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.
DUMPER
6T-1 Front Tip, 6T-1 Swivel Tip, Contents
7T-1 Front Tip Hi-Viz, 9T-1 Front Tip
01 - Machine
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
25 - Steering System
EN - 9813/8950 - ISSUE 2 - 03/2018 27 - Driveline
30 - Hydraulic System
33 - Electrical System
This manual contains original instructions, verified by

72 - Fasteners and Fixings
the manufacturer (or their authorized representative). 75 - Consumable Products
78 - After Sales
Copyright 2018 © JCB SERVICE

All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9813/8950-2
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
6T-1 Front Tip, 6T-1 Swivel Tip, 6T-1 Front Tip, 6T-1 Swivel Tip,
7T-1 Front Tip Hi-Viz, 9T-1 Front Tip 7T-1 Front Tip Hi-Viz, 9T-1 Front Tip
EN 9813/8950 EN 9813/8950
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
6T-1 Front Tip, 6T-1 Swivel Tip, 6T-1 Front Tip, 6T-1 Swivel Tip,
7T-1 Front Tip Hi-Viz, 9T-1 Front Tip 7T-1 Front Tip Hi-Viz, 9T-1 Front Tip
EN 9813/8950 EN 9813/8950
9813/8950-2
Notes:
9813/8950-2
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 .............................................................................................. 01-17
01-06-06 Using the Manual ........................................................................................................... 01-18
01-09 Description
01-09-12 Main Component Locations ........................................................................................... 01-21
01-09-15 Service Point Locations ................................................................................................. 01-24
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-31
9813/8950-2
2018-03-12
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9813/8950-2
2018-03-12
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 9813/8950-2 01 - 1
Notes:
01 - 2 9813/8950-2 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 9813/8950-2 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual there are safety notices. Each notice

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

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

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

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

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

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.
Figure 1. The safety alert system symbol
01 - 4 9813/8950-2 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. Ensure that you receive the correct training drop and injure you if the hydraulic system fails
before operating any machinery. Failing to do so will or if the control is operated (even with the engine
result in incorrect operation of the machine and you stopped).
will be putting yourself and others at risk. In some Make sure that no-one goes near the machine while
markets, and for work on certain jobsites, you may you install or remove the mechanical device.
be required to have been trained and assessed in
accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements – it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9813/8950-2 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6 m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9813/8950-2 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 9813/8950-2 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 9813/8950-2 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, mirrors and cameras clean (when machine.
fitted).
If the machine is struck by lightning do not use the
Do not operate the machine if you cannot see clearly. machine until it has been checked for damage and
Modification of the machine's configuration by the malfunction by trained personnel.
user (e.g. the fitting of large and non-approved
attachments) may result in a restriction of the
machine visibility.
01 - 9 9813/8950-2 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 9813/8950-2 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 9813/8950-2 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12 For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-Viz],
9T-1 Front Tip ........................... Page 01-12
Health and Safety .......................................... 01-15
For: 6T-1 Swivel Tip .................. Page 01-13
(For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-

Viz], 9T-1 Front Tip)
Dumper Body Lowered

1. Park the machine on level solid ground.
2. Lower the dumper body.
3. Apply the park brake.
4. Stop the engine and remove the ignition key.
5. Disconnect the battery to prevent accidental
operation of the engine.
6. If necessary, put blocks against the two sides
of the wheels before you get underneath of the
machine.
Dumper Body Raised

DANGER A maintenance strut or other method
of supporting the skip in the raised position must
be installed and locked in position before working
under a raised skip. Do not reach or work under
a raised skip unless a prop is installed.
If you raise the dumper to get access for

maintenance, you must install the maintenance strut
on the dumper body.
The maintenance strut is only for use with a empty

dumper.
Install
1. Discharge any material from the dumper and
then raise the dumper fully.
3. Remove the strut.
3.1. Release the fastener.
3.2. Remove the strut from its stowage bracket.
4. Install the strut on the lift ram. Refer to Figure 2.
4.1. Push the strut over the ram piston rod.
4.2. Secure the strut in position with strap.
5. Lower the dumper onto the strut.
5.1. Start the engine and slowly lower the
dumper onto the safety strut, stop the
01 - 12 9813/8950-2 01 - 12
01 - Machine
03 - Safety
movement immediately when the weight of

the dumper is supported by the safety strut. (For: 6T-1 Swivel Tip)
Figure 2.
Dumper Body Lowered
1. Park the machine on level solid ground.
2. Lower the dumper.
3. Apply the park brake.
5. Disconnect the battery to prevent accidental
operation of the engine.
6. If necessary, put blocks against the two sides of
the wheels before you get below the machine.
Dumper Body Raised

A Maintenance strut - installed position of supporting the skip in the raised position must
under a raised skip. Do not reach or work under
Remove
a raised skip unless a prop is installed.
1. Fully raise the dumper to take the weight off the
safety strut. If you raise the dumper to get access for
maintenance, you must install the maintenance strut
2. Stop the engine and remove the ignition key. on the dumper.
3. Remove the strut. The maintenance strut is only for use with a empty
3.1. Loosen the strap. dumper.
3.2. Remove the strut from the ram piston rod. Install
4. Stow the strut. 1. Discharge any material from the dumper.
4.1. Secure the strut in the stowage position with 2. Fully raise the dumper.
fastener. Refer to Figure 3.
3. Remove the grip clip and pin. Refer to Figure 4.
Figure 3.
4. Raise the dumper support from its storage
bracket.
5. Align the hole in the dumper support with the
holes in the dumper rail.
6. Install the pin and secure with the grip clip.Refer
to Figure 4.
A
A Maintenance strut - stowage position
01 - 13 9813/8950-2 01 - 13
01 - Machine
03 - Safety
Figure 4.
A
C
A Maintenance strut - installed position B Pin

C Maintenance strut - stowage position
Remove
1. Raise the dumper to take the weight off the strut.
2. Remove the pin and grip clip.
3. Remove the strut.
4. Secure the strut in its storage bracket.
5. Lower the dumper.
01 - 14 9813/8950-2 01 - 14
01 - Machine
03 - Safety
Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery (by means
of the battery isolator if installed) when you are
not using electrical power. If you do not take these
precautions you could be killed or injured.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
01 - 15 9813/8950-2 01 - 15
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-17

01-06-06 Using the Manual ........................................................................................................... 01-18
01 - 16 9813/8950-2 01 - 16
01 - Machine
03 - Model and Serial Number
03 - Model and Serial Number
Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
6T-1 Front Tip 2561001
6T-1 Swivel Tip 2561001
Hi-Viz
01 - 17 9813/8950-2 01 - 17
01 - Machine
06 - Using the Manual
06 - Using the Manual
Introduction
Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification
Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included information is contained within another PIL reference
under a set of standard headings such as a cross reference is provided.
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System PIL 30-00-50 Schematic Circuit
Electrical System PIL 33-03-03 Battery - Isolator Switch
PIL 33-09-00 Power Distribution (including fuses
and relays)
PIL 33-00-50 Schematic Circuit
Electronic Diagnostic PIL 33-57-00 Electronic Diagnostic (including
Servicemaster)
Machine Variants • Use the applicable Servicemaster diagnostics

tools.
Where information is different depending on machine
variant, the applicable information sets are included Torque Tightening
within the same PIL reference. Headings are
included to identify which information is for which When you replace components, always tighten the
variant. Make sure you use the correct information. applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
Diagnostics procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified, use
Information in this manual can help you diagnose the standard torque tightening values. For the torque
machine faults. setting to be effective, do the following before you
install the fixings. Refer to PIL 72-00-00.
Before attempting to diagnose possible faults check
the following. • Make sure that all the applicable component
assemblies are correct.
• Make sure that the operator understands the • Make sure that the applicable fixings are to the
machine controls, functions and use. Refer to correct specification. If necessary discard the
the applicable Operator Manual. original fixings and replace them with new ones.
• Check that the maintenance record complies The relevant procedures indicate when this is
with the applicable schedule for the operating necessary.
environment. • Make sure that the applicable fixings and
• Check that the fluids in use comply with the threaded holes are free from contamination.
standards specified. This includes dirt, debris, old sealants and
• Make sure that the machine electronic set-up compounds, fluids and lubricants.
is applicable. Use the applicable Servicemaster
vehicle set-up tool.
01 - 18 9813/8950-2 01 - 18
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-12 Main Component Locations ........................................................................................... 01-21

01-09-15 Service Point Locations ................................................................................................. 01-24
01 - 19 9813/8950-2 01 - 19
Notes:
01 - 20 9813/8950-2 01 - 20
01 - Machine
09 - Description
12 - Main Component Locations
Introduction
For: 6T-1 Swivel Tip, Without Cab

................................................... Page 01-21
For: 6T-1 Front Tip, 9T-1 Front Tip, Without
Cab ........................................... Page 01-22
For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-Viz],
9T-1 Front Tip, Cab ................... Page 01-23
(For: 6T-1 Swivel Tip, Without Cab)
Figure 5.
A ROPS (Roll-Over Protective Structure) B Beacon

C Engine D Tyres/Wheels
E Steps F Head lights
01 - 21 9813/8950-2 01 - 21
01 - Machine
09 - Description
G Skip H Mirrors
J Hand rails K FOPS (Falling Object Protective Structure)
(For: 6T-1 Front Tip, 9T-1 Front Tip, Without Cab)
Figure 6.
A ROPS B Beacon
C Engine D Tyres/Wheels
G Skip H Mirrors
J Hand rails K FOPS
01 - 22 9813/8950-2 01 - 22
01 - Machine
09 - Description
(For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-Viz], 9T-1 Front Tip, Cab)
Figure 7.
B
A
E
J D
A ROPS/FOPS/Cab B Beacons
C Engine D Tyres/ Wheels
G Skip H Mirrors
J Hand rails
01 - 23 9813/8950-2 01 - 23
01 - Machine
09 - Description
15 - Service Point Locations
Introduction
Engine Compartment
Figure 8.
A Fuel filter (Separator) B Engine oil filter

C Engine oil dipstick D Engine oil filler cap
E Fuel filler cap F Air filter
G Engine fuel filter
01 - 24 9813/8950-2 01 - 24
01 - Machine
09 - Description
Figure 9.
A Coolant expansion tank B Hydraulic oil filler neck

C Washer fluid tank
01 - 25 9813/8950-2 01 - 25
01 - Machine
09 - Description
Battery Isolator
Figure 10.
A Battery isolator B Relays

C Fuses
01 - 26 9813/8950-2 01 - 26
01 - Machine
09 - Description
Brake System
Figure 11.
A Brake fluid tank cap
01 - 27 9813/8950-2 01 - 27
01 - Machine
09 - Description
Gearbox
Figure 12.
A Gearbox dipstick
01 - 28 9813/8950-2 01 - 28
01 - Machine
09 - Description
Batteries
Remove the floor plate battery access cover to
access the battery.
Figure 13.
A Floor plate battery access cover B Battery
01 - 29 9813/8950-2 01 - 29
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-31
01 - 30 9813/8950-2 01 - 30
01 - Machine
33 - Cleaning
00 - General
00 - General Introduction
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 9813/8950-2 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 9813/8950-2 01 - 32
Contents Page No.
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-5
06-03-36 Upper Crossmember ........................................................................................................ 06-8
06-03-37 Lower Crossmember ...................................................................................................... 06-11
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-13
06-06-06 Engine Compartment ..................................................................................................... 06-14
06-06-10 Transmission Compartment ........................................................................................... 06-18
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-21
06-24 Slew Ring
06-24-00 General ........................................................................................................................... 06-29
06-24-24 Shim ............................................................................................................................... 06-32
06-27 Transportation Lock
06-27-15 Articulated Joint .............................................................................................................. 06-37
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-41
06-33 Articulated Joint
06-33-00 General ........................................................................................................................... 06-45
06-33-21 Bearing ........................................................................................................................... 06-49
06-39 Carriage
06-39-00 General ........................................................................................................................... 06-51
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-55
06-63-03 Machine .......................................................................................................................... 06-56
06-63-06 Engine ............................................................................................................................ 06-57
06-63-12 Gearbox .......................................................................................................................... 06-59
06-66 Tools
06-66-00 General ........................................................................................................................... 06-63
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-65
06-81 Dumper Body
06-81-00 General ........................................................................................................................... 06-67
06-88 Exterior Light Guard
06-88-00 General ........................................................................................................................... 06-73
9813/8950-2
2018-02-26
Acronyms Glossary

PIN Product Identification Number
9813/8950-2
2018-02-26
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9813/8950-2 06 - 1
Notes:
06 - 2 9813/8950-2 06 - 2
00 - General
00 - General 2. Carry out a thorough inspection of the operator's

station.
Check (Condition) 3. Any damage must be repaired before the

machine is used again.
Check the Machine Body and Structure 4. Make sure that all of the ROPS (Roll-
Over Protective Structure)/FOPS (Falling Object
1. Make the machine safe. Protective Structure) mounting bolts are
undamaged and in position.
Refer to: PIL 01-03.
5. Make sure that the ROPS/FOPS mounting bolts
2. Make sure that all the guards and protective are tightened to the correct torque setting.
devices are in place, attached by their locking
devices and free from damage.
3. Inspect all steelwork for damage. Pay particular
attention to the following:
3.1. Inspect all the lifting point welds.
3.2. Inspect all the pivot point welds.
3.3. Inspect the condition of all the pivot pins.
3.4. Check that the pivot pins are correctly in
place and secured by their locking devices.
4. Check the steps and the handrails for damage.
Make sure that the steps and the handrails are
properly secured.
5. Check for broken, cracked or crazed window
glass and mirrors. Replace any damaged items.
6. Check all the lamp lenses for damage.
7. Check all the attachment teeth for damage.
Make sure that all attachment teeth are properly
secured.
8. Check all the safety and instructional labels are
in place and are free from damage.
9. Install new labels where necessary. Make a note
of the damaged paintwork for future repair.
Check the ROPS/FOPS Structure

WARNING You could be killed or seriously injured
if you operate a machine with a damaged or
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/
FOGS has been in an accident, do not use the
machine until the structure has been renewed.
Modifications and repairs that are not approved
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification.
A failure to do these precautions can cause death or

injury to the operator.
1. Make the machine safe.

06 - 3 9813/8950-2 06 - 3
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-5

06-03-36 Upper Crossmember ........................................................................................................ 06-8
06-03-37 Lower Crossmember ...................................................................................................... 06-11
06 - 4 9813/8950-2 06 - 4
03 - Chassis
00 - General
Introduction ...................................................... 06-5 The chassis is the underpart of the vehicle or
Health and Safety ........................................... 06-6 machine, consisting of the frame on which the body
Component Identification ................................. 06-7 or cab is mounted.
06 - 5 9813/8950-2 06 - 5
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 - 6 9813/8950-2 06 - 6
03 - Chassis
00 - General
Component Identification
Figure 14.
A B
A Front chassis B Rear chassis
06 - 7 9813/8950-2 06 - 7
03 - Chassis
36 - Upper Crossmember
36 - Upper Crossmember Figure 16.
Remove and Install

For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1
Front Tip [Hi-Viz] ......................... Page 06-8 B
For: 9T-1 Front Tip ...................... Page 06-8
(For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 C

Front Tip [Hi-Viz])
Remove
Refer to: PIL 01-03-27. B Upper crossmember
C Bolts
2. Isolate the battery.
8. Remove the upper crossmember from the
machine.
3. Open the engine compartment cover.
Refer to: PIL 06-06-06. Install
4. Remove the rear road light electrical harness. 1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
5. Disconnect the reverse alarm electrical step.
connector.
2. Tighten the bolts to the correct torque value.
Figure 15.
Table 3. Torque Values
Item Description Nm
C Bolts 230
A (For: 9T-1 Front Tip)
Remove
A Electrical connector Refer to: PIL 01-03-27.
6. Remove the bolts. 2. Isolate the battery.

7. Support the upper crossmember with suitable
lifting equipment. 3. Open the side access panel.
06 - 8 9813/8950-2 06 - 8
03 - Chassis
Figure 17. Figure 20.
A Side access panel D Bolts 3

4. Remove the top bolts 1 from the engine 7. Disconnect the reverse alarm electrical
compartment cover. connector.
E
C
E Electrical connector
8. Support the upper crossmember with suitable
B Bolts 1
lifting equipment.
5. Remove the bolts 2 from the upper
9. Remove the upper crossmember from the
crossmember.
machine.
Figure 19.
C Bolts 2
6. Remove the bolts 3 from the reverse alarm cover.
06 - 9 9813/8950-2 06 - 9
03 - Chassis
Figure 22.
F Lifting equipment
G Upper crossmember
Install
1. The installation procedure is the opposite of the
step.
2. Tighten the bolts 2 to the correct torque value.

Item Description Nm
C Bolts 2 105
06 - 10 9813/8950-2 06 - 10
03 - Chassis
37 - Lower Crossmember
37 - Lower Crossmember
Remove and Install

method and device.
Remove
Refer to: PIL 01-03-27.
3. Remove the pin from the tow hitch.
4. Remove the screws.
5. Support the lower crossmember with suitable
lifting equipment.
6. Remove the lower crossmember from the
machine.
Figure 23.
A
D
B
C
A Lower crossmember
B Screws
C Pin
D Tow hitch
Install
removal procedure.
06 - 11 9813/8950-2 06 - 11
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-13

06-06-06 Engine Compartment ..................................................................................................... 06-14
06-06-10 Transmission Compartment ........................................................................................... 06-18
06 - 12 9813/8950-2 06 - 12
00 - General
00 - General
Introduction
Access panels provide easy access to the machine

major components test and service points and
other parts which require routine testing, servicing,
adjusting, replacement or repair.
Before you operate the machine, make sure that all

of the access panels are in their operation position
and secure.
06 - 13 9813/8950-2 06 - 13
06 - Engine Compartment
06 - Engine Compartment Open and Close

WARNING The engine has exposed rotating
Open and Close ............................................ 06-14 parts. Switch off the engine before working in the
Remove and Install ....................................... 06-16 engine compartment. Do not use the machine
with the engine cover open.
Open
2. Stop the engine.
3. Apply the park brake and remove the ignition key.
4. Use the ignition key to unlock the access panel.
Refer to Figure 24.
5. Do not open the access panel when the engine
is running.
6. Pull the T-handle to open the rear engine cover.
Refer to Figure 24.
7. Check around the machine to make sure that it
is safe to open.
Figure 24.
A Rear engine cover B Access panel

C Front engine cover D T-handle
06 - 14 9813/8950-2 06 - 14
Close
1. Check around the machine to make sure that no
object will become trapped with lowering of the
rear engine cover.
2. Pull down to close the rear engine cover. Refer
to Figure 24.
3. Use the ignition key to lock the access panel.
Refer to Figure 24.
06 - 15 9813/8950-2 06 - 15
Remove and Install
5. Remove the nut (x2) and washer 1 (x2) from the

Remove rod end of the gas strut (x2).
1. Make the machine safe. 6. Disconnect the gas strut (x2) from the engine
compartment.
7. Remove the bolt (x4) and washer 2 (x4) from the
2. Isolate the battery. hinge.
8. Remove the engine compartment cover from the
3. Open the engine compartment cover. machine.
Refer to: PIL 06-06-06. 9. Remove the nut (x2) and washer 1 (x2) from the
head end of the gas strut.
4. Support the engine compartment cover with
suitable lifting equipment. 10. Remove the gas strut from the machine.
Figure 25.
A
E
D
A Engine compartment cover B Gas strut (x2)

C Hinge D Nut (x4)
E Washer 1 (x4) F Bolt (x4)
G Washer (x4)
06 - 16 9813/8950-2 06 - 16
Install
removal procedure.
06 - 17 9813/8950-2 06 - 17
10 - Transmission Compartment
Open and Close
WARNING The engine has exposed rotating 2. Stop the engine and remove the ignition key.
parts. Switch off the engine before working in the
engine compartment. Do not use the machine 3. Use the ignition key to unlock the transmission
with the engine cover open. cover. Refer to Figure 26.
4. Lift the transmission cover.
Open
Figure 26.
A Transmission cover lock
5. Remove the gear lever rubber seal. Refer to Figure 27.

