the axle oscillates freely
before finally tightening the securing bolts. 7. Slacken off the rear road wheel retaining nuts
and then raise and support the rear end of the
2. Before you drive the machine do the following machine on axle stands or blocks positioned
steps: under the chassis. Remove the rear road wheels.
2.1. Bleed the brake system. Refer to (PIL Refer to (PIL 27-30).
24-03). 8. Support the axle on a trolley jack.
25-00). 9. Remove the bolt 2 securing the axle pivot pin and
the drive out the pivot pin towards the rear of the
2.3. Re-phase the steering system. Refer to (PIL machine.
25-00).
2.4. Put grease in the axle pivot. Refer to (PIL remove from the machine.
75-00).
2.5. Do the LLMI calibration procedure. Refer to Install
(PIL 33-66).
Table 418. Torque Values removal procedure. Additionally do the following
steps.
Item Nm
A 476 1.1. Install the road wheels and do the tightness
E 98 checks. Refer to (PIL 27-30).
G 78 2. Before you drive the machine, do the following
steps.
(For: 55 Series (1 Piece Axle), 55-Series,
Rear)
SD55 1 Piece Steer Drive Axle

Remove
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00 - General
Figure 900. SD55 1 Piece Steer Drive Axle
A Bolt 1 B Hydraulic feed hose

C Bolt 2 D Axle pivot pin
2.1. Bleed the steering system. Refer to (PIL 2.3. Put grease in the axle pivot. Refer to (PIL
25-00). 25-00).
2.2. Re-phase the steering system. Refer to (PIL
25-00).

Item Nm
C 118
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00 - General
(For: 80 Series (3 Piece Axle), 80-Series, during removal or installation. During pin
Rear) removal, make sure that the cut out is
aligned with the crownwheel. If you do not
align the pivot pin, the pin will damage the
SD80 3 Piece Steer Drive Axle- Integral crownwheel.
Brakes
Figure 901.
Remove B

Refer to (PIL 01-03). A
4. Remove the bolts 1 and disconnect the propshaft
coupling from the axle. Refer to (PIL 27-48).
5. Disconnect and install the caps on the hydraulic
feed hoses to the steer rams (one hose on each
ram). C
6. Slacken off the rear road wheel retaining nuts A 5/8 UNF Thread
and then raise and support the rear end of the B Rear axle pivot pin
machine on axle stands or blocks positioned C Cutout
under the chassis. Remove the rear road wheels. 12. Lower the axle away from the mounting yoke and
Refer to (PIL 27-30). remove from the machine.
7. Remove the rear fenders (if installed). Refer to
(PIL 06-54). Install
8. Disconnect the brake hose. Install caps on the 1. The installation procedure is the opposite of the
open connections. removal procedure. Additionally do the following
steps.
1.1. Install new seals on the pivot pin.
10. Remove the bolt 2 and take out the right side 1.2. Make sure the axle pivot pin cut out is
RAS (Rear Axle Stabilization) ram pivot pin. correctly aligned to allow it to pass the
Repeat the procedure for the left side RAS ram crownwheel.
pivot.
1.3. Install the road wheels. Refer to (PIL 27-29).
11. Remove the bolt 3 securing the axle pivot pin
and remove the pivot pin towards the rear of the 2. Before you drive the machine do the following
machine. steps.
11.1. The axle pivot pin has a cut out on one

end to allow it to clear the crownwheel
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Figure 902. SD80 3 Piece Steer Drive Axle- Integral Brakes
C
B
D
F
G
A Bolt 1 B Hydraulic feed hose

C Brake hose D Bolt 2
E RAS ram pivot pin F Bolt 3
G Axle pivot pin
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00 - General
2.1. Bleed the brake system. Refer to (PIL 2.3. Re-phase the steering system. Refer to (PIL
24-03). 25-00).
2.2. Bleed the steering system. Refer to (PIL 2.4. Put grease in the axle pivot. Refer to (PIL
25-00). 25-00).

Item Nm
F 118
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00 - General
For: 70-Series, 80 Series (3 Piece Axle) 10. Scoring of the counter plates to a certain limit is
................................................. Page 27-321 permissible.
For: 55 Series (1 Piece Axle) ... Page 27-325
11. Install a new brake pack, if it is damaged.
(For: 70-Series, 80 Series (3 Piece Axle)) 12. Make sure that you do not install new plates
individually.
Consumables
Description Part No. Size 13. Remove all the three reaction pins and check
JCB Gear Oil HP 4000/0505 20L them for damage.
4000/0503 200L
14. In the controlled retraction piston type, If new
JCB Multi-Gasket 4102/1212 0.05L brake and friction plates are installed then a new
JCB Threadlocker 4101/0250 0.01L brake back off pin 1 and tension bushes also
and Sealer (Medium 4101/0251 0.05L need to be installed. Failure to do so could result
Strength) in the brake being permanently on.
Disassembly Brake piston and seals- Controlled

retraction type
It is recommended that axle must be removed from
the machine while you disassemble the rear axle Make sure that only one side at a time is
brake. disassembled to prevent damage to the bearings and
preserve the crownwheel and the backlash settings.
Before you disassemble the rear axle brakes, it is
mandatory to mark the components for alignment Before you remove the brake housing and the piston
and to identify the right hand and left hand side, to assembly make sure that you support the differential
make sure that it is correctly assembled at the time with the driveshaft or any other suitable support.
of assembly.
1. Mark the brake piston housing and the
Brake pack drivehead.
1. Use a heavy duty (6 point) socket to remove the 2. Remove the capscrews.
bolt 1. 3. Remove the brake housing and the piston
2. Carefully remove the axle arm from the assembly.
drivehead. 4. Make sure that you do not turn the nut, if it is
3. If necessary, tap the case with a soft faced turned then the bearing pre-load needs to be
hammer and remove all traces of the old sealant reset.
from the mating faces. 5. Remove the six reaction pin assemblies.
4. The brake pack consist of five friction plates and 5.1. Remove the circlip 2.
six counter plates. There are two counter plates,
one at each end of the brake pack, which are not 5.2. Remove the back off pins 1.
attached to the plate carrier. 5.3. Remove the tension bushes and the spring
5. If it is necessary to install the plates again 1.
then make a note of their position and correct 6. Remove the brake piston from the brake housing.
orientation.
7. Remove and discard the seal 1 and seal 2.
6. Remove the circlip 1.
8. Check the housing bore for damage and scoring.
7. If it is necessary to install the brake pack again
then make a note of their original position before 9. Nicks or cuts in the seals may be the reason for
you remove them. loss of brake fluid.
8. The wear limit of friction plates is to the depth of
the cross hatching.
9. Check all plates for flatness and damage.
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Brake Piston and Seals- Positive retraction 4. Make sure that you do not turn the nut, if it is
type turned then the bearing pre-load needs to be
reset.
Make sure that only one side at a time is
disassembled to prevent damage to the bearings and 5. Remove the six reaction pin assemblies.
do the preservation procedure for the crownwheel 5.1. Remove the back off pins 2.
and the backlash settings.
5.2. Remove the spring 2.
Before you remove the brake housing and the piston
assembly make sure that you support the differential 6. Remove the brake piston from the brake housing.
with the driveshaft or any other suitable support.
7. Remove and discard both the seal 1 and seal 2.
1. Mark the brake piston housing and the 8. Check the housing bore for damage and scoring.
drivehead.
9. Nicks or cuts in the seals may be the reason for
2. Remove the capscrews. loss of brake fluid.
3. Remove the brake housing and the piston
assembly.
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Figure 903.
E J
L
K
M
N Q R
T
B
B
C D
Item Description
Table 421. D Circlip 1
Item Description E Reaction pin
A Bolt 1 F Support for differential
B Counter plate G Brake piston housing
C Plate carrier H Capscrew
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Item Description Brake piston and seals- Positive retraction

J Nut type
K Circlip 2 1. Remove all traces of the old sealant from the
L Back off pin 1 mating faces of the drivehead and the brake
M Tension bush piston housing.
N Spring 1
2. Install a new seal 1 and seal 2. Make sure that
P Brake piston they are seated squarely in their grooves.
Q Seal 1
R Seal 2 3. Carefully push the piston all the way into the
housing. Make sure that the brake back off holes
S Back off pin 2 are aligned with the housing.
T Spring 2
U Cross hatching 4. Apply sealant to the threads of the back off pin 2.
Install the spring 2 over the back off pin 2. Screw
V Oil flow holes the back off pin 2 into the brake piston.
W Drivehead housing
(Medium Strength)
Assemble
5. Apply JCB multigasket to the drivehead mating
Brake piston and seals- Controlled surface and then install the brake piston housing
retraction type assembly. Make sure that they are aligned
against the marking, made at the time of
1. Remove all traces of the old sealant from the disassembly.
mating faces of the drivehead and the brake
piston housing.
6. Install the capscrews, tighten the capscrews to
2. Install a new seal 1 and seal 2. Make sure that
they are seated squarely in their grooves.
7. Remove the differential support.
3. Apply sealant to the threads of the back off pin 1.
Screw the back off pin 1 into the brake piston.
Brake pack
(Medium Strength) 1. In the controlled retraction piston type, If new
brake and friction plates are installed then a new
4. Carefully push the piston all the way into the brake back off pin 1 and tension bushes also
housing. Make sure that the brake back off holes need to be installed. Failure to do so could result
are aligned with the housing. in the brake being permanently on.
5. Install the spring 1 over the back off pin 1. 2. Assemble the five friction plates and six counter
plates onto the brake carrier. If the original brake
6. Put the tension bush over the back off pin 1. pack is reinstalled then return the plates to their
7. Use a suitable tool to drive the tension bush onto original positions.
the back off pin 1, use a soft faced hammer until 3. Soak the new friction plates in JCB Special Gear
the circlip 2 is installed. Oil before assembly.
8. Apply JCB multigasket to the drivehead mating Consumable: JCB Gear Oil HP
surface and then install the brake piston housing
assembly. Make sure that they are aligned 4. Install the circlip 1.
against the marking, made at the time of
disassembly. 5. At the time of assembly of the brake packs, the oil
flow holes must be aligned with each other when
Consumable: JCB Multi-Gasket installed to the brake pack carrier.
9. Install the capscrews, tighten the screws to the 6. Put the three reaction pins into their grooves and
correct torque value.Refer to Table 422. lubricate them.
10. Remove the differential support. 7. Push the pins fully into their location holes in the
housing. Makes sure they stay in place.
8. Install one counter plate into the housing,
lubricate it and then the other counter plate.
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9. If the old counter plates are re installed then put Consumable: JCB Threadlocker and Sealer
them into their original position. (Medium Strength)
10. Fully press the brake pack in the housing. 13. Put the axle arm on to the drivehead. Make sure
it is aligned correctly.
11. Apply JCB multigasket to the mating surface of
the drive head. 14. Install the bolts 1 and tighten the bolt to the
12. Apply threadlocker and sealer to the bolt thread. 14.1. Check the grade of the installed bolt and
make sure you tighten them to the correct
torque.Refer to Table 422.
Table 422. Torques

Item Torque
If the bolt 1 is 8.8 grade 244
If the bolt 1 is 12.9 grade 400
Item H (capscrew) 56
(For: 55 Series (1 Piece Axle))

This axle is a 1 piece assembly. No disassemble
procedure is required.
To remove the internal components refer to the

applicable sections.
For drive head components refer to (PIL 27-22).
For differential components refer to (PIL 27-24).
For hub and components refer to (PIL 27-27).
For drive shaft components refer to (PIL 27-51).
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15 - Breather
15 - Breather
Check (Condition)
Breathers are installed to axles to release the If the breather is dislodged or removed, make sure
pressure build up due to braking and prolonged that it is installed again with the hole pointing towards
roading. the wheel.
If the breathers are blocked, there can be oil leakage Make sure that the breather is installed on the
past seals and brake problems due to pressure opposite side of the crownwheel (in less turbulent oil
build up. Most of the axles are have long stem type areas) to avoid oil seepage.
breather.
Make sure that the plug is installed on the
Make sure that there is sufficient clearance around crownwheel side.
the breather.
Figure 904.
A Long stem breather B Plug

C Hole
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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.
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22 - Drivehead
Contents Page No.
27-22-00 General ......................................................................................................................... 27-329

27-22-06 Crownwheel .................................................................................................................. 27-350
27-22-09 Pinion Gear .................................................................................................................. 27-352
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Introduction .................................................. 27-329 The axle drivehead transmits drive from the input
Component Identification ............................. 27-330 coupling yoke to the driveshafts through the
Disassemble and Assemble ........................ 27-337 differential unit.
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For: 55 Series (1 Piece Axle), 80 Series (1 Figure 906.

Piece Axle) .............................. Page 27-330
(For: 55 Series (1 Piece Axle), 80 Series (1

Piece Axle))
Unit Identification
The axle serial number is stamped on the unit
identification plate as shown. When you make an
order for parts replacement, always give the details
of gear replacements, always check the part number
Figure 905.
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Figure 907.
4 5
2 3 6 7 8
Item Description
5 Bevel gears
Table 423.
6 Side nut locking pin
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
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Location Drawing (448/00040)
Figure 908.
15 10
14
12
13
1
2
11
3
4
5
Item Description
Table 424. 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
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Item Description Figure 909.

10 Bolt-Verbus Ripp
11 Crown wheel and pinion
assembly
12 Bearing (taper roller)
13 Side nut
15 Differential assembly
A
Unit Identification A Identification plate

The axle serial number is stamped on the unit Figure 910.
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Figure 911.
4 5
2 6 3 7 8
Item Description
5 Bevel gears
Table 425.
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
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Location Drawing (450/00019, 450/00023)
Figure 912.
10 11 15 27 1 21
24
25
13
26
12
31 33
32
34
16
29
28 2
30
3
4
6
5
7
7
8
Item Description
Table 426. 8 Stake nut
10 Bolt Verbus-ripp
Item Description
11 Crownwheel and pinion
1 Housing assembly
2 Bearing (taper roller) 12 Bearing (taper roller)
3 Shim 13 Side nut
4 Spacer 15 Differential assembly
5 Bearing (taper roller) 16 Brake piston housing
6 Pinion seal 21 Dowel
7 Coupling yoke
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Item Description
24 Brake piston
25 O-Ring
26 O-Ring
27 Drain plug
28 Spring
29 Pin (brake back-off)
30 Flanged bush
33 Spring
34 Pin (brake back-off)
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For: 55 Series (1 Piece Axle), 80 Series (1 7. Remove the bearing outer race 1 and bearing
Piece Axle) .............................. Page 27-337 outer race 2 from the drivehead carrier bores.
8. Drive off the taper roller bearing cone 1 from the
crownwheel differential case half.
(For: 55 Series (1 Piece Axle), 80 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
Drive Coupling 892/00812 1 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.
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 0.01L 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.
6. Pull out the tension pin 1 and tension pin 2, and 7. Remove the crownwheel from the differential
remove the castellated nut 1 and castellated nut case half.
2.
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Figure 913.
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
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00 - General
housing halves are also matched. Do not use

unmatched halves.
Table 427.
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.
Special Tool: Setting Tool Kit (Qty.: 1)
• 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
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00 - General
bearing is installed properly. Also check that the Figure 915.

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 914.
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: 35N·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 430.
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 (Dial Test Indicator). Make sure that Special Tool: Spacer Kit (Qty.: 1)
the DTI is mounted on the drivehead and not on 17.4. If there is no spacer of this size, then install
the bracket. 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.
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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: 0.17–0.28mm
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 428. 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: 250N·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 429. Torque Settings (70 and 80 Series)
Torque: 2.3–3.4N·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 430. 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.
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Table 431. Torque Values Figure 916.

Item Description Nm
L Differential assembly 46
AB AA
retaining bolt
AJ Adaptor 50

Special Tools
Spanner
Setting Tool Kit 892/00918 1
Shim Kit 921/01900 1
Flange Spanner 992/04800 1
(10-100Nm)
Support Bracket 997/11000 1 AA Park brake disc
AB Flange spanner
Consumables
Description Part No. Size 2. Remove the pinion nut.
JCB Multi-Gasket 4102/1212 0.05L Figure 917.
and Sealer (Medium 4101/0251 0.05L AC AE
Strength)
Disassembly
When the drivehead is installed on the machine it
cannot be disassembled. It is recommended that you
remove the complete axle. Refer to Brakes and Hub
and Driveshaft for axle arm removal procedure.
The crownwheel and the 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 AC Coupling yoke
are the differential side gears and planet gears, do AE Drive coupling spanner
not use unmatched halves or gears.
3. As applicable, use a flange spanner or a drive
1. The drivehead pinion may be installed with either coupling spanner to remove the brake disc.
a park brake disc or a coupling yoke, depending Special Tool: Flange Spanner (Qty.: 1)
on the axle application. Special Tool: Drive Coupling Spanner (Qty.: 1)
4. In a drivehead with the park brake disc, the
brake caliper bracket is orientated differently
depending on the axle application.Refer to
Figure 918.
5. Make sure that you mark the bracket and the
drivehead case before you remove the bracket.
27 - 342 9813/9100-1 27 - 342

27 - Driveline
22 - Drivehead
00 - General
Figure 918. 12. Move the differential side nut locking pin to do the
adjustment on assembly. Refer to Figure 920.
AF AG Figure 920.
C Differential side nut locking pin

AF Brake caliper bracket
AG Brake caliper bracket mounting bolt 13. Remove the other brake piston housing only if
damaged, but it is mandatory to remove the
6. Remove and discard the brake caliper mounting locking pin (to allow for side load adjustment on
bracket bolts. Refer to Figure 918. assembly). Refer to Figure 920.
7. Remove the brake caliper mounting bracket. 14. Lift out the crownwheel and differential assembly.
Refer to Figure 918. Refer to Figure 921.
8. Place the drivehead with the crownwheel at the Figure 921.

top. Refer to Figure 919.
9. Mark the drivehead case to show the crownwheel D
position. Refer to Figure 919.
Figure 919.
B A
D Crownwheel and differential assembly

15. If it is necessary to remove the brake piston
housings, mark the crownwheel end of the
A Capscrew drivehead case to make sure that the assembly
B Brake piston housing is returned to its original position. Refer to Figure
921.
10. Mark the brake piston housing and the
drivehead. Refer to Figure 919. 16. Use a soft faced hammer to hit the pinion end
shaft until the pinion is free from its front bearing
11. Remove the capscrews and then remove the and then remove the pinion. Refer to Figure 922.
brake piston housing. Refer to Figure 919.
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27 - Driveline
22 - Drivehead
00 - General
17. Remove the pinion seal and the outer bearing 23. Remove the inner bearing cone. Refer to Figure
cone. Refer to Figure 922. 923.
18. If necessary, drive out the pinion inner bearing 24. Disassembly of the differential unit. Refer to
cup and shims. Refer to Figure 922. Figure 924.
Figure 922. 24.1. Remove the bolts.
24.2. Lift off the top half housing.
H
Figure 924.
J
E M
G Q
N
F
S
E Pinion P
F Pinion seal
G Outer bearing cone
H Inner bearing cup
J Shim
19. Discard the shims. Refer to Figure 922.
20. If necessary, Do the step to 18 remove the outer
bearing cup. Refer to Figure 922.
21. There are no shims for the outer bearing cup.
Refer to Figure 922. M Bolt
N Top half housing
22. Remove the pinion spacer. Refer to Figure 923. P Spherical washer
Q Differential bearing cone
Figure 923. S Differential gear
24.3. Remove the differential gears and the
K L spherical washers.
24.4. Remove the differential bearing cones.
Assembly
Axles not installed with the park brake discs feature
have a different type of drivehead case to those
illustrated. Differences in assembly procedure are
given as necessary.
1. If necessary, install a new crownwheel to the

differential case half.
K Bearing cone 2. Install the crownwheel retaining bolt.

L Pinion spacer
3. Tighten the bolt to the specified torque value.
Torque: 200N·m
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27 - Driveline
22 - Drivehead
00 - General
4. Assemble the differential gear and the spherical Figure 926.

washers into the bottom half of the differential
housing. Refer to Figure 925.
K L
5. Install the differential bearing cones. Refer to
Figure 925.
Figure 925.
Q
N K Bearing cone
L Pinion spacer
11. Install the inner bearing cup with the necessary
thickness of the shim to give correct pinion depth.
S Refer to Front Drivehead, Pinion Gear- Calibrate
(PIL 27-22-09). Refer to Figure 927.
P
12. Select the shims from the shim kit. Refer to
Figure 927.
Special Tool: Shim Kit (Qty.: 1)
13. Use a puller tool to make sure that the inner
bearing cup is installed in square. Do not use a
hammer. Refer to Figure 927.
14. Install the outer bearing cup. Refer to Figure 927.
M Bolt 15. Put the pinion into its bore. Refer to Figure 927.
N Top half housing Figure 927.
P Spherical washer
Q Differential bearing cone
S Differential gear H
6. Put the top half of the differential housing on to J

the differential and make sure that you align it
correctly. Refer to Figure 925. E
7. Apply sealant to the threads of the bolts and then
install them. Refer to Figure 925.
(Medium Strength)
8. Tighten the bolt to the correct torque value. Refer G
to Figure 925.
F
9. Check the gears for free rotation. Refer to Figure
925.
10. Install the pinion inner bearing cone and the
largest available spacer (14.20mm). Refer to E Pinion
Figure 926. F Pinion seal
G Outer bearing cone
H Inner bearing cup
J Shim
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27 - Driveline
22 - Drivehead
00 - General
16. Before you put the pinion into the bore, make 25. Make sure that the correct size spacer is
sure that it is matched with the crownwheel. installed. Refer to Figure 928.
26. Use two bolts (M10x30) to install the special
17. The code numbers etched on the pinion end bracket to the drivehead housing. Refer to Figure
face and the crownwheel perimeter should be the 928.
same. Refer to Figure 927. Special Tool: Support Bracket (Qty.: 1)
18. Install the pinion outer bearing cone. Refer to 27. Install the special tool support pillar to the bracket
Figure 927. so that the fork end engages in the adaptor. Refer
19. Do not install the oil seal at this stage. Refer to to Figure 929.
Figure 927.
28. Make sure that the fork is centrally located on the
20. Install the special tool sleeve and the special adaptor. Refer to Figure 929.
pinion shaft adaptor. Refer to Figure 928.
29. If necessary, align the bracket again. Refer to
Special Tool: Setting Tool Kit (Qty.: 1) Figure 929.
21. Tighten the adaptor to the correct torque value. Figure 929.
22. Make sure that the pinion is free to rotate and Z
there is end float. Refer to Figure 928.
Figure 928. Y
X
U
X Support pillar
Y DTI
W Z Torque wrench
30. Install a DTI. Refer to Figure 929.
1
T Pinion shaft adaptor 31. Make sure that the DTI is installed on the
U Special tool sleeve drivehead not on the bracket. Refer to Figure
V Special bracket 929.
W Bolt (M10x30)
32. Set the torque wrench to the specified value and
23. End float will prevent the bearing from damage. measure the end float while you rotate the shaft.
Refer to Figure 928. Refer to Figure 929.
24. If the pinion is not free to rotate or there is no end Torque: 35N·m
float at this stage check the bearing is installed Special Tool: Torque Wrench (10-100Nm) (Qty.:
correctly. Refer to Figure 928. 1)
33. Correct size solid spacer selection. Refer to
Figure 929.
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27 - Driveline
22 - Drivehead
00 - General
33.1. To select the correct size spacer, subtract Figure 930.

the end float obtained at step 32 from the
solid spacer size (14.20 mm). AC AH
33.2. Also subtract 0.04 mm to allow for
theoretical bearing tolerance and pre-load. AA
33.3. The result is the size of spacer to be
installed from the solid spacer kit.
AG
33.4. If there is no spacer of this size, install the
next nearest size spacer from the spacer
kit. T
AJ
34. Remove the sleeve and the temporary spacer.
U
AF
35. When you remove the temporary spacer make
sure that the outer bearing is not damaged. Refer
to Figure 930.
36. Install the correct size spacer from the solid
spacer setting kit. Refer to Figure 930.
37. Install the sleeve. Refer to Figure 930.
38. Tighten the adaptor to the specified value, to
protect against bearing damage while spacer T Pinion shaft adaptor
selection is verified and make sure that the pinion U Special tool sleeve
is free to rotate. Refer to Figure 930. AA Park brake disc
AC Coupling yoke
Torque: 50N·m
AF Brake caliper bracket
39. Check there is no end float and the pinion is free AG Brake caliper bracket mounting bolt
to turn smoothly by hand. Refer to Figure 930. AH Stake nut
AJ Oil seal
40. Remove the adaptor and install the stake nut.
Refer to Figure 930. 41. Check that rolling torque is less than 2.0 Nm. If
the rolling torque exceeds 2.0 Nm, check that the
shaft is assembled correctly. Refer to Figure 930.
42. If the pinion is not free to rotate then check the
correct size spacer is installed or not. Refer to
Figure 930.
43. If the rolling torque measured at step 41 is too
high then install the next largest size spacer. If
the rolling torque is too low then install the next
smallest size spacer. Refer to Figure 930.
44. If a correct spacer is not available from the range,
check that drivehead is assembled correctly.
45. Remove the stake nut and the sleeve. Refer to
Figure 930.
46. Lubricate the seal lips and then install the new oil
seal. Refer to Figure 930.
47. Drivehead with park brake disc. Refer to Figure
930.
47.1. Put the brake caliper bracket on the
drivehead case correctly.
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27 - Driveline
22 - Drivehead
00 - General
47.2. Apply sealant to the new brake caliper 49. Gradually tighten the stake nut up to the specified
mounting bracket bolts and install them. limit, occasionally rotate the coupling yoke or the
brake disc.
47.3. Tighten the bolts to the correct torque
value. 50. If the correct size spacer is selected, the rolling
47.4. Install the brake disc and a new stake nut. torque should be within the specified torque
value including the seal drag.
47.5. Install the drive coupling spanner. Refer to
Figure 931. Torque: 2.3–3.4N·m
Special Tool: Drive Coupling Spanner 51. The stake nut tightening can be increased to a
(Qty.: 1) maximum value, if the pinion rolling torque does
not exceed the maximum of 3.4 Nm. Maximum
Figure 931. torque values for M30 stake nut and M24 stake
nut are mentioned below.
AB AA 51.1. M24 Stake nut.

Torque: 300N·m
51.2. M30 Stake nut.
Torque: 370N·m
52. Finally stake the nut into the slot.
53. If the brake piston housing is removed then install
one at the opposite end to the crownwheel.
54. Apply JCB Multigasket to the drivehead mating
face, then install the brake piston housing.
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 Park brake disc 934.
AB Flange spanner
56. Then install the crownwheel and differential
48. Drivehead with coupling yoke. assembly into the drivehead. Refer to Figure 933.
48.1. Install the coupling yoke and a new stake Figure 933.
nut. Refer to Figure 930.
48.2. Locate the flange spanner. Refer to Figure
932. D
Special Tool: Flange Spanner (Qty.: 1)
Figure 932.
AC AE
D Crownwheel and differential assembly

AC Coupling yoke
AE Drive coupling spanner
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27 - Driveline
22 - Drivehead
00 - General
57. Install the other side brake piston housing onto correctly. Refer to Front Drivehead, Crownwheel-
the drivehead. Refer to Figure 934. Check(Operation) (PIL 27-22-06).
58. Install the capscrews. Refer to Figure 934. 66. To measure the backlash, use a magnet drilled
and tapped 6 mm to accept a length of rod
Figure 934. threaded 6 mm on one end. Put the magnet
between the crownwheel locking bolts.
C
Figure 935.
AD
B A
Table 432. Spacer selection example

A Capscrew Value
(1)
B Brake piston housing

C Side nut locking pin Temporary spacer size 14.20
AD Differential side nut Subtract end float 0.25
Total 13.95
59. Tighten the capscrews to the correct torque
value. Refer to Figure 934. Subtract tolerance and 0.04
pre-load
60. Adjust the differential side nuts to give a bearing Result 13.91
pre-load of the specified value. Refer to Figure Use next smallest spac- 13.90
934. er
Torque: 1.13–2.26N·m (1) All the values are in millimetre (mm).
61. Measure the pre-load by taking another rolling Table 433. Torque Values
torque reading and subtracting the torque figure
measured at step 50. The difference is the Item Description Nm
bearing pre-load. Refer to Figure 934. M Bolt 56
T Pinion shaft adaptor 50
62. Measure the crownwheel backlash, it should be
within the specified limit. Refer to Figure 934. AG Brake caliper mounting bolt 166
A Capscrew 56
AH Stake nut 250
63. Adjust the differential side nuts by equal amounts
when you change the backlash. Refer to Figure
934.
64. When the backlash and pre-load are both
correct, install the side nut locking pins. Refer to
Figure 934.
65. Check the tooth mark to make sure
that the crownwheel and pinion are set
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27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-350 A crown wheel is a rotating gear wheel with teeth set
Check (Operation) ....................................... 27-351 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.
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27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Operation) Figure 938.
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 936.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 937.
3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.
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27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear Introduction

Introduction .................................................. 27-352 A pinion gear is a small gear that meshes with a
Calibrate ...................................................... 27-353 larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.
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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 941.
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 434. 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 939.
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 435. 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 940. 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 436. 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
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27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-355
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27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-355 A differential is a particular type of simple planetary
Component Identification ............................. 27-357 gear train.
Check (Condition) ........................................ 27-359
Disassemble and Assemble ........................ 27-360 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.
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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.
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27 - Driveline
24 - Differential
00 - General
For: Limited Slip Differential (LSD)

................................................. Page 27-357
For: Max-Trac .......................... Page 27-358
(For: Limited Slip Differential (LSD))
Figure 942. 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
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27 - Driveline
24 - Differential
00 - General
(For: Max-Trac)
Figure 943. 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
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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: 1.25mm
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).
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27 - Driveline
24 - Differential
00 - General
For: 55-Series, 80-Series, Front, Limited Slip 3. Put marks on the two halves of the differential
Differential (LSD) ..................... Page 27-360 housing before disassembly to make sure of
For: Front, Max-Trac, Rear ...... Page 27-363 correct assembly.
4. Remove the capscrews.
(For: 55-Series, 80-Series, Front, Limited
Slip Differential (LSD)) 5. Disengage the two halves of the differential and
remove the following components:
The numerical sequence shown on the illustration is
intended as a guide for disassembly. 5.1. Trunnion pins.
5.2. Side gears.
The number of friction and counter plates shown in
the illustration is typical only. The actual number of 5.3. Bevel gears.
plates is determined by the axle variant. 5.4. Spherical washers.
Important: The crownwheel and pinion are matched 5.5. Pressure plates.
and should be renewed as a pair if either one is 5.6. Counter plates.
damaged or excessively worn. The two halves of
the differential housing are also matched as are the 5.7. Friction plates.
differential side gears and bevel gears, do not use
5.8. Shims.
unmatched halves or gears.
6. Make a note of the relative positions of the
Disassemble friction plates, counter plates and spacers before
disassembly, they must be installed in the same
1. Use a heavy duty socket to remove the verbus- positions.
ripp bolts. Discard the bolts.
2. Remove the crownwheel.
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27 - Driveline
24 - Differential
00 - General
Figure 944. 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
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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 945.
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.
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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.
(For: Front, Max-Trac, Rear) Figure 946.

Consumables
JCB Threadlocker 4101/0250 0.01L A
Strength)
The crownwheel and pinion are matched and should

F
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
gears. Do not use unmatched halves or gears. C
E
If it is necessary to install a new crownwheel to the B
differential unit, then install it and torque tighten the
crownwheel retaining bolts to the specified torque D
value.94N·m
Disassembly
1. Before you disassemble match-mark the two
halves of the differential housing for the correct
assembly.
A Capscrews
2. Remove the capscrews. B Side gears
C Thrust washers
3. Disengage the two halves of the differential D Bevel gears
housing. E Spherical washers
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.
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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
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27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-367

27-27-66 Wheel Stud ................................................................................................................... 27-396
27 - 365 9813/9100-1 27 - 365

Notes:
27 - 366 9813/9100-1 27 - 366

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-367 The hub is the part of the axle where the wheel
Component Identification ............................. 27-368 is mounted and where the axle shaft (if installed)
Drain and Fill ............................................... 27-370 passes through.
Calibrate ...................................................... 27-373
Some hubs are not driven and rotate due to motion
Disassemble and Assemble ........................ 27-374 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 - 367 9813/9100-1 27 - 367

27 - Driveline
27 - Hub
00 - General
Unit Identification Main Component Identification

The axle serial number is stamped on the unit Figure 949.
G H
Figure 947. A
A J
K
D
Figure 948. L
E
F M
Table 439.
Item no Description
A Annulus ring
B Planet gear assembly
(x3)
C Thrust pad
D Sun gear
A Identification plate E Planet gear carrier
F Wheel stud (x5)
G Bearing carrier
H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)
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27 - Driveline
27 - Hub
00 - General
Sectional Drawing
Figure 950.
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 440. 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)
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27 - Hub
00 - General
Drain and Fill
Check the hub oil level of one wheel at a time. 4. Apply the park brake.
Complete the steps below to check the hub oil.
5. Set the transmission to the neutral position.
6. Lower the attachments to the ground.
2. Set the machine level with the wheels above the
ground. 7. Stop the engine and remove the ignition key.
2.1. Use suitable lifting equipment to lift the 8. Clean the area around the hub plug.
machine axles to the same level. 9. Remove the hub plug.
3. Set the hub oil level mark to the horizontal 10. Check the oil level of the hub.
position.
10.1. The hub oil level must be level with the
3.1. Turn the wheel manually to get the hub oil bottom surface of the plug hole.
level mark to the horizontal position.
10.2. If necessary, add the correct axle oil. Refer
3.2. The specified tolerance is permitted above to (PIL 75).
or below the oil level mark horizontal
position. 11. Clean the plug before you install it.
12. Install the hub plug and tighten to the correct
Figure 951. torque.
A 12.1. To Make sure you use the correct torque
tightening information, identify the correct
axle for your machine. Refer to Figure 952.
B
12.2. Make sure you identify the correct plug
for your machine. Then use the related
torque information. Refer to Figure 954.
E
D C
A Wheel
B Hub
C Plug
D Level mark
E Tolerance 5mm
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27 - Driveline
27 - Hub
00 - General
Figure 952. JCB Axles With Inboard Brakes (If installed)
A
B
A Axle drain plug 1 location
Table 441. 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 953. JCB Axles With Braked Hubs (If installed)

D
D Drain plug E Axle drain plug 2 location
Table 442. 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 954. Hexagonal Head Plug and

Bonded Washer (Prior to January 2011)
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27 - Hub
00 - General
Figure 955. Taper Plug (If in-

stalled) (January 2011 Onwards)
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27 - Hub
00 - General
Calibrate
Refer to the relevant Disassemble and Assemble

procedure (PIL 27-27).
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27 - Hub
00 - General
For: Front, PD55, PD70 ........... Page 27-374 Figure 956.

For: Front, PD80 ..................... Page 27-380 F
For: Front, PD80, PD80 with Integral Brake
................................................. Page 27-387 D
G
(For: Front, PD55, PD70) B
Special Tools
Heavy Duty Socket 892/00333 1
19mm A/F x 3/4 in
Drive
Wheel Hub Service Kit 892/01092 1
Reaction Plate M14 998/M1374 4
Studs
Reaction Plate 998/M1375 1 B Planet gear carrier
D Planet gear
Disassemble G Driveshaft thrust pad
F External circlip 1
WARNING A raised and badly supported
machine can fall on you. Position the machine 5.1. Remove the external circlip 1.
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do 5.2. Remove the planet gear.
not rely solely on the machine hydraulics or jacks 5.3. The driveshaft thrust pad is drilled and
to support the machine when working under it. tapped for removal purposes. Use a
Disconnect the battery, to prevent the machine suitable M6 screw to extract the thrust pad
being started while you are beneath it. from inside the planet gear carrier.
The illustrations in this procedure show the axle 6. Remove the external circlip 2.
removed from the machine but the hubs can be 7. Remove the sun gear from the driveshaft.
disassembled without removing the axle. Refer to
Figure 962. 8. To remove the verbus-ripp bolts it is necessary
to remove the spacer (if installed). Rotate the
1. Drain the oil from the hub. spacer with a suitable drift to align the holes in
the spacer with the space between the bolts.
2. Remove the screws.
9. Use two dowels and two heel bars to remove the
3. Remove the planet gear carrier from the bearing
spacer as shown. Refer to Figure 957.
carrier.
4. Remove and discard the O-ring.
5. Remove the planet gears only if they are
damaged. Note: Planet gears can only be
replaced as an assembly which contains the
gear, bearing, and two L-shaped circlips. Refer
to Figure 956. and Refer to Figure 961.
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27 - Hub
00 - General
Figure 957. 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 958. onto two diametrically opposite wheel
studs and put the reaction tube over the
Figure 958. driveshaft. Refer to Figure 959.
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.
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27 - Hub
00 - General
Figure 959. 15. Remove the inner wheel bearing as follows:

W Y
Figure 961.
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 960. bearing.
Figure 960. 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
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
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27 - Hub
00 - General
Figure 962.
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
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00 - General
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 963.
Figure 963. 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 966.
4. Make sure you use the correct side of the seal
dolly as follows: Figure 966.
4.1. For axles with a steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 964.
Figure 964. 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 967.
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 965.
K Verbus-ripp bolts
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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 969.

Figure 968.
Figure 968.
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 969.
(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
16. Assemble the reaction tube and handle onto the
shown.
extension shaft.
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.
Torque: 2–22N·m
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.
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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 969.
33. Apply sealant to the threads of the screws. Refer
28.1. Important: Make sure that you install the
to Figure 972.
planet gears in the correct orientation.
Install the large radius end of the bearing Figure 972.
over the pin first. Refer to Figure 970.
Q
Figure 970.
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 971.
F Table 443. Torque Values
Item Nm
D
G A 56
B K 320
(For: Front, PD80)

Special Tools
Heavy Duty Socket 892/00333 1
19mm A/F x 3/4 in
Drive
Wheel Hub Service Kit 892/01092 1
B Planet gear carrier Disassemble

D Planet gear
G Driveshaft thrust pad WARNING A raised and badly supported
F External circlip 1 machine can fall on you. Position the machine
29. Install the spacer (If installed). Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks
30. Install the sun gear onto the driveshaft and to support the machine when working under it.
secure with the external circlip 2. Disconnect the battery, to prevent the machine
being started while you are beneath it.
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00 - General
9. Put marks on the stub shaft, annulus carrier

The illustrations in this procedure show the axle and annulus ring to identify their relative angular
removed from the machine but the hubs can be position during installation.
disassembled without removing the axle. Refer to
Figure 977. 10. Remove the annulus carrier with the annulus ring
from the axle stub shaft.
1. Drain the oil from the hub.
10.1. Note: It is normal for fretting to occur on
2. Remove the screws. the mating surfaces between the axle stub
shaft and annulus carrier. Do not attempt
3. Remove the planet gear carrier from the bearing to repair it.
carrier.
11. Remove the internal circlip to separate the
4. Remove and discard the O-ring. annulus ring from the annulus carrier.
5. Remove the planet gears only if they are 12. Remove the outer wheel bearing and the bearing
damaged, Note: Planet gears can only be carrier as follows:
replaced as an assembly which contains the
gear, the bearing, and two L-shaped circlips. 12.1. Attach the legs of the bearing puller
Refer to Figure 973. onto two diametrically opposite wheel
studs and put the reaction tube over the
Figure 973. driveshaft. Refer to Figure 974.
F Special Tool: Wheel Hub Service Kit (Qty.:
1)
D
G 12.2. The reaction tube must be used otherwise
B damage to the driveshaft and driveshaft
wheels studs from the Wheel Hub Service
Kit must be used. Bolt to two diametrically
carrier.
carrier and the outer wheel bearing are
released from the axle stub shaft.
B Planet gear carrier 12.5. If the wheel hub starts to rotate use a
D Planet gear suitable bar to prevent further rotation.
G Driveshaft thrust pad
F External circlip 1 12.6. If the screw becomes hard to turn, tap the
back of the bearing carrier with a soft faced
5.1. Remove the external circlip 1. mallet to help release the bearing.
5.2. Remove the planet gear. Figure 974.
5.3. The driveshaft thrust pad is drilled and W Y
tapped for removal purposes.
6. Remove the external circlip 2 and remove the sun
gear from the driveshaft.
7. Remove the verbus-ripp bolts with a heavy duty
socket.
Special Tool: Heavy Duty Socket 19mm A/F x 3/4
in Drive (Qty.: 1)
X
7.1. Note: the verbus-ripp bolts are very tight Q
and care must be taken not to distort the Q Bearing carrier
bolt heads. Use an extension bar as short W Reaction tube
as possible. Discard the verbus-ripp bolts X Screw
after removal. Y Bar
8. Remove the retaining plate.
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00 - General
13. Remove and discard the outer part of the Figure 976.
combination oil seal by cutting the outer seal with
a sharp chisel.
14. Carefully force the inner seal fully on to the stub
axle, take care not to damage the seal seat on
the stub axle. Refer to Figure 975. X
Figure 975.
Z
W Reaction tube
X Screw
15.1. Clamp the inner bearing plates around the
inner wheel bearing.
15.2. Attach the puller rods and put the reaction
tube over the driveshaft.
T
15.3. The reaction tube must be used otherwise
T Combination oil seal damage to the driveshaft and driveshaft
Z Chisel bearings will occur.
15. Remove the inner wheel bearing as follows:
shaft.
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27 - Hub
00 - General
Figure 977.
F
D
V
E
V
C N
P L
B
J K
G T
R U
S
A

E Bearing F External circlip 1
G Driveshaft thrust pad H External circlip 2
J Sun gear K Verbus-ripp bolt
L Annulus carrier M Annulus ring
N Internal circlip P Retaining plate
Q Bearing carrier R Outer wheel bearing
S Inner wheel bearing T Combination oil seal
U Dirt shield (If installed) V L-shaped circlip
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27 - Driveline
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00 - General
1. Attach the bearing centre puller to the centre of AA U

the hub with the existing verbus-ripp bolts. Refer
to Figure 978.
Figure 978.
K Verbus-ripp bolts
Q Bearing carrier
2. Install the outer wheel bearing race into the U Dirt shield
bearing carrier. AA Seal dolly
3. Install the inner wheel bearing into the bearing 5.2. For axles without a steel dirt shield use side
carrier. 'B' of the seal dolly. Refer to Figure 981.
4. Use the seal dolly 892/00891 from the wheel hub Figure 981.
service kit to install a new combination oil seal.
The seal dolly has two sides 'A' and 'B' marked AA
for identification. Do not lubricate the seal before
installation. Refer to Figure 979.
Special Tool: Wheel Hub Service Kit (Qty.: 1)
Figure 979.
AA
A B
B
AA Seal dolly
Q Bearing carrier
5. Make sure you use the correct side of the seal AA Seal dolly
dolly as follows:
5.1. For axles with steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 980. 7. Use a soft-faced mallet to drive the seal squarely
into the bearing carrier until the dolly flange is up
against the carrier. Refer to Figure 981.
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00 - General
Figure 982. 15. Slowly turn the puller handle to press the inner
wheel bearing correctly into position.
16. Remove the puller handle and bearing
installation tube.
AA
17. Install the outer wheel bearing into the bearing
carrier.
Q 18. Assemble the puller handle and bearing

installation tube onto the centre puller.
19. Slowly turn the handle to press the outer bearing
removed.
Q Bearing carrier
AA Seal dolly 20. Remove the handle and reaction tube.
8. Attach the bearing press extension shaft onto the 21. Assemble the annulus ring onto the annulus
end of the axle stub with four verbus-ripp bolts. carrier. Make sure that the marks made during
disassembly are aligned.
9. Lightly apply oil on the inner wheel bearing.
22. Install the internal clip.
10. Position the bearing carrier (complete with inner
bearing) onto the axle stub over the centre puller. 23. Attach the annulus assembly to the axle stub
shaft in the same angular position based on the
11. Assemble the bearing press as shown. Refer to marks made during installation.
Figure 983.
24. Install the retaining plate with new verbus-ripp
Figure 983. bolts.
25. Do not tighten the verbus-ripp bolts at this stage.
R AC
26. Measure the seal drag rolling force: Refer to
Figure 984.
Figure 984.
BB
AD
BA
AB
R Outer wheel bearing

AB Puller handle
AC Thrust washers (x2)
AD Bearing installation tube
12. Slide the bearing installation tube over the centre
bearing puller (the wide opening towards the
bearing). BA Cord
BB Spring balance
13. Make sure that the bearing and the bearing
carrier are properly positioned against the axle 26.1. Install the planet gear carrier.
stub shaft. 26.2. Do not install the sun gear.
14. Attach the puller handle and make sure that the 26.3. Wrap a cord around the planet gear carrier
thrust bearing is installed between the two thrust flange and attach a spring balance to it as
washers. shown.
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27 - Driveline
27 - Hub
00 - General
26.4. Pull the spring balance so that the hub 30.2. Secure the planet gears with the external
rotates, do this several times to let the seal circlip 1.
bed in and record the reading.
Figure 986.
F
27. Tighten the verbus-ripp bolts to the correct torque
value. D
G
28. Measure the rolling force: B
28.1. Install the planet gear carrier.
28.2. Do not install the sun gear.
28.3. Wrap a cord around the planet gear carrier
shown.
rotates and record the reading.
28.5. To calculate the rolling force, subtract the
B Planet gear carrier
seal drag force (refer step 26.4) from the
D Planet gear
value obtained in the step 28.4.
G Driveshaft thrust pad
28.6. The rolling force should be within the F External circlip 1
specified range.
31. Install the sun gear onto the driveshaft and
Torque: 2–22N·m secure with the external circlip 2. Refer to Figure
28.7. If the values are outside the limits specified 987.
then check if the seal is installed correctly,
and/or replace the wheel bearings if Figure 987.
necessary.
C
gear carrier.
that were removed during disassembly. Refer to Q
Figure 986.
30.1. Important: Make sure that you install the J
planet gears in the correct orientation. H
Install the large radius end of the bearing
Figure 985.
C O-ring
H Circlip 2
J Sun gear
Q Bearing carrier
AE
31.1. The sun gear must be installed with the 1.5
mm x 45° chamfer inboard.
32. Install a new O-ring.
33. Install the planet gear carrier onto the bearing
carrier. Make sure that the two tapped holes are
in line with those on the bearing carrier.
AE Large radius end
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27 - Driveline
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00 - General
34. Do not strike the centre of the planet gear Ensure the other end is securely chocked. Do
carrier during installation as this may dislodge the not rely solely on the machine hydraulics or jacks
driveshaft thrust pad. to support the machine when working under it.
Disconnect the battery, to prevent the machine
35. Apply sealant to the threads of the screws. Refer being started while you are beneath it.
to Figure 988.
Figure 988. The illustrations in this procedure show the axle
removed from the machine, the hubs can be
Q disassembled without removing the axle. Refer to
Figure 994.
B 1. Drain the oil from the hub.

2. Remove the screws.
3. Remove the planet gear carrier from the bearing
carrier.
A
4. Remove and discard the O-ring.
5. Remove the planet gears only if they are
damaged. Note: Planet gears can only be
A Screw replaced as an assembly which contains the
B Planet gear carrier gear, the bearing, and two L-shaped circlips.
Q Bearing carrier Refer to Figure 989.
36. Install the screw to attach the planet gear carrier. Figure 989.
E
37. Tighten the screws to the correct torque value.
D
38. Fill the hub with the correct grade oil. H
Table 444. Torque Values B
Item Nm
A 56
K 166
(For: Front, PD80, PD80 with Integral

Brake)
Special Tools
Hand Pump Pressure 892/00223 1 D Planet gear
Test E External circlip 1
Heavy Duty Socket 892/00333 1 H Driveshaft thrust pad
19mm A/F x 3/4 in
Drive 5.1. Remove the external circlip 1.
Wheel Hub Service Kit 892/01092 1 5.2. Remove the planet gear.
Consumables 6. The driveshaft thrust pad is drilled and tapped for

Description Part No. Size removal purposes. Use a suitable M6 screw to
JCB Threadlocker 4101/0250 0.01L extract the thrust pad from inside the planet gear
and Sealer (Medium carrier.
4101/0251 0.05L
Strength) 7. Remove the external circlip 2 and, remove
the sun gear and brake plate carrier from the
Disassemble driveshaft.
WARNING A raised and badly supported 8. Remove the circlip 1 and remove the brake pack
machine can fall on you. Position the machine assembly from the driveshaft.
27 - 387 9813/9100-1 27 - 387

27 - Driveline
27 - Hub
00 - General
9. Remove the brake pressure plate, counter carrier must be replaced as a pair, not
plates, and friction plates. individually.
9.1. Note: If the brake pack is to be used again, 16. Remove the internal circlip to separate the
note the positions of the plates before annulus ring from the annulus carrier.
removing.
17. Remove the brake seal 2 from the hub swivel.
10. Examine the friction plates:
18. Remove the brake retraction bolt and spring (2
10.1. Wear limit of the friction plates is to the off- if installed).
depth of the crosshatching. Refer to Figure
990. 19. If removal is necessary, carefully withdraw the
brake piston from its housing. A hydraulic hand
Figure 990. pump can be used to force the piston out of the
housing.
Q Special Tool: Hand Pump Pressure Test (Qty.: 1)
AM
20. Remove and discard the seal 1 and seal 2.
21. Examine the housing bore for damage and
scoring. Nicks and cuts in the seal maybe
responsible for loss of brake fluid.
22. Remove the outer wheel bearing and the bearing
carrier as follows:
22.1. Attach the legs of the bearing puller
onto two diametrically opposite wheel
Q Friction plate studs and put the reaction tube over the
AM Crosshatching driveshaft. Refer to Figure 991.
10.2. Check all plates for flatness and damage Special Tool: Wheel Hub Service Kit (Qty.:
(wear and polishing of friction plates is 1)
normal).
22.2. Important: The reaction tube must be used
10.3. Replace the brake pack completely if otherwise damage to the driveshaft and
excessively worn or damaged. Do not driveshaft bearings will occur.
replace individual plates.
11. Remove the Verbus-ripp bolts with a heavy duty wheels studs from the Wheel Hub Service
socket. Kit must be used. Bolt to two diametrically
Special Tool: Heavy Duty Socket 19mm A/F x 3/4 carrier.
in Drive (Qty.: 1)
11.1. Note: the Verbus-ripp bolts are very tight carrier along with the outer bearing cone
and care must be taken not to distort the and its cup are released from the axle stub
bolt heads. Use an extension bar as short shaft.
as possible. Discard the Verbus-ripp bolts
after removal. 22.5. If the wheel hub starts to rotate use a
suitable bar to prevent further rotation.
12. Remove the retaining plate. 22.6. If the screw becomes hard to turn, tap the
back of the bearing carrier with a soft faced
13. Remove the brake seal 1.
mallet to help release the bearing.
14. Put marks on the annulus carrier, annulus ring,
and the hub swivel to identify their relative
angular position during installation.
15. Remove the annulus carrier with the annulus ring
from the hub swivel.
15.1. Note: It is normal for fretting to occur on
the mating surfaces between the axle stub
shaft and annulus carrier. Do not attempt
to repair it. The hub swivel and annulus
27 - 388 9813/9100-1 27 - 388

27 - Driveline
27 - Hub
00 - General
Figure 991. 25. Remove the inner wheel bearing as follows:

AS
Figure 993.
AP AR
AP AR
AQ AN
AN Puller legs AQ AV AU
AP Bearing puller
AQ Screw
AR Reaction tube
AS Bar AP Puller
AQ Screw
23. Remove and discard the outer part of the AR Reaction tube
combination oil seal by cutting the outer seal with AU Inner bearing plates
a sharp chisel. AV Puller rods
24. Carefully force the inner seal fully on to the stub 25.1. Clamp the inner bearing plates around the
axle, take care not to damage the seal seat on inner wheel bearing.
the stub axle. Refer to Figure 992.
25.2. Attach the puller rods and put the reaction
Figure 992. tube over the driveshaft.
25.3. Important: The reaction tube must be used
otherwise damage to the driveshaft and
driveshaft bearings will occur.
AT
shaft.
AF
AF Combination oil seal
AT Chisel
27 - 389 9813/9100-1 27 - 389

27 - Driveline
27 - Hub
00 - General
Figure 994. PD80 with Integral Brake

V
E
F
D
G
F
C
B J
L
K
H AJ W
U
AB
S
AC
AA
Y
R
AL
Q
P AK
N
M AH
T
AD
AE
X
AF
AG

27 - 390 9813/9100-1 27 - 390

27 - Driveline
27 - Hub
00 - General
E External circlip 1 F L-shaped circlip

G Bearing H Driveshaft thrust pad
J External circlip 2 K Sun gear
L Brake plate carrier M Circlip
N Brake pressure plate P Counter plate
Q Friction plate R Verbus-ripp bolt
S Retaining plate T Brake seal 1
U Annulus carrier V Annulus ring
W Internal circlip X Brake seal 2
Y Brake retraction bolt Z Spring
AA Piston AB Seal 1
AC Seal 2 AD Bearing carrier
AE Outer wheel bearing AF Combination oil seal
AG Inner wheel bearing AH Blanking screw 1
AJ Blanking screw 2 AK Dirt shield (If installed)
AL Hub
27 - 391 9813/9100-1 27 - 391

27 - Driveline
27 - Hub
00 - General
1. Attach the bearing centre puller to the centre of AW AK

the hub with the existing Verbus-ripp bolts. Refer
to Figure 995.
Figure 995.
AL
A
AR
AD
R Verbus-ripp bolts
AD Bearing carrier
1.1. When you install the retaining plate, new AK Dirt shield
Verbus-ripp bolts must be used. AW Seal dolly
2. Install the outer wheel bearing race into the 5.2. For axles without a steel dirt shield use side
bearing carrier. 'B' of the seal dolly. Refer to Figure 998.
3. Install the inner wheel bearing into the bearing Figure 998.
carrier.
AW
4. 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'
marked for identification. Do not lubricate the
seal before installation. Refer to Figure 996.
Special Tool: Wheel Hub Service Kit (Qty.: 1)
B
Figure 996.
AW
A AD
B AD Bearing carrier
AW Seal dolly
AW Seal dolly
5. Make sure you use the correct side of the seal
dolly as follows: 7. Use a soft-faced mallet to drive the seal squarely
into the bearing carrier until the dolly flange is up
5.1. For axles with steel dirt shield use side 'A' against the carrier. Refer to Figure 999.
of the seal dolly. Refer to Figure 997.
27 - 392 9813/9100-1 27 - 392

27 - Driveline
27 - Hub
00 - General
Figure 999. 16. Remove the puller handle and bearing

installation tube.
17. Install the outer wheel bearing into the bearing
carrier.
AW
18. Assemble the puller handle and bearing
installation tube onto the centre puller.
AD 19. Slowly turn the handle to press the outer bearing
removed.
20. Remove the handle and reaction tube.
AD Bearing carrier 21. Install a new brake seal 1 onto the hub swivel.
AW Seal dolly
22. Make sure that the blanking screws 1 are
8. Attach the bearing press extension shaft onto the installed. Apply sealant to the threads of the
end of the axle stub with four Verbus-ripp bolts. blanking screws.
9. Lightly apply oil on the inner wheel bearing. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
10. Position the bearing carrier (complete with inner
bearing) onto the axle stub over the centre puller. 23. Install a new seal 1 and seal 2 into the grooves
in the brake piston and annulus carrier. Make
11. Assemble the bearing press as shown. Refer to sure the seals are correctly positioned in their
Figure 1000. grooves.
Figure 1000. 24. Carefully press the piston all the way into the
annulus carrier housing.
AE AY
25. Install the brake retraction bolt and spring (2 off
- if installed).
26. Tighten the brake retraction bolt to the correct
torque value.
27. Assemble the annulus ring onto the annulus
carrier. Make sure that the marks made during
AZ disassembly are aligned.
28. Install the internal clip.
AX 29. Make sure that the two blanking plugs 2 are
installed to the annulus carrier. Apply sealant to
the threads of the blanking screws.
AE Outer wheel bearing
AX Puller handle Consumable: JCB Threadlocker and Sealer
AY Thrust washers (x2) (Medium Strength)
AZ Bearing installation tube
30. Attach the annulus assembly to the axle stub
12. Slide the bearing installation tube over the centre shaft in the same angular position based on the
bearing puller (the wide opening towards the marks made during installation.
bearing).
31. Push the annulus assembly onto the splined hub
13. Make sure that the bearing and the bearing until the splines of the annulus assembly are
carrier are properly positioned against the axle flush with the end of the splined hub.
stub shaft.
32. Install the brake seal 2 onto the hub swivel.
14. Attach the puller handle and make sure that the
thrust bearing is installed between the two thrust 33. Install the retaining plate with new Verbus-ripp
washers. bolts. Make sure that the breather hole and brake
galleries are aligned.
15. Slowly turn the puller handle to press the inner
wheel bearing correctly into position. 34. Do not tighten the Verbus-ripp bolts at this stage.
27 - 393 9813/9100-1 27 - 393

27 - Driveline
27 - Hub
00 - General
35. Measure the seal drag rolling force: Refer to 38. Install the brake plate carrier onto the driveshaft.
Figure 1001.
39. Assemble the friction plates and counter plates
Figure 1001. onto the carrier.
40. If the existing brake pack is used, install the
plates to their original positions.
BB
41. Soak the new friction plates in oil before
assembly.
BA
42. Assemble the brake pressure plate. Install the
circlip 1.
gear carrier.
that were removed during disassembly. Refer to
Figure 1003.
BA Cord
BB Spring balance 44.1. Important: Make sure that you install the
planet gears in the correct orientation.
35.1. Install the planet gear carrier. Install the large radius end of the bearing
35.3. Wrap a cord around the planet gear carrier Figure 1002.
shown.
rotates, do this several times to let the seal
bed in and record the reading. BC
36. Tighten the Verbus-ripp bolts to the correct
torque value.
37. Measure the rolling force:
37.1. Install the planet gear carrier. BC Large radius end
44.2. Secure the planet gears with the external
37.3. Wrap a cord around the planet gear carrier circlip 1.
shown.
rotates and record the reading.
37.5. To calculate the rolling force, subtract the
seal drag force (refer step 35.4 ) from the
value obtained in the step 37.4 .
37.6. The rolling force should be within the
specified range.
Torque: 2–22N·m
37.7. If the values are outside the limits specified
then check if the seal is installed correctly,
and/or replace the wheel bearings if
necessary.
27 - 394 9813/9100-1 27 - 394

27 - Driveline
27 - Hub
00 - General
Figure 1003. 51. Tighten the screws to the correct torque value.
E
52. Fill the hub with the correct grade oil.
D
H Table 445. Torque Values
B Item Nm
A 56
R 166

D Planet gear
E External circlip 1
H Driveshaft thrust pad
45. Install the sun gear onto the driveshaft and
secure with the external circlip 2.
45.1. The sun gear must be installed with the 1.5
mm x 45° chamfer inboard.
46. Install a new O-ring.
47. Install the planet gear carrier onto the bearing
carrier. Make sure that the two tapped holes are
in line with those on the bearing carrier.
48. Do not strike the centre of the planet gear
carrier during installation as this may dislodge the
driveshaft thrust pad.
49. Apply sealant to the threads of the screws. Refer
to Figure 1004.
(Medium Strength)
Figure 1004.
AD
A Screw
AD Bearing carrier
50. Install the screw to attach the planet gear carrier.
27 - 395 9813/9100-1 27 - 395

27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 1006.