Figure 27. B
6. Remove the bolts and washers from the floor
plate. Refer to Figure 27.
7. Lift the floor plate and clear of the machine to gain
access to the engine compartment.
8. Do not open the floor plate when the engine is A
running.
A Floor plate
B Gear lever rubber seal
Close
1. Check around the machine to make sure that no
object will become trapped with lowering of the
floor plate.
2. Use the bolts and washers to install the floor
plate. Refer to Figure 27.
06 - 18 9813/8950-2 06 - 18
3. Install the gear lever rubber seal.

4. Close the transmission cover.
5. Use the ignition key to lock the transmission
cover. Refer to Figure 26.
06 - 19 9813/8950-2 06 - 19
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-21
06 - 20 9813/8950-2 06 - 20
12 - Lift Arm
00 - General
Introduction .................................................... 06-21 The lift arm on this machine is a one piece assembly.
Health and Safety .......................................... 06-22 The assembly is a heavy item, you must not
Check (Condition) .......................................... 06-22 attempt to lift this component without suitable lifting
Remove and Install ....................................... 06-23 equipment.
06 - 21 9813/8950-2 06 - 21
12 - Lift Arm
00 - General
Health and Safety Check (Condition)

Lifting Equipment 1. Make sure that the bushes and the pivot pins
You can be injured if you use incorrect or faulty lifting are within the permitted tolerances. Replace the
equipment. You must identify the weight of the item to pivot pin or bushes as necessary.
enough and suitable for the job. Make sure that lifting 2. Examine the lift arm structure for wear, damage
equipment is in good condition and complies with all or corrosion. Replace as necessary.
local regulations. 3. Examine the pivot levers for wear, damage or
WARNING! Do not work under raised lift arms corrosion. Replace as necessary.
unless they are adequately supported by stands and/
or slings.
CAUTION! The lift arm pivot levers are potentially
dangerous, when pivoting about their centre they
form a scissor point with the lift arm. Make sure the
pivot levers are securely blocked when working in the
lift arm area.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
06 - 22 9813/8950-2 06 - 22
12 - Lift Arm
00 - General
Remove and Install Figure 29.
For: 6T-1 Front Tip, 7T-1 Front Tip [Hi-Viz], G

9T-1 Front Tip ........................... Page 06-23

method and device.
G Lifting equipment
Remove
10. Remove the split pins.
Refer to: PIL 01-03-27. 11. Collect the washers 2.
2. Isolate the battery. 12. Remove the bolts 2 and the nut 2 from the pivot
pin 2.
12.1. Left hand side shown, right hand side
3. Remove the dumper body from the machine. similar.
13. Use a suitable tool to remove the pivot pin 2.
4. Remove the dumper carriage.
14. Remove the lift arm assembly from the machine.
Figure 30.
5. Remove the bolt 1, washer 1 and the nut 1 from
the pivot pin 1.
J
6. Support the cylinders suitably.
M
7. Use a suitable tool to remove the pivot pin 1.
H A
8. Collect the spacer.
Figure 28. K L
A Lift arm equipment

B H Bolt 2
J Nut 2
K Split pin
E L Washers 2
C M Pivot pin 2
D
Install
A
A Lift arm assembly 1. The installation procedure is the opposite of the
B Bolt 1 removal procedure.
C Washer 1
D Nut 1
E Pivot pin 1 (For: 6T-1 Swivel Tip)
F Spacer
If the slew ring is to be removed, it is important that
9. Support the lift arm assembly with suitable lifting all the shims used in mounting the slew base onto
equipment. the slew ring and the slew ring onto the chassis
are recovered and that there original positions are
06 - 23 9813/8950-2 06 - 23
12 - Lift Arm
00 - General
recorded. Failure to carry out this instruction will Figure 33.

result in the need to do the shimming procedure.
Remove
1. Make the machine safe. E
3. Remove the dumper body.
4. Remove the bolt 1 and the nut 1 from the pivot
pin.
E Hoses 2
5. Use a suitable slide hammer to remove the pivot
pin. 8. Put a label on the hoses to help installation.
Figure 31. 9. Plug all the open ports and hoses to prevent
contamination.
10. Remove the dumper tip ram hose clamp bracket.
Figure 34.
C
A
B
A Nut 1 F
B Bolts 1
C Pivot pin
6. Disconnect the hydraulic hoses 1 from the
dumper body lift ram. F Hose clamp bracket
Figure 32. 11. Reposition the hydraulic hoses 2.

Figure 35.
D E
D Hoses 1
7. Disconnect the hydraulic hoses 2 from the E Hoses 2
dumper tip ram.
12. Rotate the slew base clockwise to release the
hydraulic pressure.
06 - 24 9813/8950-2 06 - 24
12 - Lift Arm
00 - General
K
L,M
G
K Slew ram
G Slew base L Bolt 3
M Nut 3
13. Remove the bolt 2 and nut 2.
18. Remove the bolts 4.
14. Disconnect the right side slew ram.
Figure 40.
Figure 37.
H,J
H Bolt 2
J Nut 2 N Bolts 4
K Slew ram
19. Remove the lift arm with suitable lifting
15. Rotate the slew base anticlockwise to release the equipment.
hydraulic pressure.
Figure 41.
Figure 38.
Q
G
G Slew base
P Lifting equipment
16. Remove the bolt 3 and nut 3. Q Lift arm
17. Disconnect the left side slew ram. 20. Collect the shims and make a note of their
locations to help installation.
06 - 25 9813/8950-2 06 - 25
12 - Lift Arm
00 - General
Install
removal procedure.
06 - 26 9813/8950-2 06 - 26
24 - Slew Ring
24 - Slew Ring
Contents Page No.
06-24-00 General ........................................................................................................................... 06-29

06-24-24 Shim ............................................................................................................................... 06-32
06 - 27 9813/8950-2 06 - 27
Notes:
06 - 28 9813/8950-2 06 - 28
24 - Slew Ring
00 - General
Introduction .................................................... 06-29
Remove and Install ....................................... 06-30
(For: 6T-1 Swivel Tip)
The slew ring bearing is a rotational rolling-element
bearing that supports the heavy but slow-turning
upper structure. They often use three race elements,
such as an inner ring and two outer ring halves that
clamp together axially. Slew ring bearings are made
with gear teeth integral with the inner or outer race,
used to drive the platform relative to the base.
06 - 29 9813/8950-2 06 - 29
24 - Slew Ring
00 - General
Remove and Install 7. Manually turn the slew base to the specified
angle whilst an assistant operates the hydraulic
control valve to prevent hydraulic lock-up.
(For: 6T-1 Swivel Tip) Angle: 45 °
If the slew ring is to be removed it is important that Figure 44.
all the shims used in mounting the slew base onto
the slew ring and the slew ring onto the chassis
are recovered and that there original positions are
recorded. Failure to carry out this instruction will
result in the need to do the shimming procedure.
Remove
A
Refer to: PIL 06-81-00. A Slew base
3. Turn the slew base to the specified angle. 8. Remove the pin 2 from the slew ram 2.
Angle: 90 ° 9. Disconnect the slew ram 2.
A C
C Pin 2
A Slew base
10. Remove the hose brackets.
4. Discharge the hydraulic pressure.
Refer to: PIL 30-00-00. 11. Disconnect the hydraulic hoses.
5. Remove the pin 1 from the slew ram 1. 12. Put a label on the hoses to help installation.
6. Disconnect the slew ram 1. 13. Plug all the open ports and hoses to prevent
contamination.
Figure 43.
B Pin 1
06 - 30 9813/8950-2 06 - 30
24 - Slew Ring
00 - General

G
D Hose brackets
E Hoses
14. Remove the bolts 1. G Bolts 2
15. Remove the slew base from the chassis with 19. Collect the shims and make a note of their
suitable lifting equipment. locations to help installation.
Figure 47.
Install
steps.
F
2. If necessary, do the shimming procedure.
4. Bleed the hydraulic system.

Item Description Nm
F Bolts 1 F Bolts 1 230
16. Support the slew base with the blocks. G Bolts 2 230

18. Remove the slew ring from the chassis with
suitable lifting equipment.
06 - 31 9813/8950-2 06 - 31
24 - Slew Ring
24 - Shim
24 - Shim Introduction
Introduction .................................................... 06-32
Shims can be used as spacers to fill gaps between
parts subject to wear. Shims are also used to adjust
for a better fit, or to provide a level surface.
06 - 32 9813/8950-2 06 - 32
24 - Slew Ring
24 - Shim
Remove and Install
mounting bolt holes and then lower the slew

(For: 6T-1 Swivel Tip) frame to its correct position.
5. Check the gap between the underside of the slew
Shimming frame and the top face on the slew ring.
Shimming the slew ring prevents any distortion in 6. If there are any high points, hit the slew frame to
the fabricated parts of the chassis induced by the install in position.
manufacturing process from deforming the slew ring
which will lead to premature failure of the slew ring. 7. Install suitable shims 1 into the large gaps. Make
sure that you install the same number of shims 1
Slew frame to the Slew Ring on each side to keep the slew frame horizontal.
This will prevent the rocking action and keep the
1. Put the slew frame onto the slew ring in the assembly level.
correct position with suitable lifting equipment.
8. Check the gap under the slew frame at all the
2. Align the mounting bolt holes. retaining bolts 1 locations. If necessary, install
the shims 1 into the gap.
3. Insert the retaining bolts 1 into the mounting bolt
holes in the slew frame. 9. Install the nuts 1.
3.1. Do not install the nuts 1 at this stage. 10. Tighten the bolts 1 to the correct torque value.
4. Lower the slew frame into position so that 11. Check that the slew frame rotates freely. If
the front two bolts locate into their respective necessary, do the shimming procedure again.
Figure 49.
A
H
J
L
D
E
F
G
06 - 33 9813/8950-2 06 - 33
24 - Slew Ring
24 - Shim
A Slew ring B Chassis

C Slew frame D Bolt 1 (x10)
E Shims 1 F Washer 1 (x20)
G Nut 1 (x10) H Bolt 2 (x10)
J Washer 2 (x20) K Shims 2
L Nuts 2 (x10)
06 - 34 9813/8950-2 06 - 34
24 - Slew Ring
24 - Shim
Slew Ring to the Chassis

1. Put the slew ring onto the chassis in the correct
position with suitable lifting equipment.
2. Use a round section heel bar to align the
mounting bolt holes.
2.1. The retaining holes in the slew ring and
parts of the machine are not evenly spaced.
Make sure that the retaining holes in the
slew ring base align with the retaining bolts
holes in the chassis.
3. Insert the retaining bolts 2 in the base to locate
the slew ring.
3.1. Do not install the nuts 2 at this stage.
3.2. Make a note that the bolt 2 (x1) located just
above the horn is slightly shorter than rest
all other bolts (x9).
4. Check the gap between the underside of the slew
ring and the mounting face on the chassis.
5. If there are any high points, hit the slew ring to
install in position.
6. Install suitable shims 2 into the large gaps. Make
sure that you install the same number of shims
2 on each side to keep the slew ring horizontal.
This will prevent the rocking action and keep the
assembly level.
7. Check the gap under the slew ring at all retaining
bolt 2 locations. If necessary, install the shims 2
into the gap.
8. Install the nuts 2.
10. Check that the slew ring rotates freely. If
necessary, do the shimming procedure again.

Item Description Nm
D Bolts (x10) 140
H bolts (x10) 140
06 - 35 9813/8950-2 06 - 35
27 - Transportation Lock
Contents Page No.
06-27-15 Articulated Joint .............................................................................................................. 06-37
06 - 36 9813/8950-2 06 - 36
15 - Articulated Joint
Introduction
WARNING Make sure the articulation lock is in 3. Set the drive lever in the neutral position
the transport position before you transport the (hydrostatic, synchro shuttle and powershift
machine. The articulation lock must also be in models).
the transport position if you are carrying out daily
checks or doing any maintenance work in the 4. Put the gearbox in neutral (manual, synchro
articulation danger zone. If the articulation lock is shuttle and powershift models).
not in the transport position you could be crushed
between the two parts of the chassis. 5. Stop the engine and remove the ignition key.
WARNING Always make sure the articulation lock 6. Remove the locking pin and clip to release the
has been removed before attempting to drive the articulation lock from its drive (stowage) position.
machine. The machine cannot be steered with the Refer to Figure 50.
articulation lock installed.
7. Install the articulation lock bar. Refer to Figure 50.
Transport Position 8. Adjust the lock bar around until the hole in the
bar aligns with the hole in the rear chassis. Refer
The articulation lock prevents the machine to Figure 50.
movement when lifting the machine or during
9. If necessary, turn the steering wheel slightly to
transport or maintenance.
align the holes.
1. Steer the machine to put the front and rear 10. Install the locking pin and secure with the clip.
wheels in a straight line. Make sure that the pins are correctly secured to
2. Engage the park brake. prevent the articulation lock becoming insecure.
Refer to Figure 50.
Figure 50.
B A
C
A Articulation lock B Locking pin

C Clip
Drive (Stowage) Position 6. Remove the clip and locking pin that secures the
articulation lock in the transport position. Refer to
1. Stop the machine. Figure 51.
2. Engage the park brake. 7. Remove the articulation lock and position it in its
drive (stowage) position. Refer to Figure 51.
3. Set the drive lever in the neutral position
(hydrostatic, synchro shuttle and powershift 8. Install the locking pin and secure with the clip.
models). Make sure that the pins are correctly secured to
prevent the articulation lock becoming insecure.
4. Put the gearbox in neutral (manual, synchro Refer to Figure 51.
shuttle and powershift models).
06 - 37 9813/8950-2 06 - 37
Figure 51.
B A
C
A Articulation lock
B Locking pin
C Clip
06 - 38 9813/8950-2 06 - 38
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-41
06 - 39 9813/8950-2 06 - 39
Notes:
06 - 40 9813/8950-2 06 - 40
30 - Pivot Pins
00 - General
Introduction .................................................... 06-41 Pivot pins are a short shaft or pin that supports
Remove and Install ....................................... 06-42 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 - 41 9813/8950-2 06 - 41
30 - Pivot Pins
00 - General
Remove and Install
Pivot pins are a short shaft or pin that supports

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 - 42 9813/8950-2 06 - 42
Contents Page No.
06-33-00 General ........................................................................................................................... 06-45

06-33-21 Bearing ........................................................................................................................... 06-49
06 - 43 9813/8950-2 06 - 43
Notes:
06 - 44 9813/8950-2 06 - 44
00 - General
Introduction .................................................... 06-45 The articulated joint is a device which has a
Component Identification ............................... 06-46 permanent or semi-permanent pivoting joint in its
Remove and Install ....................................... 06-47 construction, by which two or more sections of a
vehicle are linked together so as to allow greater
capacity, flexibility of movement etc.
06 - 45 9813/8950-2 06 - 45
00 - General
Figure 52.
H
A
G
F
A King link pivot B Bearing closing plate

C Bearing D Lower bearing gaiter
E Upper bearing pin F Lower bearing pin
G Locking plate H Grease hose
J Upper bearing gaiter
06 - 46 9813/8950-2 06 - 46
00 - General
Remove
2. Isolate the battery. C
3. Raise the dumper body.
C Jack
4. Support the dumper body with suitable lifting
equipment. 8. Support the front of the rear chassis with a
suitable stand.
Figure 53.
Figure 56.
V Dumper body D Support stand
5. Remove the bolts 1 and the nuts 1. 9. Support the rear of the front chassis of the
machine with a suitable jack.
6. Disconnect the front propshaft.
Figure 57.
Figure 54.
B C
C Jack
A Bolts 1 10. Remove the articulated joint covers (if installed).
B Propshaft
11. Remove the capscrews 1 (x4).
7. Support the rear chassis of the machine with a
suitable jack. 12. Remove the pins with suitable drift and hammer.
13. Remove the seals and the bearings.
14. Disconnect the steering ram rod end.
15. Separate the front and rear chassis.
06 - 47 9813/8950-2 06 - 47
00 - General
16. Disconnect the grease hose.

17. Remove the capscrews 2 (x2).
18. Remove the pins with suitable drift and hammer.
19. Remove the seals and the bearings.
20. Remove the king link plate.
Figure 58.
E
F
H
E G
E Capscrews 1 (x4)
F Capscrews 2 (x2)
G Grease hose
H King link plate
Install
step.
2. Tighten the fasteners to the correct torque value.
06 - 48 9813/8950-2 06 - 48
21 - Bearing
21 - Bearing
Remove and Install
Refer to Articulated Joint - Remove and Install PIL

06-33-00 .
06 - 49 9813/8950-2 06 - 49
39 - Carriage
39 - Carriage
Contents Page No.
06-39-00 General ........................................................................................................................... 06-51
06 - 50 9813/8950-2 06 - 50
39 - Carriage
00 - General
Introduction .................................................... 06-51 The carriage is a support structure where the dumper
Remove and Install ....................................... 06-52 body (skip) is mounted to the lift arm.
06 - 51 9813/8950-2 06 - 51
39 - Carriage
00 - General
Remove and Install 8. Use the a suitable tool to remove the pivot pin 1
from the self level arm.
9T-1 Front Tip ........................... Page 06-52 Figure 61.

D
Remove E
1. Make the machine safe. G

Refer to: PIL 01-03-27. F

A
Refer to: PIL 06-81-00. A Dumper body
D Bolt 1
4. Raise the lift arm assembly until the lower link E Washer
pivot pin is visible and can be removed. F Nut
5. Support the lift arm assembly on a suitable G Pivot pin 1
support block. 9. Support the dumper body ram with a suitable
Figure 59. support.
10. Remove the bolt 2 and the spring washer from
the banjo bolt.
B 11. Remove the banjo bolt.

12. Use the a suitable tool to remove the pivot pin 2
from the carriage lift arm assembly.
Figure 62.
B Support block
6. Remove the pipe clamp.
Figure 60.
H
C
K
L
H Bolt 2
J Spring washer
K Banjo bolt
L Pivot pin 2
C Pipe clamp 13. Support the carriage with suitable lifting
equipment.
7. Remove the bolt 1, washers and the nut from the
self level arm pivot pin.
06 - 52 9813/8950-2 06 - 52
39 - Carriage
00 - General
Figure 63. 7. Use a suitable slide hammer to remove the rear

pins 2.
N Figure 65.
C
D
M Carriage
N Lifting equipment C Bolts 2
D Pins 2
14. Remove the carriage.
8. Remove the dumper carriage with suitable lifting
Install equipment.
1. The installation procedure is the opposite of the Figure 66.

removal procedure.

E
Remove
2. Remove the dumper tip ram.
E Dumper carriage
Refer to: PIL 33-03-00. Install
4. Remove the bolts 1 (x2). 1. The installation procedure is the opposite of the
removal procedure.
5. Use a suitable slide hammer to remove the front
pins 1.
Figure 64.
A Bolts 1
B Pins 1
6. Remove the bolts 2 (x2).
06 - 53 9813/8950-2 06 - 53
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-55

06-63-03 Machine .......................................................................................................................... 06-56
06-63-06 Engine ............................................................................................................................ 06-57
06-63-12 Gearbox .......................................................................................................................... 06-59
06 - 54 9813/8950-2 06 - 54
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 - 55 9813/8950-2 06 - 55
03 - Machine
03 - Machine
Introduction
new one, the serial number on the identification plate

Your machine has an identification plate. The will be wrong. Either get a replacement identification
PIN (Product Identification Number), weight, engine plate from your JCB dealer or simply remove the
power, year of manufacture and serial number of the old number. This will prevent the wrong unit number
machine are shown on the identification plate. being quoted when replacement parts are ordered.
The serial number of each major unit is also shown

on the unit itself. If a major unit is replaced by a
Figure 67.
A Identification plate
The machine model and build specification are

indicated by the PIN. The PIN has 17 digits and must
be read from left to right.
Table 7. Typical PIN

JCB 6TFTR A B 1234567
Table 8. Explanation of the PIN

Digit Description
1 to 3 World manufacturer identification. For ex-
ample, JCB = UK Build.
4 to 8 Machine type and model
9 Randomly Generated Check Letter. The
check letter is used to verify the authenticity
of a machine's PIN.
10 Year of manufacturer J=2018, K=2019
11 to Machine serial number
17
06 - 56 9813/8950-2 06 - 56
06 - Engine
06 - Engine
Introduction
The engine data labels are attached to the cylinder

block as shown.
Figure 68.
E
D
B
C B
A Engine data label B Stamp

C Engine data label - crankcase D Engine data label - rocker cover
E Engine identification number
The data label includes the engine identification

number.
Table 9. Example of the engine identification number

SH 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 10.
Digit 1-2 Engine Type
SL 4.4 L turbocharged and aftercooled
electronic common rail fuel injection
(Tier 4F) < 55 kW
Table 11. Explanation of the engine identification number

Digit Explanation
3-10 Engine part number
11 Country of manufacture. U = United Kingdom
12-16 Engine serial number
17-18 Year of manufacture
06 - 57 9813/8950-2 06 - 57
06 - Engine
The country of manufacturer, engine serial number

and year of manufacture of the engine are also
stamped on the crankcase. Refer to Figure 68.
06 - 58 9813/8950-2 06 - 58
12 - Gearbox
12 - Gearbox
Introduction
Gearbox
The gearbox serial number is stamped on the unit
identification plate as shown.
Figure 69.
06 - 59 9813/8950-2 06 - 59
12 - Gearbox
Dropbox
The dropbox serial number is stamped on the unit
identification plate as shown.
Figure 70.
06 - 60 9813/8950-2 06 - 60
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-63
06 - 61 9813/8950-2 06 - 61
Notes:
06 - 62 9813/8950-2 06 - 62
66 - Tools
00 - General
00 - General
Introduction
When you carry tools onto the machine, you must

keep three points of contact with the machine at all
times. If necessary, lift the tools on to the machine in
intervals. Put the tools down before you adjust your
grips on the machine. Do not try to adjust your grips
on the machine while holding tools.
06 - 63 9813/8950-2 06 - 63
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-65
06 - 64 9813/8950-2 06 - 64
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 - 65 9813/8950-2 06 - 65
81 - Dumper Body
81 - Dumper Body
Contents Page No.
06-81-00 General ........................................................................................................................... 06-67
06 - 66 9813/8950-2 06 - 66
81 - Dumper Body
00 - General
Introduction .................................................... 06-67 The dumper body (or skip) is used for transporting
Health and Safety .......................................... 06-68 loose free flowing materials e.g. sand, gravel, or
Check (Condition) .......................................... 06-68 soil for construction purposes. The dumper body
Remove and Install ....................................... 06-69 is hinged and equipped with hydraulic rams to lift
the body, this allows the material in the body to be
deposited on the ground.
06 - 67 9813/8950-2 06 - 67
81 - Dumper Body
00 - General

DANGER Keep all bystanders well clear when
loading or unloading a dumper. 1. Inspect all steelwork for damage. Pay particular
attention to the following:
of supporting the skip in the raised position must 1.1. Inspect all the lifting point welds.
under a raised skip. Do not reach or work under 1.2. Inspect all the pivot point welds.
a raised skip unless a prop is installed. 1.3. Inspect the condition of all the pivot pins.
WARNING A high skip or heaped skip can block 1.4. Check that the pivot pins are correctly in
your view and reduce the machine's stability. place and secured by their locking devices.
Travel with the skip lowered. Travel slowly and
with caution over rough, muddy or loose surfaces.
WARNING Never attempt to move the machine
with the lift arm and skip in the elevated position.
Danger of the overturning.
WARNING Applicable certain markets - Skip lock
- The lock must be installed when travelling on
the public highway to prevent the skip raising or
tipping accidentally.
06 - 68 9813/8950-2 06 - 68
81 - Dumper Body
00 - General

C
9T-1 Front Tip ........................... Page 06-70
(For: 6T-1 Swivel Tip) A

method and device.
Remove
A Dumper body
3. Install the safety strut.
C Lifting equipment
7. Remove the split pin from the eye end pivot pin.
Figure 71.
8. Remove the pivot pin 1.
8.1. Left-hand side shown, right-hand side
A similar.
Figure 73.
D
A Dumper body
B Safety strut
D Split pin
Refer to: PIL 33-03-00. E Pivot pin 1
5. Support the dumper body with suitable lifting 9. Make a note of the position of any shims on the
equipment. pivot pins.
6. Remove the dumper tip cylinder ram.
06 - 69 9813/8950-2 06 - 69
81 - Dumper Body
00 - General
Figure 74. Remove

Figure 76.
F F
K
F Shims
A
10. Remove the bolt.
11. Remove the pivot pin 2.
B
Figure 75.
A Dumper body
B Safety strut
K Lifting equipment
H 4. Support the dumper body with suitable lifting
equipment.
G Bolt
H Pivot pin 2 5. Isolate the battery.
12. Remove the dumper body from the machine. Refer to: PIL 33-03-00.
6. Remove the split pin from the eye end pivot pin.
Install
7. Remove the bolt 1.
removal procedure. 8. Remove the pivot pin 1.
2. Tighten the bolt to the correct torque value.

Item Description Nm
G Bolt 1 60

method and device.
06 - 70 9813/8950-2 06 - 70
81 - Dumper Body
00 - General
E
C
D
G
C Split pin
D Bolt 1
E Pivot pin 1
G Shims
9. Carefully reposition the cylinder rams out of the
way. Do not drop the hydraulic cylinders onto the 11. Remove the bolt 2.
chassis or this will cause damage to the cylinder
rod. 12. Collect the shims.
Figure 78. 13. Remove the pivot pin 2.

Figure 80.
F Rams H Bolt 2
J Pivot pin 2
10. Make a note of the position of any shims on the
pivot pins. 14. Collect the shims.
15. Remove the dumper body from the machine.
Install
removal procedure.
2. Tighten the bolt 1 to the correct torque value.

Item Description Nm
D Bolt 1 60
06 - 71 9813/8950-2 06 - 71
88 - Exterior Light Guard
Contents Page No.
06-88-00 General ........................................................................................................................... 06-73
06 - 72 9813/8950-2 06 - 72
00 - General
Introduction .................................................... 06-73 The exterior light guards provide protection from
Remove and Install ....................................... 06-74 rocks, falling objects and can also protect against
acts of vandalism.
06 - 73 9813/8950-2 06 - 73
00 - General
Remove and Install
Refer to the relevant exterior light removal

procedure.
06 - 74 9813/8950-2 06 - 74
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-4
09-00-06 Operator Protective Structure .......................................................................................... 09-9
09-09 Window
09-09-00 General ........................................................................................................................... 09-13
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-23
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-27
09-27 Controls
09-27-36 Accelerator Pedal ........................................................................................................... 09-29
09-27-54 Service Brake Pedal ...................................................................................................... 09-30
09-30 Trim Panel
09-30-09 Dashboard ...................................................................................................................... 09-33
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-39
09-78 Floor plate
09-78-00 General ........................................................................................................................... 09-43
9813/8950-2
2018-02-26
Acronyms Glossary

9813/8950-2
2018-02-26
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-4
09-00-06 Operator Protective Structure .......................................................................................... 09-9
09 - 1 9813/8950-2 09 - 1
Notes:
09 - 2 9813/8950-2 09 - 2
00 - General
00 - General
Introduction
Some of these machines are installed with the cab

option.
The machines without cab have only the ROPS (Roll-

Over Protective Structure) frame overhead of the
operator seat.
The machines with cab have the FOPS (Falling

Object Protective Structure) in addition to ROPS
frame. The cab machines are also installed with the
heater only option.
09 - 3 9813/8950-2 09 - 3
03 - Cab Frame
03 - Cab Frame Health and Safety

Health and Safety ........................................... 09-4
Remove and Install ......................................... 09-5
(For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1
Front Tip [Hi-Viz], 9T-1 Front Tip, Cab)
Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
09 - 4 9813/8950-2 09 - 4
03 - Cab Frame
Remove and Install
7. Disconnect the electrical connectors (x2).

(For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 Figure 82.
movement.
Lifting Equipment
enough and suitable for the job. Make sure that lifting B
local regulations.
and device.
Remove
B Electrical connectors
8. Open the left and right side doors.
Refer to: PIL 30-00-00. 9. Move the seat fully forward and tilt the seat
backrest fully forward.
3. Disconnect the battery.
10. Open the transmission compartment.
4. Make sure that all of the wheels are blocked.
11. Remove the floor plate.
5. Open the engine cover. Refer to: PIL 09-78-00.
12. Remove the nut and disconnect the earth strap
6. Disconnect the window washer fluid hose. from the earth point on the machine.
A Washer fluid hose connector

C Earth point
09 - 5 9813/8950-2 09 - 5
03 - Cab Frame
13. Close the transmission compartment. Figure 85.

14. Remove the screws (x8) and remove the front
cover.
Figure 84.
D F
E
F Electrical connectors
16. Clamp the heater hoses on the machine side of
the quick connectors.
16.1. Make sure you do not damage the heater
D Front cover hoses.
E Screws 17. Disconnect the heater hoses.
15. Disconnect the electrical connectors (x2). 17.1. Plug all the open ports and hoses to
prevent fluid loss and contamination.
Figure 86.
G
G
G Heater hose connections
09 - 6 9813/8950-2 09 - 6
03 - Cab Frame
18. Remove the bolts (x2) and remove the handles 19. Remove the nuts and bolts (x4), and the bolts
from both sides of the transmission cover. (x2).
Figure 87.
H
H Bolts (x2)
J Handle
Figure 88.
K
L
K Nuts and bolts (x4) L Bolts (x2)
20. Close the left and right side doors.
09 - 7 9813/8950-2 09 - 7
03 - Cab Frame
21. Remove the nut and remove the door lock back Figure 91.
pins from both sides of the cab frame.
Figure 89.
M Nut
N Door lock back pin
22. Remove the beacons.
R Harness entrance hole
23. Attach suitable lifting equipment to the front grab
handles and to the door lock back pin brackets. 25. Remove the electrical harness and the window
washer hose from the harness entrance hole.
Figure 90.
26. Lift the cab away from the machine. Make
sure that it does not swing or snag any other
components.
P
Install
steps.
2. Make sure that the electrical harness and the
window washer fluid hose is routed correctly.
4. Check the coolant level and top up to the correct
level.
P Cab frame lifting points

24. Lift the cab sufficiently to access the harness
entrance hole in the side of the machine.
09 - 8 9813/8950-2 09 - 8
06 - Operator Protective Structure
06 - Operator Protective Structure Introduction

Introduction ...................................................... 09-9 There are service factors which tend to degrade
Health and Safety .......................................... 09-10 a ROPS (Roll-Over Protective Structure)/FOPS
Check (Condition) .......................................... 09-10 (Falling Object Protective Structure) systems energy
Remove and Install ....................................... 09-11 absorbing or load carrying capability. A few of these
are:
• Structural damage from vibrations and/or

loadings during some operations.
• A corrosive environment.
• Continued use of the machine after a rollover or
accident involving structural damage.
• Unauthorized modification to the ROPS/FOPS.
• Bolt replacement with less than the correct
grade bolt.
• Incorrect bolt torque.
• Improper installation.
09 - 9 9813/8950-2 09 - 9

WARNING You could be killed or seriously injured
if you operate a machine with a damaged or 1. Check the structure for damage.
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/
FOGS has been in an accident, do not use the 2. Make sure that all the ROPS (Roll-Over
machine until the structure has been renewed. Protective Structure)/FOPS (Falling Object
Modifications and repairs that are not approved Protective Structure) mounting bolts are in place
by the manufacturer may be dangerous and will and not damaged.
invalidate the ROPS/FOPS/FOGS certification. 3. Tighten the ROPS/FOPS frame mounting bolts
WARNING When replacing or repairing the to the correct torque value.
ROPS/FOPS/FOGS structure you must replace Refer to: PIL 72-06-00.
the fixings. Never re-use fixings. Use only new
genuine JCB fixings tightened to the torque
figures specified in the operator's manual.
09 - 10 9813/8950-2 09 - 10

Front Tip, Without Cab .............. Page 09-11 C
Front Tip [Hi-Viz], 9T-1 Front Tip, Cab
................................................... Page 09-11
D
Front Tip, Without Cab)
Remove
2. Isolate the battery. C ROPS/FOPS
Refer to: PIL 33-03-00. D Bolts (x8)
3. Support the ROPS (Roll-Over Protective Install
Structure)/FOPS (Falling Object Protective
Structure) with suitable lifting equipment. 1. The installation procedure is the opposite of the
removal procedure.
4. Disconnect the beacon wiring harness.
2. Tighten the ROPS/FOPS frame bolts to the
5. Remove the beacon wiring from the grommet.
correct torque values.
Figure 92. Refer to: PIL 72-06-00.

B Front Tip [Hi-Viz], 9T-1 Front Tip, Cab)
The operator protective structure on these machines
is the part of the cab frame. Refer to: PIL 09-00-03.
A
A Beacon wiring
B Grommet
6. Remove the bolts (x8).
7. Remove the ROPS/FOPS from the machine.
09 - 11 9813/8950-2 09 - 11
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-13
09 - 12 9813/8950-2 09 - 12
09 - Window
00 - General
Introduction .................................................... 09-13 For: Cab, Regular/Laminated .... Page
09-13
Health and Safety .......................................... 09-14
For: Cab, Coated Polycarbonate
Preparation .................................................... 09-15 ................................................... Page 09-13
(For: Cab, Regular/Laminated)
The service procedures, explain how to correctly
remove and install panes of glass that are directly
bonded to the cab frame apertures. When you carry
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).
(For: Cab, Coated Polycarbonate)

Your machine may be installed with a Coated
Polycarbonate front window.
This type of window is resistant to most of the

chemicals, and unique coating on these windows
and gives UV protection up to 99.96 %.
09 - 13 9813/8950-2 09 - 13
09 - Window
00 - General
The service procedures, explain how to correctly Health and Safety

install Coated Polycarbonate windows that are
directly bonded to the cab frame apertures. When CAUTION Laminated glass must be handled
you carry out any service procedure, you must with extra care to prevent breakage. Wherever
always refer to the relevant safety precautions, possible, store and handle it in a vertical attitude.
Health and Safety. Refer to: PIL 09-09-00. When placing or lifting the glass in a horizontal
attitude it must be supported over its whole area,
1. Always leave the protective plastic foil on the not just at the edges.
window until installation is completely finished.
WARNING Always wear safety glasses when
2. If the protective plastic foil is in the way, fold the removing or installing screen glass. Never use a
edges of the foil and secure with tape, where it power operated knife when removing the sealant
is in the way. around a toughened glass screen. The action
of the knife could cause particles of glass to
3. After the window is fully installed, you can be thrown with sufficient force to cause serious
remove the protective plastic foil. injury, even when safety glasses are being worn.
Use only hand operated tools when working with
4. To minimize the generation of static electricity, toughened glass.
pull the plastic foil off slowly.
5. If there is static electricity, it can be wiped off with
a fabric softener.
09 - 14 9813/8950-2 09 - 14
09 - Window
00 - General
Preparation Figure 94.
(For: Cab, Regular/Laminated)