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 1005.
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 - 396 9813/9100-1 27 - 396

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-399
27 - 397 9813/9100-1 27 - 397

Notes:
27 - 398 9813/9100-1 27 - 398

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-399 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-400 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-400 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 - 399 9813/9100-1 27 - 399

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 8h, 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
rear wheels to ensure machine stability is not
WARNING An exploding tyre can kill. Inflated
compromised in the event of a deflated tyre.
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the Make sure that all tyres are inflated to the correct
tyres. Do not cut or weld the rims. Use a tyre/ pressure and have run flat inserts as required.
wheel specialist for all repair work. Where run flat inserts have been specified for use,
WARNING Deflate the tyre you wish to change ensure that replacement wheels also have run flat
before removing the wheel from the machine. inserts to ensure the machine stability.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner Remove (One Wheel)
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Wheels installed with semi-solid tyres 2. Follow the general health and safety procedures.
are heavy. Removing and installing them requires Refer to (PIL 01-03).
special equipment and training. Have the work
carried out by your JCB dealer or a tyre specialist. 3. Put chocks 1 under the rear wheels.
WARNING Do not install pneumatic tyres on a 4. Loosen the five wheel nuts by half a turn.
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If 5. Put a jack under the axle arm. Use the correct
you are unsure of the correct specification for jack.
your machine, contact your local JCB dealer or a
6. Use the jack to lift the machine until the front
trained specialist.
wheel is off the ground.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the 7. Put chocks 2 under the axle arm.
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre. 8. Hold the wheel and remove the wheel nuts.
Make sure that all tyres are inflated to the correct 9. Remove the wheel.
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 - 400 9813/9100-1 27 - 400

27 - Driveline
29 - Wheel
00 - General
Figure 1007.
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.
Table 446. Torque table

Item Torque value
B 680N·m
27 - 401 9813/9100-1 27 - 401

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-403
27 - 402 9813/9100-1 27 - 402

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-403 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-404 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-404 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.

Refer to Health and Safety and Check Condition (PIL
27-33).
27 - 403 9813/9100-1 27 - 403

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
entering the valve. Inspect for leaks when you check
WARNING Do not use the machine with the tyre pressures.
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed Inspect the tyre valve for leaks, when you check the
limitation of the tyres installed and do not operate tyre pressures.
at more than their recommended maximum
speed.
Tyre Inflation
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which Always try to maintain the tyre pressure to the
at high speeds may endanger life. recommended settings. Using a machine with under-
WARNING Deflate the tyre you wish to change inflated tyres means:
before removing the wheel from the machine.
• Decreasing the machines stability.
Air pressure in the tyres can cause the tyre and
• Higher tyre temperatures.
rim sections to explode causing serious injury or
• Excessive strain of the tyre fabric.
death. Never loosen the nuts that hold the inner
• Causes bulging of the sidewalls.
and outer wheel halves together when there is air
• Shortens the tyres life.
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a Using the machine with over-inflated tyres is
wheel made for a solid tyre. Do not install a solid dangerous:
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for • It causes excessive tensile loads in the fabric:
your machine, contact your local JCB dealer or a this makes a tyre more susceptible to cuts and
trained specialist. punctures.
WARNING When ordering tyres, you must Do not cut or weld on the rim of an inflated tyre.
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are After checking or amending the tyre pressure always
shown in the Operator's Manual. On no account replace and secure the valve cap.
should you use tyres of other designations
without first gaining approval from the machine Always deflate the tyre before removing foreign
manufacturer. obstacles from the tread.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully Procedure
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode. These instructions are for adding air to a tyre which is
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 - 404 9813/9100-1 27 - 404

27 - Driveline
33 - Tyre
00 - General
Figure 1008.
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 - 405 9813/9100-1 27 - 405

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-407
27 - 406 9813/9100-1 27 - 406

27 - Driveline
47 - Propshaft
00 - General

Check (Condition) ........................................ 27-407 1. Make the machine safe. Refer to (PIL 01-03).
Lubricate ...................................................... 27-408
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 - 407 9813/9100-1 27 - 407

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 - 408 9813/9100-1 27 - 408

27 - Driveline
47 - Propshaft
00 - General
Remove and Install
Consumables Figure 1009.

Strength)
Special MPL-EP 4003/1501 0.4kg
Grease 4003/1506 12.5kg
4003/1510 50kg
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 - 409 9813/9100-1 27 - 409

27 - Driveline
47 - Propshaft
00 - General
Figure 1010.
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 1011.
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 1011.
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 - 410 9813/9100-1 27 - 410

27 - Driveline
47 - Propshaft
00 - General
Figure 1011.
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 - 411 9813/9100-1 27 - 411

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-413

27-51-15 Shaft Hub Side ............................................................................................................. 27-417
27 - 412 9813/9100-1 27 - 412

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-413 The driveshaft is a mechanical component for
Component Identification ............................. 27-414 transmitting torque and rotation, usually used to
Check (Condition) ........................................ 27-416 connect other components of the driveline that
Lubricate ...................................................... 27-416 cannot be connected directly because of distance
or the need to allow for relative movement between
them.
27 - 413 9813/9100-1 27 - 413

27 - Driveline
51 - Driveshaft
00 - General
Figure 1012.
1 2 3 4
Item Description
4 Axle arm
Table 448.
5 Driveshaft
Item Description
1 Hub swivel
7 Trunnion (lower)
2 Trunnion (upper)
27 - 414 9813/9100-1 27 - 414

27 - Driveline
51 - Driveshaft
00 - General
Sectional Drawing
Figure 1013.
1 2 3 4 5 6 7 8
5 9
Table 449.
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 - 415 9813/9100-1 27 - 415

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 - 416 9813/9100-1 27 - 416

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: 98N·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 1014.
Figure 1014. 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 - 417 9813/9100-1 27 - 417

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 1015.
Figure 1015. 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: 98N·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 450. Example of

shim thickness calculation
Gap 1.55mm
Subtract 1mm
Shim Thickness 0.55mm
27 - 418 9813/9100-1 27 - 418

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Special Tools 4. Remove the hub swivel.

5. To easily remove the trunnions, pump grease
Impulse Extractor 892/00224 1 through the grease nipple.
Bearing Removal Tool 892/00225 1
Adaptor 993/59500 1
6. If it is necessary to replace, remove the top and
Consumables bottom trunnion oil seals and bearings.
JCB Threadlocker 4101/0250 0.01L 7. Use an adaptor with a slide hammer tool to
and Sealer (Medium remove the driveshaft oil seal1 and the needle
4101/0251 0.05L roller bearing from the hub swivel.
Strength)
Special HP Grease 4003/2017 0.4kg Special Tool: Impulse Extractor (Qty.: 1)
4003/2006 12.5kg Special Tool: Adaptor (Qty.: 1)
4003/2005 50kg 8. Remove the driveshaft from the axle.
Disassembly 9. Prise out the driveshaft oil seal 2 from the axle
ram.
The hub assembly must be removed before you 10. Use a tool (892/00225) to remove the drive shaft
attempt to remove the hub swivel and driveshaft. inner bearing.
Refer to the applicable axle hub removal procedure.
Special Tool: Bearing Removal Tool (Qty.: 1)
1. Disconnect the track rod and steering cylinder
from the axle steer knuckles. 11. If there has been a component failure, remove
all traces of debris from the axle and clean the
2. The top and bottom trunnions are the same. magnetic drain plug.
3. Mark the position of the top and bottom trunnions.

Remove the bolts and remove the trunnions.
27 - 419 9813/9100-1 27 - 419

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Figure 1016.
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 - 420 9813/9100-1 27 - 420

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 451. 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: 56N·m
27 - 421 9813/9100-1 27 - 421

Notes:
27 - 422 9813/9100-1 27 - 422

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-09 Levelling System ............................................................................................................ 30-40
30-00-36 Interlock System ............................................................................................................. 30-45
30-00-49 Schematic Symbols ........................................................................................................ 30-49
30-00-50 Schematic Circuit ........................................................................................................... 30-53
30-03 Tank
30-03-00 General ........................................................................................................................... 30-95
30-03-12 Suction Strainer .............................................................................................................. 30-97
30-04 Filter
30-04-00 General ........................................................................................................................... 30-99
30-04-03 Main .............................................................................................................................. 30-100
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-104
30-11 Gear Pump
30-11-00 General ......................................................................................................................... 30-107
30-15 Cylinder / Ram
30-15-00 General ......................................................................................................................... 30-119
30-15-06 Lift Arm ......................................................................................................................... 30-136
30-15-07 Lift Extension ................................................................................................................ 30-142
30-15-08 Lift Compensating ........................................................................................................ 30-147
30-15-11 Lift Arm Crowd ............................................................................................................. 30-149
30-15-24 Stabiliser ....................................................................................................................... 30-154
30-15-63 Sway ............................................................................................................................. 30-158
30-15-99 Seal Kit ......................................................................................................................... 30-159
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-163
30-51 Lift Arm Control Valve Block
30-51-00 General ......................................................................................................................... 30-169
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-183
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-184
30-51-21 Load Sense Relief Valve .............................................................................................. 30-187
30-51-24 Flow Regulator ............................................................................................................. 30-189
30-53 Servo System Control Valve Block
30-53-00 General ......................................................................................................................... 30-193
30-53-27 Pressure Compensator Valve ...................................................................................... 30-199
30-53-36 Load Hold Check Valve ............................................................................................... 30-200
30-54 Parallel Circuit Control Valve Block
30-54-00 General ......................................................................................................................... 30-203
9813/9100-1
2017-11-16
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-223
30-60-12 Electro Proportional Control ......................................................................................... 30-225
30-60-15 Joystick ......................................................................................................................... 30-238
30-60-27 Auxiliary Circuit ............................................................................................................ 30-248
30-60-82 Sway ............................................................................................................................. 30-249
30-60-90 Flow Regulator ............................................................................................................. 30-257
30-61 Counterbalance Valve
30-61-00 General ......................................................................................................................... 30-259
30-61-06 Lift Arm ......................................................................................................................... 30-264
30-61-07 Lift Extension ................................................................................................................ 30-267
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-271
30-70 Pilot Pressure Supply Valve
30-70-00 General ......................................................................................................................... 30-275
30-93 Hose
30-93-00 General ......................................................................................................................... 30-279
30-93-03 Lift Arm ......................................................................................................................... 30-292
30-96 Pipe
30-96-03 Lift Arm ......................................................................................................................... 30-313
30-97 Connectors
30-97-03 Quick Release Coupling .............................................................................................. 30-315
30-97-09 Adaptor ......................................................................................................................... 30-317
30-97-24 Push Lock Fitting ......................................................................................................... 30-319
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-320
9813/9100-1
2017-11-16
Acronyms Glossary
ARV Auxiliary Relief Valve

HBCV Hose Burst Check Valve
HVCS Hydraulic Variable Control Solenoid
Valve
LED Light Emitting Diode
LHCV Load Hold Check Valve
LLMC Longitudinal Load Moment Control
LMI Load Moment Indicator
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PMV Pressure Maintenance Valve
PRV Pressure Relief Valve
PWM Pulse Width Modulation
QRC Quick Release Coupling
SAE Society of Automotive Engineers
SRS Smooth Ride System
9813/9100-1
2017-11-16
Notes:
9813/9100-1
2017-11-16
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-09 Levelling System ............................................................................................................ 30-40
30-00-36 Interlock System ............................................................................................................. 30-45
30-00-49 Schematic Symbols ........................................................................................................ 30-49
30-00-50 Schematic Circuit ........................................................................................................... 30-53
30 - 1 9813/9100-1 30 - 1
Notes:
30 - 2 9813/9100-1 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3
Health and Safety ........................................... 30-4
Technical Data ................................................. 30-5
Operation ....................................................... 30-19
Operation (Hydraulic) .................................... 30-26
Diagram ......................................................... 30-27
Fault-Finding .................................................. 30-28
Discharge and Pressurise ............................. 30-30
Clean ............................................................. 30-31
Check (Level) ................................................ 30-32
Check (Pressure) .......................................... 30-33
Table 452.
Machine Valve Block Options Hydraulic Pump
533-105 Manual lever - Gear
535-v125 Manual lever Electro Servo Gear
540-140, 550-140 Manual lever - Gear
540-170, 550-170 Oil Pilot Electro servo Gear
540-200 Electro servo - Gear
540-v140 Electro servo - Gear
540-v180- Manual lever Electro servo Gear
30 - 3 9813/9100-1 30 - 3
00 - General
00 - General
Health and Safety

Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
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 hoses. Make sure the machine cannot be
started while the hoses are open.
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 - 4 9813/9100-1 30 - 4
00 - General
00 - General
Technical Data
For: 533-105 [T4F] ...................... Page 30-5

For: 540-140 [T4F], 550-140 [T4F]
..................................................... Page 30-5
For: 535-v125 [T4F], 540-v140 [T4F]
..................................................... Page 30-6
For: 540-200 [T4F] ...................... Page 30-9
For: 540-v180 [T4F] .................. Page 30-10
For: 540-170 [T4F], 550-170 [T4F], Electro
Hydraulic ................................... Page 30-12
(For: 533-105 [T4F])
Tier 4 Machines
Table 453. System Pressures
Circuit Restriction Relief Valve Setting
Neutral Circuit Pressure limited by main valve 240bar (3,478.2psi)
block MRV (Main Relief Valve)
Neutral Circuit Fan Motor Circuit limited by the 230bar (3,333.3psi)
ARV (Auxiliary Relief Valve)
- - -
- - -
Lift End The lift circuit is limited to MRV 240bar (3,478.2psi)
pressure
Lift End The extension circuit is limited to 240bar (3,478.2psi)
MRV pressure
Lift End The tilt circuit is limited to MRV 250bar (3,623.2psi)
pressure during normal operation
and the parallel lift function when
the tilt ram end stops is limited by
the ARV to
Auxiliaries / Hitch Auxiliary circuit is limited by the 220bar (3,188.4psi)
ARV to
Steer Circuit Steer circuit is limited by the ARV 190bar (2,753.6psi)
to
(For: 540-140 [T4F], 550-140 [T4F]) Refer to Figure 1017.
Refer to hydraulic system, parallel circuit control

6 Spool Valve Block valve block, (PIL 30-54).
These specifications are only applicable to some
machine models, make sure you are referring to the
correct machine.
Table 454. (334/G0555) 6 Spool, Parallel Service, Double Acting Spools

Spool 1 Lift arm raise & lower service Manually operated
Spool 2 Lift arm extend & retract service Manually operated
Spool 3 Carriage tilt service Manually operated
Spool 4 Auxiliary / sway service Manually operated
Spool 5 RH Stabiliser Manually operated
Spool 6 LH Stabiliser Manually operated
30 - 5 9813/9100-1 30 - 5
00 - General
00 - General
Table 455. Relief Valve Pressures

Item Description Pressure
- MRV 240bar (3,478.2psi)
8 Auxiliary ram rod side ARV 138bar (2,000.0psi)
9 Auxiliary ram head side ARV 138bar (2,000.0psi)
10 Carriage tilt ram rod side ARV 276bar (4,000.0psi)
11 Carriage tilt ram head side ARV 330bar (4,782.6psi)
Figure 1017. 334/G0555
6 B A
5 B A
4 B A
9 3 B A 8
11 2 B A 10
1 B A
C106760
T P
(For: 535-v125 [T4F], 540-v140 [T4F]) Refer to Figure 1018.

(334/D6157) 6 Spool Valve Block (If valve block, (PIL 30-54).
Installed)
These specifications are only applicable to some
machine models, make sure you are referring to the
correct machine.
Table 456. Valve Options

Option Valve
1 (334/D6157-1 ) 6 Spool Manual Valve
- -
2 (334/F2855-2) 6 Spool Electro Hydraulic Valve
Table 457. 334/D6157-1 Relief Valve Pressures (If Installed)

Item Description Pressure
- MRV 260bar (3,768.1psi)
8 Auxiliary ram rod side ARV 138bar (2,000.0psi)
9 Auxiliary ram head side ARV 138bar (2,000.0psi)
10 Carriage tilt ram rod side ARV 276bar (4,000.0psi)
11 Auxiliary Ram Rod Side ARV 276bar (4,000.0psi)
30 - 6 9813/9100-1 30 - 6
00 - General
00 - General
Figure 1018.
6 B A
5 B A
4 B A
9 3 B A 8
11 2 B A 10
1 B A
C106760
T P
1 Lift arm raise & lower service 2 Lift arm extend & retract service
3 Carriage tilt service 4 Auxiliary / sway service
5 RH Stabiliser 6 LH Stabiliser
30 - 7 9813/9100-1 30 - 7
00 - General
00 - General
(334/F2855-2) 6 Spool Electro Hydraulic Valve (If installed)

Table 458. 334/F2855-2 Relief Valve Pressures
LSRV (Load Sense Relief Valve) 245 (3,550.7)
Tilt port 3A 280 (4,058.0)
Tilt port 3B 280 (4,058.0)
Auxiliary port 4A 140 (2,029.0)
Figure 1019. 334/F2855-2

A
3 C C
C C
4
A Inlet port B Sump port

C Relief valves 1 Lift spool
2 Extend spool 3 Tilt spool
4 Auxiliary spool 5 RH Stabiliser
6 LH Stabiliser
30 - 8 9813/9100-1 30 - 8
00 - General
00 - General
(For: 540-200 [T4F])
Valves
(334/F2857-4) Electro Servo Control
Valve, 6 Spool, Load Sensing, Pressure
Compensated, Double Acting Spools
Table 459. Pressures
G - Load sense relief valve
(1)
245bar (3,550.7psi)
D and L - Auxiliary service ARV's
(2)
140bar (2,029.0psi)
E and K - Carriage tilt ARV's
(2)
280bar (4,058.0psi)
F - Extend service ARV
(2)
200bar (2,898.5psi)
J - Extend service ARV
(2)
280bar (4,058.0psi)
(1) Before testing the LSRV pressure, allow the hydraulic system to warm up to 50 °C (122 °F) to ensure an
accurate reading.
(2) The ARV’s are not adjustable. If the pressure setting is incorrect the ARV must be replaced.
Figure 1020.
D 2
L
E 3
K
F 4
J
30 - 9 9813/9100-1 30 - 9
00 - General
00 - General
1 Left stabiliser spool 2 Right stabiliser spool

3 Auxiliary spool 4 Tilt spool
5 Extend spool 6 Lift spool
C Outlet section H Inlet Section
(For: 540-v180 [T4F]) 6 Spool Valve Block

Your machine may be installed with a different valve These specifications are only applicable to some
depending on the specification of your machine. machine models, make sure you are referring to the
correct machine.
Two valve variants are shown below. Make sure you
identify which valve you have installed. Refer to Figure 1021.

valve block, (PIL 30-54)
Table 460. 6 Spool, Parallel Service, Double Acting Spools

Spool 1 Boom raise & lower service Manually operated
Spool 2 Boom extend & retract service Manually operated
Spool 3 Carriage tilt service Manually operated
Spool 4 Auxiliary / sway service Manually operated
Spool 5 RH Stabiliser Manually operated
Spool 6 LH Stabiliser Manually operated
Table 461. Relief Valve Pressures

Item
(1)
Description Pressure
7 Auxiliary ram ARV 138bar (2,000.0psi)
8 Tilt ram head side ARV 276bar (4,000.0psi)
9 Extend ram head side ARV 276bar (4,000.0psi)
10 Auxiliary ram ARV 138bar (2,000.0psi)
11 Tilt ram head side ARV 276bar (4,000.0psi)
12 Extend ram head side ARV 276bar (4,000.0psi)
(1) Refer to figure 1
30 - 10 9813/9100-1 30 - 10
00 - General
00 - General
Figure 1021.
6 B A
7
5 B A
10
4 B A
11
8
3 B A
2 B A
9 12
1 B A
T P
Husco Valve Block (Option) Refer to Figure 1022.
Refer to hydraulic system, servo system control valve

block, (PIL 30-53)
Table 462. 540-180 SCX120-F20 Valve Block (Option)

Main relief valve 245 (3,550.7)
Extend port 2A 280 (4,058.0)
Extend port 2 B 280 (4,058.0)
Tilt port 3A 280 (4,058.0)
Tilt port 3B 280 (4,058.0)
30 - 11 9813/9100-1 30 - 11
00 - General
00 - General
Figure 1022. 540-180 Valve Block (Husco)

A
2 C C
3 C C
C C
4
400/B3645-2
A Inlet port B Sump port

C Relief valves 1 Lift spool
2 Extend spool 3 Tilt spool
4 Auxiliary spool 5 Stabiliser RH
6 Stabiliser LH
(For: 540-170 [T4F], 550-170 [T4F],

Electro Hydraulic)
Control Valves
(333/G3814-1) 5 Spool Valve (If Installed)
Refer to hydraulic system, Lift Arm Control Valve
Block, (PIL 30-51).
Table 463. 333/G3814-1 Relief Valve Pressures
Item Value
MRV setting 260bar (3,768.1psi)
(1)
PMV (Pressure Maintenance Valve) setting 13.5–16bar (195.7–231.9psi)

(2)
Spool 2- Auxiliary A port 138 (2,000.0)

(3)
30 - 12 9813/9100-1 30 - 12
00 - General
00 - General
Item Value
Spool 2- Auxiliary B port 138 (2,000.0)
(3)
Spool 3- Tilt A port 276 (4,000.0) at crack off

Spool 3- Tilt B port 276 (4,000.0)
(1)
(1) At 40L/min
(2) At 45L/min
(3) At 10L/min
Figure 1023. 333/G3814-1 5 Spool Valve
333-G3814-1
A1 Spool 1 extend- lift arm (piston head side) B1 Spool 1 extend- lift arm (piston rod side)
A2 Spool 2 auxiliary quick fit connectors B2 Spool 2 auxiliary quick fit connectors
A3 Spool 3 displacement and carriage tilt rams, B3 Spool 3 displacement and carriage tilt rams,
(piston rod side) (piston rod side) and 2 spool valve
A4 Spool 4 right side stabiliser (piston head side) B4 Spool 4 right side stabiliser (piston rod side)
A5 Spool 5 left side stabiliser (piston rod side) B5 Spool 5 left side stabiliser (piston head side)
30 - 13 9813/9100-1 30 - 13
00 - General
00 - General
(333/G3853-1) 2 Spool Valve (If Installed)

Refer to hydraulic system, Lift Arm Control Valve
Block, (PIL 30-51).
Table 464. 333/G3853-1 Relief Valve Pressures

Item Value
MRV setting 241bar (3,492.7psi)
(1)
(1) At 82L/min
Figure 1024. 333/G3853-1 2 Spool Valve
333-G3853-2
A1 Spool 1- Lift Arm selection diverter valve B1 -

A2 Spool 2- Main lift cylinder (rod side) B2 Spool 2- Displacement & tilt cylinder (piston
head side)
Hydraulic Pump
30 - 14 9813/9100-1 30 - 14
00 - General
00 - General
For: 533-105 [T4F], 535-v125 [T4F], 540-140

[T4F], 540-v140 [T4F] ............... Page 30-15
For: 540-200 [T4F] .................... Page 30-17
For: 540-170 [T4F], 550-170 [T4F]
................................................... Page 30-18
(For: 533-105 [T4F], 535-v125 [T4F], 540-140 [T4F], 540-v140 [T4F])
Figure 1025.
G B
A
E
F
A1 A2 A3
K N
L P
M
K Oil from pump section 1 L Oil from pump section 2

M Oil suction line from the tank to the pump N Return to tank
sections
P Oil from pump section 3
30 - 15 9813/9100-1 30 - 15
00 - General
00 - General

D Hydraulic tank -
Table 465.
E Fan motor Driven by pump
Item Description Notes section 2
A Pump assembly Two or three F Hydraulic oil Oil from pump
section cooler section 2 flows
gearpump through the oil
A1 Pump section 1 - cooler
A2 Pump section 2 - G Single lever -
A3 Pump section 3 - control
B Control valve Parallel valve
block block
C Hydraulic oil fil- Positioned in
ter the return line
to tank
30 - 16 9813/9100-1 30 - 16
00 - General
00 - General
(For: 540-200 [T4F])
Figure 1026.
5a
11
8
9
3
4
2
10
A
6 C128010.eps
B
1 Fan motor 2 Pump assembly

3 Electro Servo Control Lever 4 PWM ECU (Electronic Control Unit) Power
Base
5 Control valve block 5a Load Sense Relief Valve
6 Priority Valve 7 Hydraulic Tank
8 Proportional Control Thumbwheels 9 Hydraulic control ECU
10 Joystick Isolation Switch 11 Electrical Stabiliser Control Levers
30 - 17 9813/9100-1 30 - 17
00 - General
00 - General
(For: 540-170 [T4F], 550-170 [T4F])
Figure 1027.
E
D
B
A
G
C3
C2
C1
Item Description
G Hydraulic tank
Table 466.
H Pilot pressure supply
Item Description valve
A Hydraulic oil cooler
B Fan motor
C Pump assembly
C1 Pump section 1
C2 Pump section 2
C3 Pump section 3
D Control valve block - 5
spool
E Control valve block - 2
spool
F Hydraulic oil filter
30 - 18 9813/9100-1 30 - 18
00 - General
00 - General
Operation
For: 533-105 [T4F], 535-v125 [T4F], 540-140 flows through the priority valve and joins with the flow
[T4F] .......................................... Page 30-19 from pump section 1 to feed the control valve block.
For: 540-170 [T4F], 550-170 [T4F] Pump section 3 is dedicated to driving the cooling
................................................... Page 30-24 fan. Oil from pump section 3 flows directly to the
cooling fan hydraulic motor. On sway machines a
(For: 533-105 [T4F], 535-v125 [T4F], changeover valve switches oil supply between the
sway ram service and the fan motor.
540-140 [T4F])
Some smaller machines may have a hydraulic pump
Hydraulic pump with only two sections, in this case the larger pump
section 1 has the integral priority valve, and operates
Oil is drawn from the hydraulic tank by the hydraulic in the same way as section 2.
pump assembly. The pump assembly is mounted on
the rear of the bevel gearbox and is driven by the In neutral circuit conditions (i.e. no service selected),
engine. the oil flows through the control valve block neutral
gallery into the return or exhaust line and back to the
The pump has three sections, Oil from the larger tank through an in-tank filter.
pump section 1 flows direct to the control valve block.
Pump section 2 has an integral priority valve which Some machine variants also have a hydraulic oil
always gives priority demand to the steer circuit. cooler in the return line from the fan hydraulic motor,
With the steering in the straight ahead position (i.e. to cool the system hydraulic oil as it is continually
with no steering demand), oil from pump section 2 circulated around the cooling fan circuit.
30 - 19 9813/9100-1 30 - 19
00 - General
00 - General
Figure 1028.
G H
C
J
A
E
Q
A1 A2 A3
K N
L P
M
Item Description
Table 467. E Fan motor Driven by pump
section 2
Item Description
Q Hydraulic oil Oil from pump
A Pump assembly Two or three cooler section 2 flows
section through the oil
gearpump cooler
A1 Pump section 1 -
A2 Pump section 2 -
Table 468. Hydraulic connections colour key
A3 Pump section 3 -
B Control valve Parallel valve Item Description
block block K Oil from pump section 1
C Hydraulic oil fil- Positioned in L Oil from pump section 2
ter the return line M Oil suction line from the
to tank tank to the pump sec-
D Hydraulic tank - tions
30 - 20 9813/9100-1 30 - 20
00 - General
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Item Description spools. A third lever operates the auxiliary service

N Return to tank spool. The levers operate the spools via mechanical
linkages. For machines with stabilisers two more
P Oil from pump section 3 levers are installed to operate the stabiliser service
spools (6 spool control valve).
Control valve block
Single lever control
The control valve block controls the boom hydraulic
services. For machines with stabilisers, the valve has Machines with single lever control use a lever which
two more spools to control the stabiliser hydraulic moves in two axis and operates two service spools
services. via mechanical linkages. Buttons on the control lever
operate solenoid valves on the remaining two spools.
When the control valve spools are actuated, oil from
the pump passes into the service ports, operating the
relevant hydraulic ram.
Parallel lift
The parallel lift system is used to make sure that
The control valve contains MRV (Main Relief Valve)
when the boom raise/lower or extend/retract services
and ARV (Auxiliary Relief Valve). These valves
are operated, the forks remain parallel to the ground.
prevent the hydraulic pressure increasing to a
level which would cause damage to the hydraulic
components and pipework. Boom regenerative valve (3 stage
booms)
The control valve block inlet section also includes
valves which are used for the LLMC (Longitudinal The regenerative valve is installed to the outer
Load Moment Control) system. extension ram to increase the speed of the boom
during the extend cycle, under light load conditions.
Dual lever control Hydraulic oil is displaced from the rod side of the
inner extension ram to supplement the pump flow to
Machines with dual lever control use two control the head side of the outer extension ram. The speed
levers for operation of the three loader service of the extending boom is increased.
Figure 1029.
Q S
R
Q Outer extension ram HBCV (Hose Burst Check R PRV (Pressure Relief Valve)
Valve)
S Pilot operated check valve T Non-return valve
The only servicing possible in the event of external Boom extend cycle
oil leakage is the renewal of oil seals, or the renewal
of a faulty screw-in cartridge. Light load (Regenerative cycle)
As the boom extends with the forks lightly loaded,

oil from the valve block flows through the outer
30 - 21 9813/9100-1 30 - 21
00 - General
00 - General
extension ram HBCV to the head side of the outer to the head side of inner extension ram. The inner
extension ram. extension ram starts to extend and oil is displaced
from the rod side of the cylinder. A PRV prevents oil
Oil is displaced from the rod side of outer extension leaving the regenerative valve block and returning to
ram and passes through inner extension ram HBCV tank.
Figure 1030.
U1
Y
V U
Z
U Inner extension ram U1 Counterbalance valve

V Outer extension ram W Outer extension ram HBCV
X PRV Y Pilot operated check valve
Z Check valve
A pilot operated check-valve opens to allow the oil to ram HBCV to the head side of the outer extension
supplement the main pump flow through the check ram.
valve and the speed of extension.
Oil is displaced from the rod side of outer extension
Heavy load ram and passes through the inner extension ram
HBCV to the head side of inner extension ram.
As the boom extends, oil under high pressure closes The inner extension ram starts to extend and oil
the check valve. Oil flows through the outer extension is displaced from the rod side of the cylinder. Pilot
pressure opens the PRV.
30 - 22 9813/9100-1 30 - 22
00 - General
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Figure 1031.
W
U1
V
Y
U
Z

Z Check valve
Oil displaced from the rod side of the inner Boom retract cycle
extension ram now passes through the extension
spool and back to tank. This oil is prevented from As the boom is retracted, oil flows through the PRV to
supplementing the main pump flow by the pilot the rod side of inner extension ram. Oil is prevented
operated check-valve. from entering the regenerative valve block by the
pilot operated check-valve. Oil is displaced from the
The boom will extend slower, but with more force head side of inner extension ram through the HBCV
than the regenerative cycle. and back to tank through the extension spool. Oil
cannot flow through the regenerative valve because
the check valve is closed.
Figure 1032.
U1
V
Y
U
Z
30 - 23 9813/9100-1 30 - 23
00 - General
00 - General

Z Check valve
(For: 540-170 [T4F], 550-170 [T4F]) Pump section 2 has an integral priority valve which
always gives priority demand to the steer circuit.
Hydraulic pump With the steering in the straight ahead position (i.e.
with no steering demand), oil from pump section 2
Oil is drawn from the hydraulic tank by the hydraulic flows through the priority valve and feeds the 2 spool
pump assembly. control valve block.
The pump assembly is mounted on the rear of the Pump section 3 is dedicated to driving the cooling
bevel gearbox and is driven by the engine. fan. Oil from pump section 3 flows directly to the
cooling fan hydraulic motor. The hydraulic oil cooler
The pump has three sections. in the return line from the fan hydraulic motor, cools
the system hydraulic oil as it is continually circulated
Oil from the larger pump section 1 flows direct to the around the cooling fan circuit.
5 spool control valve block.
For more information on the main hydraulic pump
refer to the correct topic in this section.
Figure 1033.
E
D
B
A
G
C3
C2
C1
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Table 469.
Item Description
A Hydraulic oil cooler
B Fan motor
C Pump assembly
C1 Pump section 1
C2 Pump section 2
C3 Pump section 3
D Control valve block - 5
spool
E Control valve block - 2
spool
F Hydraulic oil filter
G Hydraulic tank
H Pilot pressure supply
valve
Control valve block

When the spools are actuated, oil from the pump
passes into the service ports, operating the relevant
hydraulic ram.
The 2 spool valve block operates at the same time

as the 5 spool control valve to ensure sufficient
hydraulic flow for operation of the lift and extend
services.
The 5 spool control valve contains the MRV and

ARVs. These valves prevent the hydraulic pressure
increasing to a level which would cause damage to
the hydraulic components and pipework.
Since the 2 spool valve block is supplied only from

pump section 2 it also has a MRV to protect the
hydraulic system.
For more information on the control valves refer to

the correct topic in this section.
Parallel lift
The parallel lift system is used to make sure that
when the boom raise/lower or extend/retract services
are operated, the forks remain parallel to the ground.
30 - 25 9813/9100-1 30 - 25
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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 - 26 9813/9100-1 30 - 26
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Diagram
(For: 540-170 [T4F], 550-170 [T4F], Electro Hydraulic)
Figure 1034.
B
D
E
H
C
G
A Hydraulic tank B 5 spool control valve

C 2 spool control valve D Hydraulic pump
E Steering tank return F Fan motor case drain
G Breather H Hydraulic filler
30 - 27 9813/9100-1 30 - 27
00 - General
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Fault-Finding
Fault
One service fails, or is slow to operate. Table 470. Page 30-28
The engine tends to stall when hydraulics are under load. Table 471. Page 30-28
Forks creep down Table 472. Page 30-29
Parallel lift faulty Table 473. Page 30-29
Ram creep Table 474. Page 30-29
Table 470. 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 471. 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 - 28 9813/9100-1 30 - 28
00 - General
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Table 472. 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 473. 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 474. 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 - 29 9813/9100-1 30 - 29
00 - General
00 - General
Discharge and Pressurise Figure 1035. Hydraulic tank filler cap
WARNING Depending on your machines A

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).
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 A Filler cap
the controls several times of the service to
be disconnected. Figure 1036. Vent switch (If installed)
2.2. For electrical and servo operated services,
make sure the battery is connected and
the battery isolator is set to on. Turn the
ignition key to the on position and operate
the controls several times of the service to
be disconnected.
2.3. For machines installed with a vent switch,
make sure the battery is connected and
the battery isolator is set to on. Turn the
ignition key to the on position and push and
hold the vent switch while you operate the
controls of the service to be vented. Make
sure you operate the controls several times
while the vent switch is set to on. While the
vent switch is on, a buzzer will sound and
the venting symbol will be displayed on the
dash. Refer to Figure 1036.
3. Make sure that the pressure is vented correctly.
Electrical and pilot services have a limited
amount of accumulated pressure available for
venting.
4. Depending on your machines specification, other
systems will require additional venting. These
may include (but not limited to) SRS (Smooth
Ride System), refer to (PIL 30-18-00) and power 1 Position 1- Off
brakes, refer to (PIL 24-03-00). 2 Position 2- Vent position, hold switch down
5. Clean the top of the tank around the filler cap. for on position (battery connected, isolator on,
ignition switch set to on, engine off)
6. Slowly remove filler cap to allow the system to
vent fully and to prevent the oil from being forced
out of the filler neck.
6.1. Some filler caps have a side mounted barrel
lock, operated by the ignition key. Your
machine may differ from the one shown.
7. Make sure that the seal is in good condition and
installed correctly in the cap. Replace the seal if
necessary.
30 - 30 9813/9100-1 30 - 30
00 - General
00 - General
Clean • Red Blood Cell = 8 microns (0.008 mm,

0.000315 in)
Special Tools • Human Hair = 70 microns (0.07 mm, 0.00275
Description Part No. Qty. in)
Hydraulic Flushing Rig 892/01255 1 • Grain of Salt = 100 microns (0.1 mm, 0.00394
in)
Cleaning Operation The smallest particle visible to the naked eye is
40 microns (0.00157) approximately. Standards will
The purpose of cleaning oil is to remove often be quoted to ISO (International Standards
contaminants of all types and sludge by filtering Organisation) for which literature can be obtained.
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
manual.
Procedure
1. Connect the Hydraulic flushing rig in place of the
hydraulic filter.
Special Tool: Hydraulic Flushing Rig (Qty.: 1)
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 1037.
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 - 31 9813/9100-1 30 - 31
00 - General
00 - General
Check (Level)
2. Machines may be installed with a sight tube or a
dipstick for hydraulic fluid level display.
Machines with a Sight Tube

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 - 32 9813/9100-1 30 - 32
00 - General
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Check (Pressure)
For: 533-105 [T4F] .................... Page 30-33 Figure 1039. Test Point (Typical Triple Pump)
For: 535-v125 [T4F] .................. Page 30-36
For: 540-170 [T4F], 550-170 [T4F], Electro
Hydraulic ................................... Page 30-39
(For: 533-105 [T4F])

Special Tools
Digital Hydraulic 998/11051 1
Pressure Test Kit
Testing MRV Pressure

A
30-00).
A Pressure test point
3. Connect the digital hydraulic pressure test kit to
the pressure test point.
Testing ARV's Set Lower than the MRV
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1) 1. Make the machine safe. Refer to (PIL 01-03).
4. Start the engine and bring the hydraulic system 2. Discharge the hydraulic pressure. Refer to (PIL
to the specified working temperature. 30-00).
Temperature: 50°C (121.9°F) 3. Connect the digital pressure test kit to the
pressure test point.
5. Select the lift arm lower service and hold the ram
fully closed. 4. Start the engine and bring the hydraulic system
to the specified working temperature.
6. Gradually increase the engine speed to 2200
RPM (Revolutions Per Minute) while checking Temperature: 50°C (121.9°F)
the maximum gauge reading. Refer to (PIL
30-00). 5. Set the engine to idle RPM and operate the
relevant service to full travel. Hold and check
Figure 1038. Test Point (Typical Double Pump) the maximum gauge reading. Refer to Technical
Data (PIL 30-00).
6. Make sure that the engine is not run at the
maximum speed as a significant increase in
pressure will be recorded.
7. If the pressure is not correct, adjust the relevant
ARV (Auxiliary Relief Valve).
30 - 33 9813/9100-1 30 - 33
00 - General
00 - General
Figure 1040. Test Point (Typical Double Pump) tilt ram ARVs. Because the tilt ram is smaller than the
lift ram, higher hydraulic pressure is required on one
side of the tilt ram to prevent the load tilting the forks
forward.
Check the pressure setting and the ARV location for

the applicable machine.

2. Raise the lift arm and install the safety strut.
3. Tilt the forks fully forward.
4. Follow the general safety precautions for the
hydraulic system. Refer to (PIL 30-00).
A
30-00).
A Pressure test point 6. Locate the hydraulic line for the high pressure
side of the tilt ram. Refer to Figure 1042. , Refer
Figure 1041. Test Point (Typical Triple Pump)
to Figure 1043. and Refer to Figure 1044.
7. Install a tee piece in the hydraulic line. Connect
the digital pressure test kit to the tee piece.
8. Locate a connection in the tilt ram circuit at the
rear of the lift arm.
9. Start the engine and tilt the forks fully back.
10. Remove the safety strut and slowly lower the
lift arm. As the lift arm is lowered, the pressure
gauge will show the ARV pressure, which should
be as stated. Refer to Technical Data (PIL 30-00).
A
11. If the pressure is incorrect, adjust the ARV. Refer
to (PIL 30-00).
WARNING! Take care when disconnecting

A Pressure test point hydraulic hoses and fittings as the oil will be hot.
12. After you complete the test, fully lower the

Testing ARV's Set Higher than the MRV lift arm. Switch off the engine and release
(P1) the hydraulic pressure. Disconnect the pressure
gauge and connect the tilt ram hose again.
Some ARVs are set at a higher pressure than the
MRV (Main Relief Valve). This is usually one of the
30 - 34 9813/9100-1 30 - 34
00 - General
00 - General
Figure 1042. Tilt ram hose at the rear lift arm bulkhead bracket
A Hose B Connector
Figure 1043. Tilt ram hose forward of the lift arm pivot
A Hose B Connector
30 - 35 9813/9100-1 30 - 35
00 - General
00 - General
Figure 1044. Tilt ram hose on the displacement ram hose, lift arm underside
A Hose B Connector
(For: 535-v125 [T4F]) 4. Start the engine and bring the hydraulic system
to the specified working temperature.
Special Tools
Description Part No. Qty. Temperature: 50°C (121.9°F)
Digital Hydraulic 998/11051 1 5. Select the lift arm lower service and hold the ram
Pressure Test Kit fully closed.
WARNING Take care when disconnecting 6. Gradually increase the engine speed to 2200
hydraulic hoses and fittings as the oil will be hot. RPM while checking the maximum gauge
reading. Refer to (PIL 30-00).
Testing MRV Pressure
30-00).
3. Connect the digital pressure test kit to the
pressure test point.
(Qty.: 1)
30 - 36 9813/9100-1 30 - 36
00 - General
00 - General
Figure 1045. Test Point (Typical Double Pump) 6. Make sure that the engine is not run at the
maximum speed as a significant increase in
pressure will be recorded.
7. If the pressure is not correct, adjust the relevant
ARV.
Figure 1047. Test Point (Typical Double Pump)

A


A
Testing ARV's Set Lower than the MRV
30-00). A Pressure test point
3. Connect the digital pressure test kit to the Testing ARV’s Set Higher than the MRV
pressure test point. (P3)
4. Start the engine and bring the hydraulic system
to the specified working temperature. Tilt ram
Temperature: 50°C (121.9°F) 1. Head side ARV.
5. Set the engine to idle RPM and operate the 1.1. Make the machine safe. Refer to (PIL
relevant service to full travel. Hold and check the 01-03).
maximum gauge reading. Refer to (PIL 30-00).
1.2. Raise the lift arm and install the safety strut.
30 - 37 9813/9100-1 30 - 37
00 - General
00 - General
1.3. Follow the general safety precautions for 1.9. Start the engine and remove the safety
the hydraulic system. Refer to (PIL 30-00). strut. Slowly lower the lift arm to the
horizontal position. As the lift arm is lowered
1.4. Discharge the hydraulic pressure. Refer to
the pressure gauge will show the ARV
(PIL 30-00).
pressure, which should be as stated. Refer
1.5. Disconnect the hose from the pipe to Technical Data (PIL 30-00).
connector.
1.10. If the pressure is incorrect, adjust the ARV.
1.6. Install a test point to the pipe connector and Refer to (PIL 30-00).
connect the hose again.
1.11. After you complete the test, install the lift
1.7. Install the digital pressure test kit to the test arm maintenance strut and release the
point. hydraulic pressure.
1.8. Make sure that there is clearance between 1.12. Disconnect the pressure gauge, remove
the test point and the chassis when you the test point and reconnect the tilt ram
lower the lift arm. head side hose to the pipe connector.
Figure 1049.
A Hose B Connector
C Test point
2. Rod side ARV. 2.6. Install a test point to the pipe connector and
connect the hose again.
2.1. Make the machine safe. Refer to (PIL
01-03). 2.7. Install the digital pressure test kit to the test
point.
Refer to (PIL 06-69). 2.8. Make sure that there is clearance between
the test point and the chassis when you
2.3. Follow the general safety precautions for lower the lift arm.
the hydraulic system. Refer to (PIL 30-00).
2.9. Start the engine and remove the safety
2.4. Discharge the hydraulic pressure. Refer to strut. Slowly lower the lift arm to the
(PIL 30-00).
2.5. Disconnect the hose from the pipe
connector.
30 - 38 9813/9100-1 30 - 38
00 - General
00 - General
horizontal position and then slowly raise the 2.12. After you complete the test, install the lift
lift arm to the specified angle. arm maintenance strut and release the
hydraulic pressure.
Angle: 45°
2.13. Disconnect the pressure test kit, remove
2.10. As you raise the lift arm, the pressure
the test point and reconnect the tilt ram
gauge shows the ARV pressure, which
head side hose to the pipe connector.
should be as stated. Refer to (PIL 30-00).
2.11. If the pressure is incorrect, adjust the ARV.
Figure 1050.
B A
A Hose B Connector
C Test point
Relief valve adjustment Figure 1051.

1. If the pressure is incorrect, adjust the relief valve
as follows:
1.2. Follow the general safety precautions for
the hydraulic system. Refer to (PIL 30-00).
1.3. Discharge the hydraulic pressure. Refer to
(PIL 30-00).
B
1.4. Loosen the locknut and turn the adjuster
screw. Turn the adjuster screw clockwise
to increase pressure and anti-clockwise to
decrease the pressure. A
1.5. When the pressure is correct, tighten the

locknut and check the pressure again. A Locknut
Adjust as required. The location of the relief B Adjuster screw
valve depends on the machine type.
(For: 540-170 [T4F], 550-170 [T4F],
Electro Hydraulic)
30 - 39 9813/9100-1 30 - 39
00 - General
09 - Levelling System
Operation
(For: 533-105 [T4F], 535-v125 [T4F], 540-170 [T4F], 540-200 [T4F], 540-v140 [T4F], 540-
v180 [T4F], 550-140 [T4F], 550-170 [T4F])
Table 475. Parallel Lift- Typical Systems
Parallel Lift- System 1 Example of a system with single displacement ram at
the rear of the lift arm pivot
Parallel Lift- System 2 Example of a system with single and twin displace-
ment rams forward of the lift arm pivot
Parallel lift (S1) When the boom ram lifts or lowers the boom, the
displacement ram extends or retracts. The ram
Ram operation displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
The schematic diagrams show a typical system. with the ground.
Your system may be different. Refer to the relevant
machine schematic diagram, (PIL 30-00-50). Boom raise cycle
The parallel lift system operates when the boom lifts When the spool is in the lift position, the neutral
or lowers. circuit is blocked and oil feeds to the pilot operated
counterbalance valve. Check valve1 opens and
Figure 1052. supplies oil to the head side of the boom lift ram.
Oil is forced out of the head side of displacement

D ram as the boom lifts. The oil cannot flow past the tilt
spool, as the spool is not selected. Instead, it flows
to the head side of tilt ram. Oil displaced from the
rod side of the tilt ram increases pilot pressure in the
HBCV (Hose Burst Check Valve). This allows oil to
feed back to the rod side of the displacement ram.
A C
A C
A Displacement ram
C Boom ram
D Tilt ram
E Forks
30 - 40 9813/9100-1 30 - 40
00 - General
Figure 1053.
Q
H J
R
S
K
L P
N
F
F Spool G Counter balance valve

H Pilot valve J Boom lift ram
K Displacement/lift link valve L HBCV
M Displacement ram N Tilt ram
P Tank Q Check valve 1
R Check valve 2 S Check valve 3
The displacement/lift link valve is installed between accidentally leak back into the circuit when a load
lift service and tilt service lines. The function of this is on the boom. The lower service will only operate
valve is to allow a restricted flow of oil into the tilt when there is sufficient pilot pressure provided by the
circuit to increase the lift force available by utilising hydraulic pump or stored in the pilot accumulator. If
the displacement ram. there is no pilot pressure the pilot valve will not open
and the boom will not lower.
Boom lower cycle
Check valve 3 creates a circuit when the ram return
When the lift spool is selected, the neutral line is in cavitation.
circuit is blocked and oil feeds the pilot operated
counterbalance valve. The pilot pressure used to As the boom lowers, oil is forced from the rod side of
operate the spool acts upon the pilot valve. The pilot the displacement ram. The oil cannot flow past the tilt
valve allows a return to tank via check valve 2 and spool, as the spool is not selected. Instead, it flows
the valve block which enables the boom to lower. through the free flow direction of the HBCV to the rod
This is to make sure that the ram pressure cannot side of the tilt ram.
30 - 41 9813/9100-1 30 - 41
00 - General
Figure 1054.
Q
H J
R
S
G
K
L P
N
F
F Spool G Pilot operated counter balance valve

Displaced oil from the displacement ram closes the

check valve in displacement/lift link valve.
The circuit created between the displacement ram,

lift ram and tilt ram prevents cavitation/vacuum.
Parallel lift (S2)

Ram operation
The schematic diagrams show a typical system.
Your system may be different. Refer to the relevant
machine schematic diagram, (PIL 30-00-50).
The parallel lift system operates when the boom lifts

or lowers.
30 - 42 9813/9100-1 30 - 42
00 - General
Figure 1055. When the boom ram lifts or lowers the boom, the
displacement ram extends or retracts. The ram
D displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
B with the ground.
Machines have a single or twin displacement rams,

dependant on the machine variant.
E
Boom raise cycle
A C The illustration below shows twin displacement rams.
The operation is similar on machines with single
D displacement rams.
When the spool is in the lifted position, the neutral

B circuit is blocked and oil feeds to the pilot operated
counterbalance valve. Check valve 1 opens and
supplies oil to the head side of the boom lift ram.
E
Oil is forced out of the rod side of displacement ram
as the boom lifts. The oil cannot flow past the tilt
A C spool, as the spool is not selected. Instead, it flows
A Boom ram to the head side of the tilt ram. Oil displaced from the
B Boom pivot rod side of the tilt ram increases pilot pressure in the
C Displacement ram HBCV. This allows oil to feed back to the head side
D Tilt ram of the displacement ram.
E Forks
Figure 1056.
Q
J
R H
S
G
K
L
P
F N

30 - 43 9813/9100-1 30 - 43
00 - General
Displaced oil from the displacement ram closes the counterbalance valve. The pilot pressure used to
check valve in displacement/lift link valve is installed operate the spool acts upon the pilot valve. The
between lift service and tilt service lines. The function pilot valve allows oil to return to the tank via the
of this valve is to allow a restricted flow of oil into the check valve 2 and the valve block which enables
tilt circuit to increase the lift force available by utilising the boom to lower. This is to make sure that the
the displacement ram. ram pressure cannot accidentally leak back into
the circuit when a load is on the boom. The lower
Boom lower cycle service will only operate when there is sufficient pilot
pressure provided by the hydraulic pump or stored in
The illustration below shows twin displacement rams. the pilot accumulator. If there is no pilot pressure the
The operation is similar on machines with single valve will not open and the boom will not lower.
displacement rams.
Check valve 3 creates a circuit when the ram return
When lift spool is selected, the neutral circuit line is in cavitation.
is blocked and oil feeds to the pilot operated
Figure 1057.
Q
H
J
R
S
G
K
L
P
N
F
M7

As the boom lowers, oil is forced from the rod side of The circuit created between the displacement ram,
the displacement ram. The oil cannot flow past the tilt lift ram and tilt ram prevents cavitation/vacuum.
spool, as the spool is not selected. Instead, it flows
through the free flow direction of the HBCV to the rod
side of the tilt ram.
Displaced oil from the displacement ram closes the

check valve in displacement/lift link valve.
30 - 44 9813/9100-1 30 - 44
00 - General
36 - Interlock System
36 - Interlock System Introduction

Introduction .................................................... 30-45
Operation ....................................................... 30-46
(For: 540-v180 [T4F])
Work Platform machines use a system of interlocks
to prevent the operation of the machine (beyond pre-
set limits) unless specified safety measures are in
place.
The systems use sensors to make sure the required

measures are taken to allow a service to function.
The interlocks are to aid operator safety and help

prevent machine damage from misuse or error.
30 - 45 9813/9100-1 30 - 45
00 - General
Operation
(For: 540-v180 [T4F]) provided. The pump allows the platform to be safely
lowered to the ground from the platform or the cab.
Controls Pressing the machine isolation push button stops
the engine and hydraulic system in an emergency.
Control of the lift arm is via a servo control lever in the
The Platform also has an emergency stop (isolation)
cab or a remote control unit from the JCB platform.
button.
Both control systems operate the same servo control
valve.
Longitudinal Load Moment Control
A safety key system prevents operation of the lift arm (LLMC) (If installed)
by the cab control lever and remote control unit at
the same time. When the machine is operated from The LLMC (Longitudinal Load Moment Control)
the cab it is in Cabin Mode. When the machine is system is active with the lift arm retracted
operated from the remote control unit it is in Remote on machines with Work Platforms. On standard
Mode. machines the LLMC system is not active when the
lift arm is fully retracted.
All the control signals are processed by the JCB ECU
(Electronic Control Unit) located under the operator’s LLMC is always active when the JCB work platform
seat. is operated by the remote control unit.
Remote Servo Control The LLMC system automatically reduces the speed
of the lift arm hydraulic services. When the machine
The JCB work platform system enables remote is nearing its maximum working limit (when it could tip
control of the lift arm lift, lower, extend, retract, tilt and forward) an intermittent audible alarm sounds. When
engine speed functions by an operator located in the the machine is at its maximum working limit forward
platform. The control of these functions is achieved reach of the platform is prevented. A continuous
through a remote control unit radio transmitter audible alarm sounds.
and radio receiver. Before remote operation is
enabled, there are safety interlocks which require the For information about the LLMC system refer to the
machine’s park brake to be on and the stabiliser legs machine Operator Manual or Service Manual.
to be down. Switches and sensors indicate the status
of the park brake and stabilisers. System Operation
The stabiliser and sway systems are isolated when An overload switch is installed to the platform. If
the machine is in remote mode. the platform exceeds the specified weight the switch
informs the ECU. The ECU isolates all platform
The LMI (Load Moment Indicator) transducer operations. This is indicated by a Yellow light
measures the load exerted on the rear axle and illuminating on the remote control unit.
sends a signal to the JCB ECU. When the machine
is near its maximum working limit (when it could tip The remote control unit must be correctly “Docked” in
forward), the JCB ECU prevents forward reach of the the platform. If the remote control unit is not correctly
platform (extending and lowering). “Docked” it will not operate.
When the system is operated in remote mode a When docking the remote control unit on the platform
safety system monitors operation of the remote make sure not to depress the remote control unit
control unit. If the unit is not operated during the emergency stop button. The remote control unit will
specified time period the engine automatically stops. not operate if this emergency stop is depressed.
If necessary the engine can be re-started by use of
the remote control unit. The specified time period is Interlocks are installed to ensure correct operation of
10min. cabin mode and remote mode. The table explains the
operating logic.
Emergency Operation
In case of emergency, (engine failure for example)
an independent electrically driven hydraulic pump is
30 - 46 9813/9100-1 30 - 46
00 - General
Table 476. Operating Logic

Function Cabin Mode Remote Mode
Engine start Yes Yes
(1)
Stabilisers Yes (2)
Sway Yes (3)
Lift arm raise Yes Yes

Lift arm lower Yes Yes
Lift arm extend Yes Yes
Lift arm retract Yes Yes
Tilt Yes Yes
(4)
Auxiliary hydraulics Yes

Platform slew (If installed) Yes Yes
LLMC Yes Yes
(5)
Engine speed control Yes Yes

Automatic engine speed control Yes
Engine stop Yes Yes
(6)
Engine stop (After safety time peri- Yes

(7)
od)
Emergency stop (Cab isolation but- Yes
ton)
Emergency stop (Platform isolation Yes
button)
Emergency lift arm operation Yes
(8)
Yes
(8)
(1) Stabilisers must be down and the park brake must be on before engine will start.
(2) Stabiliser service is isolated. Control must be switched back to cabin mode to re-activate stabiliser service.
(3) Sway service is isolated. Control must be switched back to cabin mode to re-activate sway service.
(4) Only when lift arm angle is below 10°.
(5) LLMC operates at all times when in Remote Mode, even with the lift arm fully retracted.
(6) If the engine is running when remote mode is selected, the engine will stop. The engine must be re-started
by use of the remote control unit.
(7) If the remote control unit is not operated during a 10min period the engine automatically stops. If necessary
the engine can be re-started by use of the remote control unit.
(8) Enables the emergency electric hydraulic pump. Only lift arm lower and retract services operate. The system
will not enable lift arm operation in the event of control valve failure.
Table 477. Light and Alarm Logic

Condition Red LED (Light Yellow LED 2 LED 3 Remote Alarm Alarm active
Emitting Diode)
1
Platform over- On Flashing Slow flashing Off On
load green
LLMC cut out On Off Slow flashing Off On
green
Emergency stop On Flashing Slow flashing Off On
- platform green
Emergency stop Off Off Off 1 beep Off
- remote
Emergency stop Off Off Red 1 beep Off
- remote active -
wake up
Emergency stop On Flashing Slow flashing Off On
- cab green
Park brake off Off Off Off Off Off
30 - 47 9813/9100-1 30 - 47
00 - General
Condition Red LED (Light Yellow LED 2 LED 3 Remote Alarm Alarm active
Emitting Diode)
1
Direction selec- Off Off Off Off Off
tion - column
switch
Lowering below On Off Slow flashing Off On
2m green
Activating the On Off Slow flashing Off Off
horn green
Remote - single Off Off Red 1 beep Off
button press
Remote - button Off Off Orange Off Off
press and hold
Pairing cycle 2s on 2s on Quick flashing Off Off
green
Paired Off Off Slow flashing Off Off
green
Starting machine On Off Slow flashing Off On
green
Emergency low- Off Off Off Off Off
er platform sig-
nal
Platform locking On Flashing Slow flashing Off On
pins green
30 - 48 9813/9100-1 30 - 48
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-49 Complex hydraulic components and circuits can
Diagram ......................................................... 30-50 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 - 49 9813/9100-1 30 - 49
00 - General
Diagram Table 481. Directional control valves

Symbol Description
Used to enclose sever-
Table 478. 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 479. 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 480. 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 - 50 9813/9100-1 30 - 50
00 - General
Table 482. 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 483. 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 - 51 9813/9100-1 30 - 51
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 - 52 9813/9100-1 30 - 52
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-53 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-54 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 - 53 9813/9100-1 30 - 53
00 - General
Diagram
For: 535-v125 [T4F], 540-v140 [T4F]

................................................... Page 30-54
For: 540-170 [T4F], 550-170 [T4F], JCB Tier
4F Elec 430 Engine 4 Cyl .......... Page 30-59
For: 540-200 [T4F] .................... Page 30-69
For: 540-v180 [T4F], Manual Controls,
JCB Tier 4F Elec 430 Engine 4 Cyl
................................................... Page 30-76
For: 533-105 [T4F] .................... Page 30-81
For: 540-140 [T4F], 550-140 [T4F]
................................................... Page 30-87
(For: 535-v125 [T4F], 540-v140 [T4F])

Figure 1058. 334/L1307-7 Dual Lever Control (EN15000 Compliant Machines)................... Page 30-55
30 - 54 9813/9100-1 30 - 54
00 - General
Page 30-56 Figure 1058. 334/L1307-7 Dual Lever

Control (EN15000 Compliant Machines) Page 30-57
334/L1307-7
30 - 55 9813/9100-1 30 - 55
00 - General
Page Page
30-56 30-57
Page 30-57
C
30 - 56 9813/9100-1 30 - 56
00 - General
Page Page
30-56 30-57
B
Page 30-56
334/L1307-7
30 - 57 9813/9100-1 30 - 57
00 - General
180 Counter balance car-

tridge outer extension
Table 484. 334/L1307-5 Dual Lever Cylinder (12 And 14 M)
Control (EN15000 Compliant Machines)
190 Cartridge outer exten-
10 Pump, hydraulic 2 sec- sion Cylinder (12 And 14
tion - double pump M)
20 Control valve block 200 Counter balance car-
30 Accumulator tridge tilt Cylinder (12
40 Lift Cylinder (12 m) And 14 M)
50 Lift Cylinder (14 m) 210 Cartridge stabiliser
Cylinder
60 Cylinder sway 532
110X50 220 Check valve - Low leak
sway
70 Cylinder inner extension
100X60 (12 M) 230 Pilot piston sway
80 Cylinder inner extension 240 Sway valve
100X60 250 Filter head SAE-12
90 Cylinder extension outer 260 Filter element
120X65 12m 270 Adaptor. G1/4A - 7/16
100 Cylinder 120X65 outer SAE lift assist
extension 280 Filler breather cap
110 Tilt Cylinder 130 X 70 290 Fan motor 19 cc
120 Displacement Cylinder 300 11 cc Unidirectional vari-
90 X 50 able motor
130 Cylinder stabiliser RH 310 Variable fan motor
110 X 60 320 Steer valve
140 Cylinder stabiliser LH 330 Steer mode valve
110 X 60
340 Assembly make-up
150 Power trackrod valve 1" UNF extension
160 Counter balance car- Cylinders inner and out-
tridge lift Cylinder (12 er
And 14 M) 350 Check valve 2.5bar
170 Counter balance car- (36.2psi)
tridge inner extension
Cylinder (12 And 14 M)
30 - 58 9813/9100-1 30 - 58
00 - General
(For: 540-170 [T4F], 550-170 [T4F], JCB Tier 4F Elec 430 Engine 4 Cyl)
Figure 1059. 334/H1143-4 540- 170 Machines (55 kW) Tier 4 Final..................................... Page 30-61
Figure 1060. 333/G3987-6 540-170 Machines (81 and 93 kW) Tier 4 Final.......................... Page 30-65
Table 485. Schematics

540-170 EH Tier 4 Final (55 kW) Refer to Figure 1059.
540-170, 550-170 Tier 4 Final, STD Tier 4 Final (83 Refer to Figure 1060.
and 96 kW)
30 - 59 9813/9100-1 30 - 59
Notes:
30 - 60 9813/9100-1 30 - 60
00 - General
Page 30-62 Figure 1059. 334/H1143-4 540-