Special Tools
Description Part No. Qty.
Glass Lifter 892/00842 2
Folding Stand 892/00843 1
Cartridge Gun 892/00845 1
Rubber Spacer Blocks 926/15500 4
Mobile Oven (12V) 992/12300 1
Static Oven (240V) 992/12400 1
Consumables
Description Part No. Size
Black Primer/Activator 4104/2304 0.1 L
Polyurethane Adhesive 4103/2110 0.31 L
Surface Cleaning Fluid 4103/1204 1L A Frame aperture
B Spacer blocks
Operator Station Aperture C Glass lifters
1. If damp or wet, dry the aperture area using a hot 2. After checking for size, remove the new glass
air gun (sourced locally). and place it on a purpose made glass stand.
Small panes of glass will need locating on a
2. Use surface cleaning fluid to thoroughly clean 600 x 700 mm x 15 to 19 mm thick plywood
and prime the trimmed sealant. Use a lint free board, sourced locally to fit the glass stand. It is
cloth to apply the cleaner, allow to dry. recommended that an access hole is cut in the
Duration: 5 min board to accommodate the glass lifter, making it
Consumable: Surface Cleaning Fluid easier and safer to handle small panes of glass.
The board should be covered with felt or carpet
Note: Do not use any other type of cleaning fluids, to give an anti-scratch surface. Resting the glass
otherwise they may be absorbed into the old sealant on four spacer blocks will ensure clearance of
and ultimately prevent the new glass from bonding. the cartridge nozzle tip during application of the
polyurethane sealant.
New Glass Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
1. Make sure that the new glass correctly fits the
frame aperture. Figure 95.
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 3. Make sure the glass is positioned on the stand
and eventually break the newly installed the correct way up (i.e. with the black ceramic
glass. ink band upwards) ready for application of primer
etc.
Special Tool: Glass Lifter (Qty.: 2)
09 - 15 9813/8950-2 09 - 15
09 - Window
00 - General
Figure 96. will be difficult to remove the cartridge from

the applicator gun.
5.3. Pierce the front nozzle end of the cartridge
to its maximum diameter.
5.4. Install the pre-cut nozzle.
5.5. Install the cartridge in the applicator gun.
Note: Cold material will be very difficult to
extrude. The cartridges must be pre-heated
in a special oven for 1 hour to a temperature
of 80°C (176°F). Pre-heating the cartridges
makes the adhesive more workable and
also brings the curing time down to 30
minutes.
Figure 98.
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
free cloth to apply the cleaner, allow to A
dry. Important: Do not touch the glass after
cleaning with the surface cleaner.
Duration: 5 min B
Consumable: Surface Cleaning Fluid
A 12.5 mm
4.2. If the glass does not have a black ceramic B 9 mm
ink band, paint a band on the glass using
Black Primer. Make sure that the band 6. Apply the pre-heated adhesive to the glass (do
measures the correct width and that the not start in a corner). Keep the nozzle guide
edge is a neat straight line. against the edge of the glass and make sure
Dimension: 25 mm that the adhesive forms a continuous pyramid'
Consumable: Black Primer/Activator shape. Note: Once the pre-heated adhesive has
been applied to the glass, install the glass in the
Figure 97. aperture as soon as possible. If you wait too long
then the sealant will form a skin, this will prevent
the glass from bonding.
Duration: 10 min
Figure 99.
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) A Nozzle guide
Special Tool: Cartridge Gun (Qty.: 1)
Consumable: Polyurethane Adhesive 7. After applying the adhesive, leave a small
amount of sealant protruding from the nozzle.
5.1. Remove the aluminium disc cover from This will prevent any adhesive left in the cartridge
the base of the cartridge and discard the from curing.
dessicant capsule.
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 - 16 9813/8950-2 09 - 16
09 - Window
00 - General
Remove and Install by compressed air, should be sourced

locally. Press the handle to start the knife
For: Cab, Regular/Laminated .... Page blade oscillating. Important: This tool must
09-17 not be used on toughened glass. Insert the
For: Cab, Coated Polycarbonate knife blade into the sealant. Slowly move
................................................... Page 09-19 the knife along the sealant with the blade
positioned as close to the glass as possible.
Do not allow the knife blade to overheat or
(For: Cab, Regular/Laminated) the sealant will melt.
Special Tools
Figure 100.
Glass Lifter 892/00842 2
Glass Extractor 892/00846 1
(Handles Only)
Nylon Spatula 892/00847 1
Wire Starter 892/00848 1
Braided Cutting Wire 892/00849 1
Rubber Spacer Blocks 926/15500 2
Cut-Out Knife 992/12800 1
'L' Blades 992/12801 1 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
Consumables
into the old sealant on the inside of the
Description Part No. Size glass. Insert the braided cutting wire down
Black Polyurethane 4102/2310 0.31 L the centre of the steel tube. If necessary,
Sealant from the outside, cut out local sealant at the
Black Primer/Activator 4104/2304 0.1 L point of the tube to gain access to the wire.
Glass Replacement Kit 993/55701 - Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the
Hand Cleaner 4104/1310 -
glass. Secure the end of the braided cutting
JCB Glass Cleaner 4006/3175 0.75 L wire (found on the outer side of the glass) in
Surface Cleaning Fluid 4103/1204 1L the special handle. Slowly remove the steel
tube. Secure the second end of the braided
Removal cutting wire in the special handle. Move the
cutting wire backwards and forwards in a
1. Position the machine on level ground and apply sawing motion and at the same time gently
the park brake. Stop the engine. Put protective push or pull the wire to cut through the old
covers over the cab seat and control pedestals. sealant.
2. If a laminated pane breaks it will stay in one piece Special Tool: Wire Starter (Qty.: 1)
even though the glass is cracked. A toughened Special Tool: Glass Extractor (Handles
pane will shatter and fall apart. The method of Only) (Qty.: 1)
removal of the glass depends upon which type Special Tool: Braided Cutting Wire (Qty.: 1)
it is.
2.1. Laminated glass - leave installed until the
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
easiest methods of removing the sealant
around laminated glass. The tool, powered
09 - 17 9813/8950-2 09 - 17
09 - Window
00 - General
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
A Wire starter 4. Laminated glass - lift out the broken pane using
B Braided cutting wire glass lifters. Toughened glass - remove the cut off
C Glass extractor (handles) sealant and all remaining particles of shattered
D Glass extractor (handles) glass.
3.3. Cut-out Knife - The cut-out knife can be 5. If necessary, trim off the remaining old sealant
used as a left handed or right handed tool. to leave approximately 1 to 2 mm on the upright
Insert the knife blade into the sealant. Make face of the cab frame aperture.
sure that the blade of the knife is against the
glass. Use the 'pull-handle' to pull the knife Figure 104.
along and cut out the old sealant.
Special Tool: 'L' Blades (Qty.: 1)
Special Tool: Cut-Out Knife (Qty.: 1)
A
Figure 102.
A 1.5 mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures.
6.2. The old sealant was inadvertently cut back
A Glass to the cab frame during the glass/sealant
removal procedures.
3.4. Craft Knife - The blades are replaceable.
Insert the knife blade into the sealant. Pull Installing new Glass
the knife along and cut out the old sealant.
1. If the internal trim strip is damaged, renew it (cut
to length as required) before installing the new
09 - 18 9813/8950-2 09 - 18
09 - Window
00 - General
glass. Make sure the two spacer blocks are in 3.2. Use your finger to make the inside seal
position. Refer to Preparation - New Glass smooth.
2. Install the glass in the frame aperture: 4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
2.1. Always use the glass lifting tools when caution when wiping the inside of the new glass
moving the glass. Use a lifting strap to hold - pushing too hard on the inside of the glass will
large panes of glass in position. affect the integrity of the bonded seal.
Special Tool: Glass Lifter (Qty.: 2) Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
Figure 105. Typical Machine
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
Consumable: Surface Cleaning Fluid
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
2.2. Sit the bottom edge of the glass on the curing period of 30 minutes.
spacer blocks.
5.3. Clean the glass using a purpose made
Special Tool: Rubber Spacer Blocks (Qty.: glass cleaner.
2)
Consumable: Hand Cleaner
Figure 106. 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.
(For: Cab, Coated Polycarbonate)
Install
1. Make sure that the operator station surface is
clean, dry and free from grease, oil and dust.
2. Damp a cloth with suitable Activator (Isopropanol
or similar) and wipe off the operator station
2.3. Make sure that the glass is correctly surface.
positioned, then gently press around the
edges of the glass and ensure full adhesive 2.1. You must wipe off the operator station
contact is achieved. Do not press too hard surface and the primed parts of the front
or too much adhesive will squeeze out. window screen.
3. Make the inside seal smooth: 2.2. You must wipe the surfaces with Activator
only once.
3.1. Wearing surgical gloves, dip your finger in 2.3. Make sure that there is no residual Activator
a soapy water solution. on the surfaces.
09 - 19 9813/8950-2 09 - 19
09 - Window
00 - General
3. Wait for at least the specified duration before you

apply the glue.
Duration: 10 min
3.1. It is recommended to apply the glue
within the specified time from cleaning with
Activator.
Duration: 2 h
4. Apply a layer of glue, rich enough to leave
a bond-line of at least the specified thickness
per metre windowpane when the surfaces are
pressed together.
Dimension: 4 mm
5. Make sure that the front window screen is fixed
during the curing time.
09 - 20 9813/8950-2 09 - 20
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-23
09 - 21 9813/8950-2 09 - 21
Notes:
09 - 22 9813/8950-2 09 - 22
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-23 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-24 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 - 23 9813/8950-2 09 - 23
12 - Operator Seat
00 - General
Remove and Install
Remove
4. Disconnect the electrical connectors.
Figure 107.
A Electrical connectors
5. Remove the bolts from the operator seat.
6. Remove the operator seat.
Figure 108.
B Operator seat
C Bolts
Install
removal procedure.
09 - 24 9813/8950-2 09 - 24
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-27
09 - 25 9813/8950-2 09 - 25
Notes:
09 - 26 9813/8950-2 09 - 26
15 - Seat Belt
00 - General
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 - 27 9813/8950-2 09 - 27
27 - Controls
27 - Controls
Contents Page No.
09-27-36 Accelerator Pedal ........................................................................................................... 09-29

09-27-54 Service Brake Pedal ...................................................................................................... 09-30
09 - 28 9813/8950-2 09 - 28
27 - Controls
36 - Accelerator Pedal
36 - Accelerator Pedal
Remove and Install
Remove
4. Disconnect the electrical connector.
5. Remove the setscrew (x3).
6. Remove the accelerator pedal from the machine.
Figure 109.
A Accelerator pedal
B Setscrew (x3)
Install
step.
2. Tighten the setscrew to the correct torque value.
09 - 29 9813/8950-2 09 - 29
27 - Controls
54 - Service Brake Pedal
54 - Service Brake Pedal Figure 112.
Remove and Install
Remove
2. Isolate the battery. C
A
C Return spring
Refer to: PIL 09-78-00. 8. Remove the bolt.
4. Remove the pin. Figure 113.
5. Disconnect the brake master cylinder from the

brake pedal.
Figure 110.
D
A
D Bolt
9. Collect the washers.
10. Use the slide hammer kit to remove the pivot pin.
A Pin
6. Tighten the brake pedal stop screw to remove the
spring tension. Figure 114.
Figure 111.
A
E
B
A
E Pivot pin
B Stop screw 11. Remove the brake pedal.
7. Disconnect the return springs.
09 - 30 9813/8950-2 09 - 30
27 - Controls
54 - Service Brake Pedal
Figure 115.
A
F
F Brake pedal
Install
removal procedure.
09 - 31 9813/8950-2 09 - 31
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-09 Dashboard ...................................................................................................................... 09-33
09 - 32 9813/8950-2 09 - 32
30 - Trim Panel
09 - Dashboard
09 - Dashboard Introduction
Introduction .................................................... 09-33 The dashboard (also called dash, or fascia) is the
Remove and Install ....................................... 09-34 panel located in front of the driver. The dashboard
is used to mount the instrument panel and other
controls and switches for operation of the machine.
09 - 33 9813/8950-2 09 - 33
30 - Trim Panel
09 - Dashboard
Remove and Install
CAUTION This component is heavy. It must only 7. Remove the cover plate.
method and device. 8. Remove the screw 3 (x8).
9. Carefully move the control panel assembly.
Remove
10. Disconnect the electrical connectors from the
1. Make the machine safe. switches.
Refer to: PIL 01-03-27. 10.1. Put a label on the electrical connectors to
help installation.
Refer to: PIL 33-03-00. 11. Remove the control panel assembly.
3. Remove the steering wheel. 12. Remove the screw 4 (x8).
4. Remove the screw 1 (x4). 13. Remove the leg guard.
5. Remove the steering column cover. 14. Remove the screw 5 (x6) and washers.
6. Remove the screw 2 (x6). 15. Remove the platform cover assembly.
09 - 34 9813/8950-2 09 - 34
30 - Trim Panel
09 - Dashboard
Figure 116.
G
F
K,L
J
A Steering wheel B Screw 1 (x4)

C Steering column cover D Screw 2 (x6)
E Cover plate
09 - 35 9813/8950-2 09 - 35
30 - Trim Panel
09 - Dashboard
Figure 117.
F Screw 3 (x8) G Control panel assembly

H Screw 4 (x8) J Leg guard
K Screw 5 (x6) L Washers
M Platform cover assembly
09 - 36 9813/8950-2 09 - 36
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 37 9813/8950-2 09 - 37
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-39
09 - 38 9813/8950-2 09 - 38
00 - General
Introduction .................................................... 09-39 The safety labels are strategically placed around the
Health and Safety .......................................... 09-40 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 - 39 9813/8950-2 09 - 39
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 - 40 9813/8950-2 09 - 40
78 - Floor plate
78 - Floor plate
Contents Page No.
09-78-00 General ........................................................................................................................... 09-43
09 - 41 9813/8950-2 09 - 41
Notes:
09 - 42 9813/8950-2 09 - 42
78 - Floor plate
00 - General
00 - General Figure 119.
Remove and Install B
Remove C

Refer to: PIL 01-03-27. A
2. Isolate the battery. A

Refer to: PIL 33-03-00. E Floor plate
F Screw 2 (x12)
3. Lift up the gaiter on the gear lever. G Washers
4. Remove the bolt 1 (x4).
Install
5. Remove the gaiter clamp plate from the gear
lever. 1. The installation procedure is the opposite of the
removal procedure.
Figure 118.
A
B
C
D
A Gear lever
B Gaiter
C Gaiter clamp plate
D Bolt 1 (x4)
6. Remove the screw 2 (x12) and washers.
7. Remove the floor plate from the machine.
09 - 43 9813/8950-2 09 - 43
Notes:
09 - 44 9813/8950-2 09 - 44
12 - Heating, Ventilating and
Air-Conditioning (HVAC)
Contents Page No.
12-04 Heater Unit

12-04-00 General ............................................................................................................................. 12-3
12-18 Filter
12-18-06 Fresh Air .......................................................................................................................... 12-7
12-18-09 Recirculation ..................................................................................................................... 12-8
9813/8950-2
2018-02-21
Notes:
9813/8950-2
2018-02-21
12 - Heating, Ventilating and Air-Conditioning (HVAC)
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ............................................................................................................................. 12-3
12 - 1 9813/8950-2 12 - 1
Notes:
12 - 2 9813/8950-2 12 - 2
04 - Heater Unit
00 - General
Introduction ...................................................... 12-3
Component Identification ................................. 12-4
(For: Cab)
There is a heater system installed to warm the air in
the operator station.
The heater system is turned on by a switch in the

operator station, rotate the separate temperature
switch to select the desired temperature.
12 - 3 9813/8950-2 12 - 3
04 - Heater Unit
00 - General
(For: Cab)
Figure 120.
C
B
E
A Blower motor B Heater radiator assembly

C Filter D Heater water valve
E Control cable assembly
12 - 4 9813/8950-2 12 - 4
18 - Filter
18 - Filter
Contents Page No.
12-18-06 Fresh Air .......................................................................................................................... 12-7

12-18-09 Recirculation ..................................................................................................................... 12-8
12 - 5 9813/8950-2 12 - 5
Notes:
12 - 6 9813/8950-2 12 - 6
18 - Filter
06 - Fresh Air
06 - Fresh Air
Remove and Install

Remove
2. Remove the screw (x4).
3. Remove the cover.
4. Remove the filter element.
5. If required, clean the area around the heater unit.
Figure 121.
A Fresh air filter element

B Cover
C Screws (x4)
Install
removal procedure.
12 - 7 9813/8950-2 12 - 7
18 - Filter
09 - Recirculation
09 - Recirculation
Remove and Install

Remove
2. Get access to the heater unit.
3. Remove the filter.
Figure 122.
A Heater unit
B Filter
4. If required, clean the area around the heater unit.
Install
removal procedure.
12 - 8 9813/8950-2 12 - 8
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-39
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-43
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-51
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-59
15-12-03 Main Bearing .................................................................................................................. 15-68
15-12-06 Front Oil Seal ................................................................................................................. 15-70
15-12-09 Rear Oil Seal ................................................................................................................. 15-73
15-12-12 Pulley .............................................................................................................................. 15-77
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-79
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-87
15-18-03 Drive Belt ....................................................................................................................... 15-90
15-18-21 Tensioner ........................................................................................................................ 15-94
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-97
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-105
15-24-03 Outer Element .............................................................................................................. 15-109
15-24-06 Inner Element ............................................................................................................... 15-111
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-113
15-30 Valve
15-30-00 General ......................................................................................................................... 15-117
15-30-12 Valve Spring ................................................................................................................. 15-126
15-30-24 Stem Seal .................................................................................................................... 15-127
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-129
15-33-06 Big-End Bearing ........................................................................................................... 15-132
15-36 Piston
15-36-00 General ......................................................................................................................... 15-137
15-36-03 Piston Ring ................................................................................................................... 15-146
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-149
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-151
9813/8950-2
2018-03-14
15-42-06 Rocker Cover ............................................................................................................... 15-159
15-42-09 Push Rod ..................................................................................................................... 15-161
15-42-21 Tappet ........................................................................................................................... 15-163
15-42-24 Tappet Cover ................................................................................................................ 15-165
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-167
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-173
15-51-03 Crankshaft Gear ........................................................................................................... 15-176
15-51-06 Camshaft Gear ............................................................................................................. 15-179
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-180
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-183
15-51-22 Rear Case .................................................................................................................... 15-186
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-191
15-54-03 Housing ........................................................................................................................ 15-194
15-54-09 Gear Ring ..................................................................................................................... 15-197
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-199
15-63 Mount
15-63-00 General ......................................................................................................................... 15-207
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-211
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-217
15-72-03 Pulley ............................................................................................................................ 15-223
15-72-06 Voltage Regulator ......................................................................................................... 15-224
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-227
15-75-06 Brush Gear ................................................................................................................... 15-235
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-237
15-84-03 Crankshaft Position ...................................................................................................... 15-247
15-84-06 Camshaft Position ........................................................................................................ 15-251
15-84-09 Knock ........................................................................................................................... 15-255
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-258
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-261
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-264
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-267
15-84-19 Exhaust Temperature ................................................................................................... 15-270
15-84-24 Fuel Temperature ......................................................................................................... 15-273
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-276
15-84-33 Coolant Temperature .................................................................................................... 15-279
15-84-42 Engine Oil Temperature ............................................................................................... 15-282
15-84-43 Engine Oil Level ........................................................................................................... 15-285
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-288
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-291
15-86 Solenoid
15-86-00 General ......................................................................................................................... 15-297
15-87 Switch
15-87-00 General ......................................................................................................................... 15-299
9813/8950-2
2018-03-14
15-87-03 Engine Oil Pressure ..................................................................................................... 15-300
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-305
9813/8950-2
2018-03-14
Acronyms Glossary
CAN Controller Area Network

CCV Crankcase Ventilation
DC Direct Current
DCU Dosing Control Unit
DEF Diesel Exhaust Fluid
DTC Diagnostic Trouble Code
DTI Dial Test Indicator
ECM Engine Control Module
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
FEAD Front End Accessory Drive
HPV High Pressure Valve
IMV Inlet Metering Valve
MAF Mass Air Flow
NOx Nitrogen Oxide
PTO Power Take-Off
PWM Pulse Width Modulation
RPM Revolutions Per Minute
SCR Selective Catalytic Reduction
TDC Top Dead Centre
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
VGT Variable Geometry Turbocharger
9813/8950-2
2018-03-14
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/8950-2 15 - 1
Notes:
15 - 2 9813/8950-2 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-7 engine assembly. For specific engine technical
Technical Data ................................................. 15-8 information refer to the technical data section.
Make sure that the correct engine service tools,
Operation ....................................................... 15-13 consumables and torque figures are used when you
Fault-Finding .................................................. 15-17 perform service procedures.
Drain and Fill ................................................. 15-27
Clean ............................................................. 15-27 Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
Check (Pressure) .......................................... 15-28 damage is expected as a matter of course.
Store and Recommission .............................. 15-34 It is expected that components will be cleaned and
lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The JCB ecoMax engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The

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

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

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

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

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

coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
15 - 3 9813/8950-2 15 - 3
15 - Engine
00 - Engine
00 - General
Figure 123.
8
5
3
1
10
1 Flywheel 2 Crankshaft
3 Camshaft 4 Inlet valves (x8)
5 Exhaust valves (x8) 6 Push rods (x8)
7 High pressure fuel pump drive gear 8 Turbocharger
9 Lubrication oil pump 10 Front end drive belt
15 - 4 9813/8950-2 15 - 4
15 - Engine
00 - Engine
00 - General
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 124.
1 Rocker assembly 2 Valve bridge piece (x8)

3 Valve spring (x16) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft / connecting rod
(x4)
11 Front crankshaft oil seal 12 Flywheel
13 High duty PTO (Power Take-Off) idler gear (if
installed)
15 - 5 9813/8950-2 15 - 5
15 - Engine
00 - Engine
00 - General
Figure 125.
11
10 5
1a
6 7 4 3
1 Flywheel 1A Flywheel - crankshaft fixing bolts (x8)

2 Fuel injector (atomiser) (x4) 3 Flywheel hub
4 Crankshaft drive gear 5 High duty PTO idler gear (if installed)
6 Camshaft drive gear 7 Lubrication oil pump
8 High pressure fuel pump drive gear 9 Camshaft
10 Tappet (x8) 11 Push rod (x8)
15 - 6 9813/8950-2 15 - 6
15 - Engine
00 - Engine
00 - General
Health and Safety accordance with local regulations. Use authorised

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
Special precautions must be taken if the machine is
to be washed using a high pressure system. Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment. Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts. When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the maximum level of engine
oil in the sump. If the maximum is exceeded, the
excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can
burn you. Make sure the engine is cool before doing
this job. Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants. Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 7 9813/8950-2 15 - 7
15 - Engine
00 - Engine
00 - General
Technical Data Description SJ Engine SL Engine

Lubricating oil 1.6 –6.5 bar 1.6 –6.5 bar
pressure (De- ( 23.2 –94.2 ( 23.2 –94.2
pendent on en- psi) psi)
Table 14.
gine tempera-
Description SJ Engine SL Engine ture and speed)
Engine Variants Turbocharged Turbocharged Fuel filter type Screw-on can- Screw-on can-
with intercool- with intercooler ister (with drain ister (with drain
er and exhaust facility) facility)
(2)
aftertreatment Oil pressure re- 6 bar ( 87.0 psi) 6 bar ( 87.0 psi)
system lief valve setting
Emission com- US-EPA Tier 4 US-EPA Tier 4 Oil pressure 0.6 bar ( 8.7 0.6 bar ( 8.7
pliance Final, EU Stage Final, EU Stage switch setting psi) falling psi) falling
IV IV
Oil pump
(1)
Integral unit Integral unit
Rated speed 2200 RPM 2200 RPM with relief valve with relief valve
(Revolutions
Per Minute) Combustion Common rail di- Common rail di-
system rect Injection rect Injection
Weight (Dry) (Dry weight-No (Dry weight-No
cooling fan dri- cooling fan dri- High pressure High pressure High pressure
ve) 496 kg ve) 496 kg fuel pump with electroni- with electroni-
cally controlled cally controlled
Number of 4 4 fuel metering fuel metering
cylinders
(1) The oil pump is a non-serviceable part
Nominal bore 103 mm 103 mm
(2) Some variants have ports for connection of a
size
remote filter assembly.
Stroke 132 mm 132 mm
Cylinder In line In line
arrangement
Combustion Cy- 4-stroke 4-stroke
cle
Firing order 1-3-4-2 1-3-4-2
Displacement 4.399 L 4.399 L
Compression 16.7: 1 16.7: 1
ratio
Engine Com- Compression Compression
pression variance be- variance be-
tween each tween each
cylinder should cylinder should
be no greater be no greater
than 3.5 bar than 3.5 bar
( 50.7 psi) ( 50.7 psi)
Direction of ro- Clockwise Clockwise
tation (viewed
from front
{crankshaft pul-
ley} end)
Valves 4 per cylinder 4 per cylinder
Valve clear-
ances mea-
sured at the
tappet end of
the rockers
(measured
cold)
- Inlet 0.23 –0.04 mm 0.23 –0.04 mm
- Exhaust 0.6 –0.04 mm 0.6 –0.04 mm
15 - 8 9813/8950-2 15 - 8
15 - Engine
00 - Engine
00 - General
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 126. Left hand Side
2 23 9
1
8
15
10
4
20
14 17
5
13
16
19
12
11
21
7
18
22 6
1 Rocker cover 2 Fuel injectors and high pressure fuel pipes

3 Lubrication oil filler cap 4 Timing gear case
5 Flywheel housing 6 Bedplate
7 Lubrication oil sump 8 EGR (Exhaust Gas Recirculation) cooler
9 Air inlet manifold 10 High pressure fuel pump
11 Fuel filter 12 Lubrication oil filler cap
13 Lubrication oil filter 14 Lubrication oil cooler housing
15 - 9 9813/8950-2 15 - 9
15 - Engine
00 - Engine
00 - General
15 Lubrication oil dipstick 16 Low duty PTO (Power Take-Off) (blanking

cover if no device is installed)
17 Low pressure fuel pipe (to tank) 18 Oil drain plug (sump)
19 Oil filter housing drain plug 20 IMV (Inlet Metering Valve)
21 ECM (Engine Control Module) 22 Crankcase ventilation filter assembly
23 Inlet manifold induction heater
Figure 127. Right Hand Side

6
11 14
8
2
16
3
10
9
4
12 15 13
1 EGR valve heatshield 2 Timing gear case
3 Flywheel housing 4 Bedplate
5 Lubrication oil sump 6 VGT (Variable Geometry Turbocharger)
15 - 10 9813/8950-2 15 - 10
15 - Engine
00 - Engine
00 - General
7 Exhaust manifold 8 Alternator

9 Coolant pump housing (crankcase) 10 Coolant inlet/radiator hose connector
11 Heavy duty PTO (blanking cover if no device 12 Starter motor assembly
is installed)
13 Turbocharger oil drain pipe 14 Turbocharger oil feed pipe
15 Oil drain plug (sump) 16 Cab heater connections
Figure 128. Front End

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

3 Crankcase 4 Bedplate
5 Lubrication oil sump 6 Crankshaft pulley
7 FEAD tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
11 VGT 12 Coolant temperature sensor
15 - 11 9813/8950-2 15 - 11
15 - Engine
00 - Engine
00 - General
Figure 129. Rear End
1 Rocker cover 2 Cylinder head

3 Flywheel 4 High pressure fuel pump drive gear cover
5 Flywheel housing 6 Engine electrical harness
7 VGT linkage 8 VGT actuator
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
15 - 12 9813/8950-2 15 - 12
15 - Engine
00 - Engine
00 - General
Operation
It is important to note that number 1 cylinder is firing

The Four Stroke Cycle - 4 Cylinder and about to start its power stroke. Rotating the
Engine crankshaft a further full rotation would position the
pistons as described but the engine would be at a
This section describes the cycle sequence, for the 4 different stage in its four stroke cycle, with number 1
cylinder engine. cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons The stages in the four stroke cycle for each cylinder
in numbers 1 and 4 cylinders are at top dead centre are as follows:
and pistons in numbers 2 and 3 cylinders are at
bottom dead centre.
Table 15. The Four Stroke Cycle

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

number 1 cylinder will be next to fire. Number 3
A cylinder is said to be firing, when the fuel / air cylinder is starting its compression stroke and is next
mixture ignites and the piston is about to start its in the cycle, followed by cylinders 4 and 2.
power stroke.
The firing order is therefore; 1, 3, 4, 2.
15 - 13 9813/8950-2 15 - 13
15 - Engine
00 - Engine
00 - General
Figure 130.
CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
15 - 14 9813/8950-2 15 - 14
15 - Engine
00 - Engine
00 - General
Four Stroke Cycle revolution of the crankshaft, thus, in one cycle of a

four stroke engine, the crankshaft revolves twice.
Induction
Figure 131.
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the 3

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

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

both temperature and pressure. The high pressure 746030
generated propels the piston downward turning the 1 Induction stroke
crankshaft and producing work. 2 Compression stroke
3 Power stroke
Exhaust 4 Exhaust stroke
A Camshaft
Once the piston has reached the bottom of its travel, B Camshaft lobe - Inlet valve operation
the exhaust valves open and momentum stored C Camshaft lobe - Exhaust valve operation
in the flywheel forces the piston up the cylinder BDC Bottom dead centre
expelling the exhaust gases. TDC TDC
In a running engine these four phases are
continuously repeated. Each stroke is half a
15 - 15 9813/8950-2 15 - 15
15 - Engine
00 - Engine
00 - General
Figure 132.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
15 - 16 9813/8950-2 15 - 16
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 16. Page 15-17
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 17. Page 15-18
Engine - Will Not Crank or Cranks Slowly Table 18. Page 15-19
Engine - Starts Then Stops Table 19. Page 15-19
Engine - Poor Running Table 20. Page 15-20
Engine - Poor Running at Idle Table 21. Page 15-20
Engine - Noise Excessive Table 22. Page 15-21
Engine - Compression Knocks Table 23. Page 15-22
Engine - Reduced Power Output Table 24. Page 15-22
Engine - Will Not Reach Maximum RPM Table 25. Page 15-23
Engine - RPM Surges Table 26. Page 15-23
Engine - Vibration Excessive Table 27. Page 15-24
Engine - Exhaust Smoke Excessive (Black Smoke) Table 28. Page 15-24
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 29. Page 15-25
Engine - Will Not Shut Off Table 30. Page 15-25
Lubricating Oil - Consumption Excessive Table 31. Page 15-25
Lubricating Oil - Contaminated Table 32. Page 15-26
Lubricating Oil - Pressure Low Table 33. Page 15-26
Lubricating Oil - Pressure High Table 34. Page 15-26
Table 16. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)
Cause Remedy
No fuel in supply tank. Check the level in the fuel tank, use sight gauge or
dipstick. Replenish as required.
Ignition switch or starter electrical system failure. Check the operation of the ignition switch. Check the
correct electrical wires for open or short circuits.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Defective fuel lift pump (fuel supply inadequate). Check that the lift pump operates and delivers fuel
to the high pressure fuel pump. Check the correct
electrical wires for open or short circuits. Check
fuses.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel inlet restriction. Maximum inlet restriction to fuel lift pump must not
exceed 100mm Hg.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction. Remove as required. Check
the air filter elements for signs of blocking. Replace
as required.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
properly. connected to the top of the fuel tank.
One or more fuel injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
15 - 17 9813/8950-2 15 - 17
15 - Engine
00 - Engine
00 - General
Cause Remedy
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Do all the
necessary fault finding checks before removal of the
high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
Table 17. Engine - Will Not Start or Difficult to Start (Exhaust Smoke)
Cause Remedy
Starting procedure incorrect. Verify proper starting procedure.
Air intake system blocked or restricted. Visually check the air intake for blockage or
obstruction, remove as required. Check the air filter
elements for signs of blocking, replace as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
Fuel is contaminated or incorrect grade diesel fuel Stop the engine. Replace the fuel filters. Operate
used. the engine with a temporary supply of the correct
grade of clean fuel. Monitor the engine performance.
Dirty fuel will cause damage to the high pressure fuel
pump and injectors.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
Check fuel inlet restriction. Maximum inlet restriction to fuel transfer pump must
not exceed the specified amount:
Pressure: 0.133 bar ( 1.9 psi)
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended
clearances.
Engine compression low in one or more cylinders. Check the engine compression.
Cranking speed too slow. See Also: Table 18. Engine - Will Not Crank or
Cranks Slowly
ECM or electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at the ECM and sensors.
15 - 18 9813/8950-2 15 - 18
15 - Engine
00 - Engine
00 - General
Table 18. Engine - Will Not Crank or Cranks Slowly

Cause Remedy
Starting electrical circuit connections loose or Clean and tighten connections.
corroded.
Battery charge low. Check battery voltage, charge the battery or
replace as required. Make sure that the alternator is
functioning correctly and charging the battery.
No electrical connection to starter solenoid. Check voltage to solenoid.
Crankshaft rotation restricted. Use special tool 892/01147 (crankshaft turning tool)
to manually turn the engine and check for any severe
rotational resistance.
Solenoid or starter motor fault. Replace starter motor.
Starter motor operating but not cranking. Remove the starter motor and check for broken teeth
on the ring gear or broken starter motor spring.
Table 19. Engine - Starts Then Stops

Cause Remedy
Engine starting under load. Check for added loading from malfunctioning
accessories or driven units, brakes dragging and
other changes in vehicle loading. Disengage the
hydraulic controls.
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump.
Fuel is waxing due to extremely cold weather. Verify by inspecting the fuel filter. Clean the system
and use acclimatised fuel.
pump and injectors.
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return lines are not obstructed and
ECM or Electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at theECM and sensors.
15 - 19 9813/8950-2 15 - 19
15 - Engine
00 - Engine
00 - General
Table 20. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 21. Engine - Poor Running at Idle
Engine is cold, coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
Check the correct electrical wires for open or short
circuits.
Fuel injection lines leaking. Replace defective high pressure fuel lines. Do not
repair defective fuel lines. If there is a fuel leak
remove and discard the necessary components and
install new ones.
system
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
restriction.
pump and injectors.
Engine is cold - Thermostat fault. Drain Coolant, Remove and replace Thermostat.
Low Power (particularly at high speed) Exhaust back pressure high, Catalyst problem,
Check Servicemaster Diagnostics.
clearances.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 21. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
install new ones.
system.
inadequate). fuel to the injection pump.
15 - 20 9813/8950-2 15 - 20
15 - Engine
00 - Engine
00 - General
Cause Remedy
restriction.
pump and injectors.
clearances.
Table 22. 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 28. Engine - Exhaust Smoke
Excessive (Black Smoke)
pump and injectors.
clearances.
Turbocharger noise. Check turbocharger impeller and turbine wheel for
housing contact.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Worn crank/connecting rod bearings (knocking under Check/replace rod and main bearings.
load).
Excessive camshaft bearing wear. Check bearings (engine overhaul required).
Worn or damaged pistons and/or piston rings. Check piston assemblies (engine overhaul required).
Gear train noise. Visually inspect and measure gear backlash.
Replace gears as required.
Loss of Pilot injection on one or more cylinders. Use service master to disable pilot injections to
identify audibly if they are still present.
15 - 21 9813/8950-2 15 - 21
15 - Engine
00 - Engine
00 - General
Table 23. Engine - Compression Knocks

Cause Remedy
system.
pump and injectors.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Coolant operating temperature incorrect. Check and if necessary replace engine thermostat.
Table 24. Engine - Reduced Power Output

Cause Remedy
Oil level incorrect. Check oil level.
Engine overload. Check for added loading from malfunctioning
hydraulic controls.
Throttle position sensor (TPS) system defective. Check the throttle assembly. Check the electronic
fault codes.
pump and injectors.
Turbocharger boost control pipe leaking or damaged, Check boost control pressure. Inspect and tighten
or wastegate diaphragm ruptured. fittings, repair pipes, replace wastegate assembly.
install new ones.
restriction.
system.
inadequate). fuel to the injection pump. Check fuses.
as required.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
15 - 22 9813/8950-2 15 - 22
15 - Engine
00 - Engine
00 - General
Cause Remedy
clearances.
high pressure fuel pump
Engine in reduced torque or limp home mode. Check the electronic fault codes.
Excessive exhaust back pressure Inspect Catalyst. Check Exhaust pressure readings
using Servicemaster.
Low DEF (Diesel Exhaust Fluid) Level. Fill the DEF Tank with clean DEF
Table 25. Engine - Will Not Reach Maximum RPM

Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
system.
inadequate). fuel to the injection pump. Check fuses.
pump and injectors.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 26. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
15 - 23 9813/8950-2 15 - 23
15 - Engine
00 - Engine
00 - General
Cause Remedy
system.
Table 27. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 21. Engine - Poor Running at Idle
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and
torque figures.
Fan hub faulty. Inspect/replace the fan hub. Refer to the machine's
service manual for correct installation and torque
figures.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
clearances.
Alternator bearing worn or damaged. Check/replace the alternator.
Flywheel housing misaligned. Check/repair flywheel alignment.
Drive line components worn or unbalanced. Check and inspect drive line components such as
propshafts. Refer to the machine's service manual for
correct installation and torque figures.
Table 28. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check for added loading from malfunctioning
hydraulic controls.
as required.
Air leak between the turbocharger and the intake Check/repair leaks in the air crossover tube, hoses,
manifold. or manifold cover. Visually inspect MAF (Mass Air
Flow) sensor tube
Intercooler faulty. Check for blocked cooler matrix.
Exhaust leak at the manifold or turbocharger Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Turbocharger wastegate faulty. Repair or replace turbocharger.
15 - 24 9813/8950-2 15 - 24
15 - Engine
00 - Engine
00 - General
Cause Remedy
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
Table 29. Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Cause Remedy
Improper starting procedure. Verify proper starting procedure.
pump and injectors.
Diesel or hydraulic oil in sump. Check oil consistency. If oil contamination is
suspected check equipment such as PTO (Power
Take-Off) pump for hydraulic oil leaks past the seal
into the engine. Drain, flush and fill with clean oil.
Coolant temperature too low (over-cooling) - light Check the thermostat and replace if necessary.
blue or white high speed/light load.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
- white/ blue smoke at operating temperature. connections at the injectors.
Coolant leaking into combustion chamber. Check the EGR (Exhaust Gas Recirculation) Cooler
for leaks. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 30. Engine - Will Not Shut Off

Cause Remedy
Stop switch or stop switch electrical system failure. Check the operation of the stop switch. Check the
correct electrical wires for open or short circuits.
Table 31. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level over-full. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Tier 4 Final Engines require a special oil grade. Refer Check for reduced viscosity from dilution with fuel.
to (PIL 75-03). Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Crankcase ventilation (CCV) system blocked. Check the breather tube area for signs of lubricating
oil loss. Check and if necessary replace the CCV
filter.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
15 - 25 9813/8950-2 15 - 25
15 - Engine
00 - Engine
00 - General
Cause Remedy
Valve guide seals are leaking. Replace valve guide stem seals as required.
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
Table 32. Lubricating Oil - Contaminated

Cause Remedy
Coolant in the lubricating oil, internal engine Check oil cooler O-rings. If necessary change the oil
component leaks. cooler.
Lubricating oil sludge excessive. Change oil and filter. Review oil and filter change
period. If operating in arduous applications, change
more frequently. Make sure the correct lubricating oil
is being used.
Fuel in the lubricating oil, engine operating too cold. Review the operation for excessive idling resulting in
the engine running below normal temperature.
Table 33. 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 34. Lubricating Oil - Pressure High

Cause Remedy
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Engine running too cold. Check and if necessary replace the engine
thermostat.
Oil pump pressure relief valve stuck closed. Replace oil pump assembly.
15 - 26 9813/8950-2 15 - 26
15 - Engine
00 - Engine
00 - General
Drain and Fill Clean