170 Machines (55 kW) Tier 4 Final Page 30-63
18 20 29, 30
19
21
17 17 22
31
23 24
11 28
10
32
38
1
34
25
35
26
6
9
7
2
37 27
3
32
8
30 - 61 9813/9100-1 30 - 61
00 - General
Page Page
30-62 30-63

18
19
17 17
31
11
10
Page 30-63
6
9
7
2
37
3
30 - 62 9813/9100-1 30 - 62
00 - General
Page Page
30-62 30-63
Figure 1059. (Part 2 of 2) 20 29, 30
21
22
31
23 24
28
32
38
34
25
Page 30-62
35
26
2
27
3
32
30 - 63 9813/9100-1 30 - 63
00 - General
Table 486. 334/H1143-4 540- 170 Machines (55 kW ) Tier 4 Final

Item Description
1 DCV OC 5 Spool EH
2 DCV OC 2 Spool EH
3 Valve - Pilot Manifold
6 4-Section Pump
7 Return Filter 5 Micron
8 Suction Strainer
9 Filler Cap Hydraulic Oil
10 Steer Valve
11 Fan Motor 19cc
17 Ga Ram Steer 520 60X30
18 Steer Mode Valve
19 Steer Mode Valve
20 Sway Valve
21 GA Ram Sway 532 110X50
22 GA Ram Stab LH 110 X 60
23 GA Ram Stab RH 110 X 60
24 GA Ram Tilt 540 140X75
25 GA Ram Inner Extension 90 X 60
26 Telescopic Extension Ram
27 Lift Ram GA 160 X 90
28 GA Displacement Ram 532 90X50 740 C/C
29 Check Valve - Low Leak
30 Pilot Piston
31 Cartridge
32 Valve Counterbalance
34 Solenoid Selector Valve
35 Adaptor. G1/4A - 7/16 SAE
37 Accumulator 0.24L5bar (72.5psi)
38 Counterbalance Valve
30 - 64 9813/9100-1 30 - 64
00 - General
Page 30-66 Figure 1060. 333/G3987-6 540-170

Machines (81 and 93 kW) Tier 4 Final Page 30-67
18 20 29, 30
19
21
17 17
22
31
24
23 28
12
10
32
39
11 34 25
38 1
26
6 35
9 7
2
27
3 33
37
30 - 65 9813/9100-1 30 - 65
00 - General
Page Page
30-66 30-67

18
19
17 17
12
10
11
38 1
Page 30-67
6
9 7
3
37
30 - 66 9813/9100-1 30 - 66
00 - General
Page Page
30-66 30-67
Figure 1060. (Part 2 of 2) 20 29, 30
21
22
31
24
23 28
32
39
34 25
Page 30-66
26
35
2
27
3 33
30 - 67 9813/9100-1 30 - 67
00 - General
Table 487. 333/G3987-6 540-70 Machines (81 and 93 kW) Tier 4 Final
1 DCV OC 5 Spool EH
2 DCV OC 2 Spool EH
3 Valve - Pilot Manifold
6 Hydraulic Pump - 3 Section
8 Suction Strainer
9 Filler Cap Hydraulic Oil
10 Steer Valve
11 11cc Unidirectional Variable Motor
12 Variable Fan Motor
17 GA Ram Steer 520 60X30
18 Steer Mode Valve
19 Steer Mode Valve
20 Sway Valve
21 GA Ram Sway 532 110X50
22 GA Ram Stabiliser- Left 110 X 60
23 GA Ram Stabiliser- Right 110 X 60
24 GA Ram Tilt 540 140X75
25 GA Ram Inner Extension 90 X 60
26 Telescopic Extension Ram
27 Lift Ram GA 160 X 90
28 GA Displacement Ram 532 90X50 740 C/C
30 Pilot Piston
31 Cartridge
32 Counter Balance Cartridge
34 Solenoid Selector Valve
37 Accumulator 0.24L5bar (72.5psi)
38 Check Valve 2.5bar (36.2psi)
39 Counterbalance Valve
30 - 68 9813/9100-1 30 - 68
00 - General
(For: 540-200 [T4F])

Figure 1061. 333-D8888-13....................................................................................................Page 30-71
30 - 69 9813/9100-1 30 - 69
Notes:
30 - 70 9813/9100-1 30 - 70
00 - General
Page 30-72 Figure 1061. 333-D8888-13 Page 30-73
100
110 90
170
180
120
420
310
450 130
10 210 190
390 230
190
220 140
50 440 410
430 200
60 H 160
70 400 150
240
270
310 300
J
280
460
B C 250
A 40
20
260
290 30
G
D
F E
30 - 71 9813/9100-1 30 - 71
00 - General
Page Page
30-72 30-73
100
110 90
450
10
390
220
50 440 410
430
60
70 400
Page 30-73
310 300
280
B C
A
40
20
290 30
G
D
F E
30 - 72 9813/9100-1 30 - 72
00 - General
Page Page
30-72 30-73
170
180
120
420
310
210 190 130
230
190
140
200
H 160 150
Page 30-72
240
270
J
460
250
260
30 - 73 9813/9100-1 30 - 73
00 - General
Table 488.
Item Description
A Main hydraulic tank return line
B Hydraulic tank remote filler
C Hydraulic tank pressure breather
D Hydraulic tank suction strainer
E Hydraulic tank drain inlet
F Hydraulic tank fan return line
G Hydraulic tank secondary return line
H Hydraulic quick release connectors
J Lift assist valve
10 Hydraulic control valve - Husco SCX120
20 Hydraulic pump
30 Suction strainer
40 Hydraulic filler cap
50 Steer control valve
60 Fan motor 15cc
70 Fan motor 15cc - reversing
80 Fan direction control valve
90 Steering cylinder
100 Manual steer mode valve
110 Auto steer mode valve
120 Sway cylinder
130 Left stabiliser cylinder
140 Right stabiliser cylinder
150 Tilt cylinder
160 Displacement cylinder
170 Check valve - low leak
180 Pilot piston
190 Cartridge
200 Counterbalance cartridge
210 Accumulator
220 Sway valve
230 Poppet valve assembly - 2 port
240 Extension cylinder
250 Lift cylinder
260 Counterbalance valve - dual
270 Extension counterbalance valve
280 Filler / breather cap
290 Return filter
300 Hydraulic oil cooler
310 Check valve
390 Hydraulic control valve - Husco SCX120-F15
400 Filter
410 Restrictor
420 Adaptor
430 Fan motor 19cc
440 Variable speed fan motor
30 - 74 9813/9100-1 30 - 74
00 - General
Item Description
450 Variable speed fan motor - reversing
460 Retract relief valve
30 - 75 9813/9100-1 30 - 75
00 - General
(For: 540-v180 [T4F], Manual Controls, JCB Tier 4F Elec 430 Engine 4 Cyl)
Figure 1062. 334/H2265 issue 3 sheet 2 of 2 (Sheet 1 is for T2/T3 machines) (540-180) T4i/T4F
Engines Manual Valve block...................................................................................................Page 30-77
30 - 76 9813/9100-1 30 - 76
00 - General
Figure 1062. 334/H2265 issue 3 sheet 2 of
Page 30-78 2 (Sheet 1 is for T2/T3 machines) (540-180)

T4i/T4F Engines Manual Valve block Page 30-79
150 330
60
240
220 340
140
230
150
80
210 130
90
20
210
190 320
200 40
A 120
C H
70
300 170
D 350
360 290
E 50
160
250 270
F
280
G
30
10
180
30 - 77 9813/9100-1 30 - 77
00 - General
Page Page
30-78 30-79
150
240
150
80
90
20
190 320
A
Page 30-79
300
D
360 290
E
250
F
280
G
30
10
180
30 - 78 9813/9100-1 30 - 78
00 - General
Page Page
30-78 30-79
330
60
220 340
140
230
210 130
210
200 40
120
H
70
Page 30-78
170
350
50
160
270
30 - 79 9813/9100-1 30 - 79
00 - General
Table 489. 334/H2265 issue 3

Item Description
A Left stabiliser spool
B Right stabiliser spool
C Auxiliary spool
D Tilt spool
E Extend spool
F Lift spool
G MRV (Main Relief Valve) - 2 spool control valve
H Quick release connectors
10 Hydraulic pump - 2 section - double pump
20 Hydraulic control valve
30 Accumulator
40 Tilt cylinder
50 Lift cylinder
60 Sway cylinder
70 Extend cylinder
80 Manual steer mode valve
90 Steering control unit
100 Fan Motor - reversing - 16cc - 74kW
110 Hydraulic oil cooler
120 Displacement cylinder
130 Right stabiliser cylinder
140 Left stabiliser cylinder
150 Steering power track rod
160 Counterbalance cartridge - lift
170 Counterbalance valve -extend
180 Suction strainer
190 Check valve
200 Counterbalance cartridge - tilt
210 Cartridge - stabiliser
220 Check Valve - low leak - sway
230 Pilot piston - sway
240 Sway valve
250 Fan return filter
260 Fan motor 16cc - 74kW
270 Adaptor - check - lift assist
280 Hydraulic oil filler cap
290 Fan motor 19cc
300 Fan motor - reversing - 11cc
310 Fan direction changeover valve
320 Variable fan motor
330 Restrictor
340 Adaptor - sway
350 Regeneration valve
360 Bi-directional check valve
30 - 80 9813/9100-1 30 - 80
00 - General
(For: 533-105 [T4F])

Figure 1063. Parallel Dual Lever Control 334/L1249-8 (533-105)......................................... Page 30-83
30 - 81 9813/9100-1 30 - 81
Notes:
30 - 82 9813/9100-1 30 - 82
00 - General
Page 30-84 Figure 1063. Parallel Dual Lever

Control 334/L1249-8 (533-105) Page 30-85
30 - 83 9813/9100-1 30 - 83
00 - General
Page Page
30-84 30-85
Page 30-85
30 - 84 9813/9100-1 30 - 84
00 - General
Page Page
30-84 30-85

Page 30-84
30 - 85 9813/9100-1 30 - 85
00 - General
Table 490. Parallel Dual Lever Control 334/L1249-8 (533-105)

1 Hyd Pump 2Stage 36+16cc
Pgp625
5 Control Valve Block 5Ah En15
11 GA Lift Ram 120 X 70 Lift
12 GA Tilt Ram 130 X 75 Tilt
13 GA Ram Disp 70X40 Displacement
14 GA Ram 80X50 Inner Extension Extension Inner
P33
15 GA Out Extn Ram 100X60 Extension Outer
16 G.A. Power Trackrod Steering
18 Ram - Hyd Pin Locking Carriage
19 Ball Valve Hyd Pin Lock
20 Filter Element Fan Return
21 Suction Strainer In Tank
23 Filter Head SAE-12 Fan Return
29 Counter Balance Cartridge Lift
31 Counter Balance Cartridge Tilt + Extension
33 Counter Balance Cartridge Extension Outer
35 Adaptor. G1/4A - 7/16 SAE Lift Assist
37 Hyd Filler Cap -Breather Tank
39 Cartridge Extension Outer
40 Fan Motor 19cc 55Kw
41 Variable Fan Motor 81/93/108Kw Rev
42 11cc Unidir.Var.Motor 81/93Kw
50 Accumulator 0.24Ltr 5.0Bar Pilot
55 Steer Valve + Shocks Orbitrol
56 GA Steer Mode Valve Manual Smv
57 Steer Mode Valve Elec Smv
60 GA Ram Stab Rh 110 X 60 Stab
61 GA Ram Stab Lh 110 X 60 Stab
62 Cartridge Stab
63 Pressure Transducer 0-250 Bar Stab
65 Vented Counterbalance Valve Extension Outer
66 Cartridge Extension Outer
67 Assembly Make-Up Valve 1" UNF Extension
68 Check Valve 2.5 Bar
30 - 86 9813/9100-1 30 - 86
00 - General
(For: 540-140 [T4F], 550-140 [T4F])

Figure 1064. 333/E1782-4...................................................................................................... Page 30-89
30 - 87 9813/9100-1 30 - 87
Notes:
30 - 88 9813/9100-1 30 - 88
00 - General
Page 30-90 Figure 1064. 333/E1782-4 Page 30-91
333/E1782-4
30 - 89 9813/9100-1 30 - 89
00 - General
Page Page
30-90 30-91
Page 30-91
30 - 90 9813/9100-1 30 - 90
00 - General
Page Page
30-90 30-91

Page 30-90
333/E1782-4
30 - 91 9813/9100-1 30 - 91
00 - General
The schematic shows the sway option. If the sway

option is not installed, the pump flow goes direct to
the fan motor and then to the tank.
Table 491.
Item Description
1 6 Spool Valve Block Assy
3 Suction Strainer
4 Air Breather Filter
5 Hydraulic pump - 2 section - double pump
6 Steer Valve
7 Fan Motor 19 cc
8 11 cc Unidirectional Variable Motor
9 Variable Fan Motor
15 Cylinder Steer 520 60X30
16 Steer Mode Valve
17 Steer Mode Valve
18 Sway Valve
19 Cylinder Sway 532 110X50
20 Cylinder Stabiliser - left 110 X 60
21 Cylinder Stabiliser - right 110 X 60
22 Cylinder Tilt 140X75
23 Inner Extension Cylinder
24 Cylinder Out Extension 130 X 70
25 Lift Cylinder 160 X 80
26 Cylinder Displacement 532 90 X 50
28 Cartridge
30 Cartridge
31 Check Valve
32 Valve Counterbalance
34 Pilot Piston
36 Cartridge
38 Check Valve 2.5 Bar
30 - 92 9813/9100-1 30 - 92
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-95

30-03-12 Suction Strainer .............................................................................................................. 30-97
30 - 93 9813/9100-1 30 - 93
Notes:
30 - 94 9813/9100-1 30 - 94
03 - Tank
00 - General
Introduction .................................................... 30-95 The hydraulic tank holds excess hydraulic oil to
Component Identification ............................... 30-96 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 - 95 9813/9100-1 30 - 95
03 - Tank
00 - General
(For: 540-200 [T4F], 540-v180 [T4F])

Figure 1065. Hydraulic Tank
C
B
G
E
F
A Main return
B Remote filler
C Pressure breather
D Secondary return
E Drain
F Fan
G Suction strainer
30 - 96 9813/9100-1 30 - 96
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 - 97 9813/9100-1 30 - 97
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-99

30-04-03 Main .............................................................................................................................. 30-100
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-104
30 - 98 9813/9100-1 30 - 98
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 - 99 9813/9100-1 30 - 99
04 - Filter
03 - Main
03 - Main Figure 1066.
Remove and Install

For: 540-140 [T4F], 540-170 [T4F], 540-200
[T4F], 550-140 [T4F] ............... Page 30-100
For: 535-v125 [T4F], 540-v140 [T4F]
................................................. Page 30-101
(For: 540-140 [T4F], 540-170 [T4F],

540-200 [T4F], 550-140 [T4F])
CAUTION When the strainer is removed, oil will
gush out. Keep to one side when you remove the
strainer.
Canister Type Filter
Remove
A Canister filter
The canister filter is installed under the chassis, C Seal
located to the rear of the front axle.
4.1. Run the engine for a few minutes.
1. Make the machine safe with the lift arm lowered,
refer to (PIL 01-03). 4.2. Make the machine safe.
4.3. Check for leaks at the filter.
2. Discharge the hydraulic system pressure. Refer
to (PIL 30-00).
Oil Filter (Hydraulic Oil Tank, Top
3. Clean the area around the filter body. Mounting)
4. Place a container of suitable size beneath the
machine to catch the oil. Remove
5. From under the machine, unscrew and remove 1. Make the machine safe with the lift arm raised,
the element. The element will contain hydraulic refer to (PIL 01-03).
fluid; keep your face clear of spilling fluid. 2. Open rear cover. Refer to (PIL 06-06).
Install 3. Discharge the hydraulic system pressure. Refer
to (PIL 30-00).
1. Install the new element.
4. Clean the top of the tank around the filter.
1.1. Clean the mating faces on the new element
and filter holder. 5. Either disconnect the hose or undo clip to enable
cover plate removal.
1.2. Smear the seal with clean new hydraulic
fluid. 6. Remove the element assembly:
1.3. Screw the new element in place, hand-tight 6.1. Remove the screws. Remove the cover
only. plate and gasket, discard the gasket.
2. Check oil level and replenish as required through 6.2. Remove the spring.
filler. Refer to (PIL 30-00).
6.3. Hold the handle and pull the element
3. Install the filler cap. assembly from the hydraulic tank.
4. Check for leaks: 7. Remove the element from its canister:

7.1. Hold the canister.
7.2. Hold the handle and rotate the element 90°
counter-clockwise.
30 - 100 9813/9100-1 30 - 100

04 - Filter
03 - Main
7.3. Pull on handle, the element should separate H Seal 1

from its canister. Discard the old element. J Seal 2
K Hose
7.4. Remove and discard the seal.
7.5. Clean the inside of canister. (For: 535-v125 [T4F], 540-v140 [T4F])
Install CAUTION When the strainer is removed, oil will
gush out. Keep to one side when you remove the
1. Install the new element. strainer.
1.1. Install a new seal 1.

Canister Type Filter
1.2. Make sure that seal 2 is installed in the new
element. Remove
1.3. Push the element into its canister and rotate
the element 90° to lock it into position. The canister filter is installed to the front of the rear
Check that the element has locked into axle.
position by pulling on the handle.
1. Make the machine safe with the lift arm lowered,
1.4. Install the element assembly in the refer to (PIL 01-03).
hydraulic tank.
1.5. Install the spring and gasket.
to (PIL 30-00).
1.6. Install the cover plate and tighten the
screws. 3. Clean the area around the filter body.
2. Check oil level and replenish as required through 4. Place a container of suitable size beneath the
filler. machine to catch the oil.
3. Install the filler cap. 5. From under the machine, unscrew and remove
the element. The element will contain hydraulic
4. Close the rear cover. fluid; keep your face clear of spilling fluid.
Figure 1067.
Install
1.1. Clean the mating faces on the new element
and filter holder.
1.2. Smear the seal with clean new hydraulic
fluid.
1.3. Screw the new element in place, hand-tight
only.
2. Check oil level and replenish as required through
filler. Refer to (PIL 30-00).
3. Install the filler cap.
4. Check for leaks:
A Screws
B Cover plate
C Gasket
D Spring
E Handle
F Canister
G Element
30 - 101 9813/9100-1 30 - 101

04 - Filter
03 - Main
Figure 1068. 7.3. Pull on handle, the element should separate

from its canister. Discard the old element.
7.4. Remove and discard the seal.
7.5. Clean the inside of canister.
Install
1.1. Install a new seal 1.
1.2. Make sure that seal 2 is installed in the new
element.
1.3. Push the element into its canister and rotate
the element the specified amount to lock it
into position.
Angle: 90°
1.4. Make sure the element has locked into
position by pulling on the handle.
A Canister filter 1.5. Install the element assembly in the
C Seal hydraulic tank.
4.1. Run the engine for a few minutes. 1.6. Install the spring and gasket.
4.2. Make the machine safe. 1.7. Install the cover plate and tighten the
screws.
4.3. Check for leaks at the filter.
2. Check oil level and replenish as required through
Oil Filter (Hydraulic Oil Tank, Top filler.
Mounting)
Remove 4. Close the rear cover.
1. Make the machine safe with the lift arm raised, Figure 1069.
2. Open rear cover. Refer to (PIL 06-06).
to (PIL 30-00).
4. Clean the top of the tank around the filter.
5. Either disconnect the hose or undo clip to enable
cover plate removal.
6. Remove the element assembly:
6.1. Remove the screws. Remove the cover
plate and gasket, discard the gasket.
6.2. Remove the spring.
6.3. Hold the handle and pull the element
assembly from the hydraulic tank.
7. Remove the element from its canister:
7.1. Hold the canister. A Screws
B Cover plate
7.2. Hold the handle and rotate the element C Gasket
counter-clockwise the specified amount. D Spring
E Handle
30 - 102 9813/9100-1 30 - 102

04 - Filter
03 - Main
F Canister
G Element
H Seal 1
J Seal 2
K Hose
30 - 103 9813/9100-1 30 - 103

04 - Filter
60 - Pilot Pressure Supply Main
Remove and Install
(For: 535-v125 [T4F], 540-170 [T4F], Figure 1070. Pilot Filter- Canister Type
540-200 [T4F], 550-140 [T4F], 550-170
[T4F])
Pilot Filter
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.
Your machine will be installed with one of the

following types of pilot filter, depending on the
specification of your machine.
Remove- (Canister Type)


2. Raise the lift arm and install the lift arm
maintenance strut. Refer to (PIL 06-69).
30-00).
4. Remove the chaff guard to expose the chassis
access hole.
4.1. The Pilot Filter is located at the front of the
chassis access hole. A Chaff guard
B End cap
5. Unscrew the end cap.
6. Remove the element with associated seals and Remove- (Valve Mounted Type)
discard them according to local regulations.
Install- (Canister Type) 1. Make the machine safe. Refer to (PIL 01-03).
1. Install a new element and new seals. 2. Discharge the hydraulic pressure. Refer to (PIL
2. Install the cap and tighten to the correct torque. 30-00).
Torque: 25N·m 3. Unscrew the end cap.
3. Install the chaff guard. 4. Remove the element with associated seals.
Discard them according to local regulations.
Install- (Valve Mounted Type)
5. Make sure the hydraulic oil level is correct.
1. Install a new filter element and seals.
6. Run the engine and check the filter for leaks.
2. Install the filter cap and tighten to the correct
torque.
3. Make sure the hydraulic oil level is correct.
4. Run the engine and check the filter for leaks.
30 - 104 9813/9100-1 30 - 104

04 - Filter
Figure 1071. Pilot Filter- Valve Mounted Type
B
A
A End cap B Filter element
30 - 105 9813/9100-1 30 - 105

11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ......................................................................................................................... 30-107
30 - 106 9813/9100-1 30 - 106

11 - Gear Pump
00 - General

Technical Data ............................................. 30-107 For: 533-105 [T4F] .................. Page 30-107
Component Identification ............................. 30-109 For: 535-v125 [T4F], 540-140 [T4F], 550-140
[T4F] ........................................ Page 30-108
Operation ..................................................... 30-110
For: 533-105 [T4F] .................. Page 30-108
Diagram ....................................................... 30-111
Check (Pressure) ........................................ 30-112 (For: 533-105 [T4F])
Disassemble and Assemble ........................ 30-116 The pump installed on your machine will be one of
two types:
2 Section (Double pump)

Table 492. Double Pump
Mounting Gearbox
Direction of rotation Counter clockwise
Theoretical displace- 0.000036m³
ment per RPM (Revolu-
tions Per Minute)- Main
services pump (mount-
ing flange end)
ment per RPM-Cooling
fan pump
Flow- Main services 71.3L/min
pump
(1)
Flow- Cooling fan pump 31.7L/min

Maximum pressure- port 265 (3,840.6)
EF
P
Maximum speed 3000 RPM
Minimum speed 500 RPM
Weight 22.7kg
(1) At 2200 RPM and system pressure (90% min
displacement).
3 Section (Triple pump)

Table 493. Triple Pump
Mounting Gearbox
ment per RPM- Main
ing flange end)
fan pump
fan pump
Flow- Main services 71.3L/min
pump
(1)
30 - 107 9813/9100-1 30 - 107

11 - Gear Pump
00 - General
Flow- Steering pump 37.6L/min Flow- Main services 71.3L/min

pump
(1)
Flow- Cooling fan pump 31.7L/min
Maximum pressure- port 265 (3,840.6) Flow- Cooling fan pump 31.7L/min
EF Maximum pressure- port 265 (3,840.6)
Maximum pressure- port 200 (2,898.5) EF
P Maximum pressure- port 200 (2,898.5)
Maximum speed 2500 RPM P
Minimum speed 500 RPM Maximum speed 3000 RPM
Weight 34.1kg Minimum speed 500 RPM
(1) At 2200 RPM and system pressure (90% min Weight 22.7kg
displacement). (1) At 2200 RPM and system pressure (90% min
displacement).
(For: 535-v125 [T4F], 540-140 [T4F],
550-140 [T4F])

Mounting Gearbox
ment per RPM- Main
ing flange end)
fan pump
Flow- Main services -
pump
(1)
Flow- Cooling fan pump -

EF
P
Maximum speed 2200 RPM
Minimum speed 500 RPM
Weight 34.8kg
(1) At 2200 RPM and system pressure (90% min
displacement).
(For: 533-105 [T4F])

Mounting Gearbox
ment per RPM- Main
ing flange end)
fan pump
30 - 108 9813/9100-1 30 - 108

11 - Gear Pump
00 - General
Figure 1072. Typical Double Pump
D
C
Figure 1073. 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 - 109 9813/9100-1 30 - 109

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 1074.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
Table 496. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 110 9813/9100-1 30 - 110

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 1075.
LS P EF F G
C A
B
Item Description
Table 497. 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 498. Port details

Item Description
F Fan and pilot valve feed
G Test point
P Pump main output
30 - 111 9813/9100-1 30 - 111

11 - Gear Pump
00 - General
Check (Pressure) Figure 1077.
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 1076. 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 1078.
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)
(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 - 112 9813/9100-1 30 - 112

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: 240bar (3,478.2psi) and place the end of the slave hose inside
the filler tube.
12. Check the flow reading.
Figure 1080.
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 1079.
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 - 113 9813/9100-1 30 - 113

11 - Gear Pump
00 - General
Figure 1081. 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: 240bar (3,478.2psi)
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 1083.
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 1082.
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.
up to working temperature.
30 - 114 9813/9100-1 30 - 114

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 1085. 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 1084. 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 - 115 9813/9100-1 30 - 115

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.
installed, and phased in the same position
as removal to prevent chafing.
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

Item Description Nm
A Flange bolts 46
B Socket head screws 46
D Mounting bolts 96
30 - 116 9813/9100-1 30 - 116

15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ......................................................................................................................... 30-119

30-15-06 Lift Arm ......................................................................................................................... 30-136
30-15-07 Lift Extension ................................................................................................................ 30-142
30-15-08 Lift Compensating ........................................................................................................ 30-147
30-15-11 Lift Arm Crowd ............................................................................................................. 30-149
30-15-24 Stabiliser ....................................................................................................................... 30-154
30-15-63 Sway ............................................................................................................................. 30-158
30-15-99 Seal Kit ......................................................................................................................... 30-159
30 - 117 9813/9100-1 30 - 117

Notes:
30 - 118 9813/9100-1 30 - 118

15 - Cylinder / Ram
00 - General
Introduction .................................................. 30-119 A hydraulic cylinder ram is a mechanical actuator
Health and Safety ........................................ 30-120 that is used to give a single directional force
Technical Data ............................................. 30-122 through a single action stroke. It is used in many
Check (Condition) ........................................ 30-123 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Disassemble and Assemble ........................ 30-124 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 - 119 9813/9100-1 30 - 119

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.
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 - 120 9813/9100-1 30 - 120

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 - 121 9813/9100-1 30 - 121

15 - Cylinder / Ram
00 - General
Technical Data
Table 500. Cycle Times (Seconds)

Opera- 531-70 541-70 550-80 560-80 535-95 535-105 535- 540- 540-140 540-170
tion v125 v140
Lift 7.2 8.8 7.4 7.15 9.1 8.8 10.4 13.5 15.1 22.7
Lower 5.4 6.5 5.9 5.65 7.7 8.5 8.1 11 15.5 23.4
Extend 6.8 6.8 8.3 8.3 10.5 13.2 15.7 15.6 19.5 18.3
Retract 5 5 5.9 5.9 11.2 13.6 12.8 14.4 19.2 16.7
Shovel 3.5 3.5 2.8 2.8 2.4 2.4 1.8 1.7 3.2 4.2
dump
Shovel 2.9 2.9 3.0 3 3.5 3.4 2.3 2.0 2.5 4.6
crowd
All measurements taken with the machine at normal

operating temperature.
30 - 122 9813/9100-1 30 - 122

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 - 123 9813/9100-1 30 - 123

15 - Cylinder / Ram
00 - General
For: 533-105 [T4F] .................. Page 30-124 1. Place the ram assembly on a locally
For: 540-170 [T4F], 550-170 [T4F] manufactured strip or on a rebuild bench.
................................................. Page 30-127
Figure 1086.
(For: 533-105 [T4F])
Consumables
- General purpose
solvent based parts
cleaner
2. Use the correct size spanner to remove the end
JCB Activator 4104/0251 0.2L
cap and then remove the piston rod assembly
4104/0253 1L from the cylinder.
and Sealer (Medium 4101/0251 0.05L 3. Place the piston rod assembly on the bench in
Strength) place of the ram cylinder.
4. Remove and discard the seal 1,seal 2 and the
Lifting Equipment
wear ring 1, wear ring 2 from the piston head.
equipment. You must identify the weight of the item to 5. Put appropriate sized screw threaded into the
be lifted then choose lifting equipment that is strong extractor hole to remove dowel from the piston
enough and suitable for the job. Make sure that lifting head.
equipment is in good condition and complies with all
local regulations. 6. Use the correct size spanner to remove the
piston head from the rod and then discard the O-
ring 1.
Single piston rams
7. For extension ram, after removal of then piston,
Disassembly slide and remove the spacer from the piston rod.
CAUTION If air or hydraulic pressure is used to 8. Remove the gland bearing and the end cap from
force out the piston assembly, ensure that the end the piston rod.
cap is securely installed. Severe injury can be
caused by a suddenly released piston rod. 9. Remove the O-ring 2, wiper seal and the rod seal.
10. Check the end cap bearing for damage, scores or
The disassembly and assembly procedures for many nicks. If damaged, the bearing must be replaced
jcb hydraulic rams are same. as part of the end cap assembly.
The ram must be removed from the machine before 11. Make sure that the metal components are free
you disassemble it. from scoring, nicks and burrs. A damaged piston
rod will reduce the life of gland seals.
The ram shown in the illustration is not installed with
HBCV (Hose Burst Check Valve). If HBCV is installed 12. Check the bore of the ram cylinder for damage.
also with the ram, the disassembly and assembly
procedure will remain unchanged and can be carried
out without the removal of the check valve.
30 - 124 9813/9100-1 30 - 124

15 - Cylinder / Ram
00 - General
Figure 1087.
T S
R
U
F
A
G
J
H
E
K
L
C B
D
Q
P
N
Table 501.
Item Description
A Wear ring 1
B Seal 1
C seal 2
D Wear ring 2
E Dowel
F Piston head
G O-ring 1
H Gland bearing and end cap
J O-ring 2
K Rod seal
L Wiper seal
M Piston rod
N Seal 3
30 - 125 9813/9100-1 30 - 125

15 - Cylinder / Ram
00 - General
Item Description
P
Q Seal 4
R Seal 5
S
T Seal 6
U Cylinder
Assembly Cold weather operation, When operating in

conditions which are consistently below freezing, it is
1. Use a wire brush to the clean the threads of the recommended that the rams are operated slowly to
piston rod, end cap and cylinder. their full extent before commencing normal working.
2. Use cleaner and degreaser to make sure that all
threads are free from grease, hydraulic oil and
Piston head retention
old sealing or retaining compounds. Install the locking dowel to piston as follows:
purpose solvent based parts cleaner Existing piston head and rod
3. Make sure the degreaser is fully dried. Align holes so that dowel can be installed with the
Duration: 15min tapped extractor hole, as shown.
4. Apply the sealant. New piston head and rod

(Medium Strength) Drill and ream piston head and rod to the diameter
and depth indicated, refer to the Refer to Table
5. Make sure that the O-rings or the seals do not 502.. Remove all swarf and contamination and install
come into the contact with the JCB activator or dowel with tapped extractor hole as shown.
anaerobic sealing and retaining compounds.
Make sure that the top of the dowel is below the level
6. Install new seals, O-rings and wear rings. of the bearing ring groove and use an undersized
pilot drill before you drill to final size.
7. Make sure that lubricants used during assembly
do not come into contact with de-greased Existing piston head and new rod
components or sealing or retaining compounds.
Drill through existing hole in piston head to the
8. Install the locking dowel to the piston. diameter and depth indicated, refer to the Refer to
9. Put the cylinder on the bench and then install the Table 502.. Remove all swarf and contamination and
piston rod assembly into the cylinder. insert dowel with tapped extractor hole as shown.
10. Apply JCB activator to threads of end cap and Make sure that the top of the dowel is below the level
cylinder. Allow JCB activator to dry for the of the bearing ring groove and use an undersized
specified time before bringing into contact with pilot drill before you drill to final size.
JCB threadlocker.
New piston head and existing rod
Duration: 15min
Consumable: JCB Activator Same as existing piston head and new rod but at 90°
to existing hole in rod.
11. Apply sealant to the threads of the cylinder and
tighten the end cap to the correct torque value.
(Medium Strength)
If hydraulic oil make contacts with locking fluid it

will weaken the bond. Cure times vary according
to the ambient temperature. The approximate cure
time for JCB threadlocker & sealer (high strength) or
JCB threadlocker with JCB activator is 1h, applies at
20°C (68.0°F) and is the minimum period between
assembly and filling the ram with oil.
30 - 126 9813/9100-1 30 - 126

15 - Cylinder / Ram
00 - General
Figure 1088. Consumables

AH
JCB Activator 4104/0251 0.2L
4104/0253 1L
JCB Threadlocker and 4101/0550 0.01L
AJ Sealer (High Strength) 4101/0552 0.2L
Strength)
Twin piston ram, 4 stage boom outer ram

The telescopic extension ram has 4 main
components each above the specified length. 4m
These will require a working area and suitable

AH Diameter supports when dismantling. When extracting an inner
AJ Depth from an outer cylinder, a space of at least the
specified length will be required. 10m
Table 502. Drilling dimensions Make sure you have sufficient workshop space
before you do this task. This is a 2 person task,
Ram size Diameter (AH) Depth (AJ) assistance will be required during the procedure.
50 x 25 6.02–6.1mm 23mm
90 x 50 8.02–8.1mm 28mm New seals must always be used whenever a ram
is dismantled. Make sure all replacement parts are
100 x 60 12.02–12.1mm 33mm available before starting this procedure.
110 x 60 12.02–12.1mm 33mm
120 x 60 12.02–12.1mm 38mm The ram must be supported during the dismantling
130 x 70 12.02–12.1mm 38mm and assembly process. If not correctly supported the
ram may become unstable as work is carried out
130 x 75 12.02–12.1mm 38mm and items are removed. Soft Pads must be used to
140 x 75 12.02–12.1mm 48mm protect the ram from the supports.
160 x 80 12.02–12.1mm 48mm
Make sure that ram is supported in such a way that
Table 503. Torque Values the weight is distributed evenly, else damage may
happen.
Item Description Nm
F Piston head 405 It is necessary to lift the equipment to move the ram
H Gland bearing and end cap 678 and remove the cylinders. A hoist or crane with a
rope (not metal) sling must be used.
(For: 540-170 [T4F], 550-170 [T4F]) At various points in the procedure the ram must be
Special Tools prevented from turning so that components can be
Description Part No. Qty. unscrewed. The recommended method is to use a
V type clamp which distributes the clamping force
Ram Protection Sleeve 892/01021 1 evenly and therefore reduces risk of distorting any
(60mm rod diameter) components.
30 - 127 9813/9100-1 30 - 127

15 - Cylinder / Ram
00 - General
Figure 1089.
C048350
A Outer cylinder B Centre cylinder

C Inner cylinder D Feed pipe
30 - 128 9813/9100-1 30 - 128

15 - Cylinder / Ram
00 - General
Disassembly Remove the piston head locking screws
Remove the center cylinder from the outer Some of the piston head locking screws, are
cylinder recessed below the surface of the piston. The edges
of the locking screw holes have edges which are
1. Remove all the bleed screws and then discharge “peened” over to prevent the screws from working
the pressure from the cylinder. loose.
2. Leave bleed screws open throughout the 1. If the locking screw is not retained in a peened
disassembly and assembly procedure. This will hole use a 4 mm or 3 mm Allen key as applicable
help in the process, as no air will be trapped to remove it.
within the components.
2. If the locking screw is retained by a peened hole
3. Use a spanner of the specified diameter to loosen follow the below instructions.
the union nut 1 and union nut 2.
2.1. Plug all adjacent open ports to prevent
Dimension: 46mm metal swarf ingress and contamination.
4. Remove the adaptor bolt 1 and adaptor bolt 2 but Figure 1091.
make sure that you do no remove the pipes.
AN
5. A significant quantity of hydraulic fluid may be AK AL
released during this step and a suitable container
should be on hand.
6. Remove the centre cylinder to the specified
(approximate) length and use a rope loop to
secure it. This gives clearance to remove the seal
housing. AM AN
Length: 300mm
7. If the seal is tight then rotate the centre cylinder
as you remove it.
8. Use a 'C' spanner of the specified diameter to
loosen the groove nut.
Dimension: 155–230mm
Figure 1090. AN
AK Locking screw hole

AL Hexagonal socket
AM Locking screw hole edges
AN Piston head locking screws
2.2. Use a drill bit of the specified diameter to
drill the locking screw hole until the whole of
the hexagonal socket in the screw is visible.
Dimension: 5mm
9. A significant quantity of hydraulic fluid may be
released during this step and a suitable container 2.3. Do not attempt to drill out the locking screw
should be on hand. as this will damage the cylinders beyond
repair.
10. Remove the seal housing from the outer cylinder.
2.4. Use compressed air or cleaning fluid to
11. Tilt the ram to drain the remaining hydraulic fluid. remove any metal swarf from the area.
12. Remove the centre cylinder from the outer 2.5. Use 3 mm or 4 mm Allen key as applicable
cylinder together with the seal housing and the to remove the locking screw.
piston. 2.6. Unplug all the ports.
30 - 129 9813/9100-1 30 - 129

15 - Cylinder / Ram
00 - General
Remove the centre cylinder piston 4. Remove the seal housing from the center
cylinder.
Be careful the valve may still hold some residual
pressure. Make sure all internal pressure is Remove the inner cylinder from the outer
discharged. cylinder
1. Use a box spanner of the specified diameter 1. Remove the inner cylinder from the center
or a deep socket to remove the counterbalance cylinder along with the piston 2 and the seal
valve slowly, in order to discharge any remaining housing 1.
internal hydraulic pressure.
Dimension: 30mm Remove the inner cylinder piston
2. Use a C spanner of the specified diameter to 1. Use a allen key of the specified diameter to
remove the piston 1 from the center cylinder. remove the lock screw 3.
Dimension: 90–155mm Dimension: 3mm
3. Remove the piston 1 and the feed pipe from the 2. Remove the piston 2 and the inner feed tube
center cylinder by approximately to the specified from the inner cylinder and keep them on a clean
value. surface.
Length/Dimension/Distance: 300mm Remove the seal housings from the
4. Rotate the piston 1 and remove the locking pin. cylinders
5. Use a allen key of the specified diameter to 1. Before you remove the seal housings make sure
remove the lock screw 1. that the cylinders are free of burrs or debris.
Dimension: 3mm 2. To remove the seal housing 2, move it along the
center cylinder towards end.
6. Remove the piston 2 from the inner cylinder.
3. To remove seal housing 1. move it along the inner
7. Remove the piston 1 from the feed tube. Keep all cylinder.
the items on a clean surface.
4. Place the housings on a clean surface.
Remove the inner cylinder seal housing
5. Remove all the seals and rings from the seal
1. Carefully clamp the center cylinder to prevent housings and pistons.
damage and rotation.
6. Clean all the components.
2. Use a allen key of the specified diameter to
remove the lock screw 2. Check the condition of all the components before
you assemble them. Refer to check(condition) (PIL
Dimension: 3mm 30-15-00).
3. Remove the inner cylinder to the specified value,
to get access to the seal housing.
30 - 130 9813/9100-1 30 - 130

15 - Cylinder / Ram
00 - General
Figure 1092.
BL
BK
BJ
BN
BN
BM
AZ BB
BC
BD
BP
AY
BA
BF
BQ
AV AX
BE
BG
BH
AU
AW
AR AQ
AP AS
AT
AQ
Table 504. Item Description

BC Locking pin
Item Description
BD Locking screw 1
AP Inner cylinder
BE piston 2
AQ Pivot pin
BF Locking screw 3
AR Bleed screw 1
BG Feed tube
AS Bleed screw 2
BH
AT Seal housing 1
BJ Adaptor bolt 1
AU Seal housing 2
BK Pivot bushes
AV Bleed screw 3
BL Grease nipple
AW Locking screw 2
BM Union nut 1
AX Center cylinder
BN Outer cylinder
AY Counter balance valve
BP Union nut 2
AZ Locking screw
BQ Adaptor bolt 2
BA piston 1
BB Locking screw 4
30 - 131 9813/9100-1 30 - 131

15 - Cylinder / Ram
00 - General
Assembly Reseal the centre cylinder seal housing
Reseal the pistons and seal housings 1. Install the O-ring 4 onto the seal housing.
1. Make sure that all seals and O-rings are 2. Install the wear ring 4 and wear ring 5 into the
replaced. seal housing 2.
2. Before installation, apply a small quantity of 3. Use a seal fitting tool to install the seal 7 into the
hydraulic oil to all seals and O-rings. seal housing 2.
4. Use a press to push the wiper seal squarely into
Reseal the inner cylinder piston the seal housing with the rubber facing outwards
from the housing.
1. Put the wear ring 1 into the piston inner bore.
2. Install the O-ring 3 then the inner retainer. Reseal the inner cylinder seal housing
3. Put a new wear ring 2. 1. Install the wear ring 6, wear ring 7 and O-ring 5
into the piston side of the seal housing 1.
Figure 1093.
2. Install the O-ring 6 and the retaining ring into seal
housing 1.
3. Install the wear ring 8, wear ring 9 into the rod
side of the seal housing 1.
4. Install the O-ring 6 and retainer into the seal
housing 1.
X 4.1. The retainer has two different internal

X Rod seal diameters. Make sure the smaller diameter
goes in to the seal housing on the rod side.
4. Install outer seal 1, outer seal 2 and outer seal 3 The larger diameter must be on the piston
to the outside of the piston. side.
5. Install new wear ring 3. 5. Use a seal fitting tool to install the seal8 and seal9
into the seal housing 1.
Figure 1094.
Reseal the centre cylinder piston
1. Install internal O-ring 7 and O-ring 8 into the
piston 1.
2. Install wear ring 10 to the outside of the piston 1.
3. Install seal 10, seal 11 and seal 12 to the outside
of the piston 1.
30 - 132 9813/9100-1 30 - 132

15 - Cylinder / Ram
00 - General
Figure 1095.
BV BX
BR BT
BS BU BE BW BY
CD
CA CB CC
BZ AU CP
CM
CE CF CG CH CG AT CJ CK CL CN
CQ BA CR CS CT CU CV
Item Description
Table 505. CE Wear ring 6
Item Description CF Wear ring 7
AT Seal housing 1 CG O-ring 5
AU Seal housing 2 CH Retaining ring
BE piston 2 CJ Wear ring 8
BR Wear ring 2 CK Wear ring 9
BS O-ring 3 CL O-ring 6
BT Inner retainer CM Retainer
BU Wear ring 1 CN Seal 8
BV Outer seal 1 CP Seal 9
BW Outer seal 2 CQ Wear ring 10
BX Outer seal 3 CR O-ring 7
BY Wear ring 3 CS O-ring 8
BZ O-ring 4 CT Seal 10
CA Wear ring 4 CU Seal 11
CB Wear ring 5 CV Seal 12
CC Seal 7
CD Wiper seal
30 - 133 9813/9100-1 30 - 133

15 - Cylinder / Ram
00 - General
Ram assembly 13. Screw the piston 1 onto the cylinder. apply
sealant install the locking screw 1.
1. Move the piston 2 onto the feed pipe within the
(approximate) specified limit. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Length: 300–400mm
14. Replace seals and screw the counterbalance
2. Use a ram protection sleeve of the specified valve into the piston 1.
diameter to prevent seal damage. Move seal
housing 1 onto the inner cylinder. 15. Make sure that the top of the counter-balance
valve is recessed within the piston by a minimum
Special Tool: Ram Protection Sleeve (60mm rod of the specified value.
diameter) (Qty.: 1)
Length: 0.5mm
3. Move the feed pipe into the inner cylinder.
16. Move the centre cylinder assembly with piston
4. Screw the piston 2 onto the inner cylinder. and all internal parts, into the outer cylinder.
5. Apply sealant to the locking screw 3. Install the 17. Screw the seal housing 2 onto the outer cylinder
locking screw 3. and tighten until the adaptor bolt 1 and adaptor
Consumable: JCB Threadlocker and Sealer bolt 2 are aligned. Loosely install the groove nut.
(Medium Strength) 18. Install new seals to the union nut 1, union nut
5.1. If the locking screw 3 has a peened edge to 2 and to the adaptor bolt 1, adaptor bolt 2 then
keep it in place, use a hammer and a large loosely install them to the outer cylinder and seal
diameter centre punch to distort the locking housing 2.
screw location hole. 19. Use a 'C' spanner of the specified diameter to
5.2. Remove any burrs. secure the seal housing 2 with the groove nut.
6. Use a ram protection sleeve of the specified Dimension: 155–230mm

diameter to prevent seal damage. 20. Tighten the union nuts and the adaptor bolts.
Dimension: 105mm
21. Tighten all the bleed screws.
7. Move the seal housing 2 onto the cylinder.
Before operating the ram
8. Move the inner cylinder and feed pipe together
with the seal housing 1 into the centre cylinder. 1. The ram must not be operated for the specified
time after assembly. This will allow the locking
9. Use a 'C' spanner of the specified diameter to fluid to harden sufficiently.
screw the seal housing 1 into the centre cylinder
and secure with lock screw 2 coated with sealant. Duration: 24h
Consumable: JCB Threadlocker and Sealer 2. The ram must be bled before its initial operation.
(Medium Strength)
10. Push the inner cylinder far enough into the centre
Extension ram make up valve (if
cylinder until the feed pipe protrudes out of the installed)
opposite end.
This valve is installed on 3 stage boom machines
11. Screw the piston 1 onto the feed pipe. only. It is assembled to the piston rod using locking
fluid.
11.1. Screw the piston to the limit stop, then
screw back slowly until the locking pin 1. With the valve removed, check for freedom of
locates in the hole in the feed pipe. movement of the plunger and ball.
12. Apply sealant to the locking screw 4 and install it. 2. Make sure you renew the 'O' ring seal.
Consumable: JCB Threadlocker and Sealer 3. Thoroughly remove all oil, grease and dirt from
(Medium Strength) the threads of the valve and piston rod. Apply
12.1. If the locking screw 4 has a peened edge JCB activator and allow to dry for 15 minutes.
to keep it in place, use a hammer and a Consumable: JCB Activator
large diameter centre punch to distort the
locking screw location hole. 4. Coat three central threads of the valve with JCB
threadlocker and sealer. Make sure it does not
12.2. Remove any burrs. contact the 'O' ring seal.
30 - 134 9813/9100-1 30 - 134

15 - Cylinder / Ram
00 - General

(High Strength)
5. Install on to the piston rod making sure that the
end face is flush to within the specified limit below
the end face of the piston rod. If necessary, add
washer 1410/0003 below the valve.
6. After assembly, the plunger when pulled out,
should be above the end face of the piston rod
by the specified minimum value.
7. Make sure that at least the specified time elapses
before allowing contact with hydraulic oil.
Duration: 60min
Figure 1096. Extension ram make up valve
A
B
A 'O' ring
X Piston rod
X Valve
X End face measurement
Y Plunger protrusion

Item Description Nm
F Piston head 405
H Gland bearing and end cap 678
30 - 135 9813/9100-1 30 - 135

15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm Bleed

Bleed ........................................................... 30-136
(For: 533-105 [T4F])
Bleed Procedure
Whenever a hydraulic component is removed or
disconnected from the lift arm extension circuit, the
circuit must be bled to make sure that any residual
air is removed.
During the following procedure, it is important that

the inner ram is not allowed to extend more than the
outer ram, to prevent damage to the inner ram and
auxiliary feed and return hoses.
1. Park the machine and make it safe. Refer to (PIL

01-03).
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to the horizontal position.
5. Assemble a suitable bleed hose, fitted with a
male quick release coupling (QRC) and female
quick release coupling.
6. Make sure that the male quick release coupling is
connected to the straight swivel end of the hose.
For bleed hose specification, refer to Refer to
Table 507.
Figure 1097.
B A
C
A Bleed hose
B Male quick release coupling
C Female quick release coupling
7. Attach the bleed hose assembly to the male quick
release coupling on the top extension hose.
30 - 136 9813/9100-1 30 - 136

15 - Cylinder / Ram
06 - Lift Arm
B D
D Outer ram
12. If the inner ram extends during this sequence,
B Male quick release coupling deselect the auxiliary service. Operate the retract
service to fully retract the inner ram before
8. Connect the other end of the bleed hose
continuing to extend the outer ram with the
assembly to the female quick release coupling on
correct tank line auxiliary service.
the lift arm nose.
13. With the outer ram fully extended, and the inner
9. Put the hose beneath the lift arm so that it does
ram fully retracted, fully retract the outer ram
not entangle when the lift arm is extended or
using the lift arm retract and auxiliary service
retracted.
together. Use the auxiliary service in the opposite
Figure 1099. direction to provide an additional pressure feed
during the retract function.
14. Make sure that the hoses are located correctly in
the roller assembly at the base of the lift arm.
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.
C
15. Release the hydraulic pressure. Refer to
hydraulic system- general, refer to (PIL 30-00).
16. Check the hydraulic fluid level. Refer to hydraulic
system- general, refer to (PIL 30-00.
A
17. Install the hydraulic tank filler cap again.
A Bleed hose
C Female quick release coupling
10. Start the engine. Operate the lift arm service to
fully retract the inner and outer lift arm sections.
11. Slowly operate the lift arm extend and auxiliary
service together until the outer ram is fully
extended. Make sure that the auxiliary service
selected provides a return to tank for the outer
ram so that the inner ram does not extend.
30 - 137 9813/9100-1 30 - 137

15 - Cylinder / Ram
06 - Lift Arm
Figure 1101.
E
F
E Roller assembly
F Hydraulic tank filler cap
18. Detach the bleed hose assembly from the quick
release couplings on the machine.
19. On completion, extend and retract the lift arm
fully five times while checking that the lift arm
sections open and close fully together. Inspect
the hydraulic connections and check for leaks.
20. If the lift arm sections do not open and close fully
together, repeat the bleeding procedure.
21. If the lift arm sections do not open and close fully
together after repeating the bleeding procedure,
refer to hydraulic system fault finding, refer to
(PIL 30-00).
Table 507. Bleed Hose Specification

Length (Approx.) 6,300mm
Bore 9.5mm
Pressure rating High (Suitable for
240bar (3,478.2psi) op-
erating pressure)
30 - 138 9813/9100-1 30 - 138

15 - Cylinder / Ram
06 - Lift Arm
Remove and Install
(For: 533-105 [T4F], 535-v125 [T4F], 5. Discharge the hydraulic pressure from the
540-140 [T4F], 540-170 [T4F], 540-200 system. Refer to (PIL 30-00).
[T4F], 540-v140 [T4F]) 6. If installed, disconnect the remote greasing pipe.

method and device.
Remove
1. Make the machine safe. Refer to (PIL 01-03). K
2. Remove any attachments from the carriage. K Remote greasing pipe

3. Lower the lift arm onto a suitable support. 7. Disconnect the lift ram hydraulic hoses. Put
adaptors on all the open ports.
Figure 1102.
9. Support the lift ram. Remove the nut, bolt and
washers (if installed).
10. Remove the pivot pin 1 from the rod end.
11. At this point it is advisable to remove the lift arm
in order to provide access for lifting out the ram.
12. Attach suitable lifting equipment to the ram rod
eye end. Support the ram.
13. Remove both the bolt 1 and bolt 2.
14. Remove the spacer and the lock plate.
15. Remove the pivot pin 2 from the cylinder end.
4. Follow the general health and safety procedures. 16. Remove ram from the machine.
30 - 139 9813/9100-1 30 - 139

15 - Cylinder / Ram
06 - Lift Arm
Figure 1104. Typical Lift Ram

J H
E
G
B
A
A Lift ram B Nut and bolt

C Pivot pin 1 D Hydraulic hoses
E Bolt 1 F Bolt 2
G Spacer H Lock plate
J Pivot pin 2
30 - 140 9813/9100-1 30 - 140

15 - Cylinder / Ram
06 - Lift Arm
Install
steps.
1.1. Grease the ram pivot pins.
1.2. Check the hydraulic fluid level.
1.3. Tighten all fastenings to the correct torque
value. Refer to (PIL 72).
30 - 141 9813/9100-1 30 - 141

15 - Cylinder / Ram
07 - Lift Extension
07 - Lift Extension
Remove and Install
(For: 533-105 [T4F]) 5. Operate the controls back and forth several times
to discharge the residual hydraulic pressure from
Consumables the system.
JCB Threadlocker and 4101/0550 0.01L 6. Put label on the hoses to help installation.
Sealer (High Strength) 4101/0552 0.2L 7. Disconnect and plug feed hose 1, feed hose 2,
carry over hose 1 and carry over hose 2.
be removed or handled using a suitable lifting 8. Plug all the open ports and hoses to prevent
method and device. contamination.
9. Remove the restraining strap.
Outer ram
10. Support the extension ram.
Remove 11. Remove the nut and bolt, then remove the pivot
1. Fully retract and lower the lift arm to the ground. 1 from the cylinder end.
2. Make the machine safe. Refer to (PIL 01-03). 12. Remove the snap ring and then remove the pivot
2 from the rod end.
Refer to (PIL 01-03). 13. Remove the ram from the machine.
4. Discharge the hydraulic pressure from the

30 - 142 9813/9100-1 30 - 142

15 - Cylinder / Ram
07 - Lift Extension
Figure 1105. Machines with 3 Stage Lift Arm - Outer Ram
H
E
A
B J
F
A Feed hose 1 B Feed hose 2

C Carry over hose 1 D Carry over hose 2
E Restraining strap F Pivot 1
G Nut and bolt H Pivot 2
J Snap ring
30 - 143 9813/9100-1 30 - 143

15 - Cylinder / Ram
07 - Lift Extension
Install section must be kept equal to avoid damage

to the internal hoses.
removal procedure. Additionally do the following 6. Lower the lift arm to align the inner ram rear pivot
steps. pin with the access holes in the chassis.
1.1. Grease the pivot pins. Refer to (PIL 06-30). 7. Stop the engine and remove the ignition key.
1.2. Bleed the lift arm extension hydraulic circuit. 8. Remove the hydraulic tank filler cap and operate
the lift arm extend and retract controls to
Inner ram discharge residual pressure.
Remove 9. Open the cover at the rear of the lift arm to gain
access to the hose guides and roller assembly.
1. Make sure you follow the procedure. Failure to
10. Release the hydraulic breather tube from the
do so may damage the internal ram and auxiliary
chassis and tie it clear of the rear of the lift arm.
feed hoses.
11. Remove bolts 2 and remove the lift arm roller
2. Park the machine on firm level ground. Apply the
assembly.
park brake and remove the carriage.
12. Remove bolts 3 and remove the hose guide.
3. Raise the lift arm to just above the horizontal.
Extend the lift arm to gain access to the front pivot 13. Disconnect the hoses from the rear of the
pin. extension cylinder. Plug the open ports and mark
the connections.
4. Remove the bolt 1. Use a suitable drift to knock
the pin through the lift arm. 14. Remove the bolts 4 (x2) that secure the guide on
the hose tray.
5. Raise the lift arm and operate the retract control
to slowly retract the extension ram. The inner 15. Support the ram.
lift arm section should retract with the hydraulic
cylinder under its own weight. 16. Use a suitable drift to remove the bolt 5 and
knock the pivot pin through the lift arm. Note the
5.1. If the inner lift arm section will not retract location of the spacers.
under its own weight, lower the lift arm and
carefully push the lift arm against an outside 17. Use suitable lifting equipment to remove the ram
force (for example, another machine). from the lift arm.
5.2. The length of the inner and intermediate 18. Make sure that the hoses inside the lift arm are
lift arm sections protruding from the outer not damaged.
30 - 144 9813/9100-1 30 - 144

15 - Cylinder / Ram
07 - Lift Extension
Figure 1106.
D
A
A Pivot pin B Bolt 1

C Access hole D Hydraulic breather tube
30 - 145 9813/9100-1 30 - 145

15 - Cylinder / Ram
07 - Lift Extension
Figure 1107. If a new cylinder is to be installed, transfer the

hose tray to the new cylinder.
2. Position the cylinder inside the inner lift arm.
3. Grease the rear pivot pin. Refer to (PIL 06-30).
E
4. Install the pin and secure it with bolt 5.
5. Operate the extend control to slowly extend the
cylinder and push out the inner lift arm section.
6. Release the control when the front pivot pin is
visible.
7. Make sure the length of the inner and
C intermediate lift arm sections protruding from the
outer section are kept equal to avoid damaging
the internal hoses.
G
F 8. Grease the front pivot pin. Refer to (PIL 06-30).
E Bolts 2 9. Align the bush on the rod end of the cylinder with
F Bolts 3 the lift arm. Install the pin and secure it with bolt 1.
G Hose guide
10. Connect hoses at the rear of the extension
Figure 1108. cylinder. Install the guide to the hose tray, roller
assembly and hose guide.
J 11. Tension the hoses equally by pivoting the roller

assembly. Make sure that the lift arm hoses are
installed over the rollers without being stretched.
12. Apply sealant and tighten the bolt 2 to the correct
torque value.
(High Strength)
13. Secure the breather tube and fill the hydraulic
tank. Refer to (PIL 30-00).
14. Bleed the lift arm extension hydraulic circuit.
L
H
K
H Hoses
J Bolts 4
K Bolt 5
L Pin
M Spacers
Install
1. Make sure that the head side and rod side
bushes are aligned before installing the cylinder.
30 - 146 9813/9100-1 30 - 146

15 - Cylinder / Ram
08 - Lift Compensating
Remove and Install
(For: 535-v125 [T4F]) Remove

Special Tools 1. Make the machine safe. Refer to (PIL 01-03).
Slide Hammer Kit 993/68100 1 2. Follow all the general health and safety
procedure. Refer to (PIL 01-03).
CAUTION This component is heavy. It must only 3. Discharge the hydraulic pressure from the
be removed or handled using a suitable lifting system. Refer to (PIL 30-00).
method and device.
4. Remove the lift ram.
Figure 1109.
C D
A Lock bolt/nut 1 B Pivot pin 1

C Hydraulic hose D Displacement ram
5. Support the lift arm. 11. Remove the lock bolt/nut 1 and washers (if
installed).
6. Use suitable lifting equipment to raise the lift arm
and get access to the displacement ram top pivot. 12. Use the slide hammer kit to remove the pivot pin
1 from the cylinder end. Refer to (PIL 06-30).
7. Put labels on the hoses to help installation.
8. Disconnect the displacement ram hydraulic
hoses. 13. Remove the lock bolt/nut 2 and washers (if
installed).
contamination. 14. Use the slide hammer kit to remove the pivot pin
2 from the rod end.
10. Support the displacement ram.
30 - 147 9813/9100-1 30 - 147

15 - Cylinder / Ram
Figure 1110.
E F
E Lock bolt/nut 2 F Pivot pin 2
15. Remove the ram from the machine.
Install
steps.
1.1. Grease the ram pivot pins.
1.2. Check the hydraulic fluid level and top up as
30 - 148 9813/9100-1 30 - 148

15 - Cylinder / Ram
11 - Lift Arm Crowd
11 - Lift Arm Crowd Bleed

Bleed ........................................................... 30-149
(For: 533-105 [T4F])
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to a convenient height to access
the tilt ram.
30-00).
6. Operate the controls back and forth several times
to discharge the residual hydraulic pressure.
7. Release the locknut and remove the screw.
8. Start the engine and operate the tilt lever several
times.
9. Tighten the screw and the locknut.
10. Operate the tilt lever several times again. Stop
the engine.
11. Repeat step 7 to step 10 if required.
12. Tighten the screw and the locknut to the specified
torque value.
30 - 149 9813/9100-1 30 - 149

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1111.
A Locknut
B Screw

Item Description Nm
A Locknut 12
B Screw 15
30 - 150 9813/9100-1 30 - 150

15 - Cylinder / Ram
11 - Lift Arm Crowd
Remove and Install
(For: 533-105 [T4F]) 7. Remove the lift arm nose cover (if installed).
Special Tools 8. Put a label on the hoses to help installation.
9. Disconnect the tilt ram hydraulic hoses.
1. Remove any attachments from the carriage. 11. Support the tilt ram.
2. Extend the lift arm approximately to the specified 12. Remove the recessed capscrew.
limit.
Length: 600mm 1 from the rod end.
3. Lower the lift arm onto a suitable support so that Special Tool: Slide Hammer Kit (Qty.: 1)
the carriage is clear of the ground.
14. Remove the nut and bolt and washers (if
4. Make the machine safe. Refer to (PIL 01-03). installed).
5. Follow the general health and safety procedure. 15. Use the slide hammer kit to remove the pivot pin
Refer to (PIL 01-03). 2 from the cylinder end.
6. Discharge the hydraulic pressure from the
system. Refer to (PIL 30-00). 16. Remove the ram from the machine.
30 - 151 9813/9100-1 30 - 151

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1112.
A Capscrew B Pivot pin 1

C Tilt ram hydraulic hoses D Bolt
E Pivot pin 2
30 - 152 9813/9100-1 30 - 152

15 - Cylinder / Ram
11 - Lift Arm Crowd
Install
steps.
1.1. Grease the ram pivot pins. Refer to (PIL
06-30).
1.3. Bleed the tilt ram. Refer to (PIL 30-15-11).
30 - 153 9813/9100-1 30 - 153

15 - Cylinder / Ram
24 - Stabiliser
24 - Stabiliser
Remove and Install
For: 533-105 [T4F], 535-v125 [T4F], 540-170 2. Lower the lift arm and carriage to the ground.
[T4F], 540-200 [T4F], 550-170 [T4F]
................................................. Page 30-154 3. Lower the stabilisers to the ground. Do not allow
For: 540-140 [T4F], 540-200 [T4F], 550-140 them to support the machine.
[T4F] ........................................ Page 30-156
(For: 533-105 [T4F], 535-v125 [T4F], 5. Discharge the hydraulic pressure. Refer to (PIL
540-170 [T4F], 540-200 [T4F], 550-170 30-00).
[T4F]) 6. Follow the general health and safety procedures.
Special Tools Refer to (PIL 01-03).
7. Support the ram.
8. Put a label on each hose to help installation.
Consumables
Description Part No. Size 9. Disconnect the stabiliser ram hydraulic hoses.
Special HP Grease 4003/2017 0.4kg 10. Plug all the open ports and hoses to prevent
4003/2006 12.5kg contamination.
4003/2005 50kg
11. Disconnect the stabiliser harnesses connector
from the pressure switch harness connector.
be removed or handled using a suitable lifting 12. Remove switch and washer from the ram.
method and device.
13. Remove the upper ram pivot pin securing nut and
bolt 1.
Remove
14. Remove the upper ram pivot pin with the slide
The illustration and procedure describes removal of hammer kit. Refer to (PIL 06-30).
one stabiliser ram. The procedure for the second ram
is identical. Special Tool: Slide Hammer Kit (Qty.: 1)
15. Remove the lower ram pivot pin securing nut and
The stabiliser ram can be removed with the stabiliser
bolt 2.
leg still attached to the machine.
16. Remove the lower ram pivot pin with the slide
1. Follow the health and safety procedures for rams hammer kit. Refer to (PIL 06-30).
during removal and installation. Refer to (PIL
30-15). 17. Remove the ram from the machine.
30 - 154 9813/9100-1 30 - 154

15 - Cylinder / Ram
24 - Stabiliser
Figure 1113.
F
D
G
B
A Upper ram pivot pin B Ram

C Lower ram pivot pin D Nut and bolt 1
E Nut and bolt 2 F Hydraulic hoses
G Pressure switch
30 - 155 9813/9100-1 30 - 155

15 - Cylinder / Ram
24 - Stabiliser
Install Remove
1. The installation procedure is the opposite of the The illustration and procedure describes removal of
removal procedure. Additionally do the following one stabiliser ram. The procedure for the second ram
steps. is identical.
1.1. Put grease on the ram pivot pins. The stabiliser ram can be removed with the stabiliser
Consumable: Special HP Grease leg still attached to the machine.
1.2. Install a new pressure switch sealing 1. Follow the health and safety procedures for rams
washer. during removal and installation. Refer to (PIL
1.3. Check the hydraulic fluid level and top up as 30-15).
1.4. Tighten fastenings to the correct torque
value. Refer to (PIL 72-00). 3. Follow the general health and safety procedures.
Checking the Pressure Switch Operation 4. Lower the lift arm and the carriage to the ground.
The pressure switches (if installed) are pre-set and 5. Lower the stabilisers to the ground. Do not allow
must not be adjusted. them to support the machine.
To check for correct operation, raise and lower 6. Discharge the hydraulic pressure. Refer to (PIL
each stabiliser to make sure that the warning light 30-00).
illuminates when both stabilisers are making firm
ground contact and extinguishes when one or both 7. Remove the cover.
stabilisers are raised clear of the ground.
8. Put a label on each hose before you disconnect
for correct installation.
(For: 540-140 [T4F], 540-200 [T4F],
550-140 [T4F]) 9. Disconnect the electrical connector from the
pressure switch.
Special Tools
Description Part No. Qty. 10. Disconnect the plug and the stabiliser ram
Slide Hammer Kit 993/68100 1 hydraulic hose 1 and the ram hydraulic hose 2.
11. Support the stabiliser ram.
Consumables
Description Part No. Size 12. Remove the nut and bolt 1.
13. Remove the pivot pin 1 from the rod end with the
4003/2006 12.5kg slide hammer kit. Refer to (PIL 06-30).
4003/2005 50kg
CAUTION This component is heavy. It must only 14. Remove the bolts 2 and the retaining plate.
method and device. 15. Remove the pivot pin from the cylinder end with
the slide hammer kit. Refer to (PIL 06-30).
16. Remove the ram.
30 - 156 9813/9100-1 30 - 156

15 - Cylinder / Ram
24 - Stabiliser
Figure 1114.
D
A F
B G
J H
A Hydraulic hose 1 B Hydraulic hose 2

C Stabiliser ram D Cover
E Pivot pin 1 F Retaining plate
G Bolts 2 H Pressure switch
J Pivot pin 2
Install
steps.
1.1. Put grease on the ram pivot pins.
1.2. Check the hydraulic fluid level. Refer to
hydraulic system- general, refer to (PIL
30-00).
Checking the Pressure Switch Operation

The pressure switches (if installed) are pre-set and
must not be adjusted.
To check for correct operation, raise and lower each

stabiliser in turn to make sure that the warning light
illuminates when both stabilisers are making firm
ground contact and extinguishes when one or both
stabilisers are raised clear of the ground.
30 - 157 9813/9100-1 30 - 157

15 - Cylinder / Ram
63 - Sway
63 - Sway 6. Operate the sway lever to sway the machine fully

to the operator's left side (sway ram extended).
Bleed 7. Stop the engine and discharge the hydraulic

pressure. Refer to (PIL 30-00).
(For: 533-105 [T4F]) 8. Tell the assistant to carefully loosen the bleed
valve and expect hydraulic fluid to escape. Make
Communications sure the bleed valve is not unscrewed more than
Bad communications can cause accidents. If two Length: 6.5mm
or more people are working on the machine, make
sure each is aware of what the others are doing. 9. Start the engine.
Before starting the engine make sure the others are
clear of the danger areas. Examples of danger areas 10. Operate the sway lever to sway the machine fully
are: the rotating blades and belt on the engine, the to the operator's left side.
attachments and linkages, and anywhere beneath or 11. Hold the lever in this position.
behind the machine. People can be killed or injured
if these precautions are not taken. 12. Make sure that the air is removed completely
through the bleed valve.
Sway Ram Bleed Procedure
13. Return the control lever to the neutral position.
The sway ram has an integral bleed valve which can
be used to bleed the sway ram circuit. 14. Tighten the bleed valve immediately to prevent
air entering the circuit.
Make sure that the lift arm is in lowered position when Figure 1115.
the sway ram circuit is bled.
Two persons are required to do this procedure. One

person to operate the sway controls and another to
tighten the bleed screw when all air is removed. If this
procedure is done by one person, air may enter the
cylinder due to delay in dismounting from the cab to
attend the sway cylinder.