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

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

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

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

2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
Length/Dimension/Distance: 600 mm
15 - 27 9813/8950-2 15 - 27
15 - Engine
00 - Engine
00 - General
9. When the pressure washing is complete move Check (Pressure)

the machine away from the wash area, or
alternatively, clean away the material washed Special Tools
from the machine. Description Part No. Qty.
10. Before working on specific areas of the engine Pressure Gauge (0-40 892/00278 1
use a compressed air jet to dry off any moisture. Bar)
When the area is dry use a soft clean brush to Digital Hydraulic 998/11051 1
remove any sand or grit particles that remain. Pressure Test Kit
11. When removing components be aware of any This test is used to diagnose suspected poor
dirt or debris that may be exposed. Cover any compression in one or more of the engine cylinders.
open ports and clean away the deposits before Use ServiceMaster to control the test.
proceeding.
Engine Compression Test
Additional cleaning must be carried out prior to
working on the high pressure fuel system. Refer to: 1. Connect the Servicemaster tool to the machine.
PIL 18-00-00. Refer to (PIL 33-57).
2. Access the engine compression test and follow
the on screen commands.
3. There is a 5 second delay before the test starts.
4. The test disables the injectors and requests the
tester to crank the engine.
5. Crank the engine for at least 5 seconds, but no
longer than 10 seconds.
6. The engine ECU measures the variation in
engine cranking speed to determine if one
or more cylinders have lower than expected
compression values.
7. Turn off the ignition after the test.
Note: The engine cranking speed must be greater

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

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

Consumable Products (PIL 75-00).
• The engine oil level is correct. Refer to Oil Filter,
Check Level (PIL 15-21).
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Get access to the engine.
3. Disconnect the electrical connector to the oil
pressure switch, remove the switch from the oil
cooler housing.
15 - 28 9813/8950-2 15 - 28
15 - Engine
00 - Engine
00 - General
4. Install a suitable adaptor into the vacant pressure 5. Start the engine and allow a few seconds to
switch port (M10 x 1.5mm thread) and a pressure gain oil pressure, increase the engine revs to
test gauge. Make sure that the gauge has a the rated speed. Record the pressure gauge
sealing washer as shown. reading, refer to Technical Data (PIL 15-00), for
the recommended circuit pressure.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit 6. Remove the pressure gauge and install the
(Qty.: 1) pressure switch.
Figure 133.
High Lubrication Oil Pressure
High oil pressure will be evident when starting in cold
conditions. Typically the pressure will be 1 to 2 bar
and higher in cold operation, the pressure should
drop when the engine reaches normal operating
temperature.
If the pressure remains high when operating

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

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

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

B Sealing washer
15 - 29 9813/8950-2 15 - 29
15 - Engine
00 - Engine
00 - General
Remove and Install
Special Tools recommended lifting equipment is shown. Use a

Description Part No. Qty. spreader bar when lifting the engine. Never attempt
Lifting Bracket Front 320/09062 1 to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
Lifting Bracket Rear 320/09063 1 an assistant. Inspect the lifting brackets for signs
Engine Lifting Spreader 892/01382 1 of damage. The brackets must be correctly torqued
Bar to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
Lifting Equipment rocker cover.
equipment. You must identify the weight of the item to Component Identification
enough and suitable for the job. Make sure that lifting The following component identification is for a typical
equipment is in good condition and complies with all engine installation. There will be some component
local regulations. differences depending on the machine variant.
Before attempting to remove the engine ensure that
The lifting equipment used must be an approved all the necessary components have either been
type and capable of lifting the engine safely. The removed, or safely disconnected from the engine.
Figure 134.
14 25 22 15
6
7
8
10 23
17
16
18
21
24
12 19
11
20
6 Engine mounting bolts 7 Lifting bracket- front

8 Lifting bracket fixing bolts 10 Fuel line connector- return to tank line
11 Fuel line connector at fuel filter- feed line from 12 Electrical connector- engine ECU machine
fuel pump side connector (grey)
15 - 30 9813/8950-2 15 - 30
15 - Engine
00 - Engine
00 - General
14 Electrical connections- alternator 15 Hose connection- cab heater

16 Electrical sensor- engine oil level 17 Electrical connections- starter motor
18 Lifting bracket- rear 19 Lifting bracket fixing bolts
20 Fixing bolts- gearbox to engine 21 Electrical connector- engine harness
22 Top hose 23 Bottom hose
24 Air inlet hose 25 Exhaust pipe
15 - 31 9813/8950-2 15 - 31
15 - Engine
00 - Engine
00 - General
Before Removal 16. Disconnect and plug the hoses at the hydraulic
pump.
the engine has been running, let it cool before 17. Disconnect the wiring to the hydraulic pump.
18. Remove the gearbox to engine retaining bolts,
2. Position the machine on firm level ground. Make pull the transmission and converter clear of
the machine safe, refer to (PIL 01-03). the engine, make sure that the converter stays
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Remove Special Tool: Lifting Bracket Front (Qty.: 1)
Special Tool: Lifting Bracket Rear (Qty.: 1)
1. Disconnect and remove the battery. Refer to (PIL Special Tool: Engine Lifting Spreader Bar (Qty.:
33-03). 1)
2. Drain the engine oil. Refer to (PIL 15-21). 20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
3. Drain the engine coolant, remove the cooling
pack. Refer to (PIL 21-03). 21. Withdraw the engine in a level attitude until the
hydraulic pump is clear of the chassis. Raise the
4. Discharge the hydraulic pressure. Refer to (PIL engine to lift it clear of the machine.
30-00).
22. Lower the engine into a suitable stand that is
5. Drain the hydraulic tank. Disconnect and plug capable of supporting the weight of the engine.
the hydraulic suction and delivery lines at the
transmission pump and gear pump. Label the
hoses to ensure correct reassembly. Refer to
(PIL 30-00).
6. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to ensure correct reassembly.
7. Disconnect the exhaust system.
8. Label the cab heater hoses at the engine block
connectors. Release the hose clips and remove
the hoses.
9. Disconnect the wiring connections from the
starter motor. Refer to (PIL 15-75).
alternator. Refer to (PIL 15-72).
engine sensors and actuators. Refer to (PIL
15-84).
12. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
13. Disconnect the electrical harness at the engine
harness.
14. Uncouple the electrical harness at the
ECM (Engine Control Module) machine side
connector. Important: Do not touch the connector
pins on the ECM or harness connectors. Cover
the connectors to prevent contamination.
15. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
15 - 32 9813/8950-2 15 - 32
15 - Engine
00 - Engine
00 - General
Figure 135. 3. Fill the cooling system with the correct mix of
coolant fluid. Refer to (PIL 21-00).
4. Fill and Check the hydraulic fluid level. Refer to
B (PIL 30-00).
5. Fill and Check the engine oil level. Make sure the
correct oil is used. Refer to (PIL 75-03).
6. On completion, check the hydraulic and cooling
system for leakage and levels.
7. Check the function of the drive and loader
services.

C Item Nm
A 47
A Lifting bracket mounting bolts

B Lifting equipment
C Spreader bar
Install
1. Replacement is a reversal of the removal
procedure. Note the following:
2. Important: It is vitally important that the torque
converter is installed at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil
pump on engine start up.
15 - 33 9813/8950-2 15 - 33
15 - Engine
00 - Engine
00 - General
Store and Recommission
If an engine is to be placed into storage, all external

Engines should be stored in the original shipping signs of surface coating damage or corrosion should
packaging. Damaged or disturbed packaging should be cleaned and re-coated. Electrical connectors and
be made weatherproof immediately. components should be coated with a protective
spray.
If an engine is shipped with oil, it should be stored in
the correct (upright) position. Capping Engine Openings
If an engine is shipped dry of oil, after 6 months it
All openings on the engine must be suitably capped
should be filled with oil to the correct level and re-
to prevent ingress of water and contamination by
inhibited, refer to hot test description.
foreign particles.
All floor stock engines should be stored under cover
Some engine configurations may differ in detail to the
in dry conditions and not subjected to extreme
illustrations shown. Make sure you identify and cap
variations in temperature or humidity.
all openings.
Figure 136. Typical engine
13
5
3
4
6
14
17
16
12
11
10 2
15
15 - 34 9813/8950-2 15 - 34
15 - Engine
00 - Engine
00 - General
1 Top hose cap 2 Bottom hose cap

3 Turbocharger intake cap 4 Turbocharger compressor outlet cap
5 Turbocharger exhaust outlet cap 6 Inlet manifold cap
7 Dipstick plug 8 ECM (Engine Control Module) machine
harness connector cap
9 Fuel spill back line cap 10 Low duty PTO (Power Take-Off) (if installed)
cap
11 Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots
13 Coolant circuit de-gas spigot 14 CCV canister outlet on the closed loop
breathing circuit (55kW)
15 Low pressure fuel filter inlet spigot (engines 16 SCR (Selective Catalytic Reduction) coolant
with fuel filter attached) feed spigot (if installed)
17 Fuel pump low pressure inlet spigot (engines
with no fuel filter attached)
12 Month Revalidation Procedure Notice: Do not operate the starter motor for more
than 20 s at one time. Let the starter motor cool for
1. Pre-inspection: at least 2 min.
1.1. Inspect packaging for signs of damage. Table 36. Oil Pressure Switch Set Points
1.2. Inspect the caps for signs of damage. Oil pressure switch > 0.6 bar ( 8.7 psi)
closed
1.3. Inspect openings for signs of water or dirt
ingress. Oil pressure switch open < 0.6 bar ( 8.7 psi)
1.4. Inspect the engine for signs of external OEM Commissioning Check on Engine
corrosion. Installation After More Than 12 Months
1.5. Inspect the engine for signs of fluid leaks.
1. Flush the coolant system with proprietary
2. From storage: flushing solution.
2.1. Remove the air intake caps. 2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
2.2. Make sure the engine oil level is correct.
2.3. Using a suitable power supply at the correct 3. Hot test engine according to the hot test profile.
voltage, crank the engine over. Refer to Table 37.
2.4. During cranking, check that the oil pressure 4. Drain engine oil and replace engine oil filter.
switch opens using a multimeter. The switch
is closed when there is no or low oil 5. Refill with the correct oil and inhibit the cooling
pressure and opens when oil pressure system using the correct product.
reaches a set point. After three separate 20 6. Record details of work as required.
second cranking periods, If the oil pressure
switch does not open (indicating no, or
low oil pressure), contact your JCB engine
Hot Test Description
dealer. WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
2.5. Recap all engine openings.
the manufacturer's instructions and safety
2.6. Coat any exposed bare metal with a precautions.
suitable product.
2.7. Electrical connectors and components All engines despatched from JCB will have been
should be coated with a protective spray if subjected to a hot test (checking items such as oil
exposed. pressure, engines speeds, torque values etc.) and
therefore the interior surfaces will have been coated
2.8. Cover in weatherproof packaging. with engine oil.
2.9. Place in storage, under cover on level
ground or shelving. All coolant galleries are coated with CRODAFLUID
PA75 corrosion inhibitor.
2.10. Record details of work as required.
2.11. Do not expose to extremes of temperature Stored engines will require re-inhibiting every 12
or humidity. months, this will include hot testing the engine using
a dynamometer. The hot test profile is:
15 - 35 9813/8950-2 15 - 35
15 - Engine
00 - Engine
00 - General
Table 37. Hot Test Profile

Stage Mode Speed Torque Time
(rpm) (Nm) (secs)
1 Speed/ 830 0 50
Torque
2 Speed/ 1300 50 60
Torque
3 Speed/ 2500 0 60
Torque
4 Speed/ 1300 0 25
Torque
5 Speed/ 800 0 35
Torque
15 - 36 9813/8950-2 15 - 36
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-39
15 - 37 9813/8950-2 15 - 37
Notes:
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15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-39 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-40 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 137.
A
A Crankcase
B Crankshaft
15 - 39 9813/8950-2 15 - 39
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 38. Crankcase and Bedplate Data

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

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

Diameter of second oversize bore 104 –104.02 mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92 –92.02 mm 92 –92.02 mm
Number 5 105 –105.02 mm 105 –105.02 mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047 –88.09 mm 88.047 –88.09 mm
Number 5 100.047 –100.09 mm 100.047 –100.09 mm
Camshaft bore
Numbers 1 to 4 60.04 –60.07 mm 60.04 –60.07 mm
Number 5 (bush) 60.29 –60.32 mm 60.29 –60.32 mm
Permissible wave profile wt < 10 m (2.5 distance) wt < 10 m (2.5 distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
15 - 40 9813/8950-2 15 - 40
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-43
15 - 41 9813/8950-2 15 - 41
Notes:
15 - 42 9813/8950-2 15 - 42
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-43 The cylinder head is located above the cylinders
Technical Data ............................................... 15-44 on top of the crankcase. It closes in the top of the
Component Identification ............................... 15-45 cylinder, forming the combustion chamber. This joint
Remove and Install ....................................... 15-46 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 - 43 9813/8950-2 15 - 43
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 39. Cylinder Head Data

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

- Side to side 0.03 mm
Valve recess depth
- Inlet 0.85 mm
- Exhaust 0.85 mm
Valve seat angle
- Inlet 120 (inclusive)
- Exhaust 90 (inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat 75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10 m 2.5 distance
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
15 - 44 9813/8950-2 15 - 44
15 - Engine
06 - Cylinder Head
00 - General
Figure 138.
C
A Cylinder head
B Cylinder head gasket
C Cylinder head bolts
15 - 45 9813/8950-2 15 - 45
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 2. Make sure that the engine is safe to work on. If
Description Part No. Qty. the engine has been running, let it cool before
Torque Wrench 993/70111 1 you start the service work.
(10-100Nm) 3. Get access to the engine.
Consumables 4. Remove the thermostat, refer to (PIL 21-12).
Cleaner/Degreaser 4104/1557 0.4 L 5. Remove the fuel pipes, refer to (PIL 18-96).
- General purpose 6. Remove the rocker cover, refer to (PIL 15-42).
solvent based parts
cleaner 7. Remove the fuel injectors, refer to (PIL 18-18).
Before Removal 8. Remove the rocker assembly, refer to (PIL

15-42).
1. This procedure requires service parts. Make sure
9. Remove the exhaust manifold, refer to (PIL
you have obtained the correct parts before you
18-24).
start, refer to Parts Catalogue.
10. Remove the inlet manifold, refer to (PIL 18-24).
15 - 46 9813/8950-2 15 - 46
15 - Engine
06 - Cylinder Head
00 - General
Figure 139.
21
22
20
19
18 14 10 6 2 3 7 11
15
16
17 13 9 5 1 4 8 12
0° +90° +180°
1-18 Cylinder head fixing bolts (x18) 19 Cylinder head

20 Crankcase 21 Location dowels (x2)
22 Cylinder head gasket
15 - 47 9813/8950-2 15 - 47
15 - Engine
06 - Cylinder Head
00 - General
Remove Special Tool: Torque Wrench (10-100Nm)

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

procedure.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in five stages, use the
torque and angle method, refer to Fasteners and
Fixings, General, Introduction (PIL 72-00).
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-18) to the 1st stage pre-torque.
15 - 48 9813/8950-2 15 - 48
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-51
15 - 49 9813/8950-2 15 - 49
Notes:
15 - 50 9813/8950-2 15 - 50
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-51 The bedplate acts as the main strength component
Remove and Install ....................................... 15-52 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 140.
1
1 Bedplate
2 Crankcase
15 - 51 9813/8950-2 15 - 51
15 - Engine
09 - Bedplate
00 - General
Remove and Install
Special Tools 10. Remove the rocker assembly including the push
Description Part No. Qty. rods, refer to (PIL 15-42).
Template for Sealant 892/12356 1 11. It is not necessary to remove the cylinder head
Bedplate to Crankcase assembly to remove the crankshaft. If however
(4 Cyl) the cylinder head needs to be removed for other
Torque Wrench 993/70111 1 reasons (for piston and connecting rod removal
(10-100Nm) for example) remove it now, refer to (PIL 15-06).
Consumables 12. Remove the fuel injection pump, refer to (PIL
Description Part No. Size 18-18).
Cleaner/Degreaser 4104/1557 0.4 L 13. Remove the starter motor, refer to (PIL 15-75).
- General purpose
solvent based parts 14. Remove the high duty PTO (Power Take-Off)
cleaner device (if installed).
CAUTION This component is heavy. It must only 15. Position the engine upside down in a suitable jig
be removed or handled using a suitable lifting or fixture, supported at the front of the cylinder
method and device. block.
16. Remove the flywheel, refer to (PIL 15-54).
Before Removal
17. Remove the flywheel housing, refer to (PIL
1. This procedure requires service parts. Make 15-54).
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue. 18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
the engine has been running, let it cool before 19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
3. Remove the engine, refer to (PIL 15-00). installed), refer to (PIL 15-51).
4. Remove the drive belt, refer to (PIL 15-18). 21. Remove the crankshaft drive gear, refer to (PIL
15-51).
5. Remove the crankshaft pulley, refer to (PIL
15-12). 22. Remove the camshaft, refer to (PIL 15-15).
6. Remove the oil sump, refer to (PIL 15-45). 23. Remove the rear timing case, refer to (PIL
15-51).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
8. Remove the rocker cover, refer to (PIL 15-42). caps, refer to (PIL 15-12).
9. Remove the fuel injectors, refer to (PIL 18-18).
15 - 52 9813/8950-2 15 - 52
15 - Engine
09 - Bedplate
00 - General
Figure 141.
4 1 5
11
8 9
7 10
3 P3 2 6
X
12 18
18
18
18
18
13
18
1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)
15 - 53 9813/8950-2 15 - 53
15 - Engine
09 - Bedplate
00 - General
Remove suitable lifting equipment (if the bedplate is lifted

manually, two people will be required). DO NOT
1. Remove the bedplate peripheral bolts. use a lever to separate the bedplate.
2. Progressively remove the main bearing bolts in 4. Remove and discard the O-ring.
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts. 5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
Figure 142.
Y P2 Y A (T5) T4
T4
P2
P3
B (T5)
Y Y P2 T6
18
18 18
X
18
T6 18
4 1 5 T6
11
8 9
W
18
12
T6
7 10
3 2 6
13
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
15 - 54 9813/8950-2 15 - 54
15 - Engine
09 - Bedplate
00 - General
T4 Guide pins (x2 obtain locally) T5 Sealant template

T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
15 - 55 9813/8950-2 15 - 55
15 - Engine
09 - Bedplate
00 - General
Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
Length/Dimension/Distance: 1.5 mm
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.
7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, Before removal
the crankcase, NOT the bedplate. The sealant in reverse order.
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Table 41. Torque Table
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1) Item Torque Value
1-10 (1st Stage) 50 N·m
8. Locate the holes in the templates A and B using 1-10 (2nd Stage) 115 N·m
four fixing bolts at positions Y. Use the templates
15 - 56 9813/8950-2 15 - 56
15 - Engine
09 - Bedplate
00 - General
Item Torque Value