Refer to (PIL 01-03). A
30-00).
4. Make sure that the sway ram bleed valve is
closed, because, if opened the machine may
sway unexpectedly. A Bleed valve
4.1. Make sure to open the bleed valve only after 15. Operate the sway ram fully in both directions 10
the machine is swayed fully to the left or times.
right.
16. Repeat steps 7 to 17.
4.2. Do not stand between the chassis and
the wheel because you can be trapped or 17. Stop the engine and remove the ignition key.
crushed when the sway is operated.
18. Check the hydraulic fluid level and top up as
4.3. The bleed valve should only be completely
removed from the valve body to allow
cleaning of the integral orifice. The orifice
diameter is
Dimension: 1.2mm
5. Start the engine.
30 - 158 9813/9100-1 30 - 158

15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 1116.
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 1117.
(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 1118.
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 - 159 9813/9100-1 30 - 159

15 - Cylinder / Ram
99 - Seal Kit
Figure 1119. 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 1121.
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 1120.
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 1122.
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 - 160 9813/9100-1 30 - 160

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 1123.
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 - 161 9813/9100-1 30 - 161

18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-163
30 - 162 9813/9100-1 30 - 162

18 - Accumulator
00 - General
Introduction .................................................. 30-163 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-164 reservoir used to store hydraulic fluid, the non-
Component Identification ............................. 30-164 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ........................... 30-165 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 - 163 9813/9100-1 30 - 163

18 - Accumulator
00 - General
Health and Safety Component Identification

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 1124.
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 - 164 9813/9100-1 30 - 164

18 - Accumulator
00 - General
Discharge and Pressurise Figure 1125.
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 - 165 9813/9100-1 30 - 165

18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 1126.

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: 4bar (58.0psi) 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: 10min
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: 20N·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 - 166 9813/9100-1 30 - 166

51 - Lift Arm Control Valve Block
Contents Page No.
30-51-00 General ......................................................................................................................... 30-169

30-51-21 Load Sense Relief Valve .............................................................................................. 30-187
30-51-24 Flow Regulator ............................................................................................................. 30-189
30 - 167 9813/9100-1 30 - 167

Notes:
30 - 168 9813/9100-1 30 - 168

00 - General
Introduction .................................................. 30-169
Technical Data ............................................. 30-170
(For: 540-170 [T4F], 550-170 [T4F],
Electro Hydraulic)
Operation ..................................................... 30-171 The Electro Hydraulic system control valve blocks
Diagram ....................................................... 30-172 use a proportional solenoid system to move the valve
Fault-Finding ................................................ 30-176 block spools.
Remove and Install ..................................... 30-177 There are 2 control valves:
• The 2 spool control valve operates the boom
selection services and the lift arm lift service.
• The 5 spool control valve operates the lift arm
extend and tilt, auxiliary and stabiliser services.
30 - 169 9813/9100-1 30 - 169

00 - General
(For: 540-170 [T4F], 550-170 [T4F], (For: 540-170 [T4F], 550-170 [T4F],
Electro Hydraulic) Electro Hydraulic)
30 - 170 9813/9100-1 30 - 170

00 - General
Operation
(For: 540-170 [T4F], 550-170 [T4F],

Electro Hydraulic)
Electro Hydraulic Control Valve

When the spools are actuated, oil from the pump
passes into the service port A or the service port B,
operating the relevant hydraulic cylinder.
See the applicable hydraulic schematic for service

port connections. Refer to hydraulic system- general,
Oil from the pump enters both of the control valves

through the inlet port, passing the adjustable MRV
(Main Relief Valve).
When a hydraulic service is selected an electrical

signal is sent to the spool solenoid to allow pilot flow
to move the valve spool to the required position.
With the spool in the correct position the full pressure
hydraulic supply can pass through the valve to the
applicable hydraulic service.
With all spools in neutral, the oil passes round their

central waists, the spool lands preventing the oil
from entering the service ports. On reaching the end
housing, the oil enters the exhaust gallery and is
discharged back to the tank. The control valves also
incorporate adjustable ARV (Auxiliary Relief Valve)'s.
An accumulator is attached to the pilot pressure

supply valve. The accumulator traps and stores oil at
pilot pressure and enables operation of the service
spools a limited number of times with the engine
stopped.
30 - 171 9813/9100-1 30 - 171

00 - General
Diagram
(For: 540-170 [T4F], 550-170 [T4F], Electro Hydraulic)
2 Spool Control Valve
Figure 1127.
X P T
B
A
B
A
A Service Port A B Service Port B

C MRV (Main Relief Valve) D Lift Spool
E Extend Spool F Drain Port
P Pump Inlet T Tank Return
30 - 172 9813/9100-1 30 - 172

00 - General
X Pilot Inlet
30 - 173 9813/9100-1 30 - 173

00 - General
5 Spool Control Valve
Figure 1128.
X P C
B
A
B
A
G
B
A
B
A
J
B
A
K T
A Service Port A B Service Port B

C Pilot Supply Out Port D MRV
E Extend Spool F Auxiliary Spool
G Tilt Spool H Right Stabiliser Spool
J Left Stabiliser Spool K Drain Port
P Pump Inlet T Tank Return
30 - 174 9813/9100-1 30 - 174

00 - General
X Pilot Inlet
30 - 175 9813/9100-1 30 - 175

00 - General
Fault-Finding
(For: 540-170 [T4F], 550-170 [T4F],

Electro Hydraulic)
30 - 176 9813/9100-1 30 - 176

00 - General
Remove and Install
(For: 540-170 [T4F], 550-170 [T4F], 3. Discharge the hydraulic pressure. Refer to (PIL
Electro Hydraulic) 30-00).
CAUTION This component is heavy. It must only 4. Remove the hydraulic filler cap.
method and device. 5. Disconnect the hoses and pipes from the valve
assembly.
Incorrect handling will result in permanent damage 5.1. Put a label on the hoses to help installation.
to the valve assembly. The valve blocks should be
lifted by holding the ends of the valve body, not the
contamination.
electric solenoids.
6. Mark and disconnect the electrical connectors
The procedure is the same for both valve blocks. from the valve block solenoids.
Remove 7. With the valve block correctly supported, remove

the mounting bolts. Carefully lift the valve block
1. Make the machine safe with the lift arm raised. away from the bracket and clear of the machine.
30 - 177 9813/9100-1 30 - 177

00 - General
Figure 1129.
B
C
A
B
A
A Solenoid electrical connectors B Mounting bolts

C Hydraulic hoses
30 - 178 9813/9100-1 30 - 178

00 - General
Install
steps.
1.1. Operate the machines hydraulic system.
Check for correct operation and leaks.
1.2. Fill the hydraulic system with the
recommended hydraulic fluid as necessary.
1.3. After installation check the MRV (Main
Relief Valve) and the ARV (Auxiliary Relief
Valve) pressures. Refer to (PIL 30-00).
30 - 179 9813/9100-1 30 - 179

00 - General
(For: 540-170 [T4F], 550-170 [T4F], Note the location of all the components when
Electro Hydraulic) you disassemble. Although some components may
appear to be identical they are not interchangeable.
Consumables Make sure that you assemble the components in
Description Part No. Size their original positions.
JCB Hydraulic Fluid OP 4002/2001 5L
46 Take great care when you disassemble and
4002/2005 20L assemble the valve. Avoid the following:
4002/2003 200L
JCB Threadlocker 4101/0250 0.01L • Contamination.
and Sealer (Medium 4101/0251 0.05L • Damage to the spools.
Strength) • Damage to the seal grooves.
Working Under the Machine Any of the above may result in possible problems
with the operation of the valve.
Disassemble
the ignition key, disconnect the battery. If the machine 1. Remove the valve block from the machine.
movement. 2. Remove the tie rod nuts (x3).
The valve block is made up of a number of separate 3. Carefully separate and remove the sections from
sections. The illustration is intended as a guide to the tie rods as required.
identify the components.
Figure 1130. 5 Section Control Valve
333-G3814-1
A1 Spool 1 extend- lift arm (piston head side) B1 Spool 1 extend- lift arm (piston rod side)
A2 Spool 2 auxiliary quick fit connectors B2 Spool 2 auxiliary quick fit connectors
A3 Spool 3 displacement and carriage tilt rams, B3 Spool 3 displacement and carriage tilt rams,
(piston rod side) (piston rod side) and 2 spool valve
A4 Spool 4 right side stabiliser (piston head side) B4 Spool 4 right side stabiliser (piston rod side)
A5 Spool 5 left side stabiliser (piston rod side) B5 Spool 5 left side stabiliser (piston head side)
30 - 180 9813/9100-1 30 - 180

00 - General
Figure 1131. 2 Section Control Valve
333-G3853-2
A1 Spool 1- Lift Arm selection diverter valve B1 -

A2 Spool 2- Main lift cylinder (rod side) B2 Spool 2- Displacement & tilt cylinder (piston
head side)
30 - 181 9813/9100-1 30 - 181

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.
Consumable: JCB Hydraulic Fluid OP 46
1.4. If the tie rods were removed, apply sealant
to the threads before you install it again.
Tighten to the correct torque value.
(Medium Strength)
30 - 182 9813/9100-1 30 - 182

03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Figure 1133.

D
N
Operation
The relief valve is located in the control valve, which EX

connects either the neutral and exhaust galleries
(Parallel Control Valves) or the load sense and A
exhaust galleries (Flowshare Control Valves). It is B
designed to prevent the circuitry from damage that
could be caused by excessive pressures.
Valve at rest
The services are in neutral and pressure in the
neutral gallery is not sufficient to operate the relief
valve which is held closed by its spring.
Figure 1132.
N A Control valve block
B Relief valve
D Hollow poppet
N Neutral gallery
EX
EX Exhaust gallery
A
B
A Control valve block

B Relief valve
C Spring
N Neutral gallery
EX Exhaust gallery
Poppet opens
A service has been selected and the pressure
generated exceeds the setting of the relief valve.
Pressure acts on the periphery of the hollow poppet
which is forced downwards against the spring
releasing the pressure into the exhaust gallery.
30 - 183 9813/9100-1 30 - 183

06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-184 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-185 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 - 184 9813/9100-1 30 - 184

Operation Figure 1135. 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 1134. 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 1136. 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 - 185 9813/9100-1 30 - 185

Consumables
A
JCB Hydraulic Fluid OP 4002/2001 5L
46 4002/2005 20L
4002/2003 200L
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
1. Remove the valve assembly from the valve
block. E
2. Remove the O-ring 1 and O-ring 2 then remove

the thrust ring.
3. Use a rounded tool to remove the O-rings, that F
will not cause any damage to the seal grooves.
4. Discard all O-rings and back-up rings. Do not use A Load hold check valve assembly
worn or damaged items. B O-ring 1
C Thrust ring
5. If necessary, remove the load hold check valve D O-ring 2
assembly. Refer to (PIL 30-54-39). E Valve assembly
F Tamperproof cap
Install
steps.
1.1. Make sure the tamperproof 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. Refer to (PIL 30-00).

Item Description Nm
E Valve assembly 70
30 - 186 9813/9100-1 30 - 186

21 - Load Sense Relief Valve
21 - Load Sense Relief Valve Remove and Install

Remove
Do not remove or damage the tamperproof cap as
this may invalidate a warranty claim.
1. Follow all the hydraulic safety procedures. Refer

to (PIL 30-00).
block.
3. Remove the O-rings and the thrust ring. Make
sure you use a rounded tool that will not cause
any damage to the seal grooves. Discard all O-
rings and back-up rings. Do not use worn or
damaged items.
Figure 1138.
1 O-ring
2 Thrust ring
3 O-ring
4 Valve assembly
5 Tamperproof cap
Install
steps.
1.1. Make sure the tamperproof cap supplied
with the valve is installed.
1.2. Replace all O-rings and back-up rings.
1.3. Lubricate the parts with the correct clean
hydraulic fluid before installation.
1.4. Adjust the LSRV (Load Sense Relief Valve)
pressure setting as required.
30 - 187 9813/9100-1 30 - 187

21 - Load Sense Relief Valve
Table 510. Torque Data Disassemble and Assemble

Item Torque
4 45N·m The load sense relief valve is not serviceable.
Replace the complete valve with the correct valve if
it is defective.
30 - 188 9813/9100-1 30 - 188

24 - Flow Regulator
24 - Flow Regulator Check (Condition)

Check (Condition) ........................................ 30-189
Inspection
1. Examine the valve components for scratches,
pitting, corrosion or any other damage.
2. Clean the filter gauze installed in the end of the
valve body.
3. If any part other than the O-rings are damaged,
replace the entire valve.
Figure 1139.
A Filler gauze
30 - 189 9813/9100-1 30 - 189

24 - Flow Regulator
Disassemble and Assemble 2.2. Lubricate the parts with JCB hydraulic fluid
before you assemble them. Make sure that
Disassemble 2.3. Install new O-rings and back-up rings.
1. Loosen and remove the top plug. 2.4. Make sure to install the filter gauze in the
2. Carefully remove the shims, the spring and the
piston. Table 511. Torque Values
3. Remove the O-rings and the seals with the Item Description Nm
correct round tool. Make sure that no damage is F Valve body 20
caused to the seal grooves.
4. Discard all the O-rings and the back-up rings.
5. Do not use worn or damaged items.
Figure 1140.
A Top plug
B Shims
C Spring
D Piston
E Filter gauze
F Valve body
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. When assembling do the following steps also:
2.1. Clean the valve components in the correct
solvent.
30 - 190 9813/9100-1 30 - 190

53 - Servo System Control Valve Block
Contents Page No.
30-53-00 General ......................................................................................................................... 30-193

30-53-27 Pressure Compensator Valve ...................................................................................... 30-199
30 - 191 9813/9100-1 30 - 191

Notes:
30 - 192 9813/9100-1 30 - 192

00 - General
00 - General Diagram
Diagram ....................................................... 30-193
Fault-Finding ................................................ 30-194
(For: 540-v180 [T4F])
Your machine may be installed with a different valve
depending on the machines specification. Make sure
you know which valve is installed on your machine.
Figure 1141. 540-180 Valve Block (Husco SCX12-F20)

Na Nb Nc Nd Ne
E F
G
D 1A 1B 2A 2B 3A 3B 4A 4B 5A 5B 6A 6B H
V U
W
X
T
S
R Q P N M L K J
400/B3645-2
1A Ports 1B Ports
C Tank D Load sense drain
E Counterbalance pilot F Counterbalance pilot
G Sump H Pilot supply port
J Outlet section K Stabiliser LH spool
L Stabiliser RH spool M Auxiliary spool
N Tilt spool P Extend spool
Q Lift spool R Inlet section
S Pump inlet T Bypass compensator
U LSRV (Load Sense Relief Valve) V Tank
W Load sense X Pump gauge port
30 - 193 9813/9100-1 30 - 193

00 - General
Fault-Finding
(For: 533-105 [T4F])

Fault
All services lack power Table 512. Page 30-194
All services slow to operate Table 513. Page 30-195
The system pressure is too high Table 514. Page 30-195
A service stays selected Table 515. Page 30-195
System isolation not working Table 516. Page 30-196
All services inoperative Table 517. Page 30-196
Low flow from auxiliary service Table 518. Page 30-196
Lift arm operation is "Fierce" Table 519. Page 30-196
Servo operated spool services slow to operate or low auxiliary flow (The Table 520. Page 30-196
maximum auxiliary service flow available should be up to 95 L/min minimum
for 'manual' thumbwheel operation and up to 65 L/min with 'constant'
operation selected).
Table 512. All services lack power

Cause Remedy
Insufficient hydraulic fluid Check for leaks and top up as required.
LSRV (Load Sense Relief Valve) out of adjustment or Check and adjust as required.
defective
Internal leakage fault in the load sense circuit. Measure the load sense pressure.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
end section sticking open due to contamination.
Contamination in proportional solenoid valves or Dismantle and inspect valve block components.
mesh filters.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Machines with Variflow Pump: Insufficient output Check and adjust, or renew the LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS (Hydraulic Variable Control Solenoid sensor. Check condition of the associated electrical
Valve)) (if fitted) being permanently energised wiring for damage and short circuits.
and/or due to failure of the pump or internal tilting Install new pump and flush the hydraulic system to
swashplate mechanism because of contamination. remove all contamination.
Machines with Gear Pump: Low pump flow Check pump flow
Check for extra leaks, install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Electronic fault Use service master to determine the problem. Refer
to electrical system- electronic diagnostic, refer to
(PIL 33-57).
30 - 194 9813/9100-1 30 - 194

00 - General
Table 513. All services slow to operate

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as required.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
sticking open due to contamination.
Servo pilot pressure too low: Due to blocked Measure the servo pilot pressure and install new
servo pilot filter element and/or due to faulty servo servo pilot filter element.
regulating valve. Measure the servo pilot pressure and install new pilot
pressure supply valve.
Machines with Variflow Pump: Insufficient output Check and adjust, or install new LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS) (if fitted) being permanently sensor. Check condition of the associated electrical
energised and/or due to failure of the pump or wiring for damage and short circuits.
internal tilting swashplate mechanism because of Install new pump and flush the hydraulic system to
contamination. remove all the contamination.
Machines with GearPump: Low pump flow Check the pump flow.
Check for external leaks and install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Fault in electrical circuit wiring or joystick powerbase Check the condition of the associated electrical
ECU (Electronic Control Unit): Due to thumbwheel wiring for damage and that the fuses are intact.
switch defective/ solenoid at pilot pressure valve Then:
not energising/ solenoid coil faulty and/or faulty Check the function of the applicable thumbwheel
powerbase ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick powerbase ECU.
Table 514. The system pressure is too high

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Contamination in proportional solenoid valves, check Dismantle and inspect valve block components.
valve or mesh filters.
Table 515. A service stays selected

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Service spool or associated load hold check valves Dismantle and inspect the associated service spool
damaged or sticking due to contamination. or load hold check valves.
30 - 195 9813/9100-1 30 - 195

00 - General
Table 516. System isolation not working

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Blockage in unloader drain port. Clean port, replace inlet section if necessary.
Electronic fault Use service master to determine the problem. Refer
(PIL 33-57).
Table 517. All services inoperative

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Electronic fault. Use service master to determine the problem. Refer
(PIL 33-57).
Table 518. Low flow from auxiliary service

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 519. Lift arm operation is "Fierce"

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 520. Servo operated spool services slow to operate or low auxiliary flow (The maximum auxiliary
service flow available should be up to 95 L/min minimum for 'manual' thumbwheel operation and up
to 65 L/min with 'constant' operation selected).
Cause Remedy
Fault in the electrical circuit wiring, joystick controller Check the condition of the associated electrical
hydraulic control ECU. Due to defective thumbwheel wiring for damage and that the fuses are intact.
switch/ solenoid at the pilot pressure supply valve Then:
not energising/ faulty solenoid coil/ faulty joystick Check the function of the applicable thumbwheel
controller and/or faulty hydraulic control ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick controller.
Install new hydraulic control ECU.
Servo pilot pressure too low: Due to blocked servo Measure the servo pilot pressure and install new
pilot filter element/ faulty pilot pressure supply valve servo pilot filter element.
and/or due to proportional solenoid valve cartridge Measure the servo pilot pressure and install new pilot
damaged or sticking due to contamination. pressure supply valve.
Counterbalance valve not working correctly. Check operation of applicable counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of lift ram pressure sensor.
working correctly.
30 - 196 9813/9100-1 30 - 196

Introduction
30 - 197 9813/9100-1 30 - 197

Introduction
30 - 198 9813/9100-1 30 - 198

27 - Pressure Compensator Valve
27 - Pressure Compensator Valve
Operation
Pressure Compensation (Flowshare) When one or more services are selected, the
pressure compensator valve detects the service
Each service spool incorporates a pressure generating the highest pressure and allows the pump
compensator valve. When services are operated to deliver oil at sufficient pressure to move the load.
simultaneously the system ensures consistent The load hold check valve prevents the load falling
operating speed for all services, even when the limit back if the load pressure is greater than the pump
of the hydraulic pump performance is approached. pressure.
The oil from the main hydraulic pump arrives at The closed centre design ensures consistent service
the inlet gallery. When the relevant service spool operation regardless of load.
is selected, the spool moves against the force of
the centring spring. This allows the oil flow to move For information about service spool and pressure
the required service. When the service spool is de- compensator valve operation, refer to hydraulic
selected, the centring spring returns the spool to the system- lift arm control valve block, refer to (PIL
neutral position. 30-51).
Figure 1142.
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 - 199 9813/9100-1 30 - 199

36 - Load Hold Check Valve
36 - Load Hold Check Valve 1. The installation procedure is the opposite of the
steps.
1.1. Clean the valve components in an
Consumables applicable solvent.
Cleaner/Degreaser 4104/1557 0.4L purpose solvent based parts cleaner
- General purpose
solvent based parts 1.2. Lubricate the parts with hydraulic fluid
cleaner before assembly.
JCB Hydraulic Fluid HP 4002/0801 5L Consumable: JCB Hydraulic Fluid HP 46
46 4002/0805 20L 1.3. Make sure that all the parts move freely.
4002/0803 200L
Remove Item Description Nm
D Load hold check valve plug 15
3. Remove the valve block from the machine.
4. Remove the ARV (Auxiliary Relief Valve)
assembly.
5. Remove the LHCV (Load Hold Check Valve)
from the valve block section.
6. Remove the spring and the poppet.
Figure 1143.
B
D
A Valve block section

B Poppet
C Spring
D LHCV plug
Install
Examine the valve components for scratches, pitting,
corrosion or damage. Make sure the seating faces on
the poppets, and the mating faces in the valve block
are in good condition. Replace as necessary.
30 - 200 9813/9100-1 30 - 200

54 - Parallel Circuit Control Valve Block
Contents Page No.
30-54-00 General ......................................................................................................................... 30-203

30 - 201 9813/9100-1 30 - 201

Notes:
30 - 202 9813/9100-1 30 - 202

00 - General

Component Identification ............................. 30-203 For: Manual Lever (Parker) ..... Page 30-203
Operation ..................................................... 30-205 For: Electro Servo (Husco) ...... Page 30-204
Diagram ....................................................... 30-207
Fault-Finding ................................................ 30-208
Adjust .......................................................... 30-209
(For: Manual Lever (Parker))
Figure 1144.
D E
Item Description
E Main hydraulic supply
Table 522.
pump
Item Description F Hydraulic cooling fan
A Hydraulic tank motor pipework
B Steer return G Hydraulic cooling fan
C Control valve motor case drain line
D Fan supply pump
30 - 203 9813/9100-1 30 - 203

00 - General
(For: Electro Servo (Husco))
Figure 1145.
A
B
C D
K
L
F
A Hydraulic tank B Steer valve return

C Fan supply pump D Main hydraulic supply pump
E Control Valve F Accumulator
G Hydraulic fan motor case drain H Hydraulic fan motor return
J Filler pipe K To steer valve (Load sense line)
L To steer valve (Feed)
30 - 204 9813/9100-1 30 - 204

00 - General
Operation T To tank
X Service port 1
Y Service port 2
(For: Manual Lever (Parker)) Figure 1147. 6 Spool Control Valve Schematic
When the spools are actuated, the oil from the M N
pump passes into the service port 1 or service
port 2, operating the relevant hydraulic ram. See
the applicable hydraulic schematic for service port
connections. X F
The oil from the pump enters the control valve Y
through the inlet port, passing the adjustable MRV
(Main Relief Valve). As the spools 1 to 6 are in
neutral, the oil passes round their central waists. X E
The spool lands do not allow the oil to enter the
service ports. When the oil reaches the end housing, Y
it enters the exhaust gallery and is discharged back
to the tank. The control valve also incorporates ARV
(Auxiliary Relief Valve) 1, ARV 2, ARV 3 and ARV 4. X J H D
The unloader section isolates the stabilisers when Y
the solenoid is energised.
Figure 1146. Typical 6 Spool Control Valve X L K C

M N Y
X B
F Y X
Y
E Y X
D Y X
J H X A
C Y X Y
L K
B Y X
A Y X G
T P
A Spool 1
B Spool 2
C Spool 3
T
D Spool 4 P
E Spool 5
F Spool 6 A Spool 1
H ARV 1 B Spool 2
J ARV 2 C Spool 3
K ARV 3 D Spool 4
L ARV 4 E Spool 5
M Solenoid F Spool 6
N Unloader section G Adjustable MRV
P Inlet port H ARV 1
J ARV 2
K ARV 3I was contacting for 3
L ARV 4
30 - 205 9813/9100-1 30 - 205

00 - General
M Solenoid
N Unloader section
P Inlet port
T To tank
X Service port 1
Y Service port 2
30 - 206 9813/9100-1 30 - 206

00 - General
Diagram
(For: 540-v180 [T4F])
Figure 1148.
B A B A B A B A B A B A
C D E F G H 334/ F0681- 2
A Port A B Port B
C Lift spool D Extend spool
E Tilt spool F Auxiliary spool
G RH Stabiliser spool H LH Stabiliser spool
30 - 207 9813/9100-1 30 - 207

00 - General
Fault-Finding
Fault
Lack of power at all hydraulic functions Table 523. Page 30-208
All mechanically operated hydraulic services slow to operate Table 524. Page 30-208
All solenoid/servo operated hydraulic services slow to operate Table 525. Page 30-208
Is the machine experiencing boom extend or retract problems? Table 526. Page 30-208
Bleed air from the hydraulic cylinders - is it OK now? Table 527. Page 30-208
Table 523. 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 524. 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 525. 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 526. Is the machine experiencing boom extend or retract problems?

Cause Remedy
YES = Go to Table 5, NO = done
Table 527. Bleed air from the hydraulic cylinders - is it OK now?

Cause Remedy
YES = Done, NO = Go to Table 6
30 - 208 9813/9100-1 30 - 208

00 - General
Adjust 6. Check spool displacement 2.

6.1. Use the control lever to move and hold the
spool in the position.
(For: 533-105 [T4F])
6.2. Measure spool displacement 2.
Communications
Bad communications can cause accidents. Keep 7. Repeat the procedure for each manual spool as
people around you informed of what you will be necessary.
doing. If you will be working with other people,
make sure any hand signals that may be used are Table 528. Manual Spool Displacement
understood by everybody. Worksites can be noisy, do Displacement Measurement
not rely on spoken commands. A 7–9mm
Two people are required to complete the procedure. B 7–9mm
One person should sit in the operator cab, while the
other person requires access to the control valve Adjustment
assembly.
Spool displacement is influenced by the control lever
1. Make the machine safe with the lift arm raised. linkage. Check, adjust and replace if necessary. If
Refer to (PIL 01-03). sufficient adjustment can not be achieved it may be
necessary to replace the spool assembly
3. Follow the general health and safety procedure.
30-00).
5. Check the spool displacement 1.
Figure 1149.
A Spool displacement 1
B Spool displacement 2
5.1. Use the control lever to move and hold the
spool in the position.
5.2. Measure the spool displacement 1.
30 - 209 9813/9100-1 30 - 209

00 - General
Remove and Install
(For: Manual Lever (Parker)) 8. Plug all the open ports and hoses to prevent
contamination.
be removed or handled using a suitable lifting 9. Remove the stabiliser control lever knobs and the
method and device. gaiters from inside the cab.
10. Remove the securing clip and the pin.
Remove
11. Disconnect the control lever rod from the spool
1. Make the machine safe with the lift arm raised. end.
12. Repeat the step 10 and the step 11 again for the
2. Install the safety strut. Refer to (PIL 06-69). other control linkages.
3. Follow the general health and safety procedures. 13. Put a label on electrical connectors to help
Refer to (PIL 01-03). installation.
4. Discharge the hydraulic pressure. Refer to (PIL 14. Disconnect all the electrical connectors to the
30-00). valve block sensors.
5. Remove the cab side cover (if installed) to access 15. Support the valve block and remove the
the valve block. Refer to (PIL 06-06). mounting screws. Carefully lift the valve block
away from the bracket and clear of the machine.
6. Put a label on each hose to help installation.
7. Disconnect all the hydraulic hoses.
30 - 210 9813/9100-1 30 - 210

00 - General
Figure 1150.
A B
H
D
E
F
G
A
L
M
N
K
N
A
N J
A Mounting screws B Control lever knobs

C Control rod 1 D Securing clip
E Pin F Locknut 1
G Spool end H Electrical connectors
J Valve block K Bracket
L Locknut 2 M Control rod 2
N Control rod 3
30 - 211 9813/9100-1 30 - 211

00 - General
Install
steps.
1.1. After you install, check the operation of the
mechanical control rod 1 and control rod
3. Operate the control levers. Make sure
that the lever travel is the same in both
directions. To adjust the levers loosen the
locknut 1 or locknut 2 at each end of the
control rod 1 or control rod 2. Turn the
rod to increase or decrease the length as
necessary. Tighten the locknuts.
1.2. Operate the hydraulic system. Check for
correct operation and leaks.
1.4. After installation, check the ARV (Auxiliary
Relief Valve) and MRV (Main Relief Valve)
pressures. Refer to (PIL 30-00).
30 - 212 9813/9100-1 30 - 212

00 - General
(For: Manual Lever (Parker)) Make sure that components are assembled in their
original positions.
Consumables
Description Part No. Size Take care when you dismantle and assemble a valve.
JCB Hydraulic Fluid OP 4002/2001 5L Make sure to avoid the following:
46 4002/2005 20L
• Contamination.
4002/2003 200L • Damage to spools.
JCB Threadlocker 4101/0250 0.01L • Damage to seal grooves.
Strength) Any of the above may result in possible problems
with the operation of the valve.
The valve block is a sectional type, which is made up
of a number of separate sections. The illustration is Disassemble
intended as a guide to identifying the components.
Some valve components are omitted for illustration 1. Remove the valve block from the machine.
purposes.
2. Remove the tie rod nuts.
Be sure to note the location of all components
when dismantling. Although some components may 3. Carefully separate and remove the outlet section
appear to be identical they are not interchangeable. followed by the remaining service sections. If you
replace the inlet section, remove and retain the
tie rods.
Figure 1151.
L
A B R
C M
D
E T
M
F
G
H
J
K S
B
N
P 1
N
P
L N
M K
3 2
M
30 - 213 9813/9100-1 30 - 213

00 - General
A ARV (Auxiliary Relief Valve) B Outlet section

C LH stabiliser section D RH stabiliser section
E Auxiliary section F Extend section
G Tilt section H Lift section
J MRV (Main Relief Valve) K Inlet section
L Top nut M Nuts
N Seals P Service sections
R Top tie rod S Tie rods
T Top tie rod identification marker
30 - 214 9813/9100-1 30 - 214

00 - General
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
1.1. Make sure that the mating faces of the
valve sections are thoroughly clean before
assembly.
1.2. Renew the seals located between the valve
sections. Make sure the seals are not
trapped or damaged.
1.3. Lubricate parts with hydraulic fluid before
assembling. Make sure that all the parts
move freely.
1.4. If the tie rods were removed from the inlet
section, make sure that the tie rod with the
identification marker is used in the top hole
and that the marker is in the Inlet section.
1.5. Apply sealant to the threads of nuts. Tighten
the nuts to the correct torque value in the
sequence 1, 2, 3 and then 1 again.
(Medium Strength)

Item Description Nm
L Top nut 40
M Nuts 27
30 - 215 9813/9100-1 30 - 215

03 - Main Relief Valve (MRV) Introduction

Introduction .................................................. 30-216 Refer to (PIL 30-51-03).
30 - 216 9813/9100-1 30 - 216


(For: 533-105 [T4F]) removal procedure. Additionally do the following
steps.
The MRV (Main Relief Valve) is not serviceable.
1.1. Replace all the O-rings.
Replace the complete valve if it is defective.
1.2. Lubricate the parts with JCB hydraulic fluid
Remove before assembling.
1.3. Tighten the valve to the specified torque
value.
2. Discharge the hydraulic pressure. Refer to (PIL 1.4. Adjust the pressure setting as required.
30-00).
block. Item Description Nm
A Valve assembly 20
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 damages items.
Figure 1152.
A Valve assembly
30 - 217 9813/9100-1 30 - 217

06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-218 Refer to (PIL 30-51-06).
30 - 218 9813/9100-1 30 - 218

(For: 533-105 [T4F])

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) A
30-00).
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
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 - 219 9813/9100-1 30 - 219

39 - Load Hold Check Valve
39 - Load Hold Check Valve Figure 1154.
B
Remove and Install
Consumables
and Sealer (Medium 4101/0251 0.05L C
Strength)
Remove
working on it. Park the machine on level ground A
and lower the loader arm. Stop the engine and
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
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 - 220 9813/9100-1 30 - 220

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-223

30-60-12 Electro Proportional Control ......................................................................................... 30-225
30-60-15 Joystick ......................................................................................................................... 30-238
30-60-27 Auxiliary Circuit ............................................................................................................ 30-248
30-60-82 Sway ............................................................................................................................. 30-249
30-60-90 Flow Regulator ............................................................................................................. 30-257
30 - 221 9813/9100-1 30 - 221

Notes:
30 - 222 9813/9100-1 30 - 222

00 - General
00 - General
Introduction
Flow Control Valves Figure 1158.
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 1155.
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 1156. 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 1160.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 223 9813/9100-1 30 - 223

00 - General
Figure 1161. 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 - 224 9813/9100-1 30 - 224

12 - Electro Proportional Control
12 - Electro Proportional Control Operation

Operation ..................................................... 30-225
Diagram ....................................................... 30-237
(For: 540-170 [T4F], 550-170 [T4F])
Electronic Servo Proportional Control

A summary of the proportional control functions are
as follows:
• System enable and isolation

• Constant auxiliary selection
• Constant auxiliary flow setting
• Constant auxiliary changeover
• System isolation switches i.e. tilt lock
• Operation of the lift arm services- raise, lower,
extend, retract, crowd and dump.
The control lever and attached thumbwheels operate

the hydraulic services using electrical signals.
This type of lever has two functions, proportional

thumbwheel control and electro servo lever control.
The control lever moves in two axies and also

includes two thumbwheel switches. The control
lever and thumbwheel switches control eight electro
proportional solenoid valves which operate the four
service spools in the valve block.
In the control lever assembly is the joystick

controller ECU (Electronic Control Unit). The ECU
receives analogue electrical inputs in relation to the
movement of the lever or thumbwheel switches. The
ECU changes the analogue signals and broadcasts
messages on the machine CAN (Controller Area
Network)bus.
The hydraulic control ECU recognises the CAN

messages and generates the correct PWM (Pulse
Width Modulation) signal for operation of the control
valve proportional solenoids.
The proportional solenoid valves operate as

pressure reducing valves. These supply servo pilot
oil to move the auxiliary, or extend retract service
spool. The supply is at a pressure in relation to
the amount the operator moves the joystick or
thumbwheel switch.
30 - 225 9813/9100-1 30 - 225

Figure 1162.
B4 A4
A
B3 A3
B2 A2
B1 A1
LS
D T
CANBus
A Control lever B Joystick controller ECU

C Hydraulic control ECU D Control valve proportional solenoid
Joystick and controller When you move the control lever, an electrical
signal is produced proportional to the control lever
All of the machine hydraulic services are actuated movement. The controller ECU monitors these
electrically. CAN enabled electronic control units signals (inputs) and converts the voltage into a
and proportional solenoid valves are central to the corresponding CAN message (output) which is
system. broadcast on the machine CANbus.
30 - 226 9813/9100-1 30 - 226

Figure 1163.
G F
A H J
K L
E
4 1
3 2
1 2 3 4 5 6
12 11 10 9 8 7
A Main control lever handle B CAN joystick control ECU

C Electrical connector- Thumbwheels D Electrical connector- Joystick buttons
E Electrical connector- CAN joystick control ECU F Constant flow button
G Auxiliary II button H Axis 3- Thumbwheel
J Axis 4- Thumbwheel K Axis 1- Raise lower
L Axis 2- Carriage tilt M Electrical connector- CAN joystick control ECU
30 - 227 9813/9100-1 30 - 227

Proportional signal generation System enable and isolation

When the control lever is operated, the plunger The system will not enable unless the switch is
pushes against the return spring. A variable resistor latched. When the switch is not latched, its input
position sensor is allocated to each axis. The slider is sensed by the hydraulic control ECU. The ECU
moves up or down when the lever is moved, energises the pump shut off valve solenoid coil.
changing the electrical voltage depending on lever
position. The tilt isolation switch state is sensed by inputs
at the hydraulic control ECU. The ECU isolates the
The position sensors are integral with the joystick joystick control by switching off the PWM signals to
controller ECU. If a sensor is defective, replace the the control valve tilt spool proportional solenoids.
controller ECU.
The joystick isolation switch state is sensed by inputs
Figure 1164. at the hydraulic control ECU. The ECU isolates the
joystick controls by switching off the PWM signals to
the control valve proportional solenoids.
A Control lever
B Plunger
C Return spring
D Slider
30 - 228 9813/9100-1 30 - 228

Figure 1165.
A
E1
ECU
D
E2
IGN +VE
A Pump shut off valve solenoid B Tilt isolation switch

C Hydraulic stop watch D Joystick controls isolation switch
E1 Hydraulic control ECU- connector1 E2 Hydraulic control ECU- connector2
30 - 229 9813/9100-1 30 - 229

Second auxiliary changeover A CAN message causes the LMS (Loadall

Monitoring System) display AUX II indicator LED
When you press the momentary switch, a signal is (Light Emitting Diode) to come ON.
sent to the joystick controller ECU. It responds by
broadcasting a message on the machine CAN bus When you press the momentary switch again, the
through the joystick controller. The CAN message hydraulic control ECU responds by de-energising
is read by the hydraulic control ECUCAN bus the relay. Auxiliary changeover solenoid coil is de-
interface. The ECU responds by energising the energised and the oil is diverted to the Auxiliary I
second auxiliary relay. The auxiliary changeover circuit.
solenoid coil is energised and the oil is diverted to
the AUX II circuit. A CAN message causes the LMS display AUX II
indicator LED to go OFF.
Figure 1166.
E1
A CAN H
CAN L
CAN L
CAN H
ECU
ECU ECU
ECU
B
D
G
C
E2
IGN +VE
A CAN joystick control ECU B Joystick auxiliary changeover switch

C Joystick connector D CAN joystick control ECU
30 - 230 9813/9100-1 30 - 230

E1 Hydraulic control ECU- connector1 E2 Hydraulic control ECU- connecotr2

F Second auxiliary changeover switch G LMS display ECU- connector
H Secondary fuse J Second auxiliary relay
30 - 231 9813/9100-1 30 - 231

Front/rear auxiliary changeover When the operator switch is moved into the rear
auxiliary position, the solenoid diverter valve is de-
When the operator switch is moved into the front energised and it supplies oil to the rear auxiliary
auxiliary position, the solenoid diverter valve is circuits.
energised and it supplies oil to the lift arm auxiliary
quick release couplings.
Figure 1167.
IGN +VE
A Secondary fuse B Front/rear auxiliary changeover switch

C Front/rear auxiliary changeover solenoid
30 - 232 9813/9100-1 30 - 232

Constant auxiliary When the momentary switch is pressed, a signal is

sent to the joystick controller ECU. It responds by
The constant auxiliary switch state is sensed by broadcasting a message on the machine CANbus.
inputs at the hydraulic control ECU. When constant The CAN message is read by the hydraulic control
auxiliary is enabled by the operator, the hydraulic ECU. The ECU responds by holding the auxiliary
control ECU holds the auxiliary spool on a constant spool in the position set by the operator (thumbwheel
position by means of the PWM signals to the spool switch position). The selected spool position is also
proportional solenoids. stored by the ECU and is automatically selected
again when the operator selects the constant
A CAN message causes the LMS display constant auxiliary function again.
auxiliary indicator LED to come ON.
Figure 1168.
G1
B CAN H
CAN L
CAN L
CAN H
ECU
ECU
C
E
D
A
F
ECU
G2
IGN +VE
A Secondary fuse B CAN joystick control ECU

C Joystick constant auxiliary switch D Joystick controller
E CAN joystick control ECU F Constant auxiliary enable switch
G1 Hydraulic control ECU- connecotr1 G2 Hydraulic control ECU- connector2
30 - 233 9813/9100-1 30 - 233

Extend/retract and auxiliary services the position of the thumbwheel switch. The ECU
(Thumbwheel switches) responds by broadcasting thumbwheel position as a
message on the machine CANbus.
The ECU provides the thumbwheel switch- auxiliary
service and the thumbwheel switch- extend/retract The CAN message is read by the hydraulic
service with a 5V power supply. control ECUCANbus interface. The ECU responds
by producing a PWM signal in proportion to the
The thumbwheels send a voltage between 0.7V and thumbwheel position to the proportional solenoid
4.3V to the ECU. The voltage is determined by coils for operation of the service spools.
Figure 1169.
F1
A CAN H
CAN L
CAN L
CAN H
ECU
ECU
G H
D
F2 J K
E
IGN +VE
A CAN joystick control ECU B Thumbwheel switch- auxiliary service

C Thumbwheel- extend/retract service D Joystick controller
E Secondary fuse F1 Hydraulic control ECU- connector1
F2 Hydraulic control ECU- connector2 G Proportional control valve solenoid- retract
service
H Proportional control valve solenoid- extend J Proportional control valve solenoid- auxiliary B
service service
30 - 234 9813/9100-1 30 - 234

K Proportional control valve solenoid- auxiliary A

service
30 - 235 9813/9100-1 30 - 235

Lift/lower and tilt services The CAN message is read by the hydraulic control
ECU CANbus interface. The ECU responds by
The ECU responds to operation of the joystick by producing a PWM signal in proportion to the
broadcasting the joystick position as a message on joystick position to the proportional solenoid coils for
the machine CANbus. operation of the service spools.
Figure 1170.
C1
CAN H
ECU
CAN L
CAN L
CAN H
A
ECU
D E
C2 F G
IGN +ve
A CAN joystick control ECU B Secondary fuse

C1 Hydraulic control ECU- connector1 C2 Hydraulic control ECU- connecotr2
D Proportional control valve solenoid- dump E Proportional control valve solenoid- crowd
service service
F Proportional control valve solenoid- lift service G Proportional control valve solenoid- lower
service
30 - 236 9813/9100-1 30 - 236

Diagram
(For: 540-170 [T4F], 550-170 [T4F]) pressure flows to the proportional solenoid valves at
each service spool.
Oil from the hydraulic pump flows to the pilot
pressure control valve via internal filters. Oil at pilot
Figure 1171.
C C
D
TP1 TP2
B
ACC
P P1
T T1
P2
T2
A
B Pilot pressure control valve C Proportional solenoid valves

D Service spool
Table 533. Hydraulic Connection Colour Key

A Oil at servo pressure
30 - 237 9813/9100-1 30 - 237

15 - Joystick
15 - Joystick Introduction
Introduction .................................................. 30-238
Operation ..................................................... 30-240
(For: 540-170 [T4F], 550-140 [T4F],
550-170 [T4F])
Fault-Finding ................................................ 30-241
Remove and Install ..................................... 30-242 The lift arm and other hydraulic services are
Disassemble and Assemble ........................ 30-247 controlled by levers.
There are different types of control lever depending

on the machine model and variant.
Single Lever Controls (Electro

Proportional Control Hydraulics)
With single lever controls, a joystick with thumb
wheel switches is used to control the hydraulic
services.
Additional services can be controlled using manual

or electronic levers.
For details of operation. Refer to: PIL 30-60-12.
Figure 1172.
1
2
3

3 Drive direction selection switch
Servo Lever Controls

The servo lever controls are installed on machines
with oil pilot control.
The main control lever is a pilot valve which directs

pilot flow to the applicable services.
Also other manual control levers are used to control

auxiliary and stabiliser operations.
30 - 238 9813/9100-1 30 - 238

15 - Joystick
Figure 1173.
3
1
3

2 Stabiliser control levers
Electro Hydraulic Stabiliser Control

Some machines have electronic switches to control
the stabiliser operation. For details. Refer to: PIL
09-27-21.
30 - 239 9813/9100-1 30 - 239

15 - Joystick
Operation
For: 533-105 [T4F], 535-v125 [T4F], 540-140

[T4F], 540-200 [T4F] ............... Page 30-240
For: Manual Controls ............... Page 30-240
(For: 533-105 [T4F], 535-v125 [T4F],

540-140 [T4F], 540-200 [T4F])
For details of operation for Electro Proportional
Controls refer to (PIL 30-60-12).
(For: Manual Controls)
Figure 1174.
A
B
A Hydraulic control valve B Manual stabiliser control lever

C Manual control lever (Joystick) D Connecting rod
The levers are mechanically connected to the The stabiliser control levers are a direct connection
applicable spool on the hydraulic control valve. to the valve spool.
The manual control lever - joystick - is connected Movement of the lever moves the applicable valve
using rods. spool in the required direction enabling the hydraulic
service to operate.
30 - 240 9813/9100-1 30 - 240

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 - 241 9813/9100-1 30 - 241

15 - Joystick
Remove and Install
For: 533-105 [T4F], 535-v125 [T4F], 540-140 Figure 1175.

[T4F], 540-200 [T4F], 540-v140 [T4F]
................................................. Page 30-242 A
For: Manual Controls ............... Page 30-244
B
(For: 533-105 [T4F], 535-v125 [T4F],
540-140 [T4F], 540-200 [T4F], 540-v140
[T4F])
Remove and Install (P1) C

J
Remove
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.
H
2. Release the hydraulic pressure. Refer to (PIL
30-00).
3. Prise the screw cover from the armrest. D
4. Remove the screws 3 and washers.

5. Lift away the arm rest and the trim assembly.
6. Remove the screws 1. E
7. Remove the gaiter collar.
G
8. Remove the screws 2 and lift the control
lever and power base assembly to access the
electrical connectors. F
9. Put label on the electrical connectors for correct A Arm rest

installation. B Screw cover
10. Disconnect the electrical connectors. C Trim assembly
D Control lever
11. Remove the control lever from the housing. E Screws 1
F Housing
G Screws 2
H Gaiter collar
J Screws 3
Install
removal procedure.
Remove and Install (P2)

Remove
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.
30 - 242 9813/9100-1 30 - 242

15 - Joystick
2. Release the hydraulic pressure. Refer to (PIL Figure 1176.

30-00).
3. Prise the screw cover from the armrest.
4. Remove the screws and washers 1.
B
5. Lift away the arm rest. C
6. Remove the rear screws and washers 2. C

A
7. Remove front screws and washers 3.
8. Remove the gaiter collar. E
9. Remove the pod top cover until you can access
the switch electrical connectors.
10. Put label on the electrical connectors for correct G
installation. M
11. Disconnect the switch connectors.

M H H
12. Disconnect the electrical connector 1, electrical
connector 2 and the electrical connector 3.
13. Remove the control lever from the pod.
14. Remove the screws 4.
15. Remove the control lever and the power base F
assembly.
D D J K L
A Arm rest
B Screws and washers 1
C Screws and washers 2
D Screws and washers 3
E Gaiter collar
F Power base
G Top cover
H Switch electrical connectors
J Electrical connector 1
K Electrical connector 2
L Electrical connector 3
M Screws 4
Install
removal procedure.
30 - 243 9813/9100-1 30 - 243

15 - Joystick
(For: Manual Controls) 5. Remove the cab side cover (if installed) to access
the valve block. Refer to (PIL 06-06).
Remove 6. Remove the stabiliser control lever knobs and the
gaiters from inside the cab.
Refer to (PIL 01-03). 7. Remove the securing clip and the pin.
2. Install the safety strut. Refer to (PIL 06-69). 8. Disconnect the control lever rod from the spool
end.
Refer to (PIL 01-03). 9. Repeat the step 7 and the step 8 again for the
other control linkages.
30-00).
Figure 1177.
A B
H
D
E
F
G
A
L
M
N
K
N
A
N J
30 - 244 9813/9100-1 30 - 244

15 - Joystick
A Mounting screws B Control lever knobs

C Control rod 1 D Securing clip
E Pin F Locknut 1
G Spool end H Electrical connectors
J Valve block K Bracket
L Locknut 2 M Control rod 2
N Control rod 3
30 - 245 9813/9100-1 30 - 245

15 - Joystick
Install
steps.
1.1. After you install, check the operation of the
mechanical control rod 1 and control rod
3. Operate the control levers. Make sure
that the lever travel is the same in both
directions. To adjust the levers loosen the
locknut 1 or locknut 2 at each end of the
control rod 1 or control rod 2. Turn the
rod to increase or decrease the length as
necessary. Tighten the locknuts.
1.2. Check the lever and spool adjustment -
refer to Adjustment PIL (30-54-00)
1.3. Operate the hydraulic system. Check for
correct operation and leaks.
30 - 246 9813/9100-1 30 - 246

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 - 247 9813/9100-1 30 - 247

27 - Auxiliary Circuit
27 - Auxiliary Circuit
Discharge and Pressurise
Refer to discharge and pressurise, (PIL 30-00).
30 - 248 9813/9100-1 30 - 248

82 - Sway
82 - Sway Component Identification

Operation (Hydraulic) .................................. 30-251
(For: 540-170 [T4F])
Remove and Install ..................................... 30-253 Figure 1178. Sway Valve Location
A
A Bevel gearbox (for reference)

B Sway valve
C Location of tank connections
30 - 249 9813/9100-1 30 - 249

82 - Sway
Figure 1179. Sway Valve

D E G
F
H
332/H5331-1-1
F
D Port SB E Port SA
F Port F G Port G
H Port P
30 - 250 9813/9100-1 30 - 250

82 - Sway
Operation (Hydraulic)
(For: 540-170 [T4F]) Figure 1181. Right Sway Switch Operated
The schematic diagrams show an overview of the

system. For machine specific schematics, refer to
B
The engine cooling fan hydraulic oil supply is also
used to operate the sway system when installed.
When the sway system is operated, the supply to the
engine cooling fan is diverted to the sway system.
The hydraulic fan does not operate while the sway C
system is in use. The sway ram will stay in position
until the switch is operated.
Later machines have a pressure relief valve installed.

For details of the valve pressures, refer to the A
Operation of the switch energises the sway/fan

selection solenoid and the sway direction control
solenoid in the sway/fan changeover valve. The
sway/fan selection solenoid diverts the fan hydraulic
supply to feed the sway system. The sway direction T F P
control solenoid is a double acting solenoid which D
controls the direction of the supply to the correct side
of the sway ram.
Figure 1182. Left Sway Switch Operated
A proximity switch located on the lift arm operates
when the lift arm is at an angle of 10° or higher.
The proximity switch prevents the sway relay from
energising and operating the sway system solenoid
until the lift arm is lowered.
Figure 1180. Sway Switch Not Operated

C
B
B
A T F P D
T F P
D
30 - 251 9813/9100-1 30 - 251

82 - Sway
Table 534.
A Sway/Fan selection solenoid
B Sway direction control solenoid
C Sway ram
D Pressure relief valve
F Fan hydraulic supply
P Pump hydraulic supply
T Tank return
30 - 252 9813/9100-1 30 - 252

82 - Sway
Remove and Install
For: 535-v125 [T4F] ................ Page 30-253 Figure 1183.