1-10 (Final Stage) 180 °
11 24 N·m
15 - 57 9813/8950-2 15 - 57
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-59

15-12-03 Main Bearing .................................................................................................................. 15-68
15-12-06 Front Oil Seal ................................................................................................................. 15-70
15-12-09 Rear Oil Seal ................................................................................................................. 15-73
15-12-12 Pulley .............................................................................................................................. 15-77
15 - 58 9813/8950-2 15 - 58
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-59 The crankshaft is housed inside the crankcase. It is
Technical Data ............................................... 15-60 connected to the piston via a connecting rod, they
Component Identification ............................... 15-61 form a simple mechanism that converts reciprocating
Operation ....................................................... 15-62 motion into rotating motion. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-63
15 - 59 9813/8950-2 15 - 59
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 42.
Main bearing journal diameter (x4)
- min 87.98 mm
- max 88 mm
Main rear bearing journal diameter (x1)
- min 99.98 mm
- max 100 mm
Connecting rod bearing journal diameter
- min 72.98 mm
- max 73 mm
Maximum wear and ovality on journals
(1)
Crankshaft induction hardness 55 HRc min on surface

Thrust washer width
- min 2.44 mm
- max 2.5 mm
Crankshaft end float
- min 0.05 mm
- max 0.28 mm
(1) No visible damage/wear or marks
15 - 60 9813/8950-2 15 - 60
15 - Engine
12 - Crankshaft
00 - General
Figure 143.
A
A Crankcase
B Crankshaft
15 - 61 9813/8950-2 15 - 61
15 - Engine
12 - Crankshaft
00 - General
Operation
diameter of the upper main bearing shell allows oil

Lubrication transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
engine.
Figure 144.
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 - 62 9813/8950-2 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Check (Condition) Figure 147.
1. Check the main bearing surfaces for damage and

excessive wear.
Figure 145.
C
D
A
C J-jets
D Fixing screws
A Main bearing shells

2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 146.
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
15 - 63 9813/8950-2 15 - 63
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Consumables reasons (for piston and connecting rod removal

Description Part No. Size for example) remove it now, refer to (PIL 15-06).
Cleaner/Degreaser 4104/1557 0.4 L 12. Remove the fuel injection pump, refer to (PIL
- General purpose 18-18).
solvent based parts
cleaner 13. Remove the starter motor, refer to (PIL 15-75).
CAUTION This component is heavy. It must only 14. Remove the high duty PTO device (if installed).
method and device. 15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
Before Removal
16. Remove the flywheel, refer to (PIL 15-54).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 17. Remove the flywheel housing, refer to (PIL
before you start, refer to Parts Catalogue. 15-54).
2. Make sure that the engine is safe to work on. If 18. Remove the fuel injection pump drive gear, refer
the engine has been running, let it cool before to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
3. Remove the engine, refer to (PIL 15-00).
20. Remove the high duty PTO idler drive gear (if
4. Remove the drive belt, refer to (PIL 15-18). installed), refer to (PIL 15-51).
5. Remove the crankshaft pulley, refer to (PIL 21. Remove the crankshaft drive gear, refer to (PIL
15-12). 15-51).
6. Remove the oil sump, refer to (PIL 15-45). 22. Remove the camshaft, refer to (PIL 15-15).
7. Disconnect and remove the fuel pipes from the 23. Remove the rear timing case, refer to (PIL
injectors, refer to (PIL 18-96). 15-51).
8. Remove the rocker cover, refer to (PIL 15-42). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
9. Remove the fuel injectors, refer to (PIL 18-18). caps, refer to (PIL 15-12).
10. Remove the rocker assembly including the push 25. Remove the bedplate, refer to (PIL 15-09).
rods, refer to (PIL 15-42).
Remove
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however 1. Remove the thrust washers between the
the cylinder head needs to be removed for other crankshaft and crankcase rear main bearing.
15 - 64 9813/8950-2 15 - 64
15 - Engine
12 - Crankshaft
00 - General
Figure 148.
A
A
A Thrust Washers B Crankshaft

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

that they are installed in the correct positions
during assembly. 1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft 2. Use a suitable degreasing agent to carefully
is lifted manually, two people will be required). clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
4. Carefully lift out the bearing shells. ways or the piston cooling jets.
Figure 149. Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
D
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
D Main bearing shells then install cooling J jets as follows:
5. It is recommended that the bearing shells are

replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
15 - 65 9813/8950-2 15 - 65
15 - Engine
12 - Crankshaft
00 - General

G
D
E
F
D Main bearing shells

G Bearing location tab
E J jets (x4)
F Fixing screws 4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
3.1. Insert the cooling jets into the crankcase. shells are clean.
3.2. Note: There are different types of cooling Consumable: Cleaner/Degreaser - General
jets installed depending on the engine purpose solvent based parts cleaner
application. The jets are colour coded. 4.2. Assemble the bearing shells into the
3.3. Be sure to install the correct jets. Refer to crankcase bearing saddles. Make sure that
the relevant parts catalogue for the correct the location tab engages into the slot as
cooling jet identification. shown.
3.4. Tighten the retaining screws to the correct 4.3. Important: Make sure that the oil-way holes
torque value. in the bearing saddles align with the holes
in the bearing shell. If the holes are even
4. Install the upper bearing shells as follows: partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
15 - 66 9813/8950-2 15 - 66
15 - Engine
12 - Crankshaft
00 - General
Figure 152.
B H
A
A
A Thrust washers B Crankshaft

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

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

Item Nm
F 24
15 - 67 9813/8950-2 15 - 67
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-68 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-69 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 153.
A Main bearing
B Crankshaft
15 - 68 9813/8950-2 15 - 68
15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition) Remove and Install

1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
3. Renew any parts that are worn or not within the
specified tolerances.
15 - 69 9813/8950-2 15 - 69
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 154.

Crankshaft Front Oil 892/01157 1 C
Seal Installation Tool
B
Before Removal
before you start, refer to Parts Catalogue.
3. Get access to the engine. A
4. Remove the drive belt, refer to (PIL 15-18).

5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
A Crankshaft oil seal
Remove B Crankcase
C Crankshaft hub
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not Install
to scratch or damage the counterbore or the 1. Make sure that the counterbore and the
crankshaft hub. Damaged or dirty sealing faces crankshaft hub are clean and free from damage
will cause the oil seal to fail. and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 155.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
155.
15 - 70 9813/8950-2 15 - 70
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 155.
F D A
G G
E
A Crankshaft oil seal B Crankcase

C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw
4. Turn the screw to push the seal squarely into Figure 156.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. B
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore A
within the specified tolerance. Refer to Figure
156. G
Dimension: -0.5 -0/+0.5 mm
C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
15 - 71 9813/8950-2 15 - 71
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
15 - 72 9813/8950-2 15 - 72
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install
Special Tools Figure 158. 15mm Hub

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

B Flywheel housing
4. Remove the flywheel, refer to (PIL 15-54). C Flywheel hub
E Fixing bolt
Remove
Install (24mm Hub)
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the 1. Make sure that the counterbore and the flywheel
counterbore in the flywheel housing. Take care hub are clean and free from damage and
not to scratch or damage the counterbore or the corrosion.
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 157. 24mm Hub
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
15 - 73 9813/8950-2 15 - 73
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 159.
B
D
A
C
A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool
2. To prevent the seal lip rolling over and becoming Special Tool: Crankshaft Rear Oil Seal Alignment
damaged, make sure that you use the oil seal Tool (Qty.: 1)
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over 3. Apply lubricant P80 around the seal outer rubber
the end of the hub, then carefully push the oil seal diameter.
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed 4. Dismantle the oil seal installation tool. Bolt the
the correct way around. centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
Special Tool: Crankshaft Rear Oil Seal the centre body and install the screw.
Installation Tool (Qty.: 1)
Figure 160.
F
B
E
A C H
H
G
G F

C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw
5. Turn the screw to push the seal squarely into 6. Remove the oil seal installation tool.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. Install (15mm Hub)
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore 1. Make sure that the counterbore and the hub are
within the tolerance specified. clean and free from damage.
15 - 74 9813/8950-2 15 - 74
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 161.
B
D
A
C

C Flywheel hub D Oil seal alignment tool
2. Install the new hub on to the crankshaft gear and Special Tool: Crankshaft Rear Oil Seal
install the old hub on the outside of the new hub Installation Tool (Qty.: 1)
to create a double thickness flywheel hub, install Special Tool: Crankshaft Rear Oil Seal Alignment
the fixing bolt as shown at A. Do not touch the Tool (Qty.: 1)
PTFE seal lips of the crankshaft oil seal.
4. Apply the lubricant P80 around the seal outer
3. Make sure that you use the oil seal alignment tool rubber diameter.
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the 5. Dismantle the oil seal installation tool. Use the
alignment tool over the end of the hub, carefully two flywheel bolts to attach the centre body on to
push the oil seal over the alignment tool as far the flywheel hub. Assemble the outer sleeve on
on to the crankshaft hub as possible. Make sure to the centre body include the extension ring and
that the seal is installed the correct way around. install the screw.
Figure 162.
B F
G
A C1 K C2
H
L
K
J

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

the counterbore so that the screw will not turn.
15 - 75 9813/8950-2 15 - 75
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
7. Remove the oil seal installation tool, remove the

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

Item Nm
E 47
15 - 76 9813/8950-2 15 - 76
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
Remove and Install removal procedure. Additionally do the following
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1. This procedure requires service parts. Make 1)
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
you start the service work. Figure 164.

4. Remove the drive belt. Refer to (PIL 15-18).
Remove
1. Remove the fixing bolts and withdraw the pulley C
from the crankshaft.
Figure 163.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 45.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30 N·m
2 (2nd stage) 75 N·m
2 (Final stage) 180 °
A
B
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
15 - 77 9813/8950-2 15 - 77
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-79
15 - 78 9813/8950-2 15 - 78
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-79 When the engine runs the crankshaft drives the
Technical Data ............................................... 15-80 camshaft via gears. The camshaft opens and closes
Component Identification ............................... 15-81 the inlet and exhaust valves via push rods in time with
Operation ....................................................... 15-82 the four stroke cycle. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-83 The relationship between the rotation of the camshaft
Remove and Install ....................................... 15-83 and the rotation of the crankshaft is of critical
importance. Since the valves control the flow of the
air/fuel mixture intake and exhaust gases, they must
be opened and closed at the appropriate time during
the stroke of the piston. For this reason, the camshaft
is connected to the crankshaft directly, via a gear
mechanism.
15 - 79 9813/8950-2 15 - 79
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 46. Camshaft Data

Camshaft journal diame-
ter
- 4 off 59.99 –59.97 mm
- 1 off 60.25 –60.22 mm
Camshaft lobe wear lim-
its
Inlet lift 7.161 –7.271 mm
Exhaust lift 7.2 –7.31 mm
Camshaft bore diameter
- 4 off 60.07 –60.04 mm
- 1 off 60.32 –60.29 mm
Camshaft gear
(1)
104 teeth
(1) The camshaft gear is not available as a separate
item. The gear must be heated on to the camshaft
in the correct timed position. Specialist fixtures are
used during the production process to achieve the
correct timing.
15 - 80 9813/8950-2 15 - 80
15 - Engine
15 - Camshaft
00 - General
Figure 165.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Camshaft lobes
4 Tappets 5 Push rods
15 Inlet valves 16 Exhaust valves
15 - 81 9813/8950-2 15 - 81
15 - Engine
15 - Camshaft
00 - General
Operation
during the cycle it follows that the camshaft is driven

As the crankshaft rotates the camshaft also rotates, at half crankshaft (engine) speed.
driven by a gear on the crankshaft. The inlet and
exhaust valves are opened by lobes on the camshaft Lubrication
in time with the cycle.
Oil is fed from the main gallery via a drilling to the
The diagrams show the position of the camshaft at camshaft bearing. A groove around the diameter of
each part of the four stroke cycle, refer to Engine- the bearing and connecting the cross drilling ensures
General, Operation. Refer to: PIL 15-00-00. that oil is always fed to the centre drilling. Oil is then
transferred to the remaining camshaft bearings by
It can be seen that for a complete cycle the camshaft
further cross drillings in the shaft. The cam lobes and
revolves once. Since the crankshaft revolves twice
tappets are 'splash' lubricated.
Figure 166.
1 Main gallery 2 Camshaft bearing

3 Groove 4 Centre drilling
15 - 82 9813/8950-2 15 - 82
15 - Engine
15 - Camshaft
00 - General

1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
Before Removal
1. Drain the oil from the engine.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting. 2. Disconnect and remove the fuel pipes from the
injectors. Refer to (PIL 18-96).
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the 3. Remove the rocker cover. Refer to (PIL 15-42).
dimensions are within service limits.
4. Remove the fuel injection pump. Refer to (PIL
4. Inspect the cam bearing surfaces inside the 18-18).
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within 5. Remove the rocker assembly and push rods.
service limits. Refer to (PIL 15-42).
5. Inspect the bearing surfaces of the tappets for 6. Remove the starter motor. Refer to (PIL 15-75).
signs of excessive wear or damage. Check that
the dimensions are within service limits. 7. Remove the oil sump. Refer to (PIL 15-45).
6. Inspect the tappet bores inside the crankcase for 8. Remove the flywheel. Refer to (PIL 15-54).
the dimensions are within service limits. 9. Remove the flywheel housing. Refer to (PIL
15-54).
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries 10. Rotate the crankshaft until the camshaft timing
in the crankcase and camshaft may be blocked. pin can be inserted through the gear and into the
Make sure all oil ways are clear and free from aligning hole in the rear gear case.
debris. Figure 167.
A Timing pin- camshaft

11. Remove the taper blanking plug and insert
crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.
15 - 83 9813/8950-2 15 - 83
15 - Engine
15 - Camshaft
00 - General
Figure 168. 3. Access the tappets through the apertures in

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets to
ensure replacement in their original positions.
B
Figure 170.
C
B Timing pin- crankshaft E
C Blanking plug
E
12. Remove the fuel injection pump drive gear. Refer
to (PIL 15-51).
Remove
The engine must be inverted. Do not attempt to
remove the camshaft and its drive gears with the
engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.
1. Remove the camshaft timing pin.

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure that
you fully support the camshaft to prevent the
lobes contacting the bearing surfaces in the
crankcase. The bearing surfaces can easily be
damaged by the sharp hard edges on the cam
lobes.
Figure 169. E Tappet
F Magnetic probe
Inspection
1. Refer to Camshaft- Check Condition (PIL 15-15).
Install
1. Lubricate the tappets and tappet bores inside the
A crankcase with clean engine oil.
2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
D surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
A Timing pin - camshaft aligns with the dowel hole in the gear casing.
D Camshaft and drive gear Insert the timing pin T1 to lock the camshaft in
this position.
15 - 84 9813/8950-2 15 - 84
15 - Engine
15 - Camshaft
00 - General
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
15 - 85 9813/8950-2 15 - 85
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-87

15-18-03 Drive Belt ....................................................................................................................... 15-90
15-18-21 Tensioner ........................................................................................................................ 15-94
15 - 86 9813/8950-2 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 9813/8950-2 15 - 87
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 171. A - With air condition-
Do not try to turn the engine by pulling the fan or fan ing compressor, no cooling fan
belt. This could cause injury or premature component
failure. A
4
Switch off the engine before working in the engine 5
engine cover open.
3
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts. 7
Figure 172. B - Without air condi-

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
7 Air conditioning compressor drive pulley
15 - 88 9813/8950-2 15 - 88
15 - Engine
18 - Engine Belt
00 - General
Figure 173. C - With air conditioning com-

pressor, cooling fan pulley installed
C
6
4
5
3
7
Figure 174. D - Without air conditioning

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
6 Cooling fan drive pulley
7 Air conditioning compressor drive pulley
15 - 89 9813/8950-2 15 - 89
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-90 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-91 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-91 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-92 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 - 90 9813/8950-2 15 - 90
15 - Engine
18 - Engine Belt
03 - Drive Belt

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 175.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 91 9813/8950-2 15 - 91
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A Remove

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct 1. Make the machine safe. Refer to (PIL 01-03).
tension.
2. Stop the engine and let it cool down.
3. Use a socket of the specified size to locate
on to the hexagon spigot nut, carefully rotate
the tensioner against the spring force in the
direction shown. Do not use excessive force or
the tensioner will be damaged.
Dimension: 16 mm
4. Keep holding the tensioner against the spring
force and lift the belt off the drive tensioner pulley.
5. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
15 - 92 9813/8950-2 15 - 92
15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 176.
A Spring loaded tensioner

B Drive belt
C Example of frayed drive belt (refer to Check
Condition)
D Spigot nut
Install
step.
2. Before you install the new belt, check that the
tensioner roller and the fan pulley rotate smoothly
and that there is no play in the bearings.
15 - 93 9813/8950-2 15 - 93
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner Install
steps.
Before Removal 2. Tighten the bolts to the correct torque value.
1. Make the machine safe. Refer to (PIL 01-03). 3. Install the drive belt, refer to (PIL 15-18).
2. Make sure that the engine is safe to work on. If 4. Make sure that the drive belt is under tension
the engine has been running, let it cool before and the locking pin is removed before starting the
you start the service work. engine. Refer to Drive Belt - Adjust (PIL 15-18).
3. Get access to the engine. Table 47. Torque Values

4. Remove the drive belt, refer to (PIL 15-18). Item Nm
2 24
Figure 177.
3 2 1
2
X
T3
1 Drive belt tensioner pulley
2 Fixing bolts (x3)
3 Drive belt
T3 Locking pin
X Spigot nut
Remove
The drive belt tensioner is a non-serviceable item.
If the drive belt tensioner or the idler wheel is faulty
or damaged it must be renewed as a complete
assembly.
1. To remove the tensioner assembly, remove the

bolts and lift the tensioner pulley from the cylinder
block.
15 - 94 9813/8950-2 15 - 94
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-97
15 - 95 9813/8950-2 15 - 95
Notes:
15 - 96 9813/8950-2 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.
Component Identification ............................... 15-99
Operation ..................................................... 15-101
Check (Level) .............................................. 15-101
Remove and Install ..................................... 15-102
15 - 97 9813/8950-2 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.
accordance with local regulations. Use authorised
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 98 9813/8950-2 15 - 98
15 - Engine
21 - Oil Filter
00 - General
Figure 178.
1
13
A
16
5 6
14
4
19
15
18 8
10
10
3 9 9
11
13
B
16 11 1
14
19
15
18
12 17
3 3 8
1 Oil cooler and filter housing 2 Oil filler cap (not shown)
3 Oil filter head 4 Oil gallery - from pump to cooler
5 Oil cooler matrix 6 Sealing gasket - housing to crankcase
7 Coolant gallery 8 Oil filter drain down plug
9 Oil gallery - from cooler to filter head 10 Oil gallery - from filter head to main oil gallery
15 - 99 9813/8950-2 15 - 99
15 - Engine
21 - Oil Filter
00 - General
11 Oil filler port 12 Oil pressure switch