For: 540-140 [T4F], 540-170 [T4F]
................................................. Page 30-254
For: 540-170 [T4F] .................. Page 30-256 A
(For: 535-v125 [T4F]) B

WARNING A raised and badly supported C
machine can fall on you. Position the machine
Ensure the other end is securely chocked. Do
to support the machine when working under it.
Disconnect the battery, to prevent the machine
Remove D

4. Put labels on the hydraulic hoses to help
installation.
E E
5. Disconnect the hydraulic hoses.
A Bracket
6. Plug all the open ports and hoses to prevent B Sway/fan selector solenoid
contamination. C Sway direction control solenoids
D Sway/fan valve
7. Disconnect the electrical connector from the E Bolts
stabiliser sway/fan selector solenoid.
Figure 1184. Typical Sway Valve Harness
sway direction control solenoids.
9. Make a note of the route of the harness. F
10. Remove the harness retaining clips.
11. Support the sway/fan valve.
12. Release the bolts and remove the sway/fan valve
from the bracket.
F Harness retaining clips

G Harness
30 - 253 9813/9100-1 30 - 253

82 - Sway
Install
Remove
removal procedure. Additionally do the following 1. Make the machine safe with the lift arm raised.
steps. Refer to (PIL 01-03).
1.1. Discard the old seals and install new seals 2. Install the safety strut. Refer to (PIL 06-69).
and O-rings. When you install adaptors, do
not overtighten as this distorts the body and 3. Discharge the hydraulic pressure. Refer to (PIL
the valve may fail to operate correctly. 30-00).
1.2. Reconnect the hoses in the correct 4. Follow the hydraulic care and safety procedures.
positions as labelled during removal. Refer to (PIL 30-00).
1.3. Make sure to route the harness correctly 5. Put labels on the hydraulic hoses to help
and replace the retaining clips. installation.
1.4. Reconnect the electrical harness.
1.5. After installation, check that the valve
operates correctly and there are no 7. Plug all the open ports and hoses to prevent
hydraulic leaks. contamination.
(For: 540-140 [T4F], 540-170 [T4F]) stabiliser sway/fan selector solenoid.
WARNING A raised and badly supported
machine can fall on you. Position the machine 9. Disconnect the electrical connectors from the
on a firm, level surface before raising one end. sway direction control solenoids.
Ensure the other end is securely chocked. Do 10. Support the sway/fan valve.
to support the machine when working under it. 11. Release the bolts and remove the sway/fan valve
Disconnect the battery, to prevent the machine from the bracket.
30 - 254 9813/9100-1 30 - 254

82 - Sway
Figure 1185.
E A
B D
A Bracket B Sway/Fan selector solenoid

C Sway direction control solenoids D Sway/Fan Valve
E Bolts
30 - 255 9813/9100-1 30 - 255

82 - Sway
Install 1.4. After installation, check that the valve

operates correctly and there are no
1. The installation procedure is the opposite of the hydraulic leaks.
steps.
1.1. Discard the old seals and install new seals
not over-tighten as this distorts the body
and the valve may fail to operate correctly.
1.2. Reconnect the hoses in the correct
positions as labelled during removal.
1.4. After installation, check that the valve
operates correctly and there are no
hydraulic leaks.
(For: 540-170 [T4F])

Refer to component identification, (PIL 30-60-82).
Remove
30-00).
3. Follow the hydraulic care and safety procedures.
4. Put labels on the hydraulic hoses to help
installation.
contamination.
solenoids.
8. Support the valve.
9. Release the bolts and remove the valve from the
bracket.
Install
steps.
1.1. Discard the old seals and install new seals
not over-tighten as this distorts the body
and the valve may fail to operate correctly.
1.2. Reconnect the hoses in the correct
positions as labelled during removal.
30 - 256 9813/9100-1 30 - 256

90 - Flow Regulator
90 - Flow Regulator
Introduction
30 - 257 9813/9100-1 30 - 257

61 - Counterbalance Valve
Contents Page No.
30-61-00 General ......................................................................................................................... 30-259

30-61-06 Lift Arm ......................................................................................................................... 30-264
30-61-07 Lift Extension ................................................................................................................ 30-267
30 - 258 9813/9100-1 30 - 258

00 - General
Introduction .................................................. 30-259
Operation ..................................................... 30-260
(For: 533-105 [T4F], 535-v125 [T4F],
540-140 [T4F], 540-200 [T4F], 550-140
[T4F], 550-170 [T4F])
Operation overview
The lift, extend and tilt ram circuits include a
counterbalance valve.
When there is a load on the carriage, the weight of

the load could cause the lift arm to lower or dump.
This would be dangerous as the load could lower
suddenly or fall off the carriage.
To prevent this, counterbalance valves are installed

to make sure that only the pressure of flow from
the control valve spool will move the lift arm or the
carriage and the weight will not affect it. Therefore
when the lift/lower or crowd/dump services are not
operated, the valve is closed effectively locking the
ram in position regardless of the load.
30 - 259 9813/9100-1 30 - 259

00 - General
Operation
(For: 533-105 [T4F]) To prevent this, counterbalance valves are installed

to make sure that, only the pressure of flow from the
The extend and tilt ram circuits have a control valve spool will move the lift arm or carriage
counterbalance valve. and the weight will not affect it. Therefore when the
lift/lower or crowd/dump services are not operated,
When there is a load on the carriage, the weight of the valve is closed effectively locking the ram in
the load could cause the lift arm to lower or dump. position regardless of load.
This would be dangerous as the load may lower
suddenly or fall off the carriage.
Component Location
Figure 1186.
A Extend ram counterbalance valve B Tilt ram counterbalance valve
30 - 260 9813/9100-1 30 - 260

00 - General
Hydraulic Operation and Schematics to hydraulic system- general, schematic circuit, refer
to (PIL 30-00-50).
Valve schematic
The schematic diagrams show a typical system. For
information about machine specific schematics, refer
Figure 1187. Typical Valve Schematics
A B
A Extend counterbalance valve B Tilt counterbalance valve
30 - 261 9813/9100-1 30 - 261

00 - General
System schematic ram. The counterbalance valve housing contains two

valves to prevent the compression of the ram due to
The schematic diagrams show a typical system. For the pressure in the ram returning to tank. The check
information about machine specific schematics, refer valve only allows flow when the piston end service
to hydraulic system- general, schematic circuit, refer is operated. The pressure valve will only open and
to (PIL 30-00-50). allow a return to tank when there is pressure in the
+ line feeding the piston side of the ram. If there is
The figure shows no hydraulic service operated. no pressure in this line the pressure valve will remain
Refer to Figure 1188. There is a load on the carriage closed and the ram is locked in position.
and the weight of this load is tries to compress the
Figure 1188.
D
A
B
_
C
In this figure, the rod side service spool in the control pressure valve opens and allows the pressure from
valve is operated. Refer to Figure 1189. Pressure is the piston side of the ram to return to tank. The check
supplied to retract the ram. When the pressure in the valve remains closed.
+ line is greater than the pressure from the spring, the
Figure 1189.
D
A
C1 B
_
In this figure, the piston side service spool in the valve opens to supply the ram. The pressure valve
control valve is operated. Refer to Figure 1190. remains closed.
Pressure is supplied to extend the ram. The check
30 - 262 9813/9100-1 30 - 262

00 - General
Figure 1190.
D
A
B
+
C
Electrical Operation
There are no electrical devices used in this system.
30 - 263 9813/9100-1 30 - 263

06 - Lift Arm
06 - Lift Arm
Operation
(For: 533-105 [T4F]) If the pressure in the circuit is less than 10bar
(144.9psi) and the crowd and lift service operate at
The counter balance valve is used to hold the lift the same time, the hydraulic ECU (Electronic Control
arm in position and for it not to lower under its own Unit) deselects the crowd service. This allows the
weight. Refer to hydraulic system- counterbalance pressure to increase in the lift ram circuit.
valve, refer to (PIL 30-61).
When the pressure in the circuit raises to more than
When you operate the crowd and lift arm raise 20bar (289.9psi) the hydraulic ECU responds by
hydraulic services, there are rare occasions when restoring normal operation of the crowd service.
the flow may divert through the displacement ram
circuit and cause the lift arm to raise under the power On machines with SRS (Smooth Ride System), the
of the displacement ram. SRS pressure transducer is used. For information
about the SRS system, refer to hydraulic system-
Pressure monitoring of the lift ram full bore (rod general, refer to (PIL 30-00).
end) maintains a minimum pressure ensuring correct
operation of the lift arm service. A pressure On machines without the SRS, a pressure transducer
transducer is installed in the full bore (rod end) side is installed.
of the lift arm circuit.
30 - 264 9813/9100-1 30 - 264

06 - Lift Arm
Component Location
Figure 1191.
A Pressure transducer B Lift ram
30 - 265 9813/9100-1 30 - 265

06 - Lift Arm
Electrical Operation For machines with SD, SE and SF engines, refer to

hydraulic system- cylinder ram, refer to (PIL 30-15).
On machines with SRS, the SRS pressure
transducer is used. For information about the SRS For machines with SH, SL and DH engines, refer to
system, refer to hydraulic system- general, refer to hydraulic system- cylinder ram, refer to (PIL 30-15).
(PIL 30-00).
Figure 1192.
1 4 4 1
2 3 3 2
30 - 266 9813/9100-1 30 - 266

07 - Lift Extension
07 - Lift Extension
Operation
(For: 540-170 [T4F], 550-170 [T4F]) The counterbalance valves are used to prevent
unwanted/ unexpected boom movement due to
The extend ram circuits include a counterbalance imbalance of pressures acting upon the ram.
valve.
Figure 1193.
A Inner extend ram counterbalance valve B Outer extend ram counterbalance valve
30 - 267 9813/9100-1 30 - 267

07 - Lift Extension
Figure 1194. Valve schematic
A B
A Inner extend ram counterbalance valve B Outer extend ram counterbalance valve
Personnel platform machines have electrical devices

installed on the outer extend ram. There are no
electrical devices installed on non personnel platform
machines.
30 - 268 9813/9100-1 30 - 268

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-271
30 - 269 9813/9100-1 30 - 269

Notes:
30 - 270 9813/9100-1 30 - 270

00 - General
Introduction .................................................. 30-271 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-272 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 271 9813/9100-1 30 - 271

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.
the ignition key. Disconnect the battery when you
are not using electrical power. If you do not take 5. Run the engine at mid speed and operate the
these precautions you could be killed or injured. control lever to tilt the carriage forward. While the
carriage is moving, switch off the engine.
Check each movement in turn. 5.1. The carriage movement must slow as the
engine slows. The carriage movement must
Lift arm lift cylinders stop when the engine stops.
1. Start the engine. 5.2. If the carriage moves after the engine stops,
then the HBCV is faulty. Do not use the
2. Make sure to engage the park brake and put the machine until you correct the fault.
transmission to neutral.
Stabiliser cylinder (if installed)
3. Raise the lift arm to the specified angle.
Angle: 45° 1. Start the engine.
4. Run the engine at mid speed and operate the 2. Make sure to engage the park brake and put the
control lever to lower the lift arm. While the lift transmission to neutral.
arm is moving, switch off the engine. 3. Lower the stabilisers.
4.1. The lift arm movement must slow as the 4. Make sure that the stabiliser legs are in the down
engine slows. The lift arm movement must position and supports the machine weight. Make
stop when the engine stops. sure that the front wheels are lifted from the
4.2. If the lift arm moves after the engine stops, ground.
then both the lift arm HBCV (Hose Burst
Check Valve) are faulty. Do not use the 5. Stop the machine.
machine until you correct the fault.
6. Operate the stabiliser controls.
Lift arm extension cylinder 7. Make sure that the front wheels of the machine
do not lower to the ground.
7.1. If the machine moves when the stabiliser
2. Make sure to engage the park brake and put the controls are operated after the engine is
transmission to neutral. stopped, the HBCV are faulty. Do not use
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 - 272 9813/9100-1 30 - 272

00 - General
Figure 1195.
X Gap between the wheel and the ground
Sway cylinder (if installed)

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 - 273 9813/9100-1 30 - 273

70 - Pilot Pressure Supply Valve
Contents Page No.
30-70-00 General ......................................................................................................................... 30-275
30 - 274 9813/9100-1 30 - 274

00 - General
00 - General
Check (Pressure)
(For: 533-105 [T4F]) 1. Turn the ignition key switch to on, but do not start
the engine.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 2. Discharge the hydraulic pressure from the
Before connecting or removing any hydraulic hose, system. Refer to (PIL 30-00).
residual hydraulic pressure trapped in the service 3. Separate the hose from the filter and install tee-
hose line must be vented. Make sure the hose piece between the them.
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
Figure 1196.
A Hose B Filter
C Tee-piece D Pressure gauge
30 - 275 9813/9100-1 30 - 275

00 - General
4. Connect a pressure gauge of the specified value

to the tee-piece.
up to the specified working temperature.
6. Gradually increase the engine speed to 2200
RPM (Revolutions Per Minute). while you check
the maximum gauge reading, it should be as
stated on specification.
7. Make sure that the pressure does not fall below
the lower limit at engine idle speed.
Clean the valve

The servo pilot pressure reducing valve is not
adjustable. The valve cartridge is not serviceable
beyond cleaning. A cartridge should be renewed
complete if wear or damage is visible.
30 - 276 9813/9100-1 30 - 276

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-279

30-93-03 Lift Arm ......................................................................................................................... 30-292
30 - 277 9813/9100-1 30 - 277

Notes:
30 - 278 9813/9100-1 30 - 278

93 - Hose
00 - General
Introduction .................................................. 30-279 Hydraulic hoses are used to connect different
Component Identification ............................. 30-280 components in the hydraulic circuit. The hoses
Disconnect and Connect ............................. 30-290 are graded by pressure, temperature, and fluid
Check (Condition) ........................................ 30-291 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 - 279 9813/9100-1 30 - 279

93 - Hose
00 - General
(For: 540-170 [T4F], Electro Hydraulic)

Figure 1197. .........................................................................................................................Page 30-281
Figure 1198. .........................................................................................................................Page 30-285
30 - 280 9813/9100-1 30 - 280

93 - Hose
00 - General
Page 30-282 Figure 1197. Page 30-283
S
Y
B
L M
C T
D
E U
F V
A V
W
P
F X
G Q
H
J
K R
Y
B
334-C6688-6_SHEET 1
30 - 281 9813/9100-1 30 - 281

93 - Hose
00 - General
Page Page
30-282 30-283
B
L M
C
D
E
F
Page 30-283
N
P
F
G Q
H
J
K R
B
30 - 282 9813/9100-1 30 - 282

93 - Hose
00 - General
Page Page
30-282 30-283
S
Y
T
U
V
Page 30-282
V
W
Q X
R
Y
334-C6688-6_SHEET 1
30 - 283 9813/9100-1 30 - 283

93 - Hose
00 - General
30 - 284 9813/9100-1 30 - 284

93 - Hose
00 - General
Page 30-286 Figure 1198. Page 30-287
C T
D
E U
F V
R Q
V
W
F
G X
H
J
K
334-C6688-6_SHEET 2
30 - 285 9813/9100-1 30 - 285

93 - Hose
00 - General
Page Page
30-286 30-287
C
D
E
F
R Q
Page 30-287
F
G
H
J
K
30 - 286 9813/9100-1 30 - 286

93 - Hose
00 - General
Page Page
30-286 30-287
T
U
V
Page 30-286
V
W
334-C6688-6_SHEET 2
30 - 287 9813/9100-1 30 - 287

93 - Hose
00 - General
Figure 1199.
334-C6688-6_SHEET 3
Table 535. 16 Hose 5/8BSP 425mm

17 Hose 3/8BSP 790mm
1 GA Ram lift 160 X 90
2 GA displacement ram
532 90x50 740 C/C 19 Hose 1/4BSP 610mm
3 Solenoid selector valve 20 Hose -06 BSP HP
1750mm A
4 WA cross yoke P55
5 WA cross yoke top layer
6 Adaptor
3/8BSPX3/8BSPX3/8 25 Hose -10 BSP HP
690mm B
7 Tee adaptor M/F/F
31 Bolt M8 x 45 G8.8
32 M8 LOCK NUT
9 Adaptor G1/4A- 7/16
SAE 33 Washer 5/16" med Plain
10 Adaptor G5/8A x 3/4 34 Plain washer M8
SAE 35 Bolt M8 x 50 G8.8
11 Adaptor extended 38 Bolt M8 x 90 G8.8
12 Hose 5/8BSP 875mm 39 Set screw M8 x 25 G8.8
13 Hose 5/8BSP 425mm 41 Hose 5/8BSP 760mm
15 Hose -10 BSP HP 42 Hose 1/4BSP 350mm
610mm A
30 - 288 9813/9100-1 30 - 288

93 - Hose
00 - General

45 5/8 BSP cap
46 Hose- See 477/79900
47 Grease pipe
48 Aluminium washer
49 Straight connector
50 90 Adaptor M-F1/8BSP
51 Battery plate adaptor
52 Cable tie
54 Clamp plate
55 Pipe clamp
56 Blanking cap
A Lift ram
B Displacement ram
C Tilt rod
D Inner extension rod 1
E Outer extension rod 1
F Aux
G Inner extension head 1
H Tilt head
J Outer extension head
remote
K Outer extension head
main
L Inner extension rod 2
M Outer extension rod 2
N Lift head
P Lift rod
Q Inner extension head 2
R Outer extension head
S Diverter valve
T Tilt
U Auxiliary
V Extension
W Lift
X Servo remote valve
Y Lift arm hydraulics
30 - 289 9813/9100-1 30 - 289

93 - Hose
00 - General
Disconnect and Connect Figure 1202.
Some attachments are hydraulically powered. The

following procedures show how to connect and
disconnect the hydraulic hoses safely.
Connecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Check the hoses and adaptors for damage. 5. Check for leaks:
4. Connect the hoses: 5.1. Start the machine.
4.1. Make sure that the hose is not twisted. 5.2. Operate the related controls to increase the
Pressure applied to a twisted hose can pressure in the hydraulic system.
cause the hose to fail or the connections to 5.3. Stop the machine then remove the key.
loosen.
5.4. Check for indications of leakage at the hose
Figure 1200. connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Disconnect the hoses.
4.2. Make sure that the hose does not touch 4. Check the hoses and adaptors for damage.
hot parts. High ambient temperatures can
cause the hose to fail. 5. If necessary, install the blanking caps.
4.3. Make sure that the hose does not touch 6. Check for leaks:
parts which can rub or cause abrasion.
6.1. Start the machine.
4.4. Use the hose clamps (where possible) to
support long hose runs and keep the hoses 6.2. Operate the related controls to increase the
away from moving parts, etc. pressure in the hydraulic system.
Figure 1201. 6.3. Stop the machine then remove the key.
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.
30 - 290 9813/9100-1 30 - 290

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.
close to suspected leaks and then examine the
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 - 291 9813/9100-1 30 - 291

93 - Hose
03 - Lift Arm
03 - Lift Arm Technical Data

Technical Data ............................................. 30-292 Refer to hydraulic system, hose, lift arm, component
Component Identification ............................. 30-293 identification (PIL 30-93-03).
30 - 292 9813/9100-1 30 - 292

93 - Hose
03 - Lift Arm
(For: 540-v180 [T4F])
Figure 1203. 540-180 Lift Arm Pipes

A G
B
E
H
C
D
A RH side- partial view B Bottom side- partial view

C Bolt and washer D Setscrew and washer
E Inner lift arm hydraulics sub assembly F Pipes- under lift arm
G Ext ram pipe H Hoses- liftend
K Pipes- under lift arm L Bolt, locknut and washer
M Setscrew and washer
30 - 293 9813/9100-1 30 - 293

93 - Hose
03 - Lift Arm
Remove and Install
For: 540-200 [T4F] .................. Page 30-294 WARNING Nyloc type adjustment nuts and split
For: 540-v180 [T4F] ................ Page 30-310 pins must not be re-used. Always install the
correct new ones.
(For: 540-200 [T4F])
There are three sets of lift arm hoses:
Special Tools
Description Part No. Qty. • The inner lift arm hoses
Quick Connect Hose 825/10053 1 • The intermediate lift arm hoses and supporting
Release Tool track
• The outer lift arm hoses and supporting track
Consumables
JCB Chain Lubricant 4004/0237A 0.3L
Figure 1204.
C B
A Inner lift arm hoses B Intermediate lift arm hoses and track
C Outer lift arm hoses and track
Before Removal
1. To aid replacement- make sure you measure and
record the distances:
1.1. X- The distance between the chain anchor
thread and the nut on the extend chains
1.2. Y- The distance between the chain anchor
thread and the nut on the retract chains.
30 - 294 9813/9100-1 30 - 294

93 - Hose
03 - Lift Arm
Figure 1205. Outer Hose Track and Hoses

1
X
Remove
2. Fully retract the lift arm and lower it until it is
2 horizontal.
30-00).
4. Remove the fork carriage. Refer to (PIL
03-33-03).
Y 3
4 5. Open the lift arm rear cover.
1 Extend chain- anchor nut 6. Remove the extension ram. Refer to (PIL
2 Extend chain- anchor thread 30-15-07).
3 Retract chain- anchor thread
4 Retract chain- anchor nut 7. Disconnect the hydraulic hoses.
Figure 1206.
C
B
A A
A
A Hydraulic hoses B Female quick release connector

C Hose release tool D Male quick release connector
7.1. Put a label on the hoses to help installation. 7.3. Using the hose release tool, carefully prise
the male connector out from the female
connector on the hydraulic hose quick
contamination.
release connectors.
30 - 295 9813/9100-1 30 - 295

93 - Hose
03 - Lift Arm
Special Tool: Quick Connect Hose Release 9.1. Disconnect the hoses at the pipe
Tool (Qty.: 1) connections.
8. Remove the wear pads. Refer to (PIL 06-12-30). 9.2. Remove the complete hose and track
assembly by sliding out from the rear of the
9. The outer lift arm hoses and track can now be lift arm.
removed:
Figure 1207.
C B
A Hose and track assembly B Pipe connections

C Hoses
Install 4.1. Make sure both hose ends are clean and
free from damage.
Correct functioning of the assembled lift arm
4.2. Push the male hose end into the female
depends on careful and accurate assembly of its
pipe end until the seal is compressed.
components. Misalignment of pipework and / or
hoses will result in malfunction of the lift arm and 4.3. If the hose is correctly installed the hose
damage to the hoses and/or lift arm structure. should rotate and be free to move forwards
and backwards whilst being retained in the
1. The installation procedure is the opposite of the female housing.
steps. 4.4. If the hose pulls out of the female connector
- disconnect hose and reconnect.
2. Check the hose condition, make sure the hoses
are not warped, split, stretched or damaged.
Check the hose length.
Figure 1208.
A Less than 1mm

3. Keep chains clean, do not let them drag on the
ground when installing.
4. When connecting the inner quick release hoses
follow this procedure:
30 - 296 9813/9100-1 30 - 296

93 - Hose
03 - Lift Arm
Figure 1209. 4.5. When attaching the chain assemblies

adjust the anchor points to
the measurements recorded before
disconnection.
Figure 1210.
A B C 1
X
Y 3
D 4
1 Extend chain - anchor nut
2 Extend chain - anchor thread
3 Retract chain - anchor thread
4 Retract chain - anchor nut
4.6. Make sure to phase hoses and pipes
correctly.
4.7. Make sure that the tracks are free to move
on the rollers / guides (where installed).
4.8. Refer to the Chain Maintenance procedures
to make sure that the lift arm chains are
A Female connector correctly set up. If the chains are replaced
B Seal using the measurements recorded before
C Male connector removal then the “Initial Setup” procedure
D Hose correctly installed can be ignored. Refer to (PIL 06-12-66)
4.10. Check the lift arm wear pad clearances.
30 - 297 9813/9100-1 30 - 297

93 - Hose
03 - Lift Arm

4.12. Check the operation of all the hydraulic
services.
Intermediate Hose Track and Hoses

The lift arm has 5 sections. To replace the
intermediate track and hydraulic hoses the inner lift
arm, 3rd intermediate and 2nd intermediate lift arm
sections are removed from the machine. The 1st
intermediate and outer lift arm sections will remain
on the machine.
Figure 1211.
A B
A Inner, 3rd intermediate and 2nd intermediate lift

arm sections
B 1st intermediate and outer lift arm sections
Remove
30-00).
3. Remove the outer hose track and hoses.
4. Disconnect the largest retract chain.
30 - 298 9813/9100-1 30 - 298

93 - Hose
03 - Lift Arm
Figure 1212.
B
C
A D B
A Roller bracket B Pivot pin

C Chain end D Split pin
E Retract chain
4.1. Remove the split pin. 4.3. Pull the chain end away from the roller
bracket.
4.2. Remove the pivot pin.
5. Disconnect the largest extend chains.
30 - 299 9813/9100-1 30 - 299

93 - Hose
03 - Lift Arm
Figure 1213.
D
C E
B
A
D
C
B
A
A Extend chains B Chain ends

C Split pins D Pivot pins
E Bracket
5.1. Remove the split pins. 6.2. Plug all the open ports and hoses to prevent
contamination.
5.2. Remove the pivot pins.
6.3. Using the hose release tool, carefully prise
5.3. Pull the chain end away from the roller
brackets.
6. Disconnect the hydraulic hoses. release connectors.
Special Tool: Quick Connect Hose Release
6.1. Put a label on the hoses to help installation. Tool (Qty.: 1)
30 - 300 9813/9100-1 30 - 300

93 - Hose
03 - Lift Arm
Figure 1214.
C
B
D
A
A A
A
A
A Hydraulic hoses B Female quick release connector

C Hose release tool D Male quick release connector
7. Using suitable lifting equipment remove the 8. The intermediate lift arm hoses and track can
inner, 3rd intermediate and 2nd intermediate lift now be removed:
arm sections from the machine.
8.1. Disconnect the hoses at the pipe
Figure 1215. connections.
A B 8.2. Remove the complete hose and track
assembly by sliding out from the rear of the
lift arm.
A Inner, 3rd intermediate and 2nd intermediate lift

arm sections
B 1st intermediate and outer lift arm sections
30 - 301 9813/9100-1 30 - 301

93 - Hose
03 - Lift Arm
Figure 1216.
A B
A Hoses B Pipe connections

C Hose and track assembly
Install 4.2. Push the male hose end into the female
4.3. If the hose is correctly installed the hose
should rotate and be free to move forwards
and backwards whilst being retained in the
hoses will result in malfunction of the lift arm and
female housing.
damage to the hoses and/or lift arm structure.
4.4. If the hose pulls out of the female connector-
1. The installation procedure is the opposite of the disconnect hose and reconnect.
steps.
Check the hose length.
Figure 1217.
A Less than 1mm

4.1. Make sure both hose ends are clean and
free from damage.
30 - 302 9813/9100-1 30 - 302

93 - Hose
03 - Lift Arm
Figure 1218. 4.5. When attaching the chain assemblies

disconnection.
Figure 1219.
A B C 1
X
Y 3
D 4
1 Extend chain- anchor nut
2 Extend chain- anchor thread
3 Retract chain- anchor thread
4 Retract chain- anchor nut
correctly.
A Female connector correctly set up. If the chains are replaced
B Seal using the measurements recorded before
C Male connector removal then the “Initial Setup” procedure
D Hose correctly installed can be ignored. Refer to (PIL 06-12-66)
30 - 303 9813/9100-1 30 - 303

93 - Hose
03 - Lift Arm

services.
Inner Lift Arm Hoses

Remove
30-00).
3. Remove the fork carriage. Refer to (PIL
03-33-03).
4. Open the lift arm rear cover.
5. Remove the extension ram. Refer to (PIL
30-15-07).
6. Disconnect the rear end of the intermediate hose
track and hoses.
7. Remove the tilt ram. Refer to (PIL 30-15-11).
8. Disconnect the medium retract chain.
Figure 1220.
A B D
A Chain B Chain end

C Split pin D Pivot pin
E Roller bracket
8.1. Remove the split pin. 8.2. Remove the pivot pin.
30 - 304 9813/9100-1 30 - 304

93 - Hose
03 - Lift Arm
8.3. Pull the chain end away from the roller 9. Disconnect the medium extend chains.
bracket.
Figure 1221.
D
C E
B
A
D
C
B
A

E Bracket
9.1. Remove the split pins. 10. Use suitable lifting equipment to remove the lift
arm sections from the outer lift arm section.
9.3. Pull the chain end away from the roller 11. Disconnect the small retract chain.
brackets.
30 - 305 9813/9100-1 30 - 305

93 - Hose
03 - Lift Arm
Figure 1222.
C
E
A B D
A Chain B Chain end

C Split pin D Pivot pin
E Roller bracket
11.1. Remove the split pin. 11.3. Pull the chain end away from the roller
bracket.
11.2. Remove the pivot pin.
12. Disconnect the small extend chains.
30 - 306 9813/9100-1 30 - 306

93 - Hose
03 - Lift Arm
Figure 1223.
D
C E
B
A
D
C
B
A

E Bracket
12.1. Remove the split pins. 13. Using suitable lifting equipment remove the inner
lift arm section from the machine.
12.3. Pull the chain end away from the roller 14. Disconnect the hydraulic hoses.
brackets.
30 - 307 9813/9100-1 30 - 307

93 - Hose
03 - Lift Arm
Figure 1224.
B B C C
H
G G G
E
F D
A Hydraulic hoses B Inner hose trays

C Hose quick release connectors D Male quick release connector
E Hose release tool F Female quick release connector
G Lift arm nose connectors H Lift arm nose
14.1. Put a label on the hoses to help 14.4. Disconnect the hoses at the underside of
installation. the lift arm nose at the connectors.
14.2. Plug all the open ports and hoses to 14.5. Pull the hoses through the lift arm nose.
14.3. Using the hose release tool, carefully prise Install
release connectors.
Special Tool: Quick Connect Hose hoses will result in malfunction of the lift arm and
Release Tool (Qty.: 1) damage to the hoses and/or lift arm structure.
30 - 308 9813/9100-1 30 - 308

93 - Hose
03 - Lift Arm
1. The installation procedure is the opposite of the Figure 1226.

steps.
Check the hose length. A B C
Figure 1225.
A Less than 1mm

D
4.1. Make sure both hose ends are clean and
free from damage.
4.2. Push the male hose end into the female
4.3. If the hose is correctly installed the hose
should rotate and be free to move forwards
and backwards whilst being retained in the A Female connector
female housing. B Seal
C Male connector
4.4. If the hose pulls out of the female connector D Hose correctly installed
- disconnect hose and reconnect.
4.5. When attaching the chain assemblies
disconnection.
Figure 1227.
1
X
Y 3
4
1 Extend chain - anchor nut
2 Extend chain - anchor thread
3 Retract chain - anchor thread
4 Retract chain - anchor nut
30 - 309 9813/9100-1 30 - 309

93 - Hose
03 - Lift Arm

correctly.
correctly set up. If the chains are replaced
using the measurements recorded before
removal then the “Initial Setup” procedure
can be ignored. Refer to (PIL 06-12-66)
services.
(For: 540-v180 [T4F])
30 - 310 9813/9100-1 30 - 310

96 - Pipe
96 - Pipe
Contents Page No.
30-96-03 Lift Arm ......................................................................................................................... 30-313
30 - 311 9813/9100-1 30 - 311

Notes:
30 - 312 9813/9100-1 30 - 312

96 - Pipe
03 - Lift Arm
03 - Lift Arm
Refer to component identification, (PIL 30-93-03).
30 - 313 9813/9100-1 30 - 313

97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling .............................................................................................. 30-315

30-97-09 Adaptor ......................................................................................................................... 30-317
30-97-24 Push Lock Fitting ......................................................................................................... 30-319
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-320
30 - 314 9813/9100-1 30 - 314

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-315 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-316 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 1228.
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 - 315 9813/9100-1 30 - 315

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.
2. Discharge the hydraulic pressure.
• 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 1229.
C D E
C Ball
D Slot
E Sleeve
30 - 316 9813/9100-1 30 - 316

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-317 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-318 may utilise Positional Type SAE (Society of
Automotive Engineers) 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 1230.
A O-ring seal
B Locknut
C Washer
30 - 317 9813/9100-1 30 - 317

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 1231.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.

Item Nm
B 81
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 - 318 9813/9100-1 30 - 318

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 1233.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 319 9813/9100-1 30 - 319

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 1234.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 320 9813/9100-1 30 - 320

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 ................................................................................................................. 33-1116
33-03 Battery
33-03-00 General ....................................................................................................................... 33-1121
33-03-03 Isolator Switch ............................................................................................................ 33-1132
33-06 Battery Cable
33-06-00 General ....................................................................................................................... 33-1135
33-06-12 Earth Strap ................................................................................................................. 33-1137
33-09 Power Distribution
33-09-00 General ....................................................................................................................... 33-1141
33-09-03 Fuse ........................................................................................................................... 33-1143
33-09-06 Relay .......................................................................................................................... 33-1144
33-12 Harness
33-12-00 General ....................................................................................................................... 33-1147
33-12-04 Chassis ....................................................................................................................... 33-1160
33-12-06 Lift Arm ....................................................................................................................... 33-1186
33-12-09 Engine ........................................................................................................................ 33-1197
33-12-12 Operator Station ......................................................................................................... 33-1237
33-12-14 Sway ........................................................................................................................... 33-1250
33-12-15 Front Console ............................................................................................................. 33-1255
33-12-25 Controls ...................................................................................................................... 33-1280
33-12-30 Gearbox ...................................................................................................................... 33-1297
33-12-34 Trailer Brake ............................................................................................................... 33-1303
33-12-36 Work Lights ................................................................................................................ 33-1306
33-12-39 Road Lights ................................................................................................................ 33-1311
33-12-44 Battery ........................................................................................................................ 33-1317
33-12-53 Stabiliser ..................................................................................................................... 33-1351
33-12-58 Heater ......................................................................................................................... 33-1365
33-12-99 Exterior Fittings .......................................................................................................... 33-1367
33-15 Alarm
33-15-03 Reverse Warning ........................................................................................................ 33-1375
33-21 Immobiliser
33-21-00 General ....................................................................................................................... 33-1377
33-24 Instruments
33-24-03 Instrument Panel ........................................................................................................ 33-1379
33-24-10 Hourmeter .................................................................................................................. 33-1383
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................. 33-1385
33-33 Console Switch
33-33-04 Direction Indicators .................................................................................................... 33-1389
9813/9100-1
2017-10-23
33-40 Bulb
33-40-00 General ....................................................................................................................... 33-1401
33-45 Control Module
33-45-00 General ....................................................................................................................... 33-1405
33-45-01 Instrument Panel ........................................................................................................ 33-1408
33-45-06 Engine ........................................................................................................................ 33-1415
33-45-09 Gearbox ...................................................................................................................... 33-1419
33-45-18 Steer Mode ................................................................................................................. 33-1434
33-45-36 Hydraulic .................................................................................................................... 33-1438
33-45-60 Lighting ....................................................................................................................... 33-1450
33-48 Entertainment
33-48-03 Radio .......................................................................................................................... 33-1457
33-51 Beacon
33-51-00 General ....................................................................................................................... 33-1461
33-51-03 Socket ........................................................................................................................ 33-1462
33-54 Window Washer/Wipe
33-54-00 General ....................................................................................................................... 33-1465
33-57 Electronic Diagnostic
33-57-00 General ....................................................................................................................... 33-1467
33-57-03 Servicemaster ............................................................................................................ 33-1471
33-57-90 Fault Codes ................................................................................................................ 33-1538
33-66 Load Motion Control System
33-66-00 General ....................................................................................................................... 33-1581
33-84 Sensor
33-84-09 Speed Sensor ............................................................................................................ 33-1599
33-84-15 Transmission Oil Temperature ................................................................................... 33-1600
33-84-41 Lift Arm ....................................................................................................................... 33-1601
33-84-51 Rear Axle ................................................................................................................... 33-1616
33-84-72 Chassis ....................................................................................................................... 33-1625
9813/9100-1
2017-10-23
Acronyms Glossary
2WD Two Wheel Drive

2WS Two Wheel Steer
4WS Four Wheel Steer
AWS All Wheel Steer
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
LCD Liquid Crystal Display
LED Light Emitting Diode
LLMC Longitudinal Load Moment Control
LMI Load Moment Indicator
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
OEM Original Equipment Manufacturer
PWM Pulse Width Modulation
RAS Rear Axle Stabilization
SCR Selective Catalytic Reduction
SRS Smooth Ride System
TMAF Temperature and Mass Air Flow
USB Universal Serial Bus
VIN Vehicle Identification Number
WIF Water in Fuel
9813/9100-1
2017-10-23
Notes:
9813/9100-1
2017-10-23
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................. 33-1116
33 - 1 9813/9100-1 33 - 1
Notes:
33 - 2 9813/9100-1 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.
Fault-Finding .................................................... 33-5
Check (Condition) ............................................ 33-7 Make sure that all the health and safety warnings
in this section are followed. The machine must be
safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/9100-1 33 - 3
00 - General
Health and Safety

Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the
alternator before arc-welding on the machine or
attached implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result in
irreparable damage to these components.
Parts of the machine are made from cast iron, welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to
the same component that is being welded to avoid
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the
part being welded no more than 0.6m.
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 9813/9100-1 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 537. Page 33-5
General Relay Fault Table 538. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 539. Page 33-6
ECM Faults Table 540. Page 33-6
Table 537. 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.
Table 538. 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 9813/9100-1 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 539. 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 540. 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 9813/9100-1 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 9813/9100-1 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 9813/9100-1 33 - 8
Figure 1235.
/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 9813/9100-1 33 - 9
Figure 1236. 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 9813/9100-1 33 - 10
Diagram
For: 535-v125 [T4F], 540-140 [T4F], 540-170

[T4F], 540-200 [T4F], 550-170 [T4F]
................................................... Page 33-11
For: 533-105 [T4F], 535-v125 [T4F], 540-140
[T4F], 550-140 [T4F] ............... Page 33-156
For: 540-v140 [T4F] ................ Page 33-285
For: 533-105 [T4F], 535-v125 [T4F],
540-140 [T4F], 550-140 [T4F], Construction
................................................. Page 33-418
For: 540-v180 [T4F] ................ Page 33-566
For: 533-105 [T4F], 535-v125 [T4F], 540-140
[T4F], 540-170 [T4F], 540-200 [T4F], 540-
v140 [T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F], JCB Tier 4F Elec 430 Engine
4 Cyl ....................................... Page 33-824
For: 533-105 [T4F], 535-v125 [T4F], 540-140
[T4F], 540-170 [T4F], 540-200 [T4F], 540-
v140 [T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F], Electro Hydraulic, JCB Tier
4F Elec 430 Engine 4 Cyl ........ Page 33-844
For: 533-105 [T4F], 535-v125 [T4F], 540-140
[T4F], 540-170 [T4F], 540-200 [T4F], 540-
v140 [T4F], 540-v180 [T4F], 550-140 [T4F],
550-170 [T4F], Parallel System, JCB Tier 4F
Elec 430 Engine 4 Cyl ............. Page 33-988
(For: 535-v125 [T4F], 540-140 [T4F], 540-170 [T4F], 540-200 [T4F], 550-170 [T4F])
Figure 1237. Battery and Primary Fuses -160/F8689-3 - sheet 2 of 37................................. Page 33-13
Figure 1238. Ignition and Secondary Fuses - 160/F8689-3 - sheet 3 of 37........................... Page 33-17
Figure 1239. Engine- Fuses and Starter Motor - 160/F8689-3 - sheet 4 of 37.......................Page 33-21
Figure 1240. Engine- ECU and Sensors - 160/F8689-3 - sheet 5 of 37................................ Page 33-25
Figure 1241. Engine- After treatment - 160/F8689-3 - sheet 6 of 37..................................... Page 33-29
Figure 1242. Transmission - 160/F8689-3 - sheet 7 of 37..................................................... Page 33-33
Figure 1243. Live Link and Immobiliser - 160/F8689-3 - sheet 8 of 37..................................Page 33-37
Figure 1244. Instruments - 160/F8689-3 - sheet 9 of 37....................................................... Page 33-41
Figure 1245. Roadlights - 160/F8689-3 - sheet 10 of 37....................................................... Page 33-45
Figure 1246. Directional Indicators - 160/F8689-3 - sheet 11 of 37....................................... Page 33-49
Figure 1247. Worklights and Beacon - 160/F8689-3 - sheet 12 of 37................................... Page 33-53
Figure 1248. Wiper Motors - 160/F8689-3 - sheet 13 of 37...................................................Page 33-57
Figure 1249. HVAC - 160/F8689-3 - sheet 14 of 37.............................................................. Page 33-61
Figure 1250. In Cab Entertainment - 160/F8689-3 - sheet 15 of 37...................................... Page 33-65
Figure 1251. Reverse Fan - 160/F8689-3 - sheet 16 of 37................................................... Page 33-69
Figure 1252. CAN Bus - 160/F8689-3 - sheet 17 of 37......................................................... Page 33-73
Figure 1253. CAN Bus Engine - 160/F8689-3 - sheet 18 of 37............................................. Page 33-77
Figure 1254. Switch Illumination Splice - 160/F8689-3 - sheet 19 of 37................................ Page 33-81
Figure 1255. Panel Earth Splices - 160/F8689-3 - sheet 20 of 37.........................................Page 33-85
Figure 1256. Chassis Earth Splices - 160/F8689-3 - sheet 21 of 37..................................... Page 33-89
Figure 1257. Transmission ECU 07/11 Controller - 160/F8689-3 - sheet 22 of 37.................Page 33-93
Figure 1258. Transmission ECU 07/11 Controller 2 - 160/F8689-3 - sheet 23 of 37..............Page 33-97
Figure 1259. Hydraulic ECU - 160/F8689-3 - sheet 24 of 37...............................................Page 33-101
Figure 1260. Pin Lock - 160/F8689-3 - sheet 25 of 37........................................................ Page 33-105
Figure 1261. Hitch Harness - 160/F8689-3 - sheet 26 of 37................................................Page 33-109
33 - 11 9813/9100-1 33 - 11
Figure 1262. Steer Mode - 160/F8689-3 - sheet 27 of 37................................................... Page 33-113

Figure 1263. Park Brake and Auto Manual - 160/F8689-3 - sheet 28 of 37.........................Page 33-117
Figure 1264. SRS - 160/F8689-3 - sheet 29 of 37...............................................................Page 33-121
Figure 1265. LLMI - 160/F8689-3 - sheet 30 of 37.............................................................. Page 33-125
Figure 1266. Foot brake Dump - 160/F8689-3 - sheet 31 of 37.......................................... Page 33-129
Figure 1267. Hydraulic Control Valve - 160/F8689-3 - sheet 32 of 37................................. Page 33-133
Figure 1268. Joystick - 160/F8689-3 - sheet 33 of 37......................................................... Page 33-137
Figure 1269. Joystick and Sway Isolation - 160/F8689-3 - sheet 34 of 37...........................Page 33-141
Figure 1270. Pump Control - 160/F8689-3 - sheet 35 of 37................................................ Page 33-145
Figure 1271. Hydraulic Isolation - 160/F8689-3 - sheet 36 of 37......................................... Page 33-149
Figure 1272. Stabilisers - 160/F8689-3 - sheet 37 of 37......................................................Page 33-153
Table 541.
Battery and Primary Fuses Refer to Figure 1237.
Ignition and Secondary Fuses Refer to Figure 1238.
Engine- Fuses and Starter Motor Refer to Figure 1239.
Engine- ECU (Electronic Control Unit) and Sensors Refer to Figure 1240.
Engine- After treatment Refer to Figure 1241.
Transmission Refer to Figure 1242.
Live Link and Immobiliser Refer to Figure 1243.
Instruments Refer to Figure 1244.
Roadlights Refer to Figure 1245.
Directional Indicators Refer to Figure 1246.
Worklights and Beacon Refer to Figure 1247.
Wiper Motors Refer to Figure 1248.
HVAC (Heating Ventilation Air Conditioning) Refer to Figure 1249.
In Cab Entertainment Refer to Figure 1250.
Reverse Fan Refer to Figure 1251.
CAN (Controller Area Network) Bus Refer to Figure 1252.
CAN Bus Engine Refer to Figure 1253.
Switch Illumination Splice Refer to Figure 1254.
Panel earth splices Refer to Figure 1255.
Chassis earth splices Refer to Figure 1256.
Transmission ECU 07/11 Controller Refer to Figure 1257.
Transmission ECU 07/11 Controller 2 Refer to Figure 1258.
Hydraulic control ECU Refer to Figure 1259.
Pin lock Refer to Figure 1260.
Hitch harness Refer to Figure 1261.
Steer mode Refer to Figure 1262.
Park brake and auto / manual Refer to Figure 1263.
SRS (Smooth Ride System) Refer to Figure 1264.
LLMI (Longitudinal Load Moment Indicator) Refer to Figure 1265.
Foot brake dump Refer to Figure 1266.
Hydraulic control valve Refer to Figure 1267.
Joystick Refer to Figure 1268.
Joystick and sway isolation Refer to Figure 1269.
Hydraulic pump control Refer to Figure 1270.
Hydraulic isolation Refer to Figure 1271.
Stabilisers Refer to Figure 1272.
33 - 12 9813/9100-1 33 - 12
Page 33-14 Figure 1237. Battery and Primary

Fuses -160/F8689-3 - sheet 2 of 37 Page 33-15
1 2 3 4 5 6 7 8
F
F
95.00 mm² RED TO STARTER MOTOR

TO
/4.F5
C033
E
E
C/D A/B
PRIMARY FUSE
-P046 50A 50A -P045
TO FUSE 4.00 mm² 200D B/2 B/2 4.00 mm² 200A TO IGNITION SWITCH
/3.C4 TO TO
/3.F1
P002:11 5 3 P043:1
50A 50A
TO IGNITION RELAYS 3&4 4.00 mm² 200C A/2 A/2 4.00 mm² 202B TO IGNITION RELAYS 1&2
/3.C1 TO TO
/3.D1
SPLICE SP26 4 2 SPLICE SP35
-B001 1
FUSE LINK BOX BLUE FUSE LINK BOX GREY
M6
D
D
16.00 mm² RED

ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm² RED -S1
M8
M8 -CS1 20.00 mm² RED
16.00 mm² RED

M8
M10
M10
-C001
-C002
-C002
-B002
M10
G/H M6
E/F
CHASSIS GROUND -P047 50A 50A -P048
TO PURGE HOLD RELAY FUSE TO FUSE 2 4 TO IGNITION RELAY 6
1
10.00 mm² BLACK 4.00 mm² 200F A/2 A/2 4.00 mm² 200G
TO
/6.F3 /3.B4 TO TO
/3.A1
C001 P003:11 SPLICE SP30
50A 50A
TO IGNITION RELAY 5 4.00 mm² 200E B/2 3 5 B/2 4.00 mm² 319 TO ENGINE SUPPLY
C /3.B1 /4.B1
TO TO
SPLICE SP15 P093:1

10.00 mm² BLACK TO PURGE HOLD RELAY FUSE LINK BOX GREY 2 FUSE LINK BOX BLUE 2
C
TO
/6.F3
C003
PRIMARY FUSE
20.00 mm² RED TO GRID HEATER FUSE

TO
/4.D4
CS1:1
B
B
A
A
1 2 3 4 5 6 7 8
33 - 13 9813/9100-1 33 - 13
Page Page
33-14 33-15
Figure 1237.
1 (Part 1 of 2) 2 3 4
95.00 mm² RED TO STARTER MOTOR

TO
/4.F5
C033
C/D
PRIMARY FUSE
-P046 50A
TO FUSE 4.00 mm² 200D B/2
/3.C4 TO
P002:11 5
50A
TO IGNITION RELAYS 3&4 4.00 mm² 200C A/2
/3.C1 TO
SPLICE SP26 4
FUSE LINK BOX BLUE
M6
D
ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm² RED
M8
M8 -CS1 20.00 mm² RED
M8
M10
M10
Page 33-15
-C001
-C002
-C002
M10
G/H
M6
CHASSIS GROUND -P047 50A
TO PURGE HOLD RELAY FUSE TO FUSE 2
1
10.00 mm² BLACK 4.00 mm² 200F A/2
TO
/6.F3 /3.B4 TO
C001 P003:11
50A
TO IGNITION RELAY 5 4.00 mm² 200E B/2 3
C /3.B1 TO
SPLICE SP15
10.00 mm² BLACK TO PURGE HOLD RELAY FUSE LINK BOX GREY 2
TO
/6.F3
C003
PRIMARY FUSE
20.00 mm² RED TO GRID HEATER FUSE

TO
/4.D4
CS1:1
1 2 3 4
33 - 14 9813/9100-1 33 - 14
Page Page
33-14 33-15
Figure 1237. (Part

5 2 of 2) 6 7 8
C/D A/B
PRIMARY FUSE
-P046 50A 50A -P045
B/2 B/2 4.00 mm² 200A TO IGNITION SWITCH
TO
/3.F1
5 3 P043:1
50A 50A
A/2 A/2 4.00 mm² 202B TO IGNITION RELAYS 1&2
TO
/3.D1
4 2 SPLICE SP35
-B001 1
FUSE LINK BOX BLUE FUSE LINK BOX GREY

M6
D
16.00 mm² RED
-S1
16.00 mm² RED
Page 33-14
-B002
G/H E/F
M6
-P047 50A 50A -P048

2 4 TO IGNITION RELAY 6
1
A/2 A/2 4.00 mm² 200G TO

/3.A1
SPLICE SP30
50A 50A
B/2 3 5 B/2 4.00 mm² 319 TO ENGINE SUPPLY
TO
/4.B1
P093:1
FUSE LINK BOX GREY 2 FUSE LINK BOX BLUE 2
C
PRIMARY FUSE
5 6 7 8
33 - 15 9813/9100-1 33 - 15
33 - 16 9813/9100-1 33 - 16
Page 33-18 Figure 1238. Ignition and Secondary

Fuses - 160/F8689-3 - sheet 3 of 37 Page 33-19
1 2 3 4 5 6 7 8
FROM PRIMARY FUSE B 4.00 mm² 200A

F /2.D6 FROM
P045:B
F
-P043 -P044
IGNITION SWITCH -P001 -P004
III START
HEAT
FUSE BOX A FUSE BOX D

PRE
0 OFF
I ON
TO HYD ECU VBAT

II
4.00 mm² 200AB 4.00 mm² 200AA 1 5 4.00 mm² 001A 4.00 mm² 001A 1 5A 2 1.00 mm² 100 4.00 mm² 201G 1 20A 2 2.00 mm² 203 TO
/24.D1
-SP51 2 6 4.00 mm² 014 1 31 C045 / P039:C8
3 4.00 mm² 004B 4.00 mm² 004 TO NEUTRAL START RELAY FROM NEUTRAL START 4.00 mm² 842A 3 30A 4 4.00 mm² 842 TO ENGINE SUPPLY 3 3A 4 2.00 mm² 3711 TO 07/11 VBATT SPLICE
TO
/4.E1 /4.E2 FROM TO
/4.E3 TO
/23.C6
4 -SP52 P010:1 P010:2 2 P093:2 32 SC56 / P039:A8
8 4.00 mm² 015B 5 25A 6 2.00 mm² 150 TO HEATED GLASS 5 10A 6 1.50 mm² 300NX TO NOx SENSOR RELAY
TO
/14.E4 TO
/6.B1
9 3 P054:1 33 P101:1
7 7 15A 8 1.50 mm² 114 TO FRONT/REAR AUX SW 7 3A 8 1.00 mm² 300 TO HAZARD SWITCH
TO
/26.C2 TO
/11.C3
4 P017:2 34 P020:5
9 5A 10 1.00 mm² 1100A TO HOSE HEATER RELAY 9 15A 10 1.00 mm² 301E TO INSTRUMENT V+
TO
/6.B1 TO
/9.C3
TO REMOTE START RELAY FROM REMOTE START RELAY 4.00 mm² 004A 5 P101:3 35 SPLICE SP40 / P071
TO
/4.E1 /4.E2 FROM
P119:1 P119:2 11 3A 12 1.00 mm² 107B TO ENGINE POD CONNECTOR 1.00 mm² 1100 TO SCR ECU 4.00 mm² 011G 11 3A 12 1.00 mm² 100TR TO 07/11 CONNECTOR 2
/5.C1 /6.B1 /22.E5
E
TO TO TO
6 C032:5 / P039:E7 C010E:22 / P199:9 36 P070:1

1.00 mm² 100 4.00 mm² 010B 13 30A 14 2.00 mm² 102 TO HEATER CONNECTOR 13 5A 14 1.00 mm² 110LL TO LIVE LINK RELAY E
TO
/14.C1 TO
/8.C1
7 P033:3 37 P013:1
-P006 15 10A 16 1.00 mm² 108 TO BRAKE LIGHT RELAY 15 3A 16 1.00 mm² 101A TO LLMI
TO
/10.F5 TO
/30.E2
IGNITION RELAY 1 8 P011:1 38 P042-A
4 17 3A 18 1.00 mm² 107PB TO PARKBRAKE SW 17 3A 18 1.00 mm² 106 TO INSTRUMENT CLUSTER J1
TO
/28.C1 TO
/9.E3
4.00 mm² 200B 1 2 4.00 mm² 015B 9 RC012:3 / P049:10 39 P071:2
19 3A 20 1.00 mm² 104 TO COLUMN SWITCH RH 1.00 mm² 107SP TO SEAT PRESSURE SWITCH 19 5A 20 1.00 mm² Y TO IMMOBILISER RELAY
TO
/11.B1 TO
/15.C3 /8.D4
TO
0.75 mm² 100J 3 5 0.75 mm² 601HB TO GROUND 10 P038:14 RC012:1 / P049:14 40 P101:6
TO
/20.F4
-SP20 SPLICE SP3 1.50 mm² 155 TO CHASSIS IGN
/24.B2
TO
SC12 / P039:F9
-P006
IGNITION RELAY 2
9 -P002 -P005
FROM PRIMARY FUSE A 4.00 mm² 202B 4.00 mm² 203B 6 7 4.00 mm² 010B FUSE BOX B FUSE BOX E
/2.D6 FROM
P045:A -SP35
0.75 mm² 100B 8 10 0.75 mm² 601EK TO GROUND 4.00 mm² 013C 1 25A 2 2.00 mm² 116 TO ROOF AC FANS RELAY FROM COLUMN SWITCH RH 2.00 mm² 833 1 15A 2 1.50 mm² 834 TO DIPPED BEAM
TO
/20.F4 TO
/14.D4 /10.B3 FROM TO
/10.B4
SPLICE SP3 P015:6 P038:9 SPLICE SP18
D 11 41
3 20A 4 2.00 mm² 133 TO
TO WIPER PARK
/13.D3
TO COLUMN SWITCH RH
/10.B3 FROM 2.00 mm² 836 3 20A 4 2.00 mm² 838 TO
TO MAIN BEAM
/10.B4
D
-P007 12
SPLICE SP16 P038:13 42 SPLICE SP19
IGNITION RELAY 3 5 15A 6 1.50 mm² 110 TO WIPER FROM HEADLIGHT SWITCH 2.00 mm² 942D 5 7.5A 6 1.50 mm² 829E TO SIDE LIGHTS
TO
/13.A2 /10.C3 FROM TO
/19.C4
4 13
SPLICE SP33 SPLICE SP22 43 SPICE SP7
4.00 mm² 201C 1 2 4.00 mm² 013C 4.00 mm² 012CA 7 20A 8 2.00 mm² 997 TO AC RELAY FROM HEADLIGHT SWITCH 2.00 mm² 942E 7 5A 8 0.75 mm² 830 TO SIDE LIGHTS
TO
/14.C2 /10.C3 FROM TO
/10.C4
14
P015:1 SPLICE SP22 44 P039:E2
0.75 mm² 100H 3 5 0.75 mm² 601HL TO GROUND 9 15A 10 1.50 mm² 119 TO MOBILE PHONE FROM HEADLIGHT SWITCH 1.00 mm² 832B 9 5A 10 1.00 mm² 905 TO FOG LIGHT SWITCH
TO
/20.F4 TO
/15.B3 /10.C3 FROM TO
/10.F3
SPLICE SP3 15
P056:1 SPLICE SP21 45 P023:2
FROM PRIMARY FUSE D 4.00 mm² 200D 11 20A 12 2.00 mm² 3100A TO TANK HARNESS 1.00 mm² 601LL 11 5A 12 1.00 mm² 601L TO LIVE LINK
/2.D4 FROM TO
/6.D1 TO
/8.C4
ADDITIONAL FUSES P046:B 16
C199:1 46 P068:9 2.00 mm² 151 TO HEATED SEAT
TO
/14.F3
13 25A 14 2.00 mm² 308 TO FRONT WORKLIGHT RELAY 4.00 mm² 014 13 20A 14 RC002:1 / P049:7
TO
/12.D3
-P132 17
P012:1 47 2.00 mm² 151B TO FACE FAN
TO
/14.E3
4.00 mm² 203C 1 20A 2 1.00 mm² 300RDM TO DAILY CHECKS 15 7.5A 16 1.00 mm² 310 TO BEACON SWITCH 4.00 mm² 202E 15 10A 16 1.50 mm² 275 TO TRAILER DI RELAYS P051:1
TO
/5.E5 TO
/12.B1 TO
/11.E5
P137:1 18
P028:2 48 SPLICE SP25
17 15A 18 1.50 mm² 300TR TO 07/11 VBATT 17 20A 18 2.00 mm² 300HH TO HOSE HEATER RELAY
-P131 -SP66
TO
/22.D5 TO
/6.C1
1 20A 2 1.00 mm² 100EX 1.00 mm²,1.00 mm² 100RDM TO DAILY CHECKS 19
SPLICE SP38 49 P009:1
TO
/5.F5
P137:8 19 25A 20 2.00 mm² 312 BOOM WORK LIGHTS RELAY 19 10A 20 1.00 mm² 301 1.00 mm² 301J TO INTERIOR LIGHT
C /12.C3 /12.A1
TO TO
1.00 mm² 100WBL TO WASHER BOTTLE LEVEL 20

P011:6 50 -SP27 RC010:1 / P049:9
/13.C6 C
TO
-P007 4.00 mm² 012CB

C001:1 / P135:1 1.00 mm² 301F TO RADIO
TO
/15.E2
IGNITION RELAY 4 LIVE LINK PERM GROUND
P058:2
9 -P113 M10
1.00 mm² Y TO IMMOBILISER
-SP53
TO
/8.D5
FROM PRIMARY FUSE C 4.00 mm² 200C 4.00 mm² 202C 6 7 4.00 mm² 012C
P066:7
/2.D4 FROM
P046:A -SP26 1.00 mm² 301M TO DIAG CONNECTOR

-P003
TO
/17.D1
0.75 mm² 100G 8 10 0.75 mm² 601HK TO GROUND P073:B
TO
/20.F4
SPLICE SP3 FUSE BOX C
4.00 mm² 202E 4.00 mm² 017E 1 10A 2 1.50 mm² 109RA TO REVERSE ALARM RELAY 1.00 mm² 109E STAB TRANSDUCERS 1.00 mm² 100LL TO LIVE LINK RELAY
TO
/10.C5 TO
/37.E5 TO
/8.C1
21
P010:6 C067:2 P013:3
-P008 3 5A 4 1.00 mm² 121 TO AUXILLIARY CONNECTOR 1.00 mm² 109FB TO FOOTBRAKE TRANSDUCER
TO
/15.A3 TO
/31.C3
IGNITION RELAY 5 22
P065:1 C018:2 0.75 mm² 100QA TO ITALIAN HEADLIGHTS
TO
/12.C1
4 5 10A 6 1.00 mm² 109SA TO ISOLATION SOLENOID P126:1
TO
/36.D3
FROM PRIMARY FUSE F 4.00 mm² 200E 4.00 mm² 201E 1 2 4.00 mm² 017E 23 1.00 mm² 109CS TO COLUMN SWITCH L/H C035:1
/2.C4 FROM TO
/7.B1
P047:B -SP15 7 10A 8 1.00 mm² 181 TO RADIO SP65 / P037 1.00 mm² 109SB TO ISOLATION SOLENOID (A) 0.75 mm² 100K TO INFO BUTTON SWITCH
TO
/15.E2 TO
/36.D3 TO
/9.E7
0.75 mm² 100F 3 5 0.75 mm² 601JJ TO GROUND 24
P058:1 C035:1 P063:2
TO
/20.E4 -P039 -C015
SPLICE SP3 9 5A 10 TO SPEED SENSOR
B 1.00 mm² 109 D2/84 D2/84 1.00 mm² 109 1.00 mm² 109SS TO
/16.C5
E014:1 / C029:15 TO PURGE HOLD RELAY
25 -SC11 1.00 mm² 100ISO TO
/6.F1 B
4.00 mm² 201G FROM PRIMARY FUSE E 4.00 mm² 200F 11 5A 12 1.00 mm² 299LL TO LIVE LINK IGNITION LIVE P013:3
/2.C4 FROM TO
/8.D2
P047:A 26
P068:4
-P008 13 25A 14 2.00 mm² 309 TO REAR WORKLIGHT RELAY 1.00 mm² 100P TO REVERSE FAN SWITCH
TO
/12.C3 TO
/16.D2
IGNITION RELAY 6 27
P012:6 P061:2
9 15 10A 16 2.00 mm² 307 TO HEADLIGHT SWITCH
TO
/10.C1
FROM PRIMARY FUSE G 4.00 mm² 200G 4.00 mm² 202G 6 7 4.00 mm² 011G 28
P024:2 1.00 mm² 100RH TO PIN LOCK SWITCH 0.75 mm² 100D TO HEADLIGHT SWITCH
/2.C6 FROM TO
/25.B3 TO
/10.C1
P048:A -SP30 17 20A 18 2.00 mm² 306 TO ROADLIGHT RELAY P114:2 P024:8
TO
/10.C1
0.75 mm² 100A 8 10 0.75 mm² 601X TO GROUND 29
P013:6 0.75 mm² 100M TO FOUR WHEEL DRIVE SWITCH
TO
/20.F4 TO
/22.B4
SPLICE SP3 19 25A 20 2.00 mm² 304A TO COLUMN SWITCH R/H P027:2 0.75 mm² 100C TO ROADLIGHT RELAY
TO
/10.B1 TO
/10.C1
30
P038:4 0.75 mm² 100J TO BRAKE LIGHT RELAY P013:8
TO
/10.F5
2.00 mm² 304B TO COLUMN SWITCH L/H P011:3
TO
/7.C1
P037:11 0.50 mm² 106C TO CENTER CLUSTER
TO
/9.A5
P040:20
0.75 mm² 100H TO NEUTRAL START RELAY
TO
/4.E1
P010:3
A
A
1 2 3 4 5 6 7 8
33 - 17 9813/9100-1 33 - 17
Page Page
33-18 33-19
Figure 1238.
1 (Part 1 of 2) 2 3 4
FROM PRIMARY FUSE B 4.00 mm² 200A

F /2.D6 FROM
P045:B
-P043 -P044
IGNITION SWITCH -P001
III START
HEAT
FUSE BOX A
PRE
0 OFF
I ON
II
4.00 mm² 200AB 4.00 mm² 200AA 1 5 4.00 mm² 001A 4.00 mm² 001A 1 5A 2 1.00 mm² 100
-SP51 2 6 4.00 mm² 014 1
3 4.00 mm² 004B 4.00 mm² 004 TO NEUTRAL START RELAY FROM NEUTRAL START 4.00 mm² 842A 3 30A 4 4.00 mm² 842 TO ENGINE SUPPLY
TO
/4.E1 /4.E2 FROM TO
/4.E3
4 -SP52 P010:1 P010:2 2 P093:2
8 4.00 mm² 015B 5 25A 6 2.00 mm² 150 TO HEATED GLASS
TO
/14.E4
9 3 P054:1
7 7 15A 8
4
9 5A 10
TO REMOTE START RELAY FROM REMOTE START RELAY 4.00 mm² 004A 5
TO
/4.E1 /4.E2 FROM
P119:1 P119:2 11 3A 12 1.00 mm² 107B TO ENGINE POD CONNECTOR

/5.C1
E
TO
6 C032:5 / P039:E7
1.00 mm² 100 4.00 mm² 010B 13 30A 14 2.00 mm² 102 TO HEATER CONNECTOR
TO
/14.C1
7 P033:3
-P006 15 10A 16 1.00 mm² 108 TO BRAKE LIGHT RELAY
TO
/10.F5
IGNITION RELAY 1 8 P011:1
4 17 3A 18
4.00 mm² 200B 1 2 4.00 mm² 015B 9
19 3A 20 1.00 mm² 104 TO COLUMN SWITCH RH
TO
/11.B1
0.75 mm² 100J 3 5 0.75 mm² 601HB TO GROUND 10 P038:14
TO
/20.F4
-SP20 SPLICE SP3
-P006
IGNITION RELAY 2
9 -P002
FROM PRIMARY FUSE A 4.00 mm² 202B 4.00 mm² 203B 6 7 4.00 mm² 010B FUSE BOX B
/2.D6 FROM
P045:A -SP35
0.75 mm² 100B 8 10 0.75 mm² 601EK TO GROUND 4.00 mm² 013C 1 25A 2 2.00 mm² 116 TO ROOF AC FANS RELAY
TO
/20.F4 TO
/14.D4
SPLICE SP3 P015:6
D 11
3 20A 4 2.00 mm² 133 TO WIPER PARK
TO
/13.D3
-P007 12
SPLICE SP16
IGNITION RELAY 3 5 15A 6 1.50 mm² 110 TO WIPER
TO
/13.A2
4 13
SPLICE SP33
4.00 mm² 201C 1 2 4.00 mm² 013C 4.00 mm² 012CA 7 20A 8 2.00 mm² 997 TO AC RELAY
TO
/14.C2
14
P015:1
0.75 mm² 100H 3 5 0.75 mm² 601HL TO GROUND 9 15A 10 1.50 mm² 119 TO MOBILE PHONE
TO
/20.F4 TO
/15.B3
SPLICE SP3 15
P056:1
FROM PRIMARY FUSE D TO TANK HARNESS
Page 33-19
/2.D4 FROM 4.00 mm² 200D 11 20A 12 2.00 mm² 3100A TO
/6.D1
ADDITIONAL FUSES P046:B 16
C199:1
13 25A 14 2.00 mm² 308 TO FRONT WORKLIGHT RELAY
TO
/12.D3
-P132 17
P012:1
4.00 mm² 203C 1 20A 2 1.00 mm² 300RDM TO DAILY CHECKS 15 7.5A 16 1.00 mm² 310 TO BEACON SWITCH
TO
/5.E5 TO
/12.B1
P137:1 18
P028:2
17 15A 18 1.50 mm² 300TR TO 07/11 VBATT
-P131 -SP66
TO
/22.D5
1 20A 2 1.00 mm² 100EX 1.00 mm²,1.00 mm² 100RDM TO DAILY CHECKS 19
SPLICE SP38
TO
/5.F5
P137:8 19 25A 20 2.00 mm² 312 BOOM WORK LIGHTS RELAY
C /12.C3
TO
1.00 mm² 100WBL TO WASHER BOTTLE LEVEL 20

P011:6
TO
/13.C6
-P007 4.00 mm² 012CB
C001:1 / P135:1
IGNITION RELAY 4
9
FROM PRIMARY FUSE C 6 7 -SP53
4.00 mm² 200C 4.00 mm² 202C 4.00 mm² 012C
/2.D4 FROM
P046:A -SP26
8 10 TO GROUND -P003
0.75 mm² 100G 0.75 mm² 601HK TO
/20.F4
SPLICE SP3 FUSE BOX C
4.00 mm² 202E 4.00 mm² 017E 1 10A 2 1.50 mm² 109RA TO REVERSE ALARM RELAY
TO
/10.C5
21
P010:6
-P008 3 5A 4 1.00 mm² 121 TO AUXILLIARY CONNECTOR
TO
/15.A3
IGNITION RELAY 5 22
P065:1
4 5 10A 6
FROM PRIMARY FUSE F 4.00 mm² 200E 4.00 mm² 201E 1 2 4.00 mm² 017E 23
/2.C4 FROM
P047:B -SP15 7 10A 8 1.00 mm² 181 TO RADIO

TO
/15.E2
0.75 mm² 100F 3 5 0.75 mm² 601JJ TO GROUND 24
P058:1
TO
/20.E4
SPLICE SP3 9 5A 10
B
25
4.00 mm² 201G FROM PRIMARY FUSE E 4.00 mm² 200F 11 5A 12 1.00 mm² 299LL TO LIVE LINK
/2.C4 FROM TO
/8.D2
P047:A 26
P068:4
-P008 13 25A 14 2.00 mm² 309 TO REAR WORKLIGHT RELAY
TO
/12.C3
IGNITION RELAY 6 27
P012:6
9 15 10A 16 2.00 mm² 307 TO HEADLIGHT SWITCH
TO
/10.C1
FROM PRIMARY FUSE G 4.00 mm² 200G 4.00 mm² 202G 6 7 4.00 mm² 011G 28
P024:2
/2.C6 FROM
P048:A -SP30 17 20A 18 2.00 mm² 306 TO ROADLIGHT RELAY

TO
/10.C1
0.75 mm² 100A 8 10 0.75 mm² 601X TO GROUND 29
P013:6
TO
/20.F4
SPLICE SP3 19 25A 20
30
1 2 3 4
33 - 18 9813/9100-1 33 - 18
Page Page
33-18 33-19
Figure 1238. (Part

5 2 of 2) 6 7 8
-P001 -P004
FUSE BOX A FUSE BOX D
2 1.00 mm² 100 4.00 mm² 201G 1 20A 2 2.00 mm² 203 TO HYD ECU VBAT
TO
/24.D1
1 31 C045 / P039:C8
4 4.00 mm² 842 TO ENGINE SUPPLY 3 3A 4 2.00 mm² 3711 TO 07/11 VBATT SPLICE
TO
/4.E3 TO
/23.C6
2 P093:2 32 SC56 / P039:A8
6 2.00 mm² 150 TO HEATED GLASS 5 10A 6 1.50 mm² 300NX TO NOx SENSOR RELAY
TO
/14.E4 TO
/6.B1
3 P054:1 33 P101:1
8 1.50 mm² 114 TO FRONT/REAR AUX SW 7 3A 8 1.00 mm² 300 TO HAZARD SWITCH
TO
/26.C2 TO
/11.C3
4 P017:2 34 P020:5
10 1.00 mm² 1100A TO HOSE HEATER RELAY 9 15A 10 1.00 mm² 301E TO INSTRUMENT V+
TO
/6.B1 TO
/9.C3
5 P101:3 35 SPLICE SP40 / P071
12 1.00 mm² 107B TO ENGINE POD CONNECTOR 1.00 mm² 1100 TO SCR ECU 4.00 mm² 011G 11 3A 12 1.00 mm² 100TR TO 07/11 CONNECTOR 2
TO
/5.C1 TO
/6.B1 TO
/22.E5
6 C032:5 / P039:E7 C010E:22 / P199:9 36 P070:1
14 2.00 mm² 102 TO HEATER CONNECTOR 13 5A 14 1.00 mm² 110LL TO LIVE LINK RELAY E
TO
/14.C1 TO
/8.C1
7 P033:3 37 P013:1
16 1.00 mm² 108 TO BRAKE LIGHT RELAY 15 3A 16 1.00 mm² 101A TO LLMI
TO
/10.F5 TO
/30.E2
8 P011:1 38 P042-A
18 1.00 mm² 107PB TO PARKBRAKE SW 17 3A 18 1.00 mm² 106 TO INSTRUMENT CLUSTER J1
TO
/28.C1 TO
/9.E3
9 RC012:3 / P049:10 39 P071:2
20 1.00 mm² 104 TO COLUMN SWITCH RH 1.00 mm² 107SP TO SEAT PRESSURE SWITCH 19 5A 20 1.00 mm² Y TO IMMOBILISER RELAY
TO
/11.B1 TO
/15.C3 /8.D4
TO
10 P038:14 RC012:1 / P049:14 40 P101:6

1.50 mm² 155 TO CHASSIS IGN
/24.B2
TO
SC12 / P039:F9
-P002 -P005
FUSE BOX B FUSE BOX E
2 2.00 mm² 116 TO ROOF AC FANS RELAY FROM COLUMN SWITCH RH 2.00 mm² 833 1 15A 2 1.50 mm² 834 TO DIPPED BEAM
TO
/14.D4 /10.B3 FROM TO
/10.B4
11
P015:6 P038:9 41 SPLICE SP18
4 2.00 mm² 133 TO
TO WIPER PARK
/13.D3
TO COLUMN SWITCH RH
/10.B3 FROM 2.00 mm² 836 3 20A 4 2.00 mm² 838 TO
TO MAIN BEAM
/10.B4
D
12
SPLICE SP16 P038:13 42 SPLICE SP19
6 1.50 mm² 110 TO WIPER FROM HEADLIGHT SWITCH 2.00 mm² 942D 5 7.5A 6 1.50 mm² 829E TO SIDE LIGHTS
TO
/13.A2 /10.C3 FROM TO
/19.C4
13
SPLICE SP33 SPLICE SP22 43 SPICE SP7
8 2.00 mm² 997 TO AC RELAY FROM HEADLIGHT SWITCH 2.00 mm² 942E 7 5A 8 0.75 mm² 830 TO SIDE LIGHTS
TO
/14.C2 /10.C3 FROM TO
/10.C4
14
P015:1 SPLICE SP22 44 P039:E2
10 1.50 mm² 119 TO MOBILE PHONE FROM HEADLIGHT SWITCH 1.00 mm² 832B 9 5A 10 1.00 mm² 905 TO FOG LIGHT SWITCH
TO
/15.B3 /10.C3 FROM TO
/10.F3
15
P056:1 SPLICE SP21 45 P023:2
TO TANK HARNESS TO LIVE LINK
Page 33-18
12 2.00 mm² 3100A TO

/6.D1 1.00 mm² 601LL 11 5A 12 1.00 mm² 601L TO
/8.C4
16
C199:1 46 P068:9 2.00 mm² 151 TO HEATED SEAT
TO
/14.F3
14 2.00 mm² 308 TO FRONT WORKLIGHT RELAY 4.00 mm² 014 13 20A 14 RC002:1 / P049:7
TO
/12.D3
17
P012:1 47 2.00 mm² 151B TO FACE FAN
TO
/14.E3
16 1.00 mm² 310 TO BEACON SWITCH 4.00 mm² 202E 15 10A 16 1.50 mm² 275 TO TRAILER DI RELAYS P051:1
TO
/12.B1 TO
/11.E5
18
P028:2 48 SPLICE SP25
18 1.50 mm² 300TR TO 07/11 VBATT 17 20A 18 2.00 mm² 300HH TO HOSE HEATER RELAY
TO
/22.D5 TO
/6.C1
19
SPLICE SP38 49 P009:1
20 2.00 mm² 312 BOOM WORK LIGHTS RELAY 19 10A 20 1.00 mm² 301 1.00 mm² 301J TO INTERIOR LIGHT
TO
/12.C3 /12.A1
TO
20
P011:6 50 -SP27 RC010:1 / P049:9
1.00 mm² 301F TO RADIO C
/15.E2
TO
LIVE LINK PERM GROUND

P058:2
-P113 M10
1.00 mm² Y TO IMMOBILISER
/8.D5
TO
P066:7
1.00 mm² 301M TO DIAG CONNECTOR
-P003 /17.D1
TO
P073:B
FUSE BOX C
2 1.50 mm² 109RA TO REVERSE ALARM RELAY 1.00 mm² 109E STAB TRANSDUCERS 1.00 mm² 100LL TO LIVE LINK RELAY
TO
/10.C5 TO
/37.E5 TO
/8.C1
21
P010:6 C067:2 P013:3
4 1.00 mm² 121 TO AUXILLIARY CONNECTOR 1.00 mm² 109FB TO FOOTBRAKE TRANSDUCER
TO
/15.A3 TO
/31.C3
22
P065:1 C018:2 0.75 mm² 100QA TO ITALIAN HEADLIGHTS
TO
/12.C1
6 1.00 mm² 109SA TO ISOLATION SOLENOID P126:1
TO
/36.D3
23 1.00 mm² 109CS TO COLUMN SWITCH L/H C035:1
TO
/7.B1
8 1.00 mm² 181 TO RADIO SP65 / P037 1.00 mm² 109SB TO ISOLATION SOLENOID (A) 0.75 mm² 100K TO INFO BUTTON SWITCH
TO
/15.E2 TO
/36.D3 TO
/9.E7
24
P058:1 C035:1 P063:2
-P039 -C015
10 1.00 mm² 109 D2/84 D2/84 1.00 mm² 109 1.00 mm² 109SS TO SPEED SENSOR
TO
/16.C5
E014:1 / C029:15 TO PURGE HOLD RELAY
25 -SC11 1.00 mm² 100ISO TO
/6.F1 B
12 1.00 mm² 299LL TO LIVE LINK IGNITION LIVE P013:3
TO
/8.D2
26
P068:4
14 2.00 mm² 309 TO REAR WORKLIGHT RELAY 1.00 mm² 100P TO REVERSE FAN SWITCH
TO
/12.C3 TO
/16.D2
27
P012:6 P061:2
16 2.00 mm² 307 TO HEADLIGHT SWITCH
TO
/10.C1
28
P024:2 1.00 mm² 100RH TO PIN LOCK SWITCH 0.75 mm² 100D TO HEADLIGHT SWITCH
TO
/25.B3 TO
/10.C1
18 2.00 mm² 306 TO ROADLIGHT RELAY P114:2 P024:8
TO
/10.C1
29
P013:6 0.75 mm² 100M TO FOUR WHEEL DRIVE SWITCH
TO
/22.B4
20 2.00 mm² 304A TO COLUMN SWITCH R/H P027:2 0.75 mm² 100C TO ROADLIGHT RELAY
TO
/10.B1 TO
/10.C1
30
P038:4 0.75 mm² 100J TO BRAKE LIGHT RELAY P013:8
TO
/10.F5
2.00 mm² 304B TO COLUMN SWITCH L/H P011:3
TO
/7.C1
P037:11 0.50 mm² 106C TO CENTER CLUSTER
TO
/9.A5
P040:20
0.75 mm² 100H TO NEUTRAL START RELAY
TO
/4.E1
P010:3
5 6 7 8
33 - 19 9813/9100-1 33 - 19
33 - 20 9813/9100-1 33 - 20
Page 33-22 Figure 1239. Engine- Fuses and Starter

Motor - 160/F8689-3 - sheet 4 of 37 Page 33-23
1 2 3 4 5 6 7 8
F
F
FROM BATTERY 95.00 mm² RED 25.00 mm² RED
/2.E4 FROM
-ST03 M10
-P010 TO ENGINE ECU STARTER MOTOR ALTERNATOR

/5.D3 TO
-B002 30
NEUTRAL START E004:39
V-Batt
4 M10
-P093 -C005 -C029 -E009 -E009 -C029
FROM CRANK 4.00 mm² 004 1 2 4.00 mm² 842A TO FUSE 02A FROM FUSE 02A 4.00 mm² 842 2/2 2/2 4.00 mm² 842 4/29 4/29 4.00 mm² 842 4.00 mm² 842A 2/29 2/29 4.00 mm² 842A
M5 50 U
V
/3.E3 FROM TO
/3.E4 /3.E5 FROM
SPLICE SP52 P001:3 P001:4

W
Start
-SE04 -C002
Control
FROM IGNITION FUSE 3 5 M DF W B+

0.75 mm² 100H
M8 B+
D-
M5 W
/3.A6
W B+
L
FROM
P001:2 / SP20
REGULATOR
L
31
M5
GND
TO 07/11 CONNECTOR 1 1.00 mm² 601NS
-ST04
-ST05
/22.E3
-ST06
TO
P069:2
-P119 25.00 mm² RED

E REMOTE START
-P039 -C015 -C004 -ST01
4 TO INSTRUMENT CLUSTER J2 412 1.00 mm² 412 1.00 mm² A5/84 A5/84 412 1.00 mm² A/3 A/3 1.00 mm² 412
E
/9.E5 TO
FROM IGNITION FEED 4.00 mm² 200AB 1 2 4.00 mm² 004A TO CRANK P072:7
/3.E1 FROM TO
/3.E2 -ST01
SPLICE SP51 SPLICE SP52 TO INSTRUMENT CLUSTER J1 407B 1.00 mm² -SP14 407 1.00 mm² B5/84 B5/84 407 1.00 mm² B/3 B/3 1.00 mm² 407
/9.D3 TO
FROM HYDRAULICS ECU J3 1.00 mm² 718RSH 3 5 1.00 mm² 781RSL TO RADIO RECEIVER P071:11
/24.E7 FROM TO
/4.C1
C047:13 / P039:A9 C016:4 / P039:C3
TO ENGINE RUNNING RELAY 1.00 mm² 407F

/12.F1 TO
P014:3
D
D
GRID HEATER
-CS2 -CS4
GRID HEATER FUSE -C002 M6 1
FROM BATTERY 20.00 mm² RED 1 2 20.00 mm² RED
/2.B4 FROM
12V
150A
-E020
-E001
70 A
FUSE/RELAY BOX GRID HEATER
START SIGNAL
(MICRO RELAY)
K2 -CS5 M6 M6 -C001 20.00 mm² RED

-P039 -C015 -C016
FROM REMOTE START RELAY 1.00 mm² 781RSL C3/84 C3/84 1.00 mm² 781RSL 4/8 G B
/4.E2 FROM
P119:5 0.75 mm² E115 1/2 2/2 TO ENGINE ECU

E116 0.75 mm²
TO
/5.D5
F3
N 1.00 mm² E407 TO ENGINE ECU E004:48
TO
/5.C3
E004:28
F5 - 10A
K
C F6 - 10A
J
C
FUEL PUMP
(MICRO RELAY)
-E003
K3 FUEL PUMP
F2 - 10A
L 1 2 TO GROUND
1.50 mm² E801 M 1.50 mm² E601F TO
/21.E1
SPLICE SE02
F4 - 3A
M 1.00 mm² E408 TO ENGINE ECU
TO
/5.C3
E004:40
F7 - 10A
H 0.75 mm² E115
F8 - 10A
X 1.00 mm² E106 TO ENGINE ECU
TO
/5.C3
E004:49
F9 - 10A
W 1.00 mm² E107 TO ENGINE ECU
TO
/5.C3
E004:53
F17 - 10A
V 1.50 mm² E108 TO ENGINE ECU
TO
/5.C3
E004:57
F16 - 10A
U TO ENGINE ECU
B POWER HOLD RELAY
K1
1.50 mm² E109 TO
/5.C3
E004:60
-P093 -C005 -C029 -E009
D
B
FROM PRIMARY FUSE H 4.00 mm² 319 1/2 1/2 4.00 mm² 319 1/29 1/29 4.00 mm² E300 E F15 - 10A
T 2.00 mm² E110 TO ENGINE CONNECTOR
/2.C6 FROM TO
/5.C5
P048:B E005:A
F1 - 3A F14 - 10A
S 2.00 mm² E111 TO ENGINE CONNECTOR
TO
/5.B5
E005:E
F13 - 5A
R 1.00 mm² E119 TO COOLANT & ENG OIL LEVEL
TO
/5.E7
SPLICE SE11
F11 - 5A
A 1.00 mm² E463 TO PURGE HOLD INHIBIT RELAY
TO
/6.E3
P013:1 / E026:11
F12 - 3A
F 1.00 mm² E112 TO AGGLOMERATOR
TO
/5.D5
E002:A
F10 - 5A
C
P 1.00 mm² E400 TO ENGINE ECU

TO
/5.C3
E004:2
A
A
1 2 3 4 5 6 7 8
33 - 21 9813/9100-1 33 - 21
Page Page
33-22 33-23
Figure 1239.
1 (Part 1 of 2) 2 3 4
FROM BATTERY
/2.E4
-P010 TO ENGINE ECU

/5.D3 TO
NEUTRAL START E004:39

4
-P093 -C005 -C029 -E009
FROM CRANK 4.00 mm² 004 1 2 4.00 mm² 842A TO FUSE 02A FROM FUSE 02A 4.00 mm² 842 2/2 2/2 4.00 mm² 842 4/29 4/29 4.00 mm² 842 4.00 mm²
/3.E3 FROM TO
/3.E4 /3.E5 FROM
SPLICE SP52 P001:3 P001:4 -SE04

FROM IGNITION FUSE 0.75 mm² 100H 3 5
/3.A6 FROM
P001:2 / SP20
TO 07/11 CONNECTOR 1 1.00 mm² 601NS

/22.E3 TO
P069:2
-P119
E REMOTE START
4 TO INSTRUMENT CLUSTER J2
FROM IGNITION FEED 4.00 mm² 200AB 1 2 4.00 mm² 004A TO CRANK
/3.E1 FROM TO
/3.E2
SPLICE SP51 SPLICE SP52 TO INSTRUMENT CLUSTER J1
FROM HYDRAULICS ECU J3 1.00 mm² 718RSH 3 5 1.00 mm² 781RSL TO RADIO RECEIVER
/24.E7 FROM TO
/4.C1
C047:13 / P039:A9 C016:4 / P039:C3
TO ENGINE RUNNING RELAY
FROM BATTERY 20.00 mm² RED

/2.B4 FROM
-E001
FUSE/RELAY BOX
Page 33-23
START SIGNAL
(MICRO RELAY)
K2
-P039 -C015 -C016
FROM REMOTE START RELAY 1.00 mm² 781RSL C3/84 C3/84 1.00 mm² 781RSL 4/8 G B
/4.E2 FROM
P119:5
F3
N 1.00 mm² E407
F5 - 10A
K
C F6 - 10A
J
FUEL PUMP
(MICRO RELAY)
K3
F2 - 10A
L 1.50 mm² E801
F4 - 3A
M 1.00 mm² E408
F7 - 10A
H 0.75 mm² E115
F8 - 10A
X 1.00 mm² E106
F9 - 10A
W 1.00 mm² E107
F17 - 10A
V 1.50 mm² E108
F16 - 10A
U
B D
POWER HOLD RELAY
K1
1.50 mm² E109
-P093 -C005 -C029 -E009

FROM PRIMARY FUSE H 4.00 mm² 319 1/2 1/2 4.00 mm² 319 1/29 1/29 4.00 mm² E300 E F15 - 10A
T 2.00 mm² E110
/2.C6 FROM
P048:B
F1 - 3A F14 - 10A
S 2.00 mm² E111
F13 - 5A
R 1.00 mm² E119
F11 - 5A
A 1.00 mm² E463
F12 - 3A
F 1.00 mm² E112
F10 - 5A
C
P 1.00 mm² E400
1 2 3 4
33 - 22 9813/9100-1 33 - 22
Page Page
33-22 33-23
Figure 1239. (Part

5 2 of 2) 6 7 8
F
FROM BATTERY 95.00 mm² RED 25.00 mm² RED
/2.E4 FROM
-ST03 M10
STARTER MOTOR ALTERNATOR
-B002 30
V-Batt
M10
-E009 -C029
M5 50 U
4.00 mm² 842 4.00 mm² 842A 2/29 2/29 4.00 mm² 842A
W
V
Start
-SE04 -C002
Control
M DF W B+
M8 B+
D-
M5 W
W B+
L
REGULATOR
L
31
M5
GND
-ST04
-ST05
-ST06
25.00 mm² RED
-P039 -C015 -C004 -ST01 E

TO INSTRUMENT CLUSTER J2 412 1.00 mm² 412 1.00 mm² A5/84 A5/84 412 1.00 mm² A/3 A/3 1.00 mm² 412
/9.E5 TO
P072:7
-ST01
TO INSTRUMENT CLUSTER J1 407B 1.00 mm² -SP14 407 1.00 mm² B5/84 B5/84 407 1.00 mm² B/3 B/3 1.00 mm² 407
/9.D3 TO
P071:11
TO ENGINE RUNNING RELAY 1.00 mm² 407F

/12.F1 TO
P014:3
D
GRID HEATER
-CS2 -CS4
GRID HEATER FUSE -C002 M6 1
20.00 mm² RED 1 2 20.00 mm² RED 12V

150A
-E020
70 A
GRID HEATER
Page 33-22
-CS5 M6 M6 -C001 20.00 mm² RED
0.75 mm² E115 1/2 2/2 TO ENGINE ECU

E116 0.75 mm²
TO
/5.D5
1.00 mm² E407 TO ENGINE ECU E004:48
TO
/5.C3
E004:28
C
-E003
FUEL PUMP
1 2 TO GROUND
1.50 mm² E801 M 1.50 mm² E601F TO
/21.E1
SPLICE SE02
1.00 mm² E408 TO ENGINE ECU
TO
/5.C3
E004:40
0.75 mm² E115

TO
/5.C3
E004:49
TO
/5.C3
E004:53
TO
/5.C3
E004:57
TO
/5.C3
E004:60
B
2.00 mm² E110 TO ENGINE CONNECTOR
TO
/5.C5
E005:A
2.00 mm² E111 TO ENGINE CONNECTOR
TO
/5.B5
E005:E
1.00 mm² E119 TO COOLANT & ENG OIL LEVEL
TO
/5.E7
SPLICE SE11
1.00 mm² E463 TO PURGE HOLD INHIBIT RELAY
TO
/6.E3
P013:1 / E026:11
1.00 mm² E112 TO AGGLOMERATOR
TO
/5.D5
E002:A

TO
/5.C3
E004:2
5 6 7 8
33 - 23 9813/9100-1 33 - 23
33 - 24 9813/9100-1 33 - 24
Page 33-26 Figure 1240. Engine- ECU and

Sensors - 160/F8689-3 - sheet 5 of 37 Page 33-27
1 2 3 4 5 6 7 8
-E004
F -E008 ENGINE ECU
TMAF
F
BLANK A x/6
BATTERY VOLTAGE B 2/6 0.50 mm² E424 18/62 18/62
GROUND
C 3/6 0.50 mm² E422 52/62 52/62
4/6 0.50 mm² E421 38/62 38/62 FROM ADDITIONAL FUSE 1.00 mm² 100RDM
OUTPUT SIGNAL D /3.C3 FROM
5/6 0.50 mm² E423 22/62 22/62

P131:2 / SP66
IAT E
x/6 TO GROUND 1.00 mm² 600RDM
BLANK
F /20.E4 TO
SPLICE SP3
FROM ADDITIONAL FUSE 1.00 mm² 300RDM 0.50 mm² CAN 10 L FROM CAN L
/3.C3 FROM FROM
/17.E4
P132:2
0.50 mm² CAN 10 H FROM CAN H
FROM
/17.E4
-P137 -E030
DAILY CHECKS ENG OIL LEVEL
11/20 1/20 1.00 mm² 300RDM 7216/0001 -P135 -C023 7216/0002 -C167 -E026 1.00 mm² E119A 1/2
12/20 2/20 1.00 mm² 600RDM 3/6 3/6 1.00 mm² 419 9/12 9/12 1.00 mm² E419 2/2
E 13/20 3/20 0.50 mm² CAN 10 L
-C056 14/20 4/20 0.50 mm² CAN 10 H
E
-C029 -E009
ACCELERATOR 6/29 6/29 1.00 mm² E430 21/62 21/62 15/20 5/20 1.00 mm² 419E -SE11 0.75 mm² E119B 1/2
7216/0001 -P135 -C023 7216/0002 -C167 -E026
1.00 mm² 562 1 2 1.00 mm² 561 7/29 7/29 1.00 mm² E429 17/62 17/62 16/20 6/20 1.00 mm² 420CL 4/6 4/6 1.00 mm² 420 10/12 10/12 0.75 mm² E420 2/2
+5V TR1 SIG
3 1.00 mm² 560 8/29 8/29 1.00 mm² E428 14/62 14/62 17/20 7/20 1.00 mm² 421WBL
TR1 GND
9/29 9/29 1.00 mm² E427 15/62 15/62 18/20 8/20 1.00 mm² 100RDM -E021
5 1.00 mm² 564 10/29 10/29 1.00 mm² E426 29/62 29/62 19/20 9/20 FROM FUSE / RELAY BOX 1.00 mm² E119 COOLANT LEVEL
TR2 SIG /4.B5 FROM
1.00 mm² 563 4 6 1.00 mm² 565 11/29 11/29 1.00 mm² E425 19/62 19/62 20/20 10/20
F13 / E001:R
+5V TR2 GND
1.00 mm² 421WBL FROM WASHER BOTTLE LEVEL

FROM
/13.C6
FROM CAN L0 0.50 mm² CAN L 23/62 23/62
C001:2 / P039:G4
/17.B7 FROM
FROM CAN HI 0.50 mm² CAN H 27/62 27/62

/17.B7 FROM
FROM ENG CAN HI 0.50 mm² CAN H 45/62 45/62

/18.D2 FROM
D 48/62 48/62 0.75 mm² E116 FROM GRID HEATER

/4.C7
D
FROM
FROM ENG CAN LO 0.50 mm² CAN L 50/62 50/62

E020:2
/18.D2 FROM
FROM CRANK SIGNAL -E002

1.00 mm² E105B 39/62 39/62
/4.F4 FROM
AGGLOMERATOR
SPLICE SE04
A/3 1.00 mm² E112 FROM FUSE / RELAY BOX
FROM
/4.A5
FROM FUSE / RELAY BOX 1.00 mm² E106 49/62 49/62 55/62 55/62 1.00 mm² E401 B/3
F12 / E001:F
/4.B5 FROM
F8 / E001:X C/3 1.00 mm² E601B TO CHASSIS GROUND

TO
/21.E1
FROM FUSE / RELAY BOX 1.00 mm² E407 28/62 28/62
SPLICE SE02
/4.C5 FROM
K2 / E001:N (START)
/4.A5 FROM
K1 / E001:P (POWER HOLD)

/4.C5 FROM
K3 / E001:M (FUEL PUMP) 6/62 6/62 1.00 mm² E411

/4.B5 FROM
F9 / E001:W
C FROM FUSE / RELAY BOX 1.50 mm² E108 57/62 57/62 FROM FUSE / RELAY BOX
/4.B5 /4.B5 C
FROM FROM
F17 / E001:V F15 / E001:T

FROM FUSE / RELAY BOX 1.50 mm² E109 60/62 60/62 TO CHASSIS GROUND
/4.B5 FROM
/21.F1 TO
F16 / E001:U SPLICE SE02

-P039 -C015
FROM FUSE 06A 1.00 mm² 107B E7/84 E7/84 1.00 mm² 107B 5/29 5/29 1.00 mm² E103 44/62 44/62 FROM ENG CAN LO
/3.E5 FROM
/18.C4 FROM
P001:12
-C029 -E009
FROM ENG CAN HI 2.00 mm² E110 A/14
/18.C4 FROM
1.00 mm² E601E B/14

FROM FUSE / RELAY BOX 0.50 mm² CAN L C/14
/4.B5 FROM
F14 / E001:S 0.50 mm² CAN H D/14 -E005

TO CHASSIS GROUND 1.50 mm² E600A 58/62 58/62 TO CHASSIS GROUND 2.00 mm² E111 E/14
/21.E1 TO
/21.F1 TO
SPLICE SE01 SPLICE SE02 1.00 mm² E601D F/14

TO CHASSIS GROUND 1.50 mm² E600B 59/62 59/62 1.00 mm² E411 G/14
/21.D1 TO
SPLICE SE01
TO CHASSIS GROUND 1.50 mm² E600C 61/62 61/62
/21.D1 TO
SPLICE SE01
TO CHASSIS GROUND 1.50 mm² E600D 62/62 62/62
/21.D1 TO
-E006
SPLICE SE01
B VACUUM SWITCH
B
-P039 -C015 -C029 -E009
TO INSTRUMENT CLUSTER J2 1.00 mm² 402 B7/84 B7/84 1.00 mm² 402 27/29 27/29 0.50 mm² E441 1/2 1 2 2/2 0.50 mm² E601K TO CHASSIS GROUND
/9.E5 TO TO
/21.F1
P072:1 SPLICE SE02
-C031
FUEL LEVEL SENSOR
-P039 -C015
TO INSTRUMENT DISP J2 1.00 mm² 408 B6/84 B6/84 1.00 mm² 408 B/2 1 2 A/2 1.00 mm² 608FS TO CHASSIS GROUND
/9.D5 TO
Sig GND TO
/21.C4
P072:11 SPLICE SC4
A
A
1 2 3 4 5 6 7 8
33 - 25 9813/9100-1 33 - 25
Page Page
33-26 33-27
Figure 1240.
1 (Part 1 of 2) 2 3 4
-E004
F -E008 ENGINE ECU
TMAF
BLANK A x/6
BATTERY VOLTAGE B 2/6 0.50 mm² E424 18/62 18/62
GROUND
C 3/6 0.50 mm² E422 52/62 52/62
4/6 0.50 mm² E421 38/62 38/62 FROM ADDITIONAL FUSE
OUTPUT SIGNAL D /3.C3 FROM
5/6 0.50 mm² E423 22/62 22/62

P131:2 / SP66
IAT E
x/6 TO GROUND
BLANK
F /20.E4 TO
SPLICE SP3
FROM ADDITIONAL FUSE
/3.C3 FROM
P132:2
-P137
DAILY CHECKS
11/20 1/20
12/20 2/20
E 13/20 3/20
-C056 14/20 4/20
-C029 -E009
ACCELERATOR 6/29 6/29 1.00 mm² E430 21/62 21/62 15/20 5/20
1.00 mm² 562 1 2 1.00 mm² 561 7/29 7/29 1.00 mm² E429 17/62 17/62 16/20 6/20
+5V TR1 SIG
3 1.00 mm² 560 8/29 8/29 1.00 mm² E428 14/62 14/62 17/20 7/20
TR1 GND
9/29 9/29 1.00 mm² E427 15/62 15/62 18/20 8/20
5 1.00 mm² 564 10/29 10/29 1.00 mm² E426 29/62 29/62 19/20 9/20
TR2 SIG
1.00 mm² 563 4 6 1.00 mm² 565 11/29 11/29 1.00 mm² E425 19/62 19/62 20/20 10/20
+5V TR2 GND
FROM CAN L0 0.50 mm² CAN L 23/62 23/62

/17.B7 FROM
FROM CAN HI 0.50 mm² CAN H 27/62 27/62

/17.B7 FROM
FROM ENG CAN HI 0.50 mm² CAN H 45/62 45/62

/18.D2 FROM
D 48/62 48/62 0.75 mm² E116 FROM GRID HEATER

FROM
/4.C7
FROM ENG CAN LO 0.50 mm² CAN L 50/62 50/62
E020:2
/18.D2 FROM
FROM CRANK SIGNAL -E002

1.00 mm² E105B 39/62 39/62
/4.F4 FROM
AGGLOMERATOR
SPLICE SE04
A/3
FROM FUSE / RELAY BOX 1.00 mm² E106 49/62 49/62 55/62 55/62 1.00 mm² E401 B/3
/4.B5 FROM
F8 / E001:X
Page 33-27
C/3
/4.C5 FROM
K2 / E001:N (START)
/4.A5 FROM
K1 / E001:P (POWER HOLD)

/4.C5 FROM
K3 / E001:M (FUEL PUMP) 6/62 6/62 1.00 mm² E411

/4.B5 FROM
F9 / E001:W
C FROM FUSE / RELAY BOX 1.50 mm² E108 57/62 57/62 FROM FUSE / RELAY BOX
/4.B5 FROM
F17 / E001:V
FROM FUSE / RELAY BOX 1.50 mm² E109 60/62 60/62 TO CHASSIS GROUND
/4.B5 FROM
F16 / E001:U
-P039 -C015
FROM FUSE 06A 1.00 mm² 107B E7/84 E7/84 1.00 mm² 107B 5/29 5/29 1.00 mm² E103 44/62 44/62 FROM ENG CAN LO
/3.E5 FROM
P001:12
-C029 -E009
FROM ENG CAN HI
FROM FUSE / RELAY BOX
TO CHASSIS GROUND 1.50 mm² E600A 58/62 58/62 TO CHASSIS GROUND

/21.E1 TO
SPLICE SE01
TO CHASSIS GROUND 1.50 mm² E600B 59/62 59/62
/21.D1 TO
SPLICE SE01
TO CHASSIS GROUND 1.50 mm² E600C 61/62 61/62
/21.D1 TO
SPLICE SE01
TO CHASSIS GROUND 1.50 mm² E600D 62/62 62/62
/21.D1 TO
SPLICE SE01
B
TO INSTRUMENT CLUSTER J2 1.00 mm² 402

/9.E5 TO
P072:1
TO INSTRUMENT DISP J2 1.00 mm² 408

/9.D5 TO
P072:11
1 2 3 4
33 - 26 9813/9100-1 33 - 26
Page Page
33-26 33-27
Figure 1240. (Part

5 2 of 2) 6 7 8
FROM ADDITIONAL FUSE 1.00 mm² 100RDM

/3.C3 FROM
P131:2 / SP66
TO GROUND 1.00 mm² 600RDM
/20.E4 TO
SPLICE SP3
FROM ADDITIONAL FUSE 1.00 mm² 300RDM 0.50 mm² CAN 10 L FROM CAN L
/3.C3 FROM FROM
/17.E4
P132:2
0.50 mm² CAN 10 H FROM CAN H
FROM
/17.E4
-P137 -E030
DAILY CHECKS ENG OIL LEVEL
11/20 1/20 1.00 mm² 300RDM 7216/0001 -P135 -C023 7216/0002 -C167 -E026 1.00 mm² E119A 1/2
12/20 2/20 1.00 mm² 600RDM 3/6 3/6 1.00 mm² 419 9/12 9/12 1.00 mm² E419 2/2
13/20 3/20 0.50 mm² CAN 10 L
14/20 4/20 0.50 mm² CAN 10 H
E
15/20 5/20 1.00 mm² 419E -SE11 0.75 mm² E119B 1/2
7216/0001 -P135 -C023 7216/0002 -C167 -E026
16/20 6/20 1.00 mm² 420CL 4/6 4/6 1.00 mm² 420 10/12 10/12 0.75 mm² E420 2/2
17/20 7/20 1.00 mm² 421WBL
18/20 8/20 1.00 mm² 100RDM -E021
19/20 9/20 FROM FUSE / RELAY BOX 1.00 mm² E119 COOLANT LEVEL
/4.B5 FROM
20/20 10/20
F13 / E001:R
1.00 mm² 421WBL FROM WASHER BOTTLE LEVEL

FROM
/13.C6
C001:2 / P039:G4
FROM GRID HEATER

/4.C7
D
FROM
E020:2
-E002
AGGLOMERATOR
A/3 1.00 mm² E112 FROM FUSE / RELAY BOX

FROM
/4.A5
B/3
F12 / E001:F
TO CHASSIS GROUND
Page 33-26
C/3 1.00 mm² E601B TO

/21.E1
SPLICE SE02
FROM FUSE / RELAY BOX

/4.B5 C
FROM
F15 / E001:T
TO CHASSIS GROUND
/21.F1 TO
SPLICE SE02
FROM ENG CAN LO
/18.C4 FROM
FROM ENG CAN HI 2.00 mm² E110 A/14

/18.C4 FROM
1.00 mm² E601E B/14

FROM FUSE / RELAY BOX 0.50 mm² CAN L C/14
/4.B5 FROM
F14 / E001:S 0.50 mm² CAN H D/14 -E005

TO CHASSIS GROUND 2.00 mm² E111 E/14
/21.F1 TO
SPLICE SE02 1.00 mm² E601D F/14

1.00 mm² E411 G/14
-E006
VACUUM SWITCH
B
-P039 -C015 -C029 -E009
TO INSTRUMENT CLUSTER J2 1.00 mm² 402 B7/84 B7/84 1.00 mm² 402 27/29 27/29 0.50 mm² E441 1/2 1 2 2/2 0.50 mm² E601K TO CHASSIS GROUND
/9.E5 TO TO
/21.F1
P072:1 SPLICE SE02
-C031
FUEL LEVEL SENSOR
-P039 -C015
TO INSTRUMENT DISP J2 1.00 mm² 408 B6/84 B6/84 1.00 mm² 408 B/2 1 2 A/2 1.00 mm² 608FS TO CHASSIS GROUND
/9.D5 TO
Sig GND TO
/21.C4
P072:11 SPLICE SC4
5 6 7 8
33 - 27 9813/9100-1 33 - 27
33 - 28 9813/9100-1 33 - 28
Page 33-30 Figure 1241. Engine- After treatment

- 160/F8689-3 - sheet 6 of 37 Page 33-31
1 2 3 4 5 6 7 8
-C010E
SCR ECU
-C001
F ISOLATION FUSE
TO BATT ISOLATOR
2.50 mm² 6300A 1/94 1/94
F
-P018 /2.C2 FROM 10.00 mm² BLACK 10.00 mm² BLACK -C002 2.50 mm² 6300E 2/94 2/94
PURGE HOLD INHIBIT BATTERY SIDE GROUND 1.50 mm² 6300C 7/94 7/94 GROUND
7216/0001 -P135 -C023 7216/0002 80A
4 1.00 mm² 463A 6/6 6/6
M10
4.00 mm² 6300B -SJ8 1.50 mm² 6300F 29/94 29/94
1.00 mm² 463 1 2 -C003
ISOLATION RELAY
FROM IGNITION FUSE 1.00 mm² 100ISO 3 5 1.00 mm² 600ISO 70 A
/3.B7 FROM
P001:2 / SP20 TO BATT ISOLATOR 10.00 mm² BLACK

M6 M6
/2.C2 FROM
CHASSIS SIDE
-C086 -C001
TO GROUND 1.00 mm² 463A 1/20 1/20 1.00 mm² 463 1/2 2/2
/20.C6 TO
SPLICE SP62
-C410LH
7216/0001 -P135 -C023 7216/0002 -C167 -E026 SUPPLY MODULE
1.00 mm² 463 5/6 5/6 1.00 mm² 463 11/12 11/12 1.00 mm² E463 FROM FUSE / RELAY BOX
FROM
/4.A5 -E097
F11 / E001:A 1/12
-E035 DOSING MODULE
2/12 0.75 mm² 8207 76/94 76/94
NOx DOWNSTREAM/TAIL PIPE
1/2 3/12 0.75 mm² 8206 55/94 55/94
1/5 0.50 mm² 8223A 2/2 4/12 0.75 mm² 8208 54/94 54/94
E 2/5 0.50 mm² 6302C TO CHASSIS GROUND 5/12 0.75 mm² 8209 77/94 77/94
/21.E1 E
TO
3/5 0.50 mm² CAN L

SPLICE SE01 6/12 0.75 mm² 8210 78/94 78/94
4/5 0.50 mm² CAN H FROM ENG CAN LO -E109 7/12
FROM
/18.D4
5/5 EXHAUST INLET TEMP 8/12 0.75 mm² 8213 40/94 40/94
FROM ENG CAN HI 1 2 9/12 0.75 mm² 8212 39/94 39/94
FROM
/18.D4 + SIG
10/12 0.75 mm² 8211 17/94 17/94
-E036
11/12 1.50 mm² 8204 4/94 4/94
NOx UPSTREAM ENG OUT
12/12 1.50 mm² 8205 3/94 3/94
1/5 0.50 mm² 8223C -SE09
2/5 0.50 mm² 6302A TO CHASSIS GROUND
TO
/21.E1 -E026 -C167 -C086 -C001
3/5 0.50 mm² CAN L
SPLICE SE01 1/12 1/12 1.00 mm² 4205 2/20 2/20 0.75 mm² 4205 0.75 mm² 4205 83/94 83/94
4/5 0.50 mm² CAN H FROM ENG CAN LO 2/12 2/12 1.00 mm² 4206 3/20 3/20 0.75 mm² 4206 0.75 mm² 4206 61/94 61/94
FROM
/18.D5
5/5 0.50 mm² 6302B FROM ENG CAN HI 3/12 3/12 1.00 mm² 8202 4/20 4/20 0.75 mm² 8202 0.75 mm² 8202 80/94 80/94
/18.D3 FROM
FROM ENG CAN HI 4/12 4/12 1.00 mm² 8203 5/20 5/20 0.75 mm² 8203 0.75 mm² 8203 58/94 58/94
FROM
/18.D5
FROM ENG CAN LO 0.50 mm² CAN H 5/12 5/12 0.50 mm² CAN H -SDMC10 0.50 mm² CAN H 12/20 12/20 0.50 mm² CAN H -SDMC13 0.50 mm² CAN H 82/94 82/94
/18.D3 FROM
TO CHASSIS GROUND 0.50 mm² CAN L 6/12 6/12 0.50 mm² CAN L -SDMC11 0.50 mm² CAN L 13/20 13/20 0.50 mm² CAN L -SDMC14 0.50 mm² CAN L 60/94 60/94
TO
/21.E1
SPLICE SE01 FROM ENG CAN SHLD 7/12 7/12 0.50 mm² SCR -SDMC12 0.50 mm² SCR 14/20 14/20 0.50 mm² SCREEN -SDMC15 0.50 mm² SCREEN
/18.D3 FROM
D 8/12 8/12 1.00 mm² 8223A -SC28 1.00 mm² 8223 7/20 7/20 1.00 mm² 8223X -SCREEN 7
D
FROM CAN H 0.50 mm² CAN H 66/94 66/94
/17.A7 FROM
FROM FUSE 16B CAN BASED QUALITY SENSOR FROM CAN L

2.00 mm² 3100A -C440E 0.50 mm² CAN L 65/94 65/94
/3.C5 FROM
7214/0025 /17.A7 FROM
P002:12 -P009 1/4 1/4 0.50 mm² CAN H

HEATED HOSE POWER RELAY 2/4 2/4 0.50 mm² CAN L
0.50 mm² SCREEN

4 3/4 3/4 1.00 mm² 8223B
0.50 mm² CAN H

0.50 mm² CAN L
FROM FUSE 49E 2.00 mm² 300HH 2.00 mm² 300HH 1 2 2.00 mm² 8214A 4/4 4/4 1.00 mm² 6300F TO CHASSIS GROUND
/3.C7 FROM TO
/21.C4
P005:18 0.50 mm² SCREEN
SPLICE SC4
1.00 mm² 8215A 3 5 1.00 mm² 8216 -SCREEN 6
A/3
C/3
B/3
-P009 -C440E
C
B
A
HOSE HEATER 1 (RED) 1.00 mm² 8223Z -SJ45
9
1.50 mm² 8225 6 7 1.50 mm² 6301A -C006

C DIESEL MAX TERMINATOR RES
1.00 mm² 8215B 8 10 1.00 mm² 8217
C
2.50 mm² 3100C 5/94 5/94
-SP39 1.00 mm² 8215 2.50 mm² 3100E 6/94 6/94

V+ BATT
-P199 -C007 1.50 mm² 3100F 51/94 51/94
-P101 2.00 mm² 3100A 1/12 1/12 2.00 mm² 3100A 1.50 mm² 3100G 73/94 73/94
NOx SENSOR 1.50 mm² 8223 2/12 2/12 1.50 mm² 8223 -SAB1
4 1.00 mm² 8215 3/12 3/12 0.75 mm² 8215 0.75 mm² 8215 53/94 53/94
FROM FUSE 33D 1.50 mm² 300NX 1.50 mm² 300NX 1 2 1.50 mm² 8223 1.00 mm² 8217 4/12 4/12 0.75 mm² 8217 0.75 mm² 8217 94/94 94/94
/3.E7 FROM
P004:6 1.00 mm² 8219 5/12 5/12 0.75 mm² 8219 0.75 mm² 8219 50/94 50/94
FROM FUSE 05A 1.00 mm² 1100A 1.00 mm² 1100A 3 5 1.00 mm² 6302X 1.00 mm² 8222 6/12 6/12 0.75 mm² 8222 0.75 mm² 8222 28/94 28/94
/3.E6 FROM
P001:10 1.00 mm² 8216 7/12 7/12 0.75 mm² 8216 0.75 mm² 8216 93/94 93/94
2.00 mm² 8214A 8/12 8/12 2.00 mm² 8214A -SJ64 0.75 mm² 8214 71/94 71/94
FROM FUSE 05A 1.00 mm² 1100 1.00 mm² 1100 9/12 9/12 0.75 mm² 1100 0.75 mm² 1100 22/94 22/94
/3.E6 FROM
P001:10 1.50 mm² 8225 10/12 10/12 1.50 mm² 8225 -SJ65 0.75 mm² 8218 72/94 72/94
1.50 mm² 8226 11/12 11/12 1.50 mm² 8226 -SJ66 0.75 mm² 8220 49/94 49/94
-P102 -SJ67
B HOSE HEATER 2 (WHITE)
1.50 mm² 8227 12/12 12/12 1.50 mm² 8227A 0.75 mm² 8221 27/94 27/94
B
4 -C240E
1.50 mm² 8226 1 2 1.50 mm² 6301B HOSE HEATER 1 (RED)
1/2 1.50 mm² 8214C
1.00 mm² 8215C 3 5 1.00 mm² 8219 2/2 1.50 mm² 8225A
-C260E
HOSE HEATER 2 (WHITE) -C200E
TANK HEATER VALVE
-P102 1/2 1.50 mm² 8214E
HOSE HEATER 3 (YELLOW) -P025 2/2 1.50 mm² 8226A 1/2 0.75 mm² 8200 75/94 75/94
9 AFTER TREATMENT GND 2/2 0.75 mm² 8201 92/94 92/94
6 7 M10
1.50 mm² 8227 1.50 mm² 6031C 4.00 mm² 6001 -C280E
-SP46 HOSE HEATER 3 (YELLOW)
1.00 mm² 8215D 8 10 1.00 mm² 8222 1/2 1.50 mm² 8214F
2/2 1.50 mm² 8227
A
A
1 2 3 4 5 6 7 8
33 - 29 9813/9100-1 33 - 29
Page Page
33-30 33-31
Figure 1241.
1 (Part 1 of 2) 2 3 4
-C001
F ISOLATION FUSE
-P018 TO BATT ISOLATOR 10.00 mm² BLACK 10.00 mm² BLACK
/2.C2 FROM
PURGE HOLD INHIBIT BATTERY SIDE

7216/0001 -P135 -C023 7216/0002 80A
4 1.00 mm² 463A 6/6 6/6
1.00 mm² 463 1 2 -C003
ISOLATION RELAY
FROM IGNITION FUSE 1.00 mm² 100ISO 3 5 1.00 mm² 600ISO 70 A
/3.B7 FROM
P001:2 / SP20 TO BATT ISOLATOR 10.00 mm² BLACK

M6 M6
/2.C2 FROM
CHASSIS SIDE
-C086 -C001
TO GROUND 1.00 mm² 463A 1/20 1/20 1.00 mm² 463 1/2 2/2
/20.C6 TO
SPLICE SP62
7216/0001 -P135 -C023 7216/0002 -C167 -E026

1.00 mm² 463 5/6 5/6 1.00 mm² 463 11/12 11/12 1.00 mm² E463 FROM FUSE / RELAY BOX
FROM
/4.A5 -E097
F11 / E001:A
-E035 DOSING MODULE
NOx DOWNSTREAM/TAIL PIPE
1/2
1/5 0.50 mm² 8223A 2/2
E 2/5 0.50 mm² 6302C TO
TO CHASSIS GROUND
/21.E1
3/5 0.50 mm² CAN L
SPLICE SE01
4/5 0.50 mm² CAN H FROM ENG CAN LO -E109
FROM
/18.D4
5/5 EXHAUST INLET TEMP
FROM ENG CAN HI 1 2
FROM
/18.D4 + SIG
-E036
NOx UPSTREAM ENG OUT
1/5 0.50 mm² 8223C -SE09

2/5 0.50 mm² 6302A TO CHASSIS GROUND
TO
/21.E1 -E026 -C167
3/5 0.50 mm² CAN L
SPLICE SE01 1/12 1/12 1.00 mm² 4205
4/5 0.50 mm² CAN H FROM ENG CAN LO 2/12 2/12 1.00 mm² 4206
FROM
/18.D5
5/5 0.50 mm² 6302B FROM ENG CAN HI 3/12 3/12 1.00 mm² 8202
/18.D3 FROM
FROM ENG CAN HI 4/12 4/12 1.00 mm² 8203

FROM
/18.D5
FROM ENG CAN LO 0.50 mm² CAN H 5/12 5/12 0.50 mm² CAN H -SDMC10 0.50 mm² CAN H
/18.D3 FROM
TO CHASSIS GROUND 0.50 mm² CAN L 6/12 6/12 0.50 mm² CAN L -SDMC11 0.50 mm² CAN L
TO
/21.E1
SPLICE SE01 FROM ENG CAN SHLD 7/12 7/12 0.50 mm² SCR -SDMC12 0.50 mm² SCR
/18.D3 FROM
D 8/12 8/12 1.00 mm² 8223A -SC28 1.00 mm² 8223
FROM FUSE 16B CAN BASED QUALITY SENSOR

2.00 mm² 3100A -C440E
/3.C5 FROM
7214/0025
P002:12 -P009 1/4 1/4 0.50 mm² CAN H
HEATED HOSE POWER RELAY 2/4 2/4 0.50 mm² CAN L
4 3/4 3/4 1.00 mm² 8223B
FROM FUSE 49E 2.00 mm² 300HH 2.00 mm² 300HH 1 2 2.00 mm² 8214A 4/4 4/4 1.00 mm² 6300F TO CHASSIS GROUND
/3.C7 FROM TO
/21.C4
P005:18 SPLICE SC4
Page 33-31
0.50 mm² SCREEN
1.00 mm² 8215A 3 5 1.00 mm² 8216 -SCREEN 6
-P009 -C440E
HOSE HEATER 1 (RED)
9
1.50 mm² 8225 6 7 1.50 mm² 6301A

C
1.00 mm² 8215B 8 10 1.00 mm² 8217
-SP39 1.00 mm² 8215
-P199 -C007
-P101 2.00 mm² 3100A 1/12 1/12 2.00 mm²
NOx SENSOR 1.50 mm² 8223 2/12 2/12 1.50 mm²
4 1.00 mm² 8215 3/12 3/12 0.75 mm²
FROM FUSE 33D 1.50 mm² 300NX 1.50 mm² 300NX 1 2 1.50 mm² 8223 1.00 mm² 8217 4/12 4/12 0.75 mm²
/3.E7 FROM
P004:6 1.00 mm² 8219 5/12 5/12 0.75 mm²

FROM FUSE 05A 1.00 mm² 1100A 1.00 mm² 1100A 3 5 1.00 mm² 6302X 1.00 mm² 8222 6/12 6/12 0.75 mm²
/3.E6 FROM
P001:10 1.00 mm² 8216 7/12 7/12 0.75 mm²

2.00 mm² 8214A 8/12 8/12 2.00 mm²
FROM FUSE 05A 1.00 mm² 1100 1.00 mm² 1100 9/12 9/12 0.75 mm²
/3.E6 FROM
P001:10 1.50 mm² 8225 10/12 10/12 1.50 mm²

1.50 mm² 8226 11/12 11/12 1.50 mm²
B -P102 1.50 mm² 8227 12/12 12/12 1.50 mm²

HOSE HEATER 2 (WHITE)
4 -C240E
1.50 mm² 8226 1 2 1.50 mm² 6301B HOSE HEATER 1 (RED)
1/2 1.50 mm² 8214C
1.00 mm² 8215C 3 5 1.00 mm² 8219 2/2 1.50 mm² 8225A
-C260E
HOSE HEATER 2 (WHITE)
-P102 1/2 1.50 mm² 8214E
HOSE HEATER 3 (YELLOW) -P025 2/2 1.50 mm² 8226A
9 AFTER TREATMENT GND
6 7 M10
1.50 mm² 8227 1.50 mm² 6031C 4.00 mm² 6001 -C280E
-SP46 HOSE HEATER 3 (YELLOW)
1.00 mm² 8215D 8 10 1.00 mm² 8222 1/2 1.50 mm² 8214F
2/2 1.50 mm² 8227
1 2 3 4
33 - 30 9813/9100-1 33 - 30
Page Page
33-30 33-31
Figure 1241. (Part

5 2 of 2) 6 7 8
-C010E
SCR ECU
2.50 mm² 6300A 1/94 1/94

F
10.00 mm² BLACK -C002 2.50 mm² 6300E 2/94 2/94
GROUND 1.50 mm² 6300C 7/94 7/94 GROUND
M10
4.00 mm² 6300B -SJ8 1.50 mm² 6300F 29/94 29/94
-C410LH
SUPPLY MODULE
1/12
DOSING MODULE
2/12 0.75 mm² 8207 76/94 76/94
3/12 0.75 mm² 8206 55/94 55/94
4/12 0.75 mm² 8208 54/94 54/94
5/12 0.75 mm² 8209 77/94 77/94
6/12 0.75 mm² 8210 78/94 78/94
E
7/12
EXHAUST INLET TEMP 8/12 0.75 mm² 8213 40/94 40/94
2 9/12 0.75 mm² 8212 39/94 39/94
10/12 0.75 mm² 8211 17/94 17/94
11/12 1.50 mm² 8204 4/94 4/94
12/12 1.50 mm² 8205 3/94 3/94
-C086 -C001
2/20 2/20 0.75 mm² 4205 0.75 mm² 4205 83/94 83/94
3/20 3/20 0.75 mm² 4206 0.75 mm² 4206 61/94 61/94
4/20 4/20 0.75 mm² 8202 0.75 mm² 8202 80/94 80/94
5/20 5/20 0.75 mm² 8203 0.75 mm² 8203 58/94 58/94
0.50 mm² CAN H 12/20 12/20 0.50 mm² CAN H -SDMC13 0.50 mm² CAN H 82/94 82/94
-SDMC11 0.50 mm² CAN L 13/20 13/20 0.50 mm² CAN L -SDMC14 0.50 mm² CAN L 60/94 60/94
-SDMC12 0.50 mm² SCR 14/20 14/20 0.50 mm² SCREEN -SDMC15 0.50 mm² SCREEN
-SC28 1.00 mm² 8223 7/20 7/20 1.00 mm² 8223X -SCREEN 7
D
FROM CAN H 0.50 mm² CAN H 66/94 66/94
/17.A7 FROM
FROM CAN L 0.50 mm² CAN L 65/94 65/94

/17.A7 FROM
0.50 mm² SCREEN
0.50 mm² CAN H

0.50 mm² CAN L
TO CHASSIS GROUND
TO
/21.C4
SPLICE SC4
Page 33-30
A/3
C/3
B/3
-C440E
C
B
1.00 mm² 8223Z -SJ45
-C006
DIESEL MAX TERMINATOR RES
C
2.50 mm² 3100C 5/94 5/94

2.50 mm² 3100E 6/94 6/94
V+ BATT
-C007 1.50 mm² 3100F 51/94 51/94
1/12 2.00 mm² 3100A 1.50 mm² 3100G 73/94 73/94
2/12 1.50 mm² 8223 -SAB1
3/12 0.75 mm² 8215 0.75 mm² 8215 53/94 53/94
4/12 0.75 mm² 8217 0.75 mm² 8217 94/94 94/94
5/12 0.75 mm² 8219 0.75 mm² 8219 50/94 50/94
6/12 0.75 mm² 8222 0.75 mm² 8222 28/94 28/94
7/12 0.75 mm² 8216 0.75 mm² 8216 93/94 93/94
8/12 2.00 mm² 8214A -SJ64 0.75 mm² 8214 71/94 71/94
9/12 0.75 mm² 1100 0.75 mm² 1100 22/94 22/94
10/12 1.50 mm² 8225 -SJ65 0.75 mm² 8218 72/94 72/94
11/12 1.50 mm² 8226 -SJ66 0.75 mm² 8220 49/94 49/94
12/12 1.50 mm² 8227A -SJ67 0.75 mm² 8221 27/94 27/94
B
OSE HEATER 1 (RED)
1.50 mm² 8214C
1.50 mm² 8225A
OSE HEATER 2 (WHITE) -C200E

TANK HEATER VALVE
1.50 mm² 8214E
1.50 mm² 8226A 1/2 0.75 mm² 8200 75/94 75/94
2/2 0.75 mm² 8201 92/94 92/94
SE HEATER 3 (YELLOW)
1.50 mm² 8214F
1.50 mm² 8227
5 6 7 8
33 - 31 9813/9100-1 33 - 31
33 - 32 9813/9100-1 33 - 32
Page 33-34 Figure 1242. Transmission -

160/F8689-3 - sheet 7 of 37 Page 33-35
1 2 3 4 5 6 7 8
F
PS750 F
-P039 -C015 -C007_C_PS750 -T001 -T003

TRANS OIL PRESSURE
TO CENTER CLUSTER 0.50 mm² 405 B10/84 B10/84 1.00 mm² 405 H/23 H/23 1.00 mm² 405 1/2 2/2 1.00 mm² 600TP
/9.B5 FROM
P040:17
-T004
REVERSE LOW SOLENOID
FROM 07/11 CONNECTOR J1 1.00 mm² 860 C5/84 C5/84 1.00 mm² 2863 D/23 D/23 1.00 mm² 860 1/2 2/2 1.00 mm² 632
/22.C3 FROM
P069:17
E -T005
REVERSE HIGH SOLENOID E
FROM 07/11 CONNECTOR J1 1.00 mm² 811 C4/84 C4/84 1.00 mm² 2862 C/23 C/23 1.00 mm² 811 1/2 2/2 1.00 mm² 631
/22.C3 FROM
P069:18
-T008
FORWARD LOW SOLENOID
FROM 07/11 CONNECTOR J1 1.00 mm² 812 C6/84 C6/84 1.00 mm² 2860 B/23 B/23 1.00 mm² 812 1/2 2/2 1.00 mm² 622
/22.E3 FROM
P069:6
-T009
FORWARD HIGH SOLENOID
FROM 07/11 CONNECTOR J1 1.00 mm² 859 B12/84 B12/84 1.00 mm² 2861 A/23 A/23 1.00 mm² 859 1/2 2/2 1.00 mm² 621
/22.E3 FROM
P069:5
D
D
FROM 07/11 CONNECTOR J1 1.50 mm² 630 G4/84 G4/84 1.00 mm² 2916/630 N/23 N/23 1.50 mm² 630
/22.E3 FROM
P069:1 -ST2
-T006
MAINSHAFT SOLENOID
FROM 07/11 CONNECTOR J1 1.50 mm² 858 B1/84 B1/84 1.00 mm² 2865 F/23 F/23 1.00 mm² 858 1/2 2/2 1.00 mm² 642
/22.C3 FROM
P069:16
-C017
FROM 07/11 CONNECTOR J1
HORN /22.D3 TO 1.00 mm² 620 G3/84 G3/84 1.00 mm² 2864/620 E/23 E/23 1.50 mm² 620 -ST1
P069:13
2.00 mm² 600F TO CHASSIS GROUND -T007
TO
/21.C5 LAYSHAFT SOLENOID
2 SPLICE SC3
2.00 mm² 814 FROM 07/11 CONNECTOR J1 1.00 mm² 857 B2/84 B2/84 1.00 mm² 2866 G/23 G/23 1.00 mm² 857 1/2 2/2 1.00 mm² 641
/22.C3 FROM
1 P069:15
C
-P037 -T010 C
COLUMN SWITCH L/H 4 WHEEL DRIVE SOLENOID
FROM HYDRAULIC ECU J5 1.00 mm² 818 K/23 K/23 1.00 mm² 818 1/2 2/2
-P039 -C015 /24.D5 FROM
FROM FUSE 30C 2.00 mm² 304B 11/14 8/14 1.00 mm² 814 E9/84 E9/84
C049:13
/3.A5 FROM
HORN
P003:20
TO HYDRAULIC ECU J3 1.00 mm² 650 M/23 M/23 1.00 mm² 650
-P106 /24.E7 TO
4TH 13/14 1.00 mm² 874 1 2 1.00 mm² 415B

C047:18
-P105
3RD 5/14 1.00 mm² 873 1 2 1.00 mm² 415A -SP34 1.00 mm² 415 TO 07/11 CONNECTOR 1
TO
/22.D3
FROM FUSE 25C 1.00 mm² 109CS -SP65 1.00 mm² 109CS2 14/14
P069:11
/3.B5 FROM
-P104
P003:10 2ND 9/14 1.00 mm² 872 1 2 1.00 mm² 414B
-P103
1ST 12/14 1.00 mm² 871 1 2 1.00 mm² 414A -SP24 1.00 mm² 414 TO 07/11 CONNECTOR 1
TO
/22.E3
P069:3
-P039 -C015
4/14 1.00 mm² 416F C10/84 C10/84 1.00 mm² 416F TO HYDRAULIC ECU J2
F TO
/24.E4
C046:9
B -P039 -C015
TO HYDRAULIC ECU J1
1.00 mm² 109CS1 7/14 N 6/14 1.00 mm² 416N E12/84 E12/84 1.00 mm² 416N TO
/24.E1 B
C045:4
-P039 -C015
10/14 1.00 mm² 416R D9/84 D9/84 1.00 mm² 416R TO HYDRAULIC ECU J2
R TO
/24.F4
C046:3
-P107
-E011
1&2 GEAR PULL DOWN 332R
TO 07/11 SENSOR GROUND 1.00 mm² 688A 2 1 1.00 mm² 414C TRANS OIL TEMP
/22.E6 TO
-P039 -C015 -C029 -E009
SPLICE SP41 TO 07/11 CONNECTOR 1 1.00 mm² 100TT F12/84 F12/84 1.00 mm² 100TT 28/29 28/29 1.00 mm² 100TT 1 2
/22.E3 TO
+VE -VE
P069:4
-P108
3&4 GEAR PULL DOWN 332R -C015 -C029 -E009
TO 07/11 SENSOR GROUND 1.00 mm² 688E 2 1 1.00 mm² 415C E1/84 1.00 mm² 600TT 29/29 29/29 1.00 mm² 600TT
/22.E6 TO
SPLICE SP41
A
A
1 2 3 4 5 6 7 8
33 - 33 9813/9100-1 33 - 33
Page Page
33-34 33-35
Figure 1242.
1 (Part 1 of 2) 2 3 4
F
PS750
-P039 -C015
TO CENTER CLUSTER 0.50 mm² 405 B10/84

/9.B5 FROM
P040:17
FROM 07/11 CONNECTOR J1 1.00 mm² 860 C5/84

/22.C3 FROM
P069:17
E
/22.C3 FROM
P069:18

/22.E3 FROM
P069:6
FROM 07/11 CONNECTOR J1 1.00 mm² 859 B12/84

/22.E3 FROM
P069:5
D
FROM 07/11 CONNECTOR J1 1.50 mm² 630 G4/84
/22.E3 FROM
P069:1
FROM 07/11 CONNECTOR J1 1.50 mm² 858 B1/84

/22.C3 FROM
P069:16
Page 33-35
-C017
FROM 07/11 CONNECTOR J1
HORN /22.D3 TO 1.00 mm² 620 G3/84
P069:13
2.00 mm² 600F TO CHASSIS GROUND
TO
/21.C5
2 SPLICE SC3
2.00 mm² 814 FROM 07/11 CONNECTOR J1 1.00 mm² 857 B2/84
/22.C3 FROM
1 P069:15
C
-P037
COLUMN SWITCH L/H
FROM HYDRAULIC ECU J5
-P039 -C015
FROM FUSE 30C 2.00 mm² 304B 11/14 8/14 1.00 mm² 814 E9/84 E9/84
/3.A5 FROM
HORN
P003:20
-P106
4TH 13/14 1.00 mm² 874 1 2 1.00 mm² 415B
-P105
3RD 5/14 1.00 mm² 873 1 2 1.00 mm² 415A -SP34 1.00 mm² 415 TO 07/11 CONNECTOR 1
TO
/22.D3
FROM FUSE 25C 1.00 mm² 109CS -SP65 1.00 mm² 109CS2 14/14
P069:11
/3.B5 FROM
-P104
P003:10 2ND 9/14 1.00 mm² 872 1 2 1.00 mm² 414B
-P103
1ST 12/14 1.00 mm² 871 1 2 1.00 mm² 414A -SP24 1.00 mm² 414 TO 07/11 CONNECTOR 1
TO
/22.E3
P069:3
-P039 -C015
4/14 1.00 mm² 416F C10/84 C10/84 1.00 mm² 416F TO HYDRAULIC ECU J2
F TO
/24.E4
C046:9
B -P039 -C015
TO HYDRAULIC ECU J1
1.00 mm² 109CS1 7/14 N 6/14 1.00 mm² 416N E12/84 E12/84 1.00 mm² 416N TO
/24.E1
C045:4
-P039 -C015
10/14 1.00 mm² 416R D9/84 D9/84 1.00 mm² 416R TO HYDRAULIC ECU J2
R TO
/24.F4
C046:3
-P107
TO 07/11 SENSOR GROUND 1.00 mm² 688A 2 1 1.00 mm² 414C
/22.E6 TO
-P039
SPLICE SP41 TO 07/11 CONNECTOR 1 1.00 mm² 100TT F12/84
/22.E3 TO
P069:4
-P108
TO 07/11 SENSOR GROUND 1.00 mm² 688E 2 1 1.00 mm² 415C
/22.E6 TO
SPLICE SP41
1 2 3 4
33 - 34 9813/9100-1 33 - 34
Page Page
33-34 33-35
Figure 1242. (Part

5 2 of 2) 6 7 8
PS750 F
-P039 -C015 -C007_C_PS750 -T001 -T003

TRANS OIL PRESSURE
0.50 mm² 405 B10/84 B10/84 1.00 mm² 405 H/23 H/23 1.00 mm² 405 1/2 2/2 1.00 mm² 600TP
-T004
REVERSE LOW SOLENOID
1.00 mm² 860 C5/84 C5/84 1.00 mm² 2863 D/23 D/23 1.00 mm² 860 1/2 2/2 1.00 mm² 632
-T005
REVERSE HIGH SOLENOID E
1.00 mm² 811 C4/84 C4/84 1.00 mm² 2862 C/23 C/23 1.00 mm² 811 1/2 2/2 1.00 mm² 631
-T008
FORWARD LOW SOLENOID
1.00 mm² 812 C6/84 C6/84 1.00 mm² 2860 B/23 B/23 1.00 mm² 812 1/2 2/2 1.00 mm² 622
-T009
FORWARD HIGH SOLENOID
1.00 mm² 859 B12/84 B12/84 1.00 mm² 2861 A/23 A/23 1.00 mm² 859 1/2 2/2 1.00 mm² 621
D
1.50 mm² 630 G4/84 G4/84 1.00 mm² 2916/630 N/23 N/23 1.50 mm² 630
-ST2
-T006
MAINSHAFT SOLENOID
1.50 mm² 858 B1/84 B1/84 1.00 mm² 2865 F/23 F/23 1.00 mm² 858 1/2 2/2 1.00 mm² 642
Page 33-34
1.00 mm² 620 G3/84 G3/84 1.00 mm² 2864/620 E/23 E/23 1.50 mm² 620 -ST1
-T007
LAYSHAFT SOLENOID
1.00 mm² 857 B2/84 B2/84 1.00 mm² 2866 G/23 G/23 1.00 mm² 857 1/2 2/2 1.00 mm² 641
-T010 C
4 WHEEL DRIVE SOLENOID
FROM HYDRAULIC ECU J5 1.00 mm² 818 K/23 K/23 1.00 mm² 818 1/2 2/2
/24.D5 FROM
C049:13
TO HYDRAULIC ECU J3 1.00 mm² 650 M/23 M/23 1.00 mm² 650
/24.E7 TO
C047:18
TO 07/11 CONNECTOR 1
/22.D3
P069:11
/22.E3
P069:3
TO HYDRAULIC ECU J2
/24.E4
C046:9
TO HYDRAULIC ECU J1 B
/24.E1
C045:4
TO HYDRAULIC ECU J2
/24.F4
C046:3
-E011
TRANS OIL TEMP
-P039 -C015 -C029 -E009
1.00 mm² 100TT F12/84 F12/84 1.00 mm² 100TT 28/29 28/29 1.00 mm² 100TT 1 2
/22.E3 TO
+VE -VE
-C015 -C029 -E009

E1/84 1.00 mm² 600TT 29/29 29/29 1.00 mm² 600TT
5 6 7 8
33 - 35 9813/9100-1 33 - 35
33 - 36 9813/9100-1 33 - 36
Page 33-38 Figure 1243. Live Link and Immobiliser

- 160/F8689-3 - sheet 8 of 37 Page 33-39
1 2 3 4 5 6 7 8
F
F
E
E
-P066
IMMOBILISER
-P068
LIVE LINK
-P101
FROM FUSE 26C 1.00 mm² 299LL M4 IMMOBILISER IGN RELAY FROM FUSE 19B 1.00 mm² Y B7 G1
/3.B5 FROM
V_BATT /3.C7 FROM
+12/24VDC Key 7
P003:12 9 P002:18 / SP27 BATT Feed G2
Key 6
1.00 mm² 110LLA M2 FROM FUSE 40D 1.00 mm² Y 6 7 1.00 mm² Y B8 G3
V_IGN /3.E7 FROM
+12/24VDC Key 5
P004:20 IGN Feed G4
Key 4
D E2
ENG_RUN
1.00 mm² Y 8 10
Key 3
G5
ANTI-TAMPER LINKJ1 J1/48 Key 2
G6 D
ANTI-TAMPER LINK G7
Key 1
H1 K1 K1/48 TO GROUND 1.00 mm² 601TS G8
CH_1_INPUT /20.E4 TO
Key 0
SPLICE SP3
-P013 G1 G9
CH_2_INPUT Status LED LS Out
LIVE LINK RELAY G10
Status LED 5V Feed
4 F1 G11
CH_3_INPUT Antenna Coil
FROM FUSE 37D 1.00 mm² 110LL 1 2 G12
/3.E7 FROM
Antenna Coil
P004:14 C1 M3 M3/48 1.00 mm² 601LB
CH_4_INPUT BATTERY NEG
FROM IGNITION FUSE 1.00 mm² 100LL 3 5 L3 L3/48 1.00 mm² 601LA 1.00 mm² 601L FROM FUSE 46E Relay 1
/3.B7 FROM
BATTERY NEG FROM
/3.C7
P001:2 / SP20 -S1 P005:12
L2 L2/48 1.00 mm² 600LL
CHASSIS GND NO
B12 MAX 7A B5
TO GROUND 1.00 mm² 601LL COM B6
CAN_SHD
/20.E4 TO
SPLICE SP3
CAN_H
7207/1513 NC
CAN_L
-T1 M10 Relay 2
C
C3
D4
E4
B3 MAX 7A B4 C
COM NO
Relay 3
0.50 mm² CAN 5 H

/17.E3 FROM
FROM CAN H
0.50 mm² CAN 5 L B1 MAX 7A B2
/17.E3 FROM
FROM CAN L COM NO

0.50 mm² CAN 5 SCR FROM CAN H 0.50 mm² CAN H B9
/17.E3 FROM
/17.B3 FROM
CAN_H
FROM CAN SHIELD 0.50 mm² CAN L B10 B11 1.00 mm² Y TO GROUND
CAN_L GND TO
/20.C4
FROM CAN L SPLICE SP6
/17.B3 FROM
B
B
A
A
1 2 3 4 5 6 7 8
33 - 37 9813/9100-1 33 - 37
Page Page
33-38 33-39
Figure 1243.
1 (Part 1 of 2) 2 3 4
-P068
LIVE LINK
-P101
FROM FUSE 26C 1.00 mm² 299LL M4 IMMOBILISER IGN RELAY
/3.B5 FROM
V_BATT
P003:12 9
1.00 mm² 110LLA M2 FROM FUSE 40D 1.00 mm² Y 6 7

V_IGN /3.E7 FROM
P004:20
D E2
ENG_RUN
1.00 mm² Y 8 10
ANTI-TAMPER LINKJ1 J1/48
ANTI-TAMPER LINK
H1 K1 K1/48 TO GROUND 1.00 mm² 601TS
CH_1_INPUT /20.E4 TO
SPLICE SP3
-P013 G1
CH_2_INPUT
LIVE LINK RELAY
4 F1
CH_3_INPUT
FROM FUSE 37D 1.00 mm² 110LL 1 2
/3.E7 FROM
P004:14
Page 33-39
C1 M3 M3/48 1.00 mm² 601LB
CH_4_INPUT BATTERY NEG
FROM IGNITION FUSE 1.00 mm² 100LL 3 5 L3 L3/48 1.00 mm² 601LA 1.00 mm² 601L FROM FUSE 46E
/3.B7 FROM
BATTERY NEG FROM
/3.C7
P001:2 / SP20 -S1 P005:12
L2 L2/48 1.00 mm² 600LL
CHASSIS GND
TO GROUND 1.00 mm² 601LL

CAN_SHD
/20.E4 TO
SPLICE SP3
CAN_H
7207/1513
CAN_L
-T1 M10
C
C3
D4
E4
0.50 mm² CAN 5 H

/17.E3 FROM
FROM CAN H
0.50 mm² CAN 5 L
/17.E3 FROM
FROM CAN L
0.50 mm² CAN 5 SCR
/17.E3 FROM
FROM CAN SHIELD
1 2 3 4
33 - 38 9813/9100-1 33 - 38
Page Page
33-38 33-39
Figure 1243. (Part

5 2 of 2) 6 7 8
-P066
IMMOBILISER
-P101
IMMOBILISER IGN RELAY FROM FUSE 19B 1.00 mm² Y B7 G1
/3.C7 FROM
+12/24VDC Key 7
9 P002:18 / SP27 BATT Feed G2
Key 6
1.00 mm² Y 6 7 1.00 mm² Y B8 G3
+12/24VDC Key 5
IGN Feed G4
Key 4
1.00 mm² Y 8 10 G5
Key 3
Key 2
G6 D
G7
Key 1
1.00 mm² 601TS G8
Key 0
G9
Status LED LS Out
G10
Status LED 5V Feed
G11
Antenna Coil
G12
Antenna Coil
Page 33-38
Relay 1
NO
B12 MAX 7A B5
COM B6
NC
Relay 2
B3 MAX 7A B4 C
COM NO
Relay 3
B1 MAX 7A B2
COM NO
FROM CAN H 0.50 mm² CAN H B9
/17.B3 FROM
CAN_H
0.50 mm² CAN L B10 B11 1.00 mm² Y TO GROUND
CAN_L GND TO
/20.C4
FROM CAN L SPLICE SP6
/17.B3 FROM
5 6 7 8
33 - 39 9813/9100-1 33 - 39
33 - 40 9813/9100-1 33 - 40
Page 33-42 Figure 1244. Instruments -

160/F8689-3 - sheet 9 of 37 Page 33-43
1 2 3 4 5 6 7 8
F
F
TO GROUND
TO
/20.D6
SPLICE SP11
-P063
-P071 -P072 INFO BUTTON
INSTRUMENT CLUSTER INSTRUMENT CLUSTER 7 8 FROM ILLUMINATION
1.00 mm² 601HP 1.00 mm² 829AH FROM
/19.D5
FROM ILLUMINATION 1.00 mm² 829AB 1/20 1/20 1.00 mm² 402 FROM VACUUM SWITCH SPLICE SP7
/19.D6 FROM FROM
/5.B5
SPLICE SP7 J1 J2 E006:1 / P039:B7
FROM FUSE 39D 1.00 mm² 106 2/20 2/20
/3.E7 FROM
P004:18 2 0.75 mm² 100K FROM IGNITION FUSE

FROM
/3.B7
TO AC RELAY 1.00 mm² 884AC 3/20 3/20 0.75 mm² 2910 0.75 mm² 2910 3 P001:2 / SP20
/14.C2
E
TO
P015:3
1.00 mm² 877 4/20 4/20 0.75 mm² 800R FROM COLUMN SWITCH E
FROM
/11.B3
RH P038:10
5/20 5/20 1.00 mm² 887A FROM HEATER CONTROL
FROM
/14.A4
P034:3
6/20 6/20 1.00 mm² 1840C FROM REVERSE FAN SWITCH
FROM
/16.D3
P061:6
FROM CAN L 0.50 mm² CAN 7 L 7/20 7/20 1.00 mm² 412 FROM STARTER MOTOR
/17.E4 FROM FROM
/4.E5
C005:B / P039:C1
FROM CAN H 0.50 mm² CAN 7 H 8/20 8/20 1.00 mm² 593 FROM SPEED SENSOR
/17.E3 FROM FROM
/16.D5
E014:3 / C029:18
FROM CAN SHIELD 0.50 mm² CAN 7 SCR 9/20 9/20 1.00 mm² 801A FROM HEATER
/17.E4 FROM FROM
/14.B1
SPLICE SP50
1.00 mm² 301EA 10/20 10/20 2.00 mm² 805F TO INDICATOR DIODE
TO
/11.B5
SPLICE SP8
FROM ENGINE RUNNING 1.00 mm² 407B 11/20 11/20 1.00 mm² 408 FROM FUEL LEVEL SENSOR
/4.E5 FROM FROM
/5.A5
SPLICE SP14 C010:B / P039:B6
D TO REV FAN SOLENOID 1.00 mm² 1840 12/20 12/20
/16.E4
D
TO
E012:2 / P039:A10
FROM HAZARD SWITCH 0.75 mm² 509 13/20 13/20
/11.C3 FROM
P020:6
TO FOOTBRAKE DUMP SW 1.00 mm² 601EC FROM TRAILER R/H DI RELAY 0.75 mm² 806RC 14/20 14/20
/31.D4 TO
/11.E7 FROM
P019:7 P016:7 / SP36

FROM HEATER CONTROL 1.00 mm² 610HV 15/20 15/20 1.00 mm² 481A FROM FRONT/REAR AUX SWITCH
/14.B4 FROM FROM
/26.C4
-P099 P034:5 P017:3 / SP69
ECO SWITCH FROM TRAILER L/H DI RELAY 0.75 mm² 805LC 16/20 16/20 1.00 mm² 410/496 FROM RH STAB TRANSD
/11.E7 FROM FROM
/37.F5
FROM FOOTBRAKE DUMP SW 1.00 mm² 829EC 8 7 P016:2 / SP37 C067:1 / P039:G1
/31.D2 FROM
P019:8 FROM COLUMN SWITCH 0.75 mm² 800L 17/20 17/20 1.00 mm² 601DE TO GROUND
/11.B3 FROM TO
/20.E6
RH P038:11 SPLICE SP11
FROM REVERSE FAN SWITCH 1.00 mm² 1840D 18/20 18/20 1.00 mm² 997 FROM HEATER CONTROL
/16.D3 FROM FROM
/14.A4
1.00 mm² 601EO 2 P061:3 SPLICE SP5
-P039
3 1.00 mm² 601EC 1.00 mm² 601EC 19/20 19/20 1.00 mm² 592 F6/84
FROM FUSE 35D 1.00 mm² 301E 1.00 mm² 301EB 20/20 20/20 2.00 mm² 806A TO INDICATOR DIODE
/3.E7 FROM TO
/11.B5
P004:10 -SP40 /9.C4 /9.C4 SPLICE SP9
C
C
-P040
CENTER CLUSTER
FROM ILLUMINATION 0.50 mm² 829WL 1/20 11/20 0.50 mm² 941A FROM FOG LIGHT SWITCH
/19.B5 FROM FROM
/10.E4
SPLICE SP7 P023:3
FROM MAIN BEAM 0.50 mm² 838A 2/20 12/20
/10.A4 FROM
-P014 SPLICE SP19

TRAILER SENSE FROM INDICATORS 0.50 mm² 804B 3/20 13/20
/11.C3 FROM
9 SPLICE SP49
FROM ENGINE RUNNING RELAY 0.75 mm² 601TS 6 7 0.50 mm² 601TSW 0.50 mm² 601TSW 4/20 14/20
/12.E1 FROM
P014:5
1.00 mm² 877 8 10 0.75 mm² 601TSA 5/20 15/20
B FROM WORKLIGHTS SWITCH

/12.F5 FROM 0.50 mm² 609BC 6/20 16/20 B
P026:6
FROM WORKLIGHTS SWITCH 0.50 mm² 609AB 7/20 17/20 0.50 mm² 405 TO TRANS OIL PRESSURE
/12.F5 FROM TO
/7.F4
P026:3 T003:1 / P039:B10
FROM BOOM WORKLIGHTS SWITCH 0.50 mm² 610AB 8/20 18/20
/12.E5 FROM
P029:3
9/20 19/20
TO GROUND 0.50 mm² 601P 10/20 IGN 20/20 0.50 mm² 106C FROM IGNITION FUSE
/20.C4 TO FROM
/3.A7
SPLICE SP6 P001:2 / SP20
A
A
1 2 3 4 5 6 7 8
33 - 41 9813/9100-1 33 - 41
Page Page
33-42 33-43
Figure 1244.
1 (Part 1 of 2) 2 3 4
-P071 -P072
INSTRUMENT CLUSTER INSTRUMENT CLUSTER
FROM ILLUMINATION 1.00 mm² 829AB 1/20 1/20
/19.D6 FROM
SPLICE SP7 J1 J2
FROM FUSE 39D 1.00 mm² 106 2/20 2/20
/3.E7 FROM
P004:18
TO AC RELAY 1.00 mm² 884AC 3/20 3/20
/14.C2
E
TO
P015:3
1.00 mm² 877 4/20 4/20
5/20 5/20
6/20 6/20
FROM CAN L 0.50 mm² CAN 7 L 7/20 7/20

/17.E4 FROM
FROM CAN H 0.50 mm² CAN 7 H 8/20 8/20

/17.E3 FROM
FROM CAN SHIELD 0.50 mm² CAN 7 SCR 9/20 9/20

/17.E4 FROM
1.00 mm² 301EA 10/20 10/20
FROM ENGINE RUNNING 1.00 mm² 407B 11/20 11/20

/4.E5 FROM
SPLICE SP14
D TO REV FAN SOLENOID 1.00 mm² 1840 12/20 12/20
/16.E4 TO
E012:2 / P039:A10
FROM HAZARD SWITCH 0.75 mm² 509 13/20 13/20
/11.C3 FROM
P020:6
TO FOOTBRAKE DUMP SW 1.00 mm² 601EC FROM TRAILER R/H DI RELAY 0.75 mm² 806RC 14/20 14/20
/31.D4 TO
/11.E7 FROM
P019:7 P016:7 / SP36

FROM HEATER CONTROL 1.00 mm² 610HV 15/20 15/20
/14.B4 FROM
-P099 P034:5
ECO SWITCH FROM TRAILER L/H DI RELAY 0.75 mm² 805LC 16/20 16/20
/11.E7 FROM
FROM FOOTBRAKE DUMP SW P016:2 / SP37
Page 33-43
1.00 mm² 829EC 8 7
/31.D2 FROM
P019:8 FROM COLUMN SWITCH 0.75 mm² 800L 17/20 17/20

/11.B3 FROM
RH P038:11
FROM REVERSE FAN SWITCH 1.00 mm² 1840D 18/20 18/20
/16.D3 FROM
1.00 mm² 601EO 2 P061:3

3 1.00 mm² 601EC 1.00 mm² 601EC 19/20 19/20
FROM FUSE 35D 1.00 mm² 301E 1.00 mm² 301EB 20/20 20/20
/3.E7 FROM
P004:10 -SP40 /9.C4 /9.C4

C
-P040
CENTER CLUSTER
FROM ILLUMINATION 0.50 mm² 829WL 1/20 11/20 0.50 mm² 941A
/19.B5 FROM
SPLICE SP7
FROM MAIN BEAM 0.50 mm² 838A 2/20 12/20
/10.A4 FROM
-P014 SPLICE SP19

TRAILER SENSE FROM INDICATORS 0.50 mm² 804B 3/20 13/20
/11.C3 FROM
9 SPLICE SP49
FROM ENGINE RUNNING RELAY 0.75 mm² 601TS 6 7 0.50 mm² 601TSW 0.50 mm² 601TSW 4/20 14/20
/12.E1 FROM
P014:5
1.00 mm² 877 8 10 0.75 mm² 601TSA 5/20 15/20
B FROM WORKLIGHTS SWITCH 0.50 mm² 609BC 6/20 16/20

/12.F5 FROM
P026:6
FROM WORKLIGHTS SWITCH 0.50 mm² 609AB 7/20 17/20 0.50 mm² 405
/12.F5 FROM
P026:3
FROM BOOM WORKLIGHTS SWITCH 0.50 mm² 610AB 8/20 18/20
/12.E5 FROM
P029:3
9/20 19/20
TO GROUND 0.50 mm² 601P 10/20 IGN 20/20 0.50 mm² 106C
/20.C4 TO
SPLICE SP6
1 2 3 4
33 - 42 9813/9100-1 33 - 42
Page Page
33-42 33-43
Figure 1244. (Part

5 2 of 2) 6 7 8
TO GROUND
TO
/20.D6
SPLICE SP11
-P063
-P072 INFO BUTTON
INSTRUMENT CLUSTER 7 8 FROM ILLUMINATION
1.00 mm² 601HP 1.00 mm² 829AH FROM
/19.D5
1/20 1.00 mm² 402 FROM VACUUM SWITCH SPLICE SP7
FROM
/5.B5
J2 E006:1 / P039:B7
2/20
2 0.75 mm² 100K FROM IGNITION FUSE
FROM
/3.B7
3/20 0.75 mm² 2910 0.75 mm² 2910 3 P001:2 / SP20
4/20 0.75 mm² 800R FROM COLUMN SWITCH E

FROM
/11.B3
RH P038:10
5/20 1.00 mm² 887A FROM HEATER CONTROL
FROM
/14.A4
P034:3
6/20 1.00 mm² 1840C FROM REVERSE FAN SWITCH
FROM
/16.D3
P061:6
7/20 1.00 mm² 412 FROM STARTER MOTOR
FROM
/4.E5
C005:B / P039:C1
8/20 1.00 mm² 593 FROM SPEED SENSOR
FROM
/16.D5
E014:3 / C029:18
9/20 1.00 mm² 801A FROM HEATER
FROM
/14.B1
SPLICE SP50
10/20 2.00 mm² 805F TO INDICATOR DIODE
TO
/11.B5
SPLICE SP8
11/20 1.00 mm² 408 FROM FUEL LEVEL SENSOR
FROM
/5.A5
C010:B / P039:B6
12/20
D
13/20
14/20
15/20 1.00 mm² 481A FROM FRONT/REAR AUX SWITCH

FROM
/26.C4
P017:3 / SP69
16/20 1.00 mm² 410/496 FROM RH STAB TRANSD
FROM
/37.F5
C067:1 / P039:G1
Page 33-42
17/20 1.00 mm² 601DE TO GROUND

TO
/20.E6
SPLICE SP11
18/20 1.00 mm² 997 FROM HEATER CONTROL
FROM
/14.A4
SPLICE SP5
-P039
19/20 1.00 mm² 592 F6/84
20/20 2.00 mm² 806A TO INDICATOR DIODE

TO
/11.B5
/9.C4 SPLICE SP9
CENTER CLUSTER
11/20 0.50 mm² 941A FROM FOG LIGHT SWITCH

FROM
/10.E4
P023:3
12/20
13/20
14/20
15/20
16/20 B
17/20 0.50 mm² 405 TO TRANS OIL PRESSURE
TO
/7.F4
T003:1 / P039:B10
18/20
19/20
20/20 0.50 mm² 106C FROM IGNITION FUSE

FROM
/3.A7
P001:2 / SP20
5 6 7 8
33 - 43 9813/9100-1 33 - 43
33 - 44 9813/9100-1 33 - 44
Page 33-46 Figure 1245. Roadlights -

160/F8689-3 - sheet 10 of 37 Page 33-47
1 2 3 4 5 6 7 8
TO GROUND
/20.C4
10 - ROADLIGHTS
TO
SPLICE SP6 -P011

F -P023 BRAKE LIGHTS -C061
FOG LIGHT SWITCH 4 NUMBER PLATE LIGHT
F
1.00 mm² 816
FROM ILLUMINATION 1.00 mm² 829AE 8 7 1.00 mm² 601DC FROM FUSE 08A 1.00 mm² 108 1 2 1.00 mm² 829AA 1/2 2/2 1.00 mm² 604AA TO GROUND
/19.C6 FROM
/3.E5 FROM TO
/21.C3
SPLICE SP7 P001:16 SPLICE SC8
FROM IGNITION FUSE 0.75 mm² 100J 3 5 0.75 mm² 616B TO 07/11 CONNECTOR 1 -C064
/3.A6 FROM TO
/22.D3
P001:2 / SP20 P069:7 NUMBER PLATE LIGHT
FROM FUSE 45E 1.00 mm² 905 2 1.00 mm² 829AB 1/2 2/2 1.00 mm² 604AB TO GROUND
/3.D7 FROM TO
/21.C3
P005:10 3 1.00 mm² 941
SPLICE SC8
0.50 mm² 941A TO CENTER CLUSTER
TO
/9.B5
P040:11 -C062
L/H REAR LIGHTS
-P039 -C015
1.00 mm² 816 A7/84 A7/84 1.50 mm² 816 -SC22 1.00 mm² 816B 1/6 BRAKE
1.00 mm² 829A D11/84 D11/84 1.00 mm² 829A -SC19 1.00 mm² 829RL -SC20 1.00 mm² 829LH 2/6 SIDE
TO L/H TURN SIGNAL DIODE 2.00 mm² 805D D4/84 D4/84 2.00 mm² 805D 2.00 mm² 805D 3/6 DI
/11.C6 FROM
P031:1 / SP8 1.00 mm² 941 E5/84 E5/84 1.00 mm² 941 -SC23 1.00 mm² 941L 4/6 FOG
1.00 mm² 870A 5/6 REVERSE
GROUND 6/6 2.00 mm² 604RL TO GROUND
/21.C3
E
TO
TO JOYSTICK SWITCH ILLUMITION 1.00 mm² 829JI

SPLICE SC8
/33.F1 E
TO
C038:8 / JS01:9 -C063

R/H REAR LIGHTS
-P039 -C015 1.00 mm² 816C 1/6 BRAKE

E2/84 E2/84 1.00 mm² 830 -SC18 1.00 mm² 830F 2/6 SIDE
TO R/H TURN SIGNAL DIODE 2.00 mm² 806C D3/84 D3/84 2.00 mm² 806C -SC21 2.00 mm² 806E 3/6 DI
/11.C6 FROM
P032:1 / SP9 1.00 mm² 941R 4/6 FOG

C7/84 C7/84 1.00 mm² 807 -SC24 1.00 mm² 807B 5/6 REVERSE
GROUND 6/6 2.00 mm² 604RR TO GROUND
TO
/21.C3
SPLICE SC8
REVERSE ALARM
7212/0052 7212/0051 7212/0052
-C065 +VE -C1_RL
-C2_RL -S1_RL
1.00 mm² 807C 1/2 1/2 1.00 mm² 807 1.00 mm² 807A 1/2 1
TO CHASSIS GROUND 1.00 mm² 604RA 2/2 2/2 1.00 mm² 604 1.00 mm² 604A 2/2 2
/21.C3 TO
SPLICE SC8
-VE
D -S2_RL
D
LOW PRESSURE RELIEF VALVE
7212/0052 332/G6755
-C3_RL
-P064B 1.00 mm² 807B 1/2 1/2
DIODE
2.00 mm² 942C 2 1 2.00 mm² 947B FROM BOOM WORKLIGHTS 1.00 mm² 604B 2/2 2/2
FROM
/12.E6
SPLICE SP31 -P010
TO GROUND 0.75 mm² 601BF REVERSE ALARM -C043
/20.C4 TO
-P064A
SPLICE SP6 9 TRAILOR SOCKET
DIODE
2.00 mm² 942A 2.00 mm² 831J FROM WORKLIGHTS 1.50 mm² 807A 7 6 1.50 mm² 109RA FROM FUSE 21C FROM L/H DIRECTIONAL 1.00 mm² 805LA 1/8
FROM
/12.E6 FROM
/3.B5 /11.E7 FROM
FROM IGNITION FUSE 0.75 mm² 100D -P024 2 1 SPLICE SP23 P003:2 SPLICE SP37 / C015:E10 1.00 mm² 941TS 2/8 FOG
/3.A7 FROM
P001:2 / SP20 HEADLIGHTS 0.75 mm² 601RA 10 8 0.50 mm² 807 FROM 07/11 CONNECTOR 1 2.00 mm² 601BR 3/8
FROM
/22.D3
8 7 0.75 mm² 601BF 2.00 mm² 942D TO FUSE FROM ILLUMINATION 1.00 mm² 829A P069:14 FROM R/H DIRECTIONAL 1.00 mm² 806RA 4/8
TO
/3.D6 /19.C5 FROM
/11.E7 FROM
FROM FUSE 28C 2.00 mm² 307

P005:5 SPLICE SP7 SPLICE SP36 / C015:E11 1.00 mm² 830TS 5/8 SIDE RH
/3.B5 FROM
P003:16 FROM ROADLIGHT RELAY 1.00 mm² 816A 6/8 BRAKE

FROM
/10.B1
1 P013:10 1.00 mm² 829TS 7/8 SIDE LH
-P013 2 TO FUSE FROM FUSE 44E 0.75 mm² 830 8/8
C /3.D6 /3.D7
TO FROM
ROADLIGHTS 3 2.00 mm² 942B -SP22 P005:7 P005:8

9 4 1.00 mm² 891 TO FRONT WORKLIGHTS RELAY TO GROUND C
TO
/12.D3 TO
/21.B3
FROM FUSE 29C 2.00 mm² 306 6 7 2.00 mm² 828 5 P012:3 SPLICE SC8
/3.A5 FROM
P003:18 6 2.00 mm² 832 1.00 mm² 832B TO FUSE -P041

TO
/3.D6
FROM IGNITION FUSE 0.75 mm² 100C 8 10 -SP21 P005:9 LH HEADLIGHT
/3.A7 FROM
P001:2 / SP20
Dipped
1.50 mm² 834A 2
TO REVERSE ALARM 1.00 mm² 601RA
/10.C5 TO
Main
RELAY P010:10 2.00 mm² 838C 3
TO GROUND 1.00 mm² 601V 6 2.00 mm² 601BZ TO GROUND

/20.D4 TO
Side TO
/20.B1
SPLICE SP29 FROM ILLUMINATION 1.00 mm² 829 4 SPLICE SP61
/19.D5 FROM
SPLICE SP7
-P038 DI
TO L/H TURN SIGNAL DIODE 2.00 mm² 805C 5
COLUMN SWITCH R/H /11.D6 FROM
P031:1 / SP8 1
3/14
TWO SPEED
ONLY
2/14 -C009
RH HEADLIGHTS
B FROM FUSE 30C
/3.A5 FROM
2.00 mm² 304A 4/14 -P039 -C015 Dipped B
P003:20 9/14 2.00 mm² 833 TO FUSE FROM FUSE 41E 1.50 mm² 834 -SP18 1.50 mm² 834B D10/84 D10/84 1.50 mm² 834B 2
TO
/3.D6 /3.D7 FROM
2.00 mm² 832A 8/14 HEADLIGHT P005:1 P005:2

FLASHER -P039 -C015 Main
13/14 2.00 mm² 836 TO FUSE FROM FUSE 42E 2.00 mm² 838 -SP19 2.00 mm² 838B A11/84 A11/84 2.00 mm² 838B 3
TO
/3.D6 /3.D7 FROM
P005:3 P005:4 6 2.00 mm² 600Y TO CHASSIS GROUND

Side TO
/21.D3
1.00 mm² 830B 4 SPLICE SC05
L 10/14 TO CENTER CLUSTER 0.50 mm² 838A

/9.B4 TO
DI
14/14 INDICATORS P040:2 2.00 mm² 806D 5
11/14 1
R
7/14
1/14 WIPER 12/14
WASHER 6/14
A
A
1 2 3 4 5 6 7 8
33 - 45 9813/9100-1 33 - 45
Page Page
33-46 33-47
Figure 1245.
1 (Part 1 of 2) 2 3 4
TO GROUND
/20.C4 TO
SPLICE SP6
F -P023
FOG LIGHT SWITCH
FROM ILLUMINATION 1.00 mm² 829AE 8 7 1.00 mm² 601DC FROM FUSE 08A 1.00 mm²
/19.C6 FROM
/3.E5 FROM
SPLICE SP7 P001:16

FROM IGNITION FUSE 0.75 mm²
/3.A6 FROM
P001:2 / SP20
FROM FUSE 45E 1.00 mm² 905 2
/3.D7 FROM
P005:10 3 1.00 mm² 941

0.50 mm² 941A TO CENTER CLUSTER
TO
/9.B5
P040:11
-P039 -C015
1.00 mm² 816 A7/84 A7/84 1.50 mm²
1.00 mm² 829A D11/84 D11/84 1.00 mm²
TO L/H TURN SIGNAL DIODE 2.00 mm² 805D D4/84 D4/84 2.00 mm²
/11.C6 FROM
P031:1 / SP8 1.00 mm² 941 E5/84 E5/84 1.00 mm²
E TO JOYSTICK SWITCH ILLUMITION

/33.F1 TO 1.00 mm²
C038:8 / JS01:9
-P039 -C015
E2/84 E2/84 1.00 mm² 830
TO R/H TURN SIGNAL DIODE 2.00 mm² 806C D3/84 D3/84 2.00 mm² 806C
/11.C6 FROM
P032:1 / SP9
C7/84 C7/84 1.00 mm² 807
-P064B
DIODE
2.00 mm² 942C 2 1 2.00 mm² 947B FROM BOOM WORKLIGHTS
FROM
/12.E6
SPLICE SP31 -P010
TO GROUND 0.75 mm² 601BF REVERSE ALARM
/20.C4 TO
-P064A
Page 33-47
SPLICE SP6 DIODE
9
2.00 mm² 942A 2.00 mm² 831J FROM WORKLIGHTS 1.50 mm² 807A 7 6 1.50 mm² 109RA FROM FUSE 21C
FROM
/12.E6 FROM
/3.B5
FROM IGNITION FUSE 0.75 mm² 100D -P024 2 1 SPLICE SP23 P003:2
/3.A7 FROM
P001:2 / SP20 HEADLIGHTS 0.75 mm² 601RA 10 8 0.50 mm² 807 FROM 07/11 CONNECTOR 1
FROM
/22.D3
8 7 0.75 mm² 601BF 2.00 mm² 942D TO FUSE FROM ILLUMINATION 1.00 mm² 829A P069:14
TO
/3.D6 /19.C5 FROM
FROM FUSE 28C 2.00 mm² 307

P005:5 SPLICE SP7
/3.B5 FROM
P003:16 FROM ROADLIGHT RELAY

FROM
/10.B1
1 P013:10
-P013 2 TO FUSE FROM FUSE 44E 0.75 mm² 830
C /3.D6 /3.D7
TO FROM
ROADLIGHTS 3 2.00 mm² 942B -SP22 P005:7 P005:8

9 4 1.00 mm² 891 TO FRONT WORKLIGHTS RELAY
TO
/12.D3
FROM FUSE 29C 2.00 mm² 306 6 7 2.00 mm² 828 5 P012:3
/3.A5 FROM
P003:18 6 2.00 mm² 832 1.00 mm² 832B TO FUSE

TO
/3.D6
FROM IGNITION FUSE 0.75 mm² 100C 8 10 -SP21 P005:9
/3.A7 FROM
P001:2 / SP20
TO REVERSE ALARM 1.00 mm² 601RA

/10.C5 TO
RELAY P010:10
TO GROUND 1.00 mm² 601V
/20.D4 TO
SPLICE SP29
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY
2/14
B FROM FUSE 30C 2.00 mm² 304A 4/14

/3.A5 FROM
P003:20 9/14 2.00 mm² 833 TO FUSE FROM FUSE 41E 1.50 mm² 834 -SP18
TO
/3.D6 /3.D7 FROM
2.00 mm² 832A 8/14 HEADLIGHT P005:1 P005:2

FLASHER TO FUSE FROM FUSE 42E -SP19
13/14 2.00 mm² 836 2.00 mm² 838
TO
/3.D6 /3.D7 FROM
P005:3 P005:4
L 10/14 TO CENTER CLUSTER 0.50 mm² 838A

/9.B4 TO
14/14 INDICATORS P040:2

R 11/14
7/14
1/14 WIPER 12/14
WASHER 6/14
1 2 3 4
33 - 46 9813/9100-1 33 - 46
Page Page
33-46 33-47
Figure 1245. (Part

5 2 of 2) 6 7 8
-P011
BRAKE LIGHTS
10 - ROADLIGHTS
-C061 F
4 1.00 mm² 816 NUMBER PLATE LIGHT
FROM FUSE 08A 1.00 mm² 108 1 2 1.00 mm² 829AA 1/2 2/2 1.00 mm² 604AA TO GROUND
/3.E5 FROM TO
/21.C3
P001:16 SPLICE SC8
FROM IGNITION FUSE 0.75 mm² 100J 3 5 0.75 mm² 616B TO 07/11 CONNECTOR 1 -C064
/3.A6 FROM TO
/22.D3
P001:2 / SP20 P069:7 NUMBER PLATE LIGHT
1.00 mm² 829AB 1/2 2/2 1.00 mm² 604AB TO GROUND
TO
/21.C3
SPLICE SC8
TO CENTER CLUSTER
-C062
L/H REAR LIGHTS
-P039 -C015
A7/84 A7/84 1.50 mm² 816 -SC22 1.00 mm² 816B 1/6 BRAKE
D11/84 D11/84 1.00 mm² 829A -SC19 1.00 mm² 829RL -SC20 1.00 mm² 829LH 2/6 SIDE
D4/84 D4/84 2.00 mm² 805D 2.00 mm² 805D 3/6 DI
E5/84 E5/84 1.00 mm² 941 -SC23 1.00 mm² 941L 4/6 FOG
1.00 mm² 870A 5/6 REVERSE
GROUND 6/6 2.00 mm² 604RL TO GROUND
TO
/21.C3
TO JOYSTICK SWITCH ILLUMITION 1.00 mm² 829JI
SPLICE SC8
/33.F1 E
TO
C038:8 / JS01:9 -C063

R/H REAR LIGHTS
-C015 1.00 mm² 816C 1/6 BRAKE

E2/84 1.00 mm² 830 -SC18 1.00 mm² 830F 2/6 SIDE
D3/84 2.00 mm² 806C -SC21 2.00 mm² 806E 3/6 DI
1.00 mm² 941R 4/6 FOG
C7/84 1.00 mm² 807 -SC24 1.00 mm² 807B 5/6 REVERSE
GROUND 6/6 2.00 mm² 604RR TO GROUND
TO
/21.C3
SPLICE SC8
REVERSE ALARM
7212/0052 7212/0051 7212/0052
-C065 +VE -C1_RL
-C2_RL -S1_RL
1.00 mm² 807C 1/2 1/2 1.00 mm² 807 1.00 mm² 807A 1/2 1
TO CHASSIS GROUND 1.00 mm² 604RA 2/2 2/2 1.00 mm² 604 1.00 mm² 604A 2/2 2
/21.C3 TO
SPLICE SC8
-VE
-S2_RL
D
LOW PRESSURE RELIEF VALVE
7212/0052 332/G6755
-C3_RL
1.00 mm² 807B 1/2 1/2
1.00 mm² 604B 2/2 2/2

-P010
REVERSE ALARM -C043
TRAILOR SOCKET
Page 33-46
9
7 6 1.50 mm² 109RA FROM FUSE 21C FROM L/H DIRECTIONAL 1.00 mm² 805LA 1/8
FROM
/3.B5 /11.E7 FROM
P003:2 SPLICE SP37 / C015:E10 1.00 mm² 941TS 2/8 FOG

10 8 0.50 mm² 807 FROM 07/11 CONNECTOR 1 2.00 mm² 601BR 3/8
FROM
/22.D3
P069:14 FROM R/H DIRECTIONAL 1.00 mm² 806RA 4/8
/11.E7 FROM
SPLICE SP36 / C015:E11 1.00 mm² 830TS 5/8 SIDE RH

FROM ROADLIGHT RELAY 1.00 mm² 816A 6/8 BRAKE
FROM
/10.B1
P013:10 1.00 mm² 829TS 7/8 SIDE LH
8/8
TO GROUND C
TO
/21.B3
SPLICE SC8
-P041
LH HEADLIGHT
Dipped
1.50 mm² 834A 2
Main
2.00 mm² 838C 3
6 2.00 mm² 601BZ TO GROUND
Side TO
/20.B1
FROM ILLUMINATION 1.00 mm² 829 4 SPLICE SP61
/19.D5 FROM
SPLICE SP7
DI
TO L/H TURN SIGNAL DIODE 2.00 mm² 805C 5
/11.D6 FROM
P031:1 / SP8 1
-C009
RH HEADLIGHTS
-P039 -C015 Dipped B

834 -SP18 1.50 mm² 834B D10/84 D10/84 1.50 mm² 834B 2
-P039 -C015 Main

838 -SP19 2.00 mm² 838B A11/84 A11/84 2.00 mm² 838B 3
6 2.00 mm² 600Y TO CHASSIS GROUND
Side TO
/21.D3
1.00 mm² 830B 4 SPLICE SC05
838A DI
2.00 mm² 806D 5
1
5 6 7 8
33 - 47 9813/9100-1 33 - 47
33 - 48 9813/9100-1 33 - 48
Page 33-50 Figure 1246. Directional Indicators

- 160/F8689-3 - sheet 11 of 37 Page 33-51
1 2 3 4 5 6 7 8
F
F
-P016
TRAILER L/H DIRECTIONAL
4
FROM FUSE 48E 1.50 mm² 275 1.00 mm² 275LH 1 2 1.00 mm² 805LB -SP37 0.75 mm² 805LC TO INSTRUMENT CLUSTER J1
/3.C7 FROM TO
/9.C3
P005:16 -SP25 P071:16
0.75 mm² 805E 3 5 0.75 mm² 601SY TO GROUND
TO
/20.E4
SPLICE SP3
-P039 -C015
1.50 mm² 805LA E10/84 E10/84 1.00 mm² 805LA TO TRAILOR SOCKET
/10.C6
E
TO
C043:1
-P039 -C015 E
1.50 mm² 806RA E11/84 E11/84 1.00 mm² 806RA TO TRAILOR SOCKET
TO
/10.C6
-P016 C043:4
TRAILER R/H DIRECTIONAL
9
1.00 mm² 275RH 6 7 1.00 mm² 806RB 0.75 mm² 806RC TO INSTRUMENT CLUSTER J1
TO
/9.D3
-SP36 P071:14
0.50 mm² 806D 8 10 0.75 mm² 601JB TO GROUND
TO
/20.D4
SPLICE SP3
TO GROUND 0.75 mm² 601AD

/20.E6 TO
SPLICE SP11
D -SP49
D
1.00 mm² 804D TURN SIGNAL
-P020
HARZARD SWITCH
8 7 2.00 mm² 805C TO L/H HEADLIGHTS
TO
/10.B6
P041:5
-P031
L/H TURN SIGNAL DIODE
1 2.00 mm² 804 2.00 mm² 805B 2.00 mm² 805D FROM L/H TURN LIGHTS
TO
/10.E4
2.00 mm² 804A 2 2 1 -SP8 RL002:3 / P039:D4
3
4
-P032
FROM FUSE 34D 5
/3.E7 FROM 1.00 mm² 300 R/H TURN SIGNAL DIODE
P004:8 6 2.00 mm² 804C 2.00 mm² 806B 2.00 mm² 806C FROM L/H TURN LIGHTS
TO
/10.E4
2 1 -SP9 RL003:3 / P039:D3
-P038
COLUMN SWITCH R/H
C 3/14 TO INSTRUMENT CLUSTER J1 0.75 mm² 509
TWO SPEED
/9.D3
P071:13
TO
C
ONLY
2/14 TO CENTER CLUSTER 0.50 mm² 804B
/9.B4 TO
P040:3
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
L 10/14 0.75 mm² 800R TO INSTRUMENT CLUSTER J2 FROM INSTRUMENT CLUSTER J2 2.00 mm² 805F
TO
/9.E5 /9.D5 FROM
FROM FUSE 10A 1.00 mm² 104 14/14 INDICATORS

P072:4 P072:10
/3.E5 FROM
P001:20 R 11/14 0.75 mm² 800L TO INSTRUMENT CLUSTER J1 FROM INSTRUMENT CLUSTER J2 2.00 mm² 806A
TO
/9.C3 /9.C5 FROM
P071:17 P072:20
7/14
1/14 WIPER 12/14
B
WASHER 6/14 B
A
A
1 2 3 4 5 6 7 8
33 - 49 9813/9100-1 33 - 49
Page Page
33-50 33-51
Figure 1246.
1 (Part 1 of 2) 2 3 4
FROM FUSE 48E 1.50 mm²

/3.C7 FROM
P005:16
TO GROUND 0.75 mm² 601AD

/20.E6 TO
SPLICE SP11
D -SP49
1.00 mm² 804D TURN SIGNAL
-P020
HARZARD SWITCH
8 7
-P031
Page 33-51
1 2.00 mm² 804
2.00 mm² 804A 2 2 1
3
4
-P032
FROM FUSE 34D 5
/3.E7 FROM 1.00 mm² 300 R/H TURN SIGNAL DIODE
P004:8 6 2.00 mm² 804C
2 1
-P038
COLUMN SWITCH R/H
C 3/14 TO INSTRUMENT CLUSTER J1 0.75 mm² 509
/9.D3 TO
TWO SPEED P071:13

ONLY
2/14 TO CENTER CLUSTER 0.50 mm² 804B
/9.B4 TO
P040:3
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
L 10/14 0.75 mm² 800R TO INSTRUMENT CLUSTER J2 FROM INSTRUMENT CLUSTER J2

TO
/9.E5 /9.D5 FROM
FROM FUSE 10A 1.00 mm² 104 14/14 INDICATORS

P072:4 P072:10
/3.E5 FROM
P001:20 R 11/14 0.75 mm² 800L TO INSTRUMENT CLUSTER J1 FROM INSTRUMENT CLUSTER J2
TO
/9.C3 /9.C5 FROM
P071:17 P072:20
7/14
1/14 WIPER 12/14
B
WASHER 6/14
1 2 3 4
33 - 50 9813/9100-1 33 - 50
Page Page
33-50 33-51
Figure 1246. (Part

5 2 of 2) 6 7 8
-P016
TRAILER L/H DIRECTIONAL
4
FROM FUSE 48E 1.50 mm² 275 1.00 mm² 275LH 1 2 1.00 mm² 805LB -SP37 0.75 mm² 805LC TO INSTRUMENT CLUSTER J1
/3.C7 FROM TO
/9.C3
P005:16 -SP25 P071:16
0.75 mm² 805E 3 5 0.75 mm² 601SY TO GROUND
TO
/20.E4
SPLICE SP3
-P039 -C015
1.50 mm² 805LA E10/84 E10/84 1.00 mm² 805LA TO TRAILOR SOCKET
TO
/10.C6
C043:1
-P039 -C015 E
1.50 mm² 806RA E11/84 E11/84 1.00 mm² 806RA TO TRAILOR SOCKET
TO
/10.C6
-P016 C043:4
TRAILER R/H DIRECTIONAL
9
1.00 mm² 275RH 6 7 1.00 mm² 806RB 0.75 mm² 806RC TO INSTRUMENT CLUSTER J1
TO
/9.D3
-SP36 P071:14
0.50 mm² 806D 8 10 0.75 mm² 601JB TO GROUND
TO
/20.D4
SPLICE SP3
2.00 mm² 805C TO L/H HEADLIGHTS

TO
/10.B6
P041:5
-P031
FROM L/H TURN LIGHTS
Page 33-50
804 2.00 mm² 805B 2.00 mm² 805D TO

/10.E4
2 1 -SP8 RL002:3 / P039:D4
-P032
R/H TURN SIGNAL DIODE
804C 2.00 mm² 806B 2.00 mm² 806C FROM L/H TURN LIGHTS
TO
/10.E4
2 1 -SP9 RL003:3 / P039:D3
FROM INSTRUMENT CLUSTER J2 2.00 mm² 805F

/9.D5 FROM
P072:10
FROM INSTRUMENT CLUSTER J2 2.00 mm² 806A
/9.C5 FROM
P072:20
5 6 7 8
33 - 51 9813/9100-1 33 - 51
33 - 52 9813/9100-1 33 - 52
Page 33-54 Figure 1247. Worklights and Beacon

- 160/F8689-3 - sheet 12 of 37 Page 33-55
1 2 3 4 5 6 7 8
-P026
WORKLIGHTS
FROM ILLUMINATION 1.00 mm² 829J 8 7 1.00 mm² 601AC TO GROUND
F /19.C6 /20.B4
FROM TO
-P014 SPLICE SP7 SPLICE SP6

ENGINE RUNNING
F
4 1
TO GROUND 0.75 mm² 601LH 1 2 0.75 mm² 609LH 0.75 mm² 609LH 2
/20.E4 TO
SPLICE SP3 3 0.50 mm² 609AB 0.50 mm² 609AB TO CENTER CLUSTER
TO
/9.B4
FROM ENGINE RUNNING 1.00 mm² 407F 3 5 4 0.75 mm² 609AA P040:7
/4.E5 FROM
SPLICE SP14 0.75 mm² 609RH 5

6 0.50 mm² 609BC 0.50 mm² 609BC TO CENTER CLUSTER
TO
/9.B4
0.75 mm² 609BB P040:6
TO GROUND 0.75 mm² 601SH
/20.E4 TO
SPLICE SP3 0.50 mm² 610AB TO CENTER CLUSTER

TO
/9.B4
TO TRAILER SENSE RELAY 0.75 mm² 601TS -P029 P040:8
/9.B2 TO
P014:6 BOOM WORKLIGHTS

FROM ILLUMINATION 1.00 mm² 829AJ 8 7 1.00 mm² 601KA TO GROUND
/19.B6 FROM TO
/20.B4
SPLICE SP7 SPLICE SP6
E 0.75 mm² 610 2

3 0.50 mm² 610AB
E
0.75 mm² 610A
FRONT WORK LIGHTS DIODE

TO BOOM WORKLIGHT DIODE
REAR WORK LIGHTS DIODE

2.00 mm² 947B
BOOM WORKLIGHT DIODE

TO
/10.D3
P064B:1
2
2.00 mm² 831J TO WORKLIGHT DIODE
TO
/10.C3
P064A:1
-P128
-P129
-P130
-P012 -WLF003
FRONT WORKLIGHTS LH FRONT WORKLIGHT
1
1
4
-P059A -WLF001 -WLF001
FROM FUSE 17B 2.00 mm² 308 1 2 2.00 mm² 831 2.00 mm² 831 2.00 mm² 831B 1/2 2/4 2.00 mm² RED 1 2 2.00 mm² BLACK 4/4 2/2 2.00 mm² 601BU TO GROUND
/3.C5 FROM TO
/20.B1
P002:14 -SP23 SPLICE SP61
FROM HEADLIGHT SWICH 1.00 mm² 891 3 5 0.75 mm² 609A
/10.C3 FROM
P024:4 1.00 mm² 891A
D -WLF002
RH FRONT WORKLIGHT D
-P059B -WLF001 -WLF001
2.00 mm² 831K 1/2 1/4 2.00 mm² RED 1 2 2.00 mm² BLACK 3/4 2/2 2.00 mm² 601AL TO GROUND
TO
/20.B1
SPLICE SP61
-P012 -WLR003
REAR WORKLIGHTS LH REAR WORKLIGHT
9
-P049 -RC01 -RC05 -WLR001 -WLR003 -WLR001 -RC05
FROM FUSE 27C 2.00 mm² 309 6 7 2.00 mm² 945 6/20 6/20 2.00 mm² 945 2.00 mm² 945A 1/2 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601DG TO GROUND
/3.B5 FROM TO
/20.E1
P003:14 -SRC2 SPLICE SCR6
1.00 mm² 891A 8 10 0.75 mm² 609B
1.00 mm² 891B
2.00 mm² 947B
-P011 -WLR004
BOOM WORK LIGHTS RH REAR WORKLIGHT
9
C -RC08 -WLR002 -WLR004 -WLR002 -RC08
FROM FUSE 20B 2.00 mm² 312 6 7 2.00 mm² 947 2.00 mm² 945B 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601KG TO GROUND
/3.C5 /20.E1 C
FROM TO
P002:20 -SP31 SPLICE SCR6

-P126 -P127 -P127 -P126
FROM IGNITION FUSE 0.75 mm² 100QA 1/2 1/2 0.75 mm² LINK 2/2 2/2 1.00 mm² 100QB 8 10 1.00 mm² 610B
/3.B7 FROM
P001:2 / SP20 1.00 mm² 891B

ITALIAN HEAD LIGHTS (DEL)
-C076
REAR HITCH LIGHT
-P039 -C015
2.00 mm² 946 A3/84 A3/84 2.00 mm² 746 1 2 2.00 mm² 600RH TO GROUND
TO
/21.C3
SPLICE SC8
-P028
BEACON SWITCH
FROM ILLUMINATION 1.00 mm² 829U 8 7 1.00 mm² 601AY TO GROUND -C013
/19.C5 FROM TO
/20.B4
SPLICE SP7 SPLICE SP6 BOOM WORKLIGHT
-P039 -C015
-RC07 1 2 TO GROUND
B FROM FUSE 18B BEACON SOCKET
2.00 mm² 947A A1/84 A1/84 2.00 mm² 947A 2.00 mm² 601GB TO
/21.C5
SPLICE SC3
/3.C5 FROM 1.00 mm² 310 2
-P049 -RC01 -RC07 B
P002:16 3 1.00 mm² 844A 8/20 8/20 1.00 mm² 844A 2/2 2 1 1/2 1.00 mm² 601AX TO GROUND
TO
/20.F1
GND
SPLICE SRC5
INTERIOR LIGHT
-P049 -RC01 -RC10 -RC11
FROM FUSE 19B 1.00 mm² 301J 9/20 9/20 1.00 mm² 301J 1/1 1/1 1.00 mm² 601AV TO GROUND
/3.C7 FROM TO
/20.F1
P002:18 / SP27 SPLICE SRC5
A
A
1 2 3 4 5 6 7 8
33 - 53 9813/9100-1 33 - 53
Page Page
33-54 33-55
Figure 1247.
1 (Part 1 of 2) 2 3 4
-P026
WORKLIGHTS
FROM ILLUMINATION 1.00 mm² 829J 8 7 1.00 mm² 601AC TO GROUND
F /19.C6 /20.B4
FROM TO
-P014 SPLICE SP7 SPLICE SP6

ENGINE RUNNING
4 1
TO GROUND 0.75 mm² 601LH 1 2 0.75 mm² 609LH 0.75 mm² 609LH 2
/20.E4 TO
SPLICE SP3 3 0.50 mm² 609AB 0.50 mm² 609AB

FROM ENGINE RUNNING 1.00 mm² 407F 3 5 4 0.75 mm² 609AA
/4.E5 FROM
SPLICE SP14 0.75 mm² 609RH 5

6 0.50 mm² 609BC 0.50 mm² 609BC
0.75 mm² 609BB
TO GROUND 0.75 mm² 601SH
/20.E4 TO
SPLICE SP3 0.50 mm² 610AB

TO TRAILER SENSE RELAY 0.75 mm² 601TS -P029
/9.B2 TO
P014:6 BOOM WORKLIGHTS

FROM ILLUMINATION 1.00 mm² 829AJ 8 7 1.00 mm² 601KA TO GROUND
/19.B6 FROM TO
/20.B4
E 0.75 mm² 610 2

3 0.50 mm² 610AB
0.75 mm² 610A
FRONT WORK LIGHTS DIODE
REAR WORK LIGHTS DIODE
BOOM WORKLIGHT DIODE

2
2
-P128
-P129
-P130
-P012
FRONT WORKLIGHTS
1
4
FROM FUSE 17B 2.00 mm² 308 1 2 2.00 mm² 831
/3.C5 FROM
P002:14
FROM HEADLIGHT SWICH 1.00 mm² 891 3 5 0.75 mm² 609A
/10.C3 FROM
P024:4 1.00 mm² 891A
-P012
REAR WORKLIGHTS
Page 33-55
9
-P049 -RC01
FROM FUSE 27C 2.00 mm² 309 6 7 2.00 mm² 945 6/20 6/20 2.00 mm² 945
/3.B5 FROM
P003:14 -SRC2
1.00 mm² 891A 8 10 0.75 mm² 609B
1.00 mm² 891B
2.00 mm² 947B
-P011
BOOM WORK LIGHTS
9
C FROM FUSE 20B 2.00 mm² 312 6 7 2.00 mm² 947
/3.C5 FROM
P002:20 -SP31
-P126 -P127 -P127 -P126
FROM IGNITION FUSE 0.75 mm² 100QA 1/2 1/2 0.75 mm² LINK 2/2 2/2 1.00 mm² 100QB 8 10 1.00 mm² 610B
/3.B7 FROM
P001:2 / SP20 1.00 mm² 891B

ITALIAN HEAD LIGHTS (DEL)
-P028
BEACON SWITCH
FROM ILLUMINATION 1.00 mm² 829U 8 7 1.00 mm² 601AY TO GROUND
/19.C5 FROM TO
/20.B4
-RC07
B FROM FUSE 18B 2 BEACON SOCKET
1.00 mm² 310 -P049 -RC01 -RC07
/3.C5 FROM
P002:16 3 1.00 mm² 844A 8/20 8/20 1.00 mm² 844A 2/2 2 1 1/2 1.00 mm² 601AX TO GROUND
TO
/20.F1
GND
SPLICE SRC5
INTERIOR LIGHT
-P049 -RC01 -RC10 -RC11
FROM FUSE 19B 1.00 mm² 301J 9/20 9/20 1.00 mm² 301J 1/1 1/1 1.00 mm² 601AV TO GROUND
/3.C7 FROM TO
/20.F1
P002:18 / SP27 SPLICE SRC5
1 2 3 4
33 - 54 9813/9100-1 33 - 54
Page Page
33-54 33-55
Figure 1247. (Part

5 2 of 2) 6 7 8
0.50 mm² 609AB TO CENTER CLUSTER

TO
/9.B4
P040:7
0.50 mm² 609BC TO CENTER CLUSTER

TO
/9.B4
P040:6
0.50 mm² 610AB TO CENTER CLUSTER

TO
/9.B4
P040:8
2.00 mm² 947B TO BOOM WORKLIGHT DIODE

TO
/10.D3
P064B:1
2.00 mm² 831J TO WORKLIGHT DIODE

TO
/10.C3
P064A:1
-WLF003
LH FRONT WORKLIGHT
-P059A -WLF001 -WLF001

2.00 mm² 831 2.00 mm² 831B 1/2 2/4 2.00 mm² RED 1 2 2.00 mm² BLACK 4/4 2/2 2.00 mm² 601BU TO GROUND
TO
/20.B1
-SP23 SPLICE SP61
-WLF002
RH FRONT WORKLIGHT D
-P059B -WLF001 -WLF001
2.00 mm² 831K 1/2 1/4 2.00 mm² RED 1 2 2.00 mm² BLACK 3/4 2/2 2.00 mm² 601AL TO GROUND
TO
/20.B1
SPLICE SP61
-WLR003
LH REAR WORKLIGHT
Page 33-54
-RC01 -RC05 -WLR001 -WLR003 -WLR001 -RC05

6/20 2.00 mm² 945 2.00 mm² 945A 1/2 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601DG TO GROUND
TO
/20.E1
-SRC2 SPLICE SCR6
-WLR004
RH REAR WORKLIGHT
-RC08 -WLR002 -WLR004 -WLR002 -RC08

2.00 mm² 945B 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601KG TO GROUND
/20.E1 C
TO
SPLICE SCR6
-C076
REAR HITCH LIGHT
-P039 -C015
2.00 mm² 946 A3/84 A3/84 2.00 mm² 746 1 2 2.00 mm² 600RH TO GROUND
TO
/21.C3
SPLICE SC8
-C013
BOOM WORKLIGHT
-P039 -C015
2.00 mm² 947A A1/84 A1/84 2.00 mm² 947A 1 2 2.00 mm² 601GB TO GROUND
TO
/21.C5
SPLICE SC3
B
5 6 7 8
33 - 55 9813/9100-1 33 - 55
33 - 56 9813/9100-1 33 - 56
Page 33-58 Figure 1248. Wiper Motors -

160/F8689-3 - sheet 13 of 37 Page 33-59
1 2 3 4 5 6 7 8
F
F
TO GROUND
/20.B6 TO
SPLICE SP28
-P021
ROOF WIPER
FROM ILLUMINATION 1.00 mm² 829M 8 7 1.00 mm² 601BH
/19.C6 FROM
SPLICE SP7 TO SPLICE SRC5

TO
/20.E1
GROUND
1 2.00 mm² 854
2.00 mm² 849 2 -RC09
3 2.00 mm² 133E ROOF WIPER
4 2.00 mm² 601AR 1
5
6 2.00 mm² 901 2.00 mm² 133F 3
-
w
-P049 -RC01
+
2.00 mm² 854 2/20 2/20 2.00 mm² 854 2.00 mm² 854 2
E 2.00 mm² 849 3/20 3/20 2.00 mm² 849 2.00 mm² 849 4
2.00 mm² 925 5/20 5/20 2.00 mm² 925

E
TO GROUND
/20.B6 TO
SPLICE SP28 TO SPLICE SRC5

TO
/20.E1
-P022 GROUND
REAR WASH WIPE
FROM ILLUMINATION 1.00 mm² 829AF 8 7 1.00 mm² 601DX -RC04
/19.C5 FROM
SPICE SP7 REAR WIPER

2.00 mm² 601AW 1
1 2.00 mm² 926 2.00 mm² 926 4/20 4/20 2.00 mm² 926
2.00 mm² 925 2 2.00 mm² 133B 1/20 1/20 2.00 mm² 133B 2.00 mm² 133D 3
-
3 -SRC3
w
2.00 mm² 133C
4 -SP16
+
5 2.00 mm² 926 2
6 2.00 mm² 901B 2.00 mm² 925 4
-SP17
D
TO FUSE 12B
/3.D5 FROM 2.00 mm² 133 D
P002:4
-P053
WASHER PUMPS
2.00 mm² 901A 1/3

3/3 2.00 mm² 601JG TO SPLICE SP62
TO
/20.C6
1.50 mm² 839A 2/3
GROUND
-C001
WASHER BOTTLE LEVEL
7216/0002 -C023 -P135 7216/0001

1.00 mm² 100WBL 1 2 1.00 mm² 421WBL 2/6 2/6 1.00 mm² 421WBL TO DAILY CHECKS
TO
/5.D6
P137:7
C 7216/0002 -C023 -P135 7216/0001

1/6 1/6 1.00 mm² 100WBL FROM ADDITIONAL FUSE
/3.C3 C
FROM
P131:2 / SP66
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY 2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
B 9/14
-P055 B
FRONT WIPER MOTOR
L 10/14 1.50 mm² 983 4/8 1/8 2.00 mm² 600P TO SPLICE SP61
/20.B1
1.50 mm² 110D
TO
14/14 INDICATORS
GROUND
R 11/14 1.50 mm² 982 3/8
7/14 1.50 mm² 840 2/8 6/8 1.50 mm² 110D

FROM FUSE 13B 1.50 mm² 110 1.50 mm² 110E 1/14 WIPER 12/14 1.50 mm² 841 5/8
/3.D5 FROM
P002:6 -SP33
WASHER 6/14 1.50 mm² 839 1.50 mm² 839B 7/8
-SP32
A
A
1 2 3 4 5 6 7 8
33 - 57 9813/9100-1 33 - 57
Page Page
33-58 33-59
Figure 1248.
1 (Part 1 of 2) 2 3 4
F
TO GROUND
/20.B6 TO
SPLICE SP28
-P021
ROOF WIPER
FROM ILLUMINATION 1.00 mm² 829M 8 7 1.00 mm² 601BH
/19.C6 FROM
SPLICE SP7
1 2.00 mm² 854

2.00 mm² 849 2
3 2.00 mm² 133E
4
5
6 2.00 mm² 901
-P049 -RC01
2.00 mm² 854 2/20 2/20 2.00 mm²
E 2.00 mm² 849 3/20 3/20 2.00 mm²
2.00 mm² 925 5/20 5/20 2.00 mm²
TO GROUND
/20.B6 TO
SPLICE SP28
-P022
REAR WASH WIPE
FROM ILLUMINATION 1.00 mm² 829AF 8 7 1.00 mm² 601DX
/19.C5 FROM
SPICE SP7
1 2.00 mm² 926 2.00 mm² 926 4/20 4/20 2.00 mm²
2.00 mm² 925 2 2.00 mm² 133B 1/20 1/20 2.00 mm²
3 2.00 mm² 133C
4 -SP16
5
6 2.00 mm² 901B
-SP17
D
TO FUSE 12B 2.00 mm² 133
/3.D5 FROM
P002:4
2.00 mm² 901A
1.50 mm² 839A
Page 33-59
1.00 mm²
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY 2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
B 9/14
L 10/14 1.50 mm² 983

1.50 mm² 110D
14/14 INDICATORS
R 11/14 1.50 mm² 982
7/14 1.50 mm² 840

FROM FUSE 13B 1.50 mm² 110 1.50 mm² 110E 1/14 WIPER 12/14 1.50 mm² 841
/3.D5 FROM
P002:6 -SP33
WASHER 6/14 1.50 mm² 839 1.50 mm² 839B
-SP32
1 2 3 4
33 - 58 9813/9100-1 33 - 58
Page Page
33-58 33-59
Figure 1248. (Part

5 2 of 2) 6 7 8
TO SPLICE SRC5
TO
/20.E1
GROUND
-RC09
ROOF WIPER
2.00 mm² 601AR 1
2.00 mm² 133F 3
-
w
-P049 -RC01
+
854 2/20 2/20 2.00 mm² 854 2.00 mm² 854 2
849 3/20 3/20 2.00 mm² 849 2.00 mm² 849 4
925 5/20 5/20 2.00 mm² 925

E
TO SPLICE SRC5
TO
/20.E1
GROUND
-RC04
REAR WIPER
2.00 mm² 601AW 1
926 4/20 4/20 2.00 mm² 926

133B 1/20 1/20 2.00 mm² 133B 2.00 mm² 133D 3
-
-SRC3
w
+
2.00 mm² 926 2
2.00 mm² 925 4
D
-P053
WASHER PUMPS
2.00 mm² 901A 1/3

3/3 2.00 mm² 601JG TO SPLICE SP62
TO
/20.C6
1.50 mm² 839A 2/3
GROUND
Page 33-58
-C001
WASHER BOTTLE LEVEL
7216/0002 -C023 -P135 7216/0001

1.00 mm² 100WBL 1 2 1.00 mm² 421WBL 2/6 2/6 1.00 mm² 421WBL TO DAILY CHECKS
TO
/5.D6
P137:7
7216/0002 -C023 -P135 7216/0001

1/6 1/6 1.00 mm² 100WBL FROM ADDITIONAL FUSE
/3.C3 C
FROM
P131:2 / SP66
-P055 B
FRONT WIPER MOTOR
983 4/8 1/8 2.00 mm² 600P TO SPLICE SP61
TO
/20.B1
GROUND
982 3/8
840 2/8 6/8 1.50 mm² 110D

841 5/8
839 1.50 mm² 839B 7/8

-SP32
5 6 7 8
33 - 59 9813/9100-1 33 - 59
33 - 60 9813/9100-1 33 - 60
Page 33-62 Figure 1249. HVAC - 160/

F8689-3 - sheet 14 of 37 Page 33-63
1 2 3 4 5 6 7 8
F
-RC02
F
HEATED SEAT
-P049 -RC01
FROM FUSE 47E 2.00 mm² 151 7/20 7/20 2.00 mm² 151 2.00 mm² 151B 1/2 2/2 2.00 mm² 601EF TO GROUND
/3.C7 FROM TO
/20.E1
P005:14 -SRC1 SPLICE SRC5
-RC03
AIR SEAT
2.00 mm² 151A 1/2 2/2 2.00 mm² 601FK TO GROUND

TO
/20.E1
SPLICE SRC5
-P051 -P052
FACE FAN
FROM FUSE 47E 2.00 mm² 151B 2.00 mm² 151B
M5 1/1 1/1 M6
1.00 mm² 601DD TO GROUND
/3.C7 FROM TO
/20.C6
P005:14 SPLICE SP62
E
-P054 E
HEATED GLASS
FROM FUSE 03A 2.00 mm² 150 1/2 1/2
/3.E5 FROM
P001:6
FROM ILLUMINATION 1.00 mm² 829AN 2/2 2/2
/19.D5 FROM
SPLICE SP7
-P015
ROOF AC FANS
9
-P049
FROM FUSE 11B 2.00 mm² 116 6 7 2.00 mm² 2855 12/20
/3.D5 FROM
P002:2
D
2.00 mm² 886B 8 10 1.00 mm² 601KP TO
TO GROUND
/20.D4
D
SPLICE SP29
-P015
AIR CON
-P049
4 2.00 mm² 2856 15/20
FROM FUSE 14B 2.00 mm² 997 1 2 2.00 mm² 883
/3.D5 FROM
P002:8
FROM INSTRUMENT CLUSTER J1 1.00 mm² 884AC 3 5 1.00 mm² 601AC TO GROUND
/9.E3 FROM TO
/20.C4
P071:3 SPLICE SP29
-P039 -C015 -C029 -E009
C11/84 C11/84 2.00 mm² 885 25/29 25/29 2.00 mm² E115A
-E024-1 -E024-2 -E025

-P018
C -P033 FREEZE VALVE BINARY SWITCH AC COMPRESSOR
HEATER CONNECTOR
2.00 mm² 883 9 C
-P039 -C015 -C029 -E009
FROM FUSE 07A 2.00 mm² 102 3/6 4/6 2.00 mm² 883A 2.00 mm² 883A 6 7 2.00 mm² 884A A12/84 A12/84 2.00 mm² 884 26/29 26/29 2.00 mm² E116 1/1 1 2 1/1 2.00 mm² E115B 2.00 mm² E115 1/2 2/2 1.50 mm² E601J TO CHASSIS GROUND
/3.E5 FROM TO
/21.E1
P001:14 -SE03 SPLICE SE02
TO GROUND 2.00 mm² 600T 1/6 5/6 2.00 mm² 884 8 10 1.00 mm² 601FV TO GROUND
/20.C6 TO TO
/20.D4
1.00 mm² 801 2/6 6/6
-P112
HEATER 100R
TO INSTRUMENT CLUSTER J2 1.00 mm² 801A 1.00 mm² 801B 1 2 1.00 mm² 601HT TO GROUND
/9.D5 TO TO
/20.E6
B
B
-P034
HEATER CONTROL
FROM ILLUMINATION 1.00 mm² 829HC 2/6 5/6 1.00 mm² 610HV TO INSTRUMENT CLUSTER J1
/19.C5 FROM TO
/9.D3
SPLICE SP7 P071:15
3/6 1.00 mm² 887A TO INSTRUMENT CLUSTER J2
TO
/9.E5
P072:5
4/6 1.00 mm² 997A
1/6 6/6 1.00 mm² 997B 1.00 mm² 997 TO INSTRUMENT CLUSTER J2
TO
/9.C5
-SP5 P072:18
A
A
1 2 3 4 5 6 7 8
33 - 61 9813/9100-1 33 - 61
Page Page
33-62 33-63
Figure 1249.
1 (Part 1 of 2) 2 3 4
F
-RC02
HEATED SEAT
-P049 -RC01
FROM FUSE 47E 2.00 mm² 151 7/20 7/20 2.00 mm² 151 2.00 mm² 151B 1/2
/3.C7 FROM
P005:14 -SRC1
-RC03
AIR SEAT
2.00 mm² 151A 1/2
-P051
FACE FAN
FROM FUSE 47E 2.00 mm² 151B 2.00 mm² 151B
M5 1/1
/3.C7 FROM
P005:14
E
-P054
HEATED GLASS
FROM FUSE 03A 2.00 mm² 150 1/2 1/2
/3.E5 FROM
P001:6
FROM ILLUMINATION 1.00 mm² 829AN 2/2 2/2
/19.D5 FROM
SPLICE SP7
-P015
ROOF AC FANS
9
FROM FUSE 11B 2.00 mm² 116 6 7 2.00 mm² 2855
/3.D5 FROM
P002:2
D
2.00 mm² 886B 8 10 1.00 mm² 601KP
-P015
AIR CON
-P049
Page 33-63
4 2.00 mm² 2856 15/20
FROM FUSE 14B 2.00 mm² 997 1 2 2.00 mm² 883
/3.D5 FROM
P002:8
FROM INSTRUMENT CLUSTER J1 1.00 mm² 884AC 3 5 1.00 mm² 601AC TO GROUND
/9.E3 FROM TO
/20.C4
P071:3 SPLICE SP29
-P039 -C015 -C029 -E009
C11/84 C11/84 2.00 mm² 885 25/29 25/29
-P018
C -P033 FREEZE VALVE
HEATER CONNECTOR 9
2.00 mm² 883
-P039 -C015 -C029 -E009
FROM FUSE 07A 2.00 mm² 102 3/6 4/6 2.00 mm² 883A 2.00 mm² 883A 6 7 2.00 mm² 884A A12/84 A12/84 2.00 mm² 884 26/29 26/29
/3.E5 FROM
P001:14
TO GROUND 2.00 mm² 600T 1/6 5/6 2.00 mm² 884 8 10 1.00 mm² 601FV TO GROUND
/20.C6 TO TO
/20.D4
1.00 mm² 801 2/6 6/6
-P112
HEATER 100R
TO INSTRUMENT CLUSTER J2 1.00 mm² 801A 1.00 mm² 801B 1 2 1.00 mm² 601HT TO GROUND
/9.D5 TO TO
/20.E6
-P034
HEATER CONTROL
FROM ILLUMINATION 1.00 mm² 829HC 2/6 5/6 1.00 mm² 610HV TO INSTRUMENT CLUSTER J1
/19.C5 FROM TO
/9.D3
SPLICE SP7 P071:15
3/6 1.00 mm² 887A TO INSTRUMENT CLUSTER J2
TO
/9.E5
P072:5
4/6 1.00 mm² 997A
1/6 6/6 1.00 mm² 997B 1.00 mm² 997 TO INSTRUMENT CLUSTER J2
TO
/9.C5
-SP5 P072:18
1 2 3 4
33 - 62 9813/9100-1 33 - 62
Page Page
33-62 33-63
Figure 1249. (Part

5 2 of 2) 6 7 8
-RC02
F
HEATED SEAT
1/2 2/2 2.00 mm² 601EF TO GROUND

TO
/20.E1
SPLICE SRC5
-RC03
AIR SEAT
1/2 2/2 2.00 mm² 601FK TO GROUND

TO
/20.E1
SPLICE SRC5
-P051 -P052
FACE FAN
M5 1/1 1/1 M6
1.00 mm² 601DD TO GROUND
TO
/20.C6
SPLICE SP62
-P054 E
HEATED GLASS
1/2 1/2
2/2 2/2
-P015
ROOF AC FANS
9
-P049
6 7 2.00 mm² 2855 12/20
886B 8 10 1.00 mm² 601KP TO

TO GROUND
/20.D4
D
SPLICE SP29
Page 33-62
-C029 -E009
885 25/29 25/29 2.00 mm² E115A
-E024-1 -E024-2 -E025

BINARY SWITCH AC COMPRESSOR
C
-C029 -E009
884 26/29 26/29 2.00 mm² E116 1/1 1 2 1/1 2.00 mm² E115B 2.00 mm² E115 1/2 2/2 1.50 mm² E601J TO CHASSIS GROUND
TO
/21.E1
-SE03 SPLICE SE02
TO INSTRUMENT CLUSTER J1
5 6 7 8
33 - 63 9813/9100-1 33 - 63
33 - 64 9813/9100-1 33 - 64
Page 33-66 Figure 1250. In Cab Entertainment

- 160/F8689-3 - sheet 15 of 37 Page 33-67
1 2 3 4 5 6 7 8
F
F
-P058 -RH01 L/H SPEAKER

E FROM FUSE 24C 1.00 mm² 181 1/4 1/4 1.00 mm² 181 -RH02 -RH03
-RH04
/3.B5 E
FROM
P003:8 1.00 mm² 445 1/1 +

RADIO
FROM FUSE 19B 1.00 mm² 301F 2/4 2/4 1.00 mm² 301F
/3.C7 FROM
-RH05
P002:18 / SP27 A2 SPEED A1 1.00 mm² 446 1/1 -
MUTE SIGNAL
FROM ILLUMINATION 1.00 mm² 829AM 3/4 3/4 1.00 mm² 829AM 1.00 mm² 301F A4 A3
/19.B6 FROM
BATT + N/C
SPLICE SP7 1.00 mm² 829AM A6 AUTO A5
ILLUM
TO GROUND A8 ANNA A7
1.00 mm² 601RD 4/4 4/4 1.00 mm² 601AG 1.00 mm² 601AG 1.00 mm² 181
/20.E4 TO
GND IGN
SPLICE SP3
B2 B1
RR(-) RR(+)
1.00 mm² 448 B4 B3 1.00 mm² 447
RF(-) RF(+)
1.00 mm² 446 B6 B 1.00 mm² 445
LF(-) LF(+)
B8 B7
LR(-) LR(+) R/H SPEAKER
-RH06
1.00 mm² 447 1/1 +
-RH07
1.00 mm² 448 1/1 -
D
D
-RC17
SEAT PRESSURE SWITCH
4 4/6 1.00 mm² 847SS
C -P049 -RC01 -SRC4
Channel 1 (NC)
FROM FUSE 09A 1.00 mm² 107SP 14/20 14/20 1.00 mm² 107SS 1.00 mm² 107SA 1/6 1 Supply 5 5/6 1.00 mm² 846SS
/3.E6 C
FROM Channel 2 (NO)
P001:18 1.00 mm² 107SB 2/6

(12Vdc)
6 6/6 1.00 mm² 601SP TO GROUND

3/6
GND TO
/20.F1
1.00 mm² 107SC SPLICE SRC5
332/C8190 -P049 -RC01 332/C8203

TO 07/11 CONNECTOR 1 1.00 mm² 846SS 20/20 20/20 1.00 mm² 846SS
/22.D3 TO
P069:12
332/C8190 -P049 -RC01 332/C8203
/22.D3 TO
P069:10
-P056
MOBILE PHONE
FROM FUSE 15B 1.50 mm² 119 2 1 1.50 mm² 601AS TO GROUND
/3.D5 FROM TO
/20.B1
P002:10 SPLICE SP61
B GND
1/1
-P057 B
FROM ILLUMINATION 1.00 mm² 829AK
/19.C6 FROM
SPLICE SP7
-P065
AUXILLIARY CONNECTOR
FROM FUSE 03A 1.00 mm² 121 1/2 2/2 1.00 mm² 601KC TO GROUND
/3.B5 FROM TO
/20.B6
P001:6 SPLICE SP28
A
A
1 2 3 4 5 6 7 8
33 - 65 9813/9100-1 33 - 65
Page Page
33-66 33-67
Figure 1250.
1 (Part 1 of 2) 2 3 4
-P058 -RH01
E FROM FUSE 24C
/3.B5 FROM 1.00 mm² 181 1/4 1/4 1.00 mm² 181 -RH02 -RH03
P003:8
RADIO
FROM FUSE 19B 1.00 mm² 301F 2/4 2/4 1.00 mm² 301F
/3.C7 FROM
P002:18 / SP27 A2 SPEED A1

MUTE SIGNAL
FROM ILLUMINATION 1.00 mm² 829AM 3/4 3/4 1.00 mm² 829AM 1.00 mm² 301F A4 A3
/19.B6 FROM
BATT + N/C
SPLICE SP7 1.00 mm² 829AM A6 AUTO A5
ILLUM
TO GROUND A8 ANNA A7
1.00 mm² 601RD 4/4 4/4 1.00 mm² 601AG 1.00 mm² 601AG 1.00 mm² 181
/20.E4 TO
GND IGN
SPLICE SP3
B2 B1
RR(-) RR(+)
1.00 mm² 448 B4 B3 1.00 mm² 447
RF(-) RF(+)
1.00 mm² 446 B6 B 1.00 mm² 445
LF(-) LF(+)
B8 B7
LR(-) LR(+)
Page 33-67
-RC17
SEAT PRESSURE SWITCH
4 4/6 1.00 mm² 847SS
C -P049 -RC01 -SRC4
Channel 1 (NC)
FROM FUSE 09A 1.00 mm² 107SP 14/20 14/20 1.00 mm² 107SS 1.00 mm² 107SA 1/6 1 Supply 5 5/6 1.00 mm² 846SS
/3.E6 FROM Channel 2 (NO)
P001:18 1.00 mm² 107SB 2/6

(12Vdc)
6 6/6 1.00 mm² 601SP

GND
1.00 mm² 107SC 3/6
332/C8190 -P049 -RC01 332/C8203

/22.D3 TO
P069:12
332/C8190 -P049 -RC01 332/C8203
/22.D3 TO
P069:10
-P056
MOBILE PHONE
FROM FUSE 15B 1.50 mm² 119 2 1 1.50 mm² 601AS
/3.D5 FROM
P002:10
B GND
-P057
FROM ILLUMINATION 1/1
1.00 mm² 829AK
/19.C6 FROM
SPLICE SP7
-P065
AUXILLIARY CONNECTOR
FROM FUSE 03A 1.00 mm² 121 1/2 2/2 1.00 mm² 601KC
/3.B5 FROM
P001:6
1 2 3 4
33 - 66 9813/9100-1 33 - 66
Page Page
33-66 33-67
Figure 1250. (Part

5 2 of 2) 6 7 8
-RH03 L/H SPEAKER

-RH04 E
1.00 mm² 445 1/1 +
-RH05
A1 1.00 mm² 446 1/1 -
A3
A5
A7 1.00 mm² 181
B1
B3 1.00 mm² 447
B 1.00 mm² 445
B7
R/H SPEAKER
-RH06
1.00 mm² 447 1/1 +
-RH07
1.00 mm² 448 1/1 -
D
Page 33-66
EAT PRESSURE SWITCH
4/6 1.00 mm² 847SS

5/6 1.00 mm² 846SS
C
6/6 1.00 mm² 601SP TO GROUND
TO
/20.F1
SPLICE SRC5
1.50 mm² 601AS TO GROUND

TO
/20.B1
SPLICE SP61
B
UXILLIARY CONNECTOR
1.00 mm² 601KC TO GROUND

TO
/20.B6
SPLICE SP28
5 6 7 8
33 - 67 9813/9100-1 33 - 67
33 - 68 9813/9100-1 33 - 68
Page 33-70 Figure 1251. Reverse Fan -

160/F8689-3 - sheet 16 of 37 Page 33-71
1 2 3 4 5 6 7 8
F
F
-E012
REV FAN
-P039 -C015 -C029 -E009
TO INSTRUMENT CLUSTER J1 1.00 mm² 1840 A10/84 A10/84 1.00 mm² 1840 19/29 19/29 1.00 mm² 1840 1/2 1/2
/9.D3 FROM
P071:12
-E009
TO CHASSIS GROUND 1.00 mm² 603T 20/29 20/29 1.00 mm² 603T 2/2 2/2
/21.D3 TO
SPLICE SC5
E
E
TO GROUND -E013
/20.D6 TO
PROPORTIONAL FAN
SPLICE SP11
-C015 -C029 -E009
F6/84 1.00 mm² 592 21/29 21/29 1.00 mm² 592 1/2 1/2
-P061
-C029 -E009
REVERSE FAN TO CHASSIS GROUND TO 22/29 22/29 1.00 mm² 615 2/2 2/2
FRON ILLUMINATION 1.00 mm² 829AL 8 7 1.00 mm² 601AL
SPLICE SC4
/19.D5 FROM
SPLICE SP7
1
FROM IGNITION FUSE 1.00 mm² 100P 2
/3.B7 FROM
P001:2 / SP20 3 1.00 mm² 1840D TO INSTRUMENT CLUSTER J1

TO
/9.C3
4 P071:18
1.00 mm² 100 PA 5 -E014
-C029 -E009
6 1.00 mm² 1840C TO INSTRUMENT CLUSTER J2 TO CHASSIS GROUND 1.00 mm² 601SS 16/29 16/29 1.00 mm² 601SS SPEED SENSOR
TO
/9.E5 /21.D3 TO
P072:6 SPLICE SC06

D B+ (RED)
1 1/6
-P039 -C015 -C029 -E009 2/6 2

GND (BLK)
D
TO INSTRUMENT CLUSTER J2 1.00 mm² 593 F5/84 F5/84 1.00 mm² 593 18/29 18/29 1.00 mm² 593 3/6 3
/9.D5 TO
OUT A (WHITE)
P072:8
4
B+ (ORANGE)
5
GND (BROWN)
6
OUT B (YELLOW)
-C029 -E009
FROM FUSE 25C 1.00 mm² 109SS 15/29 15/29 1.00 mm² 109SS
/3.B6 FROM
P003:10 / SC11
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 69 9813/9100-1 33 - 69
Page Page
33-70 33-71
Figure 1251.
1 (Part 1 of 2) 2 3 4
-P039
TO INSTRUMENT CLUSTER J1 1.00 mm² 1840 A10/84
/9.D3 FROM
P071:12
TO CHASSIS GROUND
/21.D3 TO
SPLICE SC5
TO GROUND
/20.D6 TO
SPLICE SP11
-P061
REVERSE FAN TO CHASSIS GROUND TO
FRON ILLUMINATION 1.00 mm² 829AL 8 7 1.00 mm² 601AL

SPLICE SC4
/19.D5 FROM
SPLICE SP7
1
FROM IGNITION FUSE 1.00 mm² 100P 2
/3.B7 FROM
P001:2 / SP20 3 1.00 mm² 1840D TO INSTRUMENT CLUSTER J1

TO
/9.C3
4 P071:18
1.00 mm² 100 PA 5
6 1.00 mm² 1840C TO INSTRUMENT CLUSTER J2 TO CHASSIS GROUND
TO
/9.E5 /21.D3 TO
P072:6 SPLICE SC06

D
-P039
TO INSTRUMENT CLUSTER J2 1.00 mm² 593 F5/84
/9.D5 TO
P072:8
FROM FUSE 25C
Page 33-71
P003:10 / SC11
1 2 3 4
33 - 70 9813/9100-1 33 - 70
Page Page
33-70 33-71
Figure 1251. (Part

5 2 of 2) 6 7 8
-E012
REV FAN
-P039 -C015 -C029 -E009
TO INSTRUMENT CLUSTER J1 1.00 mm² 1840 A10/84 A10/84 1.00 mm² 1840 19/29 19/29 1.00 mm² 1840 1/2 1/2
/9.D3 FROM
P071:12
-E009
TO CHASSIS GROUND 1.00 mm² 603T 20/29 20/29 1.00 mm² 603T 2/2 2/2
/21.D3 TO
SPLICE SC5
E
-E013
PROPORTIONAL FAN
-C015 -C029 -E009
F6/84 1.00 mm² 592 21/29 21/29 1.00 mm² 592 1/2 1/2
-C029 -E009
TO CHASSIS GROUND TO 22/29 22/29 1.00 mm² 615 2/2 2/2
SPLICE SC4
-E014
-C029 -E009
TO CHASSIS GROUND 1.00 mm² 601SS 16/29 16/29 1.00 mm² 601SS SPEED SENSOR
/21.D3 TO
SPLICE SC06 1 1/6

B+ (RED)
-P039 -C015 -C029 -E009 2/6 2
GND (BLK)
D
TO INSTRUMENT CLUSTER J2 1.00 mm² 593 F5/84 F5/84 1.00 mm² 593 18/29 18/29 1.00 mm² 593 3/6 3
/9.D5 TO
OUT A (WHITE)
P072:8
4
B+ (ORANGE)
5
GND (BROWN)
6
OUT B (YELLOW)
-C029 -E009
FROM FUSE 25C
Page 33-70
1.00 mm² 109SS 15/29 15/29 1.00 mm² 109SS

/3.B6 FROM
P003:10 / SC11
5 6 7 8
33 - 71 9813/9100-1 33 - 71
33 - 72 9813/9100-1 33 - 72
Page 33-74 Figure 1252. CAN Bus - 160/

F8689-3 - sheet 17 of 37 Page 33-75
1 2 3 4 5 6 7 8
F
F
TO DAILY CHECKS
TO DAILY CHECKS
TO LIVE LINK
TO LIVE LINK
TO LIVE LINK
TO LLMI CAN
TO LLMI CAN
TO LLMI CAN
P042-B:C
P042-B:B
P042-B:A
/30.E2
/30.E2
/30.E2
P068:11
P068:1
/8.C2
/9.D3
/9.D3
P068:2
P071:8
P071:7
P071:9
P137:4
P137:3
/8.B2
/8.B2
/9.E3
/5.E6
/5.E6
-SCREEN 7 VEHICLE BUS (250KB/S)
TO
TO
TO
TO
TO
TO
TO
TO
TO
TO
TO
0.50 mm² CAN 5 SCR
0.50 mm² CAN 7 SCR

0.50 mm² CAN 5 H
0.50 mm² CAN 7 H

0.50 mm² CAN 5 L
0.50 mm² CAN 7 L

CAN INTERFACE
CAN TERMINATOR RES
-P074 -P039 -C015 -SVMC19 -C027

E A A/3 0.50 mm² CAN 3 H 0.50 mm² CAN 4 H 0.50 mm² CAN 6 H 0.50 mm² CAN 8 H 0.50 mm² CAN 11 H G12/84 G12/84 0.50 mm² CAN H 0.50 mm² CAN H A/3
-SVMC01 -SVMC04 -SVMC07 -SVMC10 -SVMC13
E
-P039 -C015 -SVMC20
B B/3 0.50 mm² CAN 3 L 0.50 mm² CAN 4 L 0.50 mm² CAN 6 L 0.50 mm² CAN 8 L 0.50 mm² CAN 11 L G11/84 G11/84 0.50 mm² CAN L 0.50 mm² CAN L B/3
C C/3 -SVMC02 -SVMC05 -SVMC08 -SVMC11 -SVMC14 -P039 -C015 -SVMC21
0.50 mm² CAN 3 SCR 0.50 mm² CAN 4 SCR 0.50 mm² CAN 6 SCR 0.50 mm² CAN 8 SCR 0.50 mm² CAN 11 SCR G10/84 G10/84 0.50 mm² SCR 0.50 mm² SCR C/3
/22.D5 TO
FROM FUSE 19B P070:10

/3.C7 FROM
P002:18 / SP27 TO 07/11 CONNECTOR 2

/22.E5 TO
TO GROUND P070:4
/20.D6 TO
SPLICE SP11
-PC01-V
-SCREEN 8
1/2 SCREEN 8 0.50 mm² CAN H TO HYDRAULICS ECU J4
-P073
TO
/24.C2
C048:18
DIAGNOSTIC CONNECTOR TO HYDRAULICS ECU J4
D 2/2 0.50 mm² CAN L
/24.D2
D
TO
A/9 1.00 mm² 601C

C048:12
0.50 mm² SCR TO HYDRAULICS ECU J4
-SCREEN 1 TO
/24.C1
B/9 1.00 mm² 301M
C048:16
-P0D1
E/9 C/9 1/2 0.50 mm² CAN H TO HYDRAULICS ECU J4

TO
/24.C2
F/9 MATE TO PC01-V OR PC02-P C048:17
TO HYDRAULICS ECU J4
G/9 D/9 2/2 FOR CAN COMMUNICATION 0.50 mm² CAN L TO
/24.D2
H/9
C048:11
J/9 0.50 mm² SCR TO HYDRAULICS ECU J4
TO
/24.D1
-SCREEN 4 -SCREEN 2 C048:5
-PC02-P TO JOYSTICK CAN H 0.50 mm² CAN H

/33.B1 TO
1/2
C014:28
TO JOYSTICK CAN L 0.50 mm² CAN L
/33.A1 TO
2/2
C014:29
C TO JOYSTICK CAN SCR 0.50 mm² SCR
POWERTRAIN BUS (250KB/S) C

/33.A1 TO
C014:17
-SCREEN 5
0.50 mm² CAN SCR
2.00 mm² SCR TO GROUND

0.50 mm² CAN H
/20.A1
0.50 mm² CAN L
TO
SPLICE SP61
CHASSIS CONNECTOR ENGINE POD CONNECTOR
-P125
-P039 -C015 -SPMC10 -C029 -E009
A -SPMC13 -SPMC10 TO ENGINE ECU
TERMINATOR
A/3 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H G9/84 G9/84 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 13/29 13/29 TO
/5.D3
-SPMC16 -SPMC07 -SPMC04 -SPMC01 E004:27
-P039 -C015 -SPMC11
B B/3 0.50 mm² CAN L 0.50 mm² CAN L -SPMC14 0.50 mm² CAN L -SPMC11 0.50 mm² CAN L G8/84 G8/84 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L 14/29 14/29 TO ENGINE ECU
TO
/5.D3
C C/3 -SPMC17 -SPMC08 -SPMC05 -SPMC02 E004:23
-P039 -C015 -SPMC12
0.50 mm² SCR 0.50 mm² SCR -SPMC15 0.50 mm² SCR -SPMC12 0.50 mm² SCR G7/84 G7/84 0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR 12/29 12/29
-SPMC18 -SPMC09 -SPMC06 -SPMC03 -SCREEN 1
0.50 mm² CAN H
0.50 mm² CAN H

0.50 mm² CAN L
0.50 mm² CAN L

0.50 mm² SCR
0.50 mm² SCR
-E010
B
B
B
C
A
-SCREEN 3
-SCREEN 6 -E010A
AFTER TREATMENT
TO
TO
TO
TO
TERMINATOR RESISTOR
/xx.E5
/xx.C5
/8.B5
/8.B5
P115:29
P115:47
P066:10
P066:9
TO IFM TRANS CONTROLLER
TO IMMOBILISER
TO IMMOBILISER
-C086 -C001
0.50 mm² CAN H 9/20 9/20 TO AFTER TREATMENT HARNESS
TO
/6.D6
P086:9
0.50 mm² CAN L 10/20 10/20 TO AFTER TREATMENT HARNESS
TO
/6.D6
P086:10
-C086 -C001
0.50 mm² SCR 20/20 20/20
-SCREEN 8
A
A
1 2 3 4 5 6 7 8
33 - 73 9813/9100-1 33 - 73
Page Page
33-74 33-75
Figure 1252.
1 (Part 1 of 2) 2 3 4
TO DAILY CHECKS
TO DAILY CHECKS
TO LIVE LINK
TO LIVE LINK
TO LIVE LINK
TO LLMI CAN
TO LLMI CAN
P042-B:B
P042-B:A
/30.E2
/30.E2
P068:11
P068:1
/8.C2
/9.D3
/9.D3
P068:2
P071:8
P071:7
P071:9
P137:4
P137:3
/8.B2
/8.B2
/9.E3
/5.E6
/5.E6
-SCREEN 7
TO
TO
TO
TO
TO
TO
TO
TO
TO
TO
0.50 mm² CAN 5 SCR
0.50 mm² CAN 7 SCR

0.50 mm² CAN 5 H
0.50 mm² CAN 7 H

0.50 mm² CAN 5 L
0.50 mm² CAN 7 L

CAN TERMINATOR RES
-P074
E A A/3 0.50 mm² CAN 3 H 0.50 mm² CAN 4 H 0.50 mm² CAN 6 H 0.50 mm² CAN 8 H
B B/3 0.50 mm² CAN 3 L 0.50 mm² CAN 4 L 0.50 mm² CAN 6 L 0.50 mm² CAN 8 L
C C/3 -SVMC02 -SVMC05 -SVMC08 -SVMC11 -SVMC14
0.50 mm² CAN 3 SCR 0.50 mm² CAN 4 SCR 0.50 mm² CAN 6 SCR 0.50 mm² CAN 8 SCR
/22.D5 TO
FROM FUSE 19B P070:10

/3.C7 FROM
P002:18 / SP27 TO 07/11 CONNECTOR 2

/22.E5 TO
TO GROUND P070:4
/20.D6 TO
SPLICE SP11
-PC01-V
-SCREEN 8
1/2 SCREEN 8
-P073
DIAGNOSTIC CONNECTOR
D 2/2
A/9 1.00 mm² 601C
-SCREEN 1
B/9 1.00 mm² 301M
-P0D1
E/9 C/9 1/2

F/9 MATE TO PC01-V OR PC02-P
G/9 D/9 2/2 FOR CAN COMMUNICATION
H/9
Page 33-75
J/9
-SCREEN 4 -SCREEN 2
-PC02-P TO JOYSTICK CAN H 0.50 mm² CAN H

/33.B1 TO
1/2
C014:28
/33.A1 TO
2/2
C014:29
C TO JOYSTICK CAN SCR 0.50 mm² SCR
/33.A1 TO
C014:17
-SCREEN 5
0.50 mm² CAN SCR
2.00 mm² SCR TO GROUND

0.50 mm² CAN H
/20.A1
0.50 mm² CAN L
TO
SPLICE SP61
CHASSIS CONNECTOR
-P125
-P039 -C015 -SPMC10
A -SPMC13 -SPMC10
TERMINATOR
A/3 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H G9/84 G9/84 0.50 mm² CAN H 0.50 mm²
-SPMC16 -P039 -C015
B -SPMC14 -SPMC11 -SPMC11
B/3 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L G8/84 G8/84 0.50 mm² CAN L 0.50 mm²
C C/3 -SPMC17 -P039 -C015 -SPMC12
0.50 mm² SCR 0.50 mm² SCR -SPMC15 0.50 mm² SCR -SPMC12 0.50 mm² SCR G7/84 G7/84 0.50 mm² SCR 0.50 mm²
-SPMC18
0.50 mm² CAN H
0.50 mm² CAN H

0.50 mm² CAN L
0.50 mm² CAN L

0.50 mm² SCR
0.50 mm² SCR
-SCREEN 3
-SCREEN 6
TO
TO
TO
TO
/xx.E5
/xx.C5
/8.B5
/8.B5
P115:29
P115:47
P066:10
P066:9
TO IMMOBILISER
TO IMMOBILISER
1 2 3 4
33 - 74 9813/9100-1 33 - 74
Page Page
33-74 33-75
Figure 1252. (Part

5 2 of 2) 6 7 8
F
TO LLMI CAN
TO LLMI CAN
TO LLMI CAN
P042-B:C
P042-B:B
P042-B:A
/30.E2
/30.E2
/30.E2
-SCREEN 7 VEHICLE BUS (250KB/S)

TO
TO
TO
CAN INTERFACE
-P039 -C015 -SVMC19 -C027
0.50 mm² CAN 8 H 0.50 mm² CAN 11 H G12/84 G12/84 0.50 mm² CAN H 0.50 mm² CAN H A/3
-SVMC13
E
-P039 -C015 -SVMC20
0.50 mm² CAN 8 L 0.50 mm² CAN 11 L G11/84 G11/84 0.50 mm² CAN L 0.50 mm² CAN L B/3
-SVMC11 -SVMC14 -P039 -C015 -SVMC21
0.50 mm² CAN 8 SCR 0.50 mm² CAN 11 SCR G10/84 G10/84 0.50 mm² SCR 0.50 mm² SCR C/3
-SVMC12 -SVMC15
0.50 mm² CAN H TO HYDRAULICS ECU J4

TO
/24.C2
C048:18
0.50 mm² CAN L TO HYDRAULICS ECU J4
/24.D2
D
TO
C048:12
0.50 mm² SCR TO HYDRAULICS ECU J4
TO
/24.C1
C048:16
0.50 mm² CAN H TO HYDRAULICS ECU J4

TO
/24.C2
C048:17
0.50 mm² CAN L TO HYDRAULICS ECU J4
TO
/24.D2
C048:11
TO HYDRAULICS ECU J4
Page 33-74
0.50 mm² SCR TO

/24.D1
C048:5
TO JOYSTICK CAN H 0.50 mm² CAN H

/33.B1 TO
C014:28
/33.A1 TO
C014:29
TO JOYSTICK CAN SCR 0.50 mm² SCR
POWERTRAIN BUS (250KB/S) C

/33.A1 TO
C014:17
CHASSIS CONNECTOR ENGINE POD CONNECTOR
-SPMC10 -C029 -E009

CAN H 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 13/29 13/29 TO ENGINE ECU
TO
/5.D3
-SPMC07 -SPMC04 -SPMC01 E004:27
-SPMC11 TO ENGINE ECU
CAN L 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L 14/29 14/29 TO
/5.D3
-SPMC08 -SPMC05 -SPMC02 E004:23
-SPMC12
SCR 0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR 12/29 12/29
-SPMC09 -SPMC06 -SPMC03 -SCREEN 1
-E010
B
B
C
A
-E010A
AFTER TREATMENT TERMINATOR RESISTOR
-C086 -C001
0.50 mm² CAN H 9/20 9/20 TO AFTER TREATMENT HARNESS
TO
/6.D6
P086:9
0.50 mm² CAN L 10/20 10/20 TO AFTER TREATMENT HARNESS
TO
/6.D6
P086:10
-C086 -C001
0.50 mm² SCR 20/20 20/20
-SCREEN 8
5 6 7 8
33 - 75 9813/9100-1 33 - 75
33 - 76 9813/9100-1 33 - 76
Page 33-78 Figure 1253. CAN Bus Engine

- 160/F8689-3 - sheet 18 of 37 Page 33-79
1 2 3 4 5 6 7 8
F
F
E
E
TO NOx DOWNSTREAM/TAIL PIPE

TO ????
TO ????
TO ????
/6.D3
/6.D3
/6.D3
E026:7
E026:6
E026:5
E035:4
E035:3
/6.E2
/6.E2
-SCREEN 4
TO
TO
TO
TO
TO
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR

0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
D TO ENGINE ECU 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H TO NOx UPSTREAM ENG OUT
/5.D3 /6.D2
D
TO TO
E004:45 -SDMC07 -SDMC01 E036:4

TO ENGINE ECU 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L TO NOx UPSTREAM ENG OUT
/5.D3 TO TO
/6.D2
E004:50 -SDMC08 -SDMC02 E036:3
0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR
-SCREEN 2 -SDMC09 -SDMC03 -SCREEN 5
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
-SCREEN 3
TO
TO
/5.C5
/5.C5
E005:D
E005:C
TO ENGINE CONNECTOR
TO ENGINE CONNECTOR
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 77 9813/9100-1 33 - 77
Page Page
33-78 33-79
Figure 1253.
1 (Part 1 of 2) 2 3 4

TO ????
TO ????
TO ????
/6.D3
/6.D3
/6.D3
E026:7
E026:6
E026:5
E035:4
E035:3
/6.E2
/6.E2
-SCREEN 4
TO
TO
TO
TO
TO
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR

0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
D TO ENGINE ECU 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H
/5.D3 TO TO
E004:45 -SDMC07 -SDMC01

TO ENGINE ECU 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L
/5.D3 TO TO
E004:50 -SDMC08 -SDMC02

0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR
-SCREEN 2 -SDMC09 -SDMC03 -SCREEN 5
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
Page 33-79
TO
-SCREEN 3
TO
/5.C5
/5.C5
E005:D
E005:C
TO ENGINE CONNECTOR
TO ENGINE CONNECTOR
1 2 3 4
33 - 78 9813/9100-1 33 - 78
Page Page
33-78 33-79
Figure 1253. (Part

5 2 of 2) 6 7 8
0.50 mm² CAN H TO NOx UPSTREAM ENG OUT

/6.D2
D
TO
E036:4
0.50 mm² CAN L TO NOx UPSTREAM ENG OUT
TO
/6.D2
E036:3
0.50 mm² SCR
-SCREEN 5
Page 33-78
5 6 7 8
33 - 79 9813/9100-1 33 - 79
33 - 80 9813/9100-1 33 - 80
Page 33-82 Figure 1254. Switch Illumination

Splice - 160/F8689-3 - sheet 19 of 37 Page 33-83
1 2 3 4 5 6 7 8
F
F
E
E
1.00 mm² 829SW TO SWAY SWITCH

TO
/34.D2
P141:8
0.75 mm² 829Y TO JOYSTICK ISOLATION SW
TO
/34.F2
P140:8
1.00 mm² 829 TO L/H HEADLIGHTS
TO
/10.B6
??? / P041:4
1.00 mm² 829RH TO PIN LOCK SWITCH
TO
/25.C3
P114:8
1.00 mm² 829AN TO HEATED GLASS
TO
/14.E4
P054:2
D
1.00 mm² 829X TO
TO FRONT/REAR AUX SWITCH
/26.C2
D
P017:8
1.00 mm² 829AL TO REVERSE FAN SWITCH
TO
/16.D2
P061:8
1.00 mm² 829AB TO INSTRUMENT CLUSTER J1
TO
/9.E3
P071:1
1.00 mm² 829AH TO INFO BUTTON
TO
/9.E7
P063:8
1.00 mm² 829AK TO MOBILE PHONE
TO
/15.B3
P057:1
1.00 mm² 829HC TO HEATER CONTROL
TO
/14.B2
P034:2
1.00 mm² 829AE TO FOG LIGHT SWITCH
TO
/10.F3
P023:8
1.00 mm² 829AF TO REAR WASH WIPE SW
TO
/13.E3
P022:8
-SP7
FROM FUSE 43E 1.50 mm² 829E 1.00 mm² 829M TO ROOF WIPER SW
C /3.D7 /13.F3
FROM TO
P005:6 P021:8
1.00 mm² 829A TO SIDE LIGHTS C
TO
/10.C4
P039:D11
1.00 mm² 829J TO WORKLIGHTS SWITCH
TO
/12.F2
P026:8
1.00 mm² 829U TO BEACON SWITCH
TO
/12.B1
P028:8
1.00 mm² 829AM TO RADIO
TO
/15.E2
P058:3
0.50 mm² 829WL TO CENTER CLUSTER
TO
/9.B4
P040:1
1.00 mm² 829FD TO FOOTBRAKE DUMP SW
TO
/31.D2
P019:8
1.00 mm² 829V TO FOUR WHEEL DRIVE SWITCH
TO
/22.B4
P027:8
1.00 mm² 829AJ TO BOOM WORKLIGHTS SWITCH
TO
/12.E2
P029:8
TO SRS SWITCH
B 1.00 mm² 829AR TO
/29.E2
P062:8
B
1.00 mm² 829MA TO MAN/AUTO SWITCH
TO
/28.F3
P060:8
1.00 mm² 829AX TO STAB ISO SWITCH
TO
/37.C3
P036:8
A
A
1 2 3 4 5 6 7 8
33 - 81 9813/9100-1 33 - 81
Page Page
33-82 33-83
Figure 1254.
1 (Part 1 of 2) 2 3 4
1.00 mm² 829SW
0.75 mm² 829Y
1.00 mm² 829
1.00 mm² 829RH
1.00 mm² 829AN
D
1.00 mm² 829X
1.00 mm² 829AL
1.00 mm² 829AB
1.00 mm² 829AH
Page 33-83
1.00 mm² 829AK
1.00 mm² 829HC
1.00 mm² 829AE
1.00 mm² 829AF
-SP7
FROM FUSE 43E 1.50 mm² 829E 1.00 mm² 829M
C /3.D7 FROM
P005:6
1.00 mm² 829A
1.00 mm² 829J
1.00 mm² 829U
1.00 mm² 829AM
0.50 mm² 829WL
1.00 mm² 829FD
1.00 mm² 829V
1.00 mm² 829AJ
B 1.00 mm² 829AR
1.00 mm² 829MA
1.00 mm² 829AX
1 2 3 4
33 - 82 9813/9100-1 33 - 82
Page Page
33-82 33-83
Figure 1254. (Part

5 2 of 2) 6 7 8
1.00 mm² 829SW TO SWAY SWITCH

TO
/34.D2
P141:8
0.75 mm² 829Y TO JOYSTICK ISOLATION SW
TO
/34.F2
P140:8
1.00 mm² 829 TO L/H HEADLIGHTS
TO
/10.B6
??? / P041:4
1.00 mm² 829RH TO PIN LOCK SWITCH
TO
/25.C3
P114:8
1.00 mm² 829AN TO HEATED GLASS
TO
/14.E4
P054:2
1.00 mm² 829X TO
TO FRONT/REAR AUX SWITCH
/26.C2
D
P017:8
1.00 mm² 829AL TO REVERSE FAN SWITCH
TO
/16.D2
P061:8
1.00 mm² 829AB TO INSTRUMENT CLUSTER J1
TO
/9.E3
P071:1
1.00 mm² 829AH TO INFO BUTTON
TO
/9.E7
P063:8
Page 33-82
1.00 mm² 829AK TO MOBILE PHONE

TO
/15.B3
P057:1
1.00 mm² 829HC TO HEATER CONTROL
TO
/14.B2
P034:2
1.00 mm² 829AE TO FOG LIGHT SWITCH
TO
/10.F3
P023:8
1.00 mm² 829AF TO REAR WASH WIPE SW
TO
/13.E3
P022:8
-SP7
1.00 mm² 829M TO ROOF WIPER SW
TO
/13.F3
P021:8
1.00 mm² 829A TO SIDE LIGHTS C
TO
/10.C4
P039:D11
1.00 mm² 829J TO WORKLIGHTS SWITCH
TO
/12.F2
P026:8
1.00 mm² 829U TO BEACON SWITCH
TO
/12.B1
P028:8
1.00 mm² 829AM TO RADIO
TO
/15.E2
P058:3
0.50 mm² 829WL TO CENTER CLUSTER
TO
/9.B4
P040:1
1.00 mm² 829FD TO FOOTBRAKE DUMP SW
TO
/31.D2
P019:8
1.00 mm² 829V TO FOUR WHEEL DRIVE SWITCH
TO
/22.B4
P027:8
1.00 mm² 829AJ TO BOOM WORKLIGHTS SWITCH
TO
/12.E2
P029:8
1.00 mm² 829AR TO SRS SWITCH
TO
/29.E2
P062:8
B
1.00 mm² 829MA TO MAN/AUTO SWITCH
TO
/28.F3
P060:8
1.00 mm² 829AX TO STAB ISO SWITCH
TO
/37.C3
P036:8
5 6 7 8
33 - 83 9813/9100-1 33 - 83
33 - 84 9813/9100-1 33 - 84
33 -

Service Manual: Foreword

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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 2017 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

533-105, 535-v125, 540-140, 533-105, 535-v125, 540-140,

SERVICE MANUAL SERVICE MANUAL

533-105, 535-v125, 540-140, 533-105, 535-v125, 540-140,

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 and on the machine, there are safety

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 (shown) also helps to identify

Figure 1. The safety alert system

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

(For: 533-105 [T4F], 540-170 [T4F],

Lift Arm Lowered

A Lift arm lowered

Lift Arm Raised Health and Safety

A Lift Arm Lowered

Lift Arm Raised

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-15

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-00 General ........................................................................................................................... 01-19

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

06 - Optional Equipment and

A wide range of optional attachments are available

12 - Main Component Locations

A Lift arm B Carriage

15 - Service Point Locations