13 Oil filter 14 Filter element
15 Anti-drain seal 16 Spring
17 Oil Temperature Sensor 18 O-ring
19 Anti-drain pipe A Oil filter state - engine running
B Oil filter state - engine stopped
15 - 100 9813/8950-2 15 - 100

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

completed in accordance with the service schedules.
The oil pump delivers oil at pressure to the oil filter Failure to replace the oil and filter at the
via a port. The anti-drain seal is forced off its seat and recommended interval could cause serious engine
oil flows through a large area paper element. Filtered failure.
oil enters the inner part filter before leaving the filter
head via a port. 1. Make the machine safe, refer to (PIL 01-03).
At Engine Stopped
3. Check that the oil level is between the two marks
With the engine stopped oil pressure in the galleries on the dipstick.
and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from 4. If necessary, add recommended oil through one
the filter assembly. The anti-drain pipe prevents of the filler points.
approximately half the filters oil capacity from
Figure 179.
draining. These features help protect the engine from
oil starvation on start up. B
A Dipstick
B Oil filler point
15 - 101 9813/8950-2 15 - 101

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

clean engine oil. 11. Operate the engine at idle, make sure that the
7. Screw in the new filter canister (hand tight only). oil pressure low warning light is extinguished
immediately after the engine starts. If it does not
8. Through one of the filler points, fill the engine with extinguish, stop the engine and investigate the
the recommended oil to the MAX mark on the cause.
dipstick. Wipe off any spilt oil, install the filler cap
and make sure it is secure. 12. Check for oil leakage. When the oil has cooled,
check the oil level again, and if necessary top up
with clean engine oil.
15 - 102 9813/8950-2 15 - 102

15 - Engine
21 - Oil Filter
00 - General
Figure 180.
B
A Dipstick B Oil filler points

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

Item Description Nm
C Oil sump drain plug 40
E Filter housing drain plug 40
15 - 103 9813/8950-2 15 - 103

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

15-24-03 Outer Element .............................................................................................................. 15-109
15-24-06 Inner Element ............................................................................................................... 15-111
15 - 104 9813/8950-2 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.
Component Identification ............................. 15-106
Check (Condition) ........................................ 15-107 A dirty and blocked air cleaner element will reduce
the amount of air entering the combustion chamber
Remove and Install ..................................... 15-107 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 9813/8950-2 15 - 105

15 - Engine
24 - Air Filter
00 - General

Notice: Do not run the engine when the element
has been removed. Figure 181.
Notice: The outer element must be renewed A B D
C
immediately if the warning light on the instrument
panel illuminates.
A Precleaner
B Outer air filter element
C Inner air filter element
D Housing
E Vacuum switch
15 - 106 9813/8950-2 15 - 106

15 - Engine
24 - Air Filter
00 - General
The air filter element (s) should be changed at Remove

the recommended service interval, refer to the
Maintenance Schedules. Refer to: PIL 78-24. 1. Make the machine safe.
Check all the hose connections for loose installations Refer to: PIL 01-03-27.
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 Refer to: PIL 06-06-06.
and on the crossover tube.
Renew any damaged components. the engine has been running, let it cool before
In addition, most air filter housings will be installed
with a vacuum switch. The switch will detect if there 4. Loosen the clamp 1 (x2).
is a restriction on the air intake, and activate warning 5. Remove the screw 1 (x2).
indicators such as an audible alarm and/or a visual
indicator. 6. Remove the induction moulding.
7. Loosen the clamp 2 (x2).
8. Disconnect the induction hoses.
9. Disconnect the electrical connectors from the
TMAF (Temperature and Mass Air Flow) sensor
and vacuum sensor.
10. Remove the setscrews (x4) and washers (x4).
11. Remove the filter assembly from the engine.
Figure 182.
E
D
F,G
A E
D
A
B C
A Clamp 1 (x2)
B Screw 1 (x2)
C Induction moulding
D Clamp 2 (x2)
E Induction hoses
F Setscrews (x4)
G Washers (x4)
15 - 107 9813/8950-2 15 - 107

15 - Engine
24 - Air Filter
00 - General
Install
step.
15 - 108 9813/8950-2 15 - 108

15 - Engine
24 - Air Filter
03 - Outer Element
03 - Outer Element Clean

Clean ........................................................... 15-109 1. Make the machine safe.
Remove and Install ..................................... 15-110 Refer to: PIL 01-03-27.
3. Clean the area around the air cleaner.
4. The dust ejector should be squeezed to release
any build up of dust in the air cleaner case before
removing the elements Refer to Figure 183.
Figure 183.
A B D
C
A Pre-cleaner
B Outer air filter element
C Inner air filter element
D Housing
E Vacuum switch
5. Loosen the clamps holding the sediment cup to
the air cleaner body and pull the cup clear. Refer
to Figure 183.
6. Pull out the outer element from the body.
6.1. Clean the outer element by tapping gently
on a firm object or by blowing gently with
compressed air from inside the element.
Refer to Figure 183.
6.2. Replace the outer element, if it is damaged
or severely contaminated.
7. Do not clean the inner element.
7.1. Replace the inner element, if it is
contaminated.
8. Clean the outer body and sediment cup.
9. Assemble the cleaner.
15 - 109 9813/8950-2 15 - 109

15 - Engine
24 - Air Filter
03 - Outer Element
H
Remove
G
F
3. Open the air cleaner end cap clips (x2).
F End cap with precleaner
5. Remove the screw 1 (x2). G Outer air filter element
H Inner air filter element
6. Remove the induction moulding.
7. Loosen the clamp 2 (x2). Install
8. Disconnect the induction hose. 1. The installation procedure is the opposite of the
removal procedure.
Figure 184.
A E
D
A
B C
A Clamp 1 (x2)
B Screw 1 (x2)
C Induction moulding
D Clamp 2 (x2)
E Induction hoses
9. Remove the air filter assembly end cap with
precleaner.
10. Remove the outer air filter element.
11. Remove the inner air filter element.
15 - 110 9813/8950-2 15 - 110

15 - Engine
24 - Air Filter
06 - Inner Element
06 - Inner Element
Remove and Install
15 - 111 9813/8950-2 15 - 111

15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ......................................................................................................................... 15-113
15 - 112 9813/8950-2 15 - 112

15 - Engine
00 - General
Introduction .................................................. 15-113 Depending on the specification, the engine may be
Component Identification ............................. 15-114 installed with open loop, filtered open loop or a closed
Operation ..................................................... 15-115 loop CCV (Crankcase Ventilation) system.
15 - 113 9813/8950-2 15 - 113

15 - Engine
00 - General
Figure 186. Filtered open loop crankcase ventilation (CCV) system

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

C Transfer hose D Filter element - second stage
E Filter element - first stage F Filtered vapour vent to atmosphere
G Oil droplets - return to sump H Crankcase ventilation filter assembly
15 - 114 9813/8950-2 15 - 114

15 - Engine
00 - General
Operation Remove and Install
Filtered open loop crankcase ventilation The filter element must be changed at the
recommended maintenance interval. Refer to (PIL
(CCV) system 78-24).
Crankcase emissions are created during the 1. Make the machine safe. Refer to (PIL 01-03).
combustion process. These emissions include
unburned fuel and 'blow by gases' which contain 2. Get access to the engine. Refer to (PIL 06-06).
hydrocarbon and engine oil contaminates. A large
proportion of these emissions are prevented from 3. Rotate the filter cover anti-clockwise and
entering the atmosphere by the CCV (Crankcase remove.
Ventilation) filter assembly.
4. Lift out the filter element and discard it.
A series of ports in the crankcase, cylinder head
and rocker cover allow pressure to vent from 5. Clean the inside of the filter housing. Remove all
the crankcase. The vapour from the crankcase oil and sludge contamination.
flows from the rocker cover to the filter assembly. 6. Make sure that the oil drain in the bottom of the
Combined two stage filter elements remove around filter housing is not blocked with sludge.
90 % of contaminates as the vapour passes from the
inside to the outside of the filter elements. Trapped oil 7. Install a new filter element. Make sure that the
is allowed to drain back to the sump via a non return correct type of filter element is installed.
valve. The filtered vapour vents to the atmosphere.
8. Align the arrows on both parts to install the filter
If the pressure inside the filter assembly rises due cover.
to a blocked filter non return valve in the oil drain
line prevents vapour being forced back into the Figure 187.
crankcase.
A
The ventilation circuit incorporates a pressure relief
valve. If the filter element becomes blocked the valve
opens bypassing the filter and preventing a build up
of pressure in the crankcase. Although this prevents
serious engine damage it must be remembered
that the filtration system does not function when B
bypassed. The filter element must be replaced at the
intervals specified to ensure a bypass condition is
avoided.
A Filter cover
B Filter element
C Filter housing
15 - 115 9813/8950-2 15 - 115

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

15-30-12 Valve Spring ................................................................................................................. 15-126
15-30-24 Stem Seal .................................................................................................................... 15-127
15 - 116 9813/8950-2 15 - 116

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

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

head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.
15 - 117 9813/8950-2 15 - 117

15 - Engine
30 - Valve
00 - General
Technical Data
Table 49. Inlet and Exhaust Valve Data

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

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

valve rockers.
15 - 118 9813/8950-2 15 - 118

15 - Engine
30 - Valve
00 - General
Figure 188.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Lobes
4 Tappets (x8) 5 Push rods (x8)
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)
6c Adjusting screws (x8) 6d Swivel tip - rockers
7 Rocker shaft 8 Wave washers (x8)
9 Bridge pieces (x8) 10 Valve springs (x16)
11 Retainer (x16) 12 Collets (x32)
13 Oil seal - valve stems (x16) 14 Valve seat inserts (x16)
15 - 119 9813/8950-2 15 - 119

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

17 Valve stem
Cross Sectional View
Figure 189.
17
6c 11 12
8 10
6a 6b 13
6d
745930
14
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)

6c Adjusting screws (x8) 6d Swivel tip - rockers
8 Wave washers (x8) 9 Bridge pieces (x8)
10 Valve springs (x16) 11 Retainer (x16)
12 Collets (x32) 13 Oil seal - valve stems (x16)
14 Valve seat inserts (x16) 17 Valve stem
15 - 120 9813/8950-2 15 - 120

15 - Engine
30 - Valve
00 - General
Operation Adjust
Special Tools
The camshaft drive gear is driven by the crankshaft Description Part No. Qty.
gear at half the speed of the crankshaft. Camshaft Crankshaft Turning Tool 892/01147 1
lobes, two for each cylinder, (operating exhaust and (95.25mm PCD)- JCB
inlet valves) actuate the valve tappets. 4 Cylinder Ecomax and
Dieselmax
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot Valve Clearance 892/01380 1
on the camshaft, depressing two valves at the same Service Kit
time via the bridge piece.
Engine Position
The screw is self locking in the rocker by means of
a tapered thread. Wave washers act like springs to The engine needs to be set to two different positions
keep the rockers in their correct positions along the to measure and adjust all of the valves. The graphics
camshaft and prevent them contacting one another. show which valves are applicable at which engine
The rockers incorporate a swivel tip to ensure position.
alignment with the bridge piece. This prevents
excessive wear. 1. Make sure that the engine is safe to work on. If
Each valve has a compression spring. The function you start the service work.
of the spring is to close the valve and at the same
time return the rocker arm and push rod to ensure 2. Get access to the engine.
that the tappets follow the camshaft lobes. The spring
is located on the valve stem by a retainer and split 3. Remove the tappet covers. Refer to (PIL 15-42).
collets.
4. Put the indicator pins into the holes inside the
tappet adjusters for cylinder number 4. Make
sure that the pins do not fall into the engine.
5. Use the crankshaft turning tool to turn the engine
crankshaft clockwise. Stop turning the crankshaft
when one indicator pin starts to move up after the
other pin has moved down. This is the position
where the exhaust valve is almost closed and the
inlet valve is just starting to open.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1)
Special Tool: Valve Clearance Service Kit (Qty.:
1)
6. Put a mark on the crankshaft pulley at the 12
o'clock position.
15 - 121 9813/8950-2 15 - 121

15 - Engine
30 - Valve
00 - General
Figure 190. Figure 192. 360 Degree Position

A
360
T7
2B 4B
1A 2A
1A Exhaust valve-Cylinder 1
2A Exhaust valve-Cylinder 2
2B Inlet valve-Cylinder 2
T8 T8 Valve Clearances
The procedure describes how to measure and,
if necessary, adjust one valve clearance. The
procedure for all the valves is the same. Do the
A 12 o'clock position procedure for the correct valves at each of the two
T7 Crankshaft turning tool engine positions. Remember you must remove the
T8 Indicator pins (obtain locally) valve clearance service tools before you turn the
engine crankshaft.
7. Turn the engine crankshaft 90 degrees
clockwise. Important: The engine must be cold before you
8. Measure and, if necessary, adjust the clearances measure or adjust the valve clearances.
for the correct valves.
1. Install the adaptor plate in the correct position on
Figure 191. 90 Degree Position the rocker cover using the screws A.
2. Make sure that the crankshaft is in the correct
position.
3. Put the adaptor sleeve on the correct valve
tappet adjuster screw.
90 4. Push the lock bar into the correct valve tappet
adjuster screw.
1B 3B 5. Tighten the lock bar by turning it with your hand.
3A 4A
6. Assemble the DTI support and DTI.
3A Exhaust valve-Cylinder 3 7. Push and then pull the lock bar in the direction of
3B Inlet valve-Cylinder 3 the arrows X and Y. Do this until you are sure that
4A Exhaust valve-Cylinder 4 the lock bar is correctly installed and oil is moved
away from the cam follower and push rod.
9. Remove the valve clearance service tools. Turn
the engine crankshaft 360 degrees clockwise. 8. Important: Apply a side force on the lock bar
Use the mark on the crankshaft pulley as a at the same time as pushing and pulling. This
reference. prevents the rocker moving along the rocker
shaft and giving a false reading on the DTI. Apply
10. Measure and, if necessary, adjust the clearances a force to the left on the exhaust valve tappets
for the correct valves. and to the right on the inlet valve tappets.
15 - 122 9813/8950-2 15 - 122

15 - Engine
30 - Valve
00 - General
T1
C
T5
X A
T4 Y B
A
T3
T2
T6
A Screws B Tappet adjusters
T1 Dial Test Indicator (DTI)(obtain locally) C Rockers
T2 Adaptor plate (part of valve clearance service T6 Spanner open ended (obtain locally)
kit)
T3 Adaptor sleeve (part of valve clearance service
kit)
T4 Lock bar (part of valve clearance service kit)
T5 DTI Support (obtain locally)
9. Pull the lock bar in the direction of arrow Y and
turn the DTI to zero.
10. Push the lock bar in the direction of arrow X and
record the DTI indication.
11. Compare the valve clearance measurement with
the correct clearances. If an adjustment is
necessary:
11.1. Turn the tappet adjuster using an open
ended spanner on the adaptor sleeve.
Turn the sleeve clockwise to reduce
the clearance and counterclockwise to
increase the clearance.
11.2. Important: The tappet adjusters are set in
position by thread friction with the rockers.
Make sure that the torque to turn the
tappet adjusters is more than the minimum
necessary. If any of the adjusters show a
lower torque value then the adjuster and
its related rocker must be replaced.
15 - 123 9813/8950-2 15 - 123

15 - Engine
30 - Valve
00 - General
Remove and Install Figure 195. Valve Stand
Special Tools
Valve Stem Seal 892/01152 1
Installation Tool
(444/448/672 Engine)
EXHAUST
EXHAUST
EXHAUST
INLET
INLET
INLET
Before Removal
1. This procedure requires service parts. Make CYL. 1 CYL. 2 CYL. 3

2. Make sure that the engine is safe to work on. If Remove
you start the service work. 1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure
3. Get access to the engine. that the springs are compressed squarely.
4. Remove the thermostat, refer to (PIL 21-12). Figure 196.
5. Remove all of the fuel injector pipes, refer to (PIL
18-96). B
6. Remove the rocker cover, refer to (PIL 15-42).

7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL A
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
11. Remove the cylinder head assembly from the
cylinder block, refer to (PIL 15-06). A Spring compressor tool
12. Measure the valve recession with a suitable DTI B Collets
(Dial Test Indicator). Clean the carbon deposits 2. Remove the spring compressor tool and lift off
from a small area of the valve heads for location the retainer and valve spring.
of the DTI probe. If the valve recession is outside
the serviceable limits, it is advisable to obtain Figure 197.
a new or reconditioned cylinder head assembly,
refer to Technical Data (PIL 15-06). C
13. To aid removal and replacement, use a wooden

valve stand to retain the valves after removal. D
Add labels to make sure that the valves are
correctly replaced.
C Retainer
D Valve spring
3. Turn the cylinder head on its side and withdraw
the inlet valves and exhaust valves as shown.
15 - 124 9813/8950-2 15 - 124

15 - Engine
30 - Valve
00 - General
Figure 198. If there is evidence of wear or damage to the valves,

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

F Inlet valves
G Exhaust valves 1. The installation procedure is the opposite of the
4. When removing, note the respective position of steps.
each valve. Use a suitable valve stand to keep
the valves together and identify them with their 2. Install the new valve stem seals as shown. Use
respective cylinder. Note: The exhaust valves the installation tool to avoid damaging the seals.
have smaller diameter heads. Pre-assemble the seal into the tool. Locate the
tool over the valve guide and gently press the
5. Remove the valve stem seals. Discard the seals. seal into place. Lubricate the seal with P80 fluid.
Figure 199. Special Tool: Valve Stem Seal Installation Tool
(444/448/672 Engine) (Qty.: 1)
3. With the cylinder head on its side, insert the
J H inlet valves and exhaust valves as shown. Make
sure that the valves are installed in the correct
positions. Lubricate the valve stems with clean
engine oil before assembly. Carefully push the
end of the valve stem through the stem seals.
4. Install the valve springs on to the valve
stems, together with a retainer. Use the spring
compressor tool to compress each valve spring
and insert the collets. Make sure that the collets
are correctly seated in the valve stem grooves,
before you remove the spring compressor tool.
H Valve stem seals After Installation

J Punch tool
1. Tap the valve stems in turn using a rubber mallet
top fully seat the valves.
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.
2. Check that the valves and valve seats are not
cracked, burnt or damaged.
3. Check the valve stems and valve guides for wear,
refer to Technical Data (PIL 15-30).
15 - 125 9813/8950-2 15 - 125

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

15 - 126 9813/8950-2 15 - 126

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

15 - 127 9813/8950-2 15 - 127

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

15-33-06 Big-End Bearing ........................................................................................................... 15-132
15 - 128 9813/8950-2 15 - 128

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

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

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

the big end of the connecting rod so that pressurised
lubricating engine oil squirts out on to the thrust
side of the cylinder wall to lubricate the travel of the
pistons and piston rings.
15 - 129 9813/8950-2 15 - 129

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 50. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 77 –77.01 mm
ameter
Connecting rod side
clearance
min 0.05 mm
max 0.4 mm
Big end bearings
Width 32.5 –33 mm
Thickness (at centre) 1.99 –1.981 mm
Small end bearings
Inside diameter 40.034 –40.02 mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 130 9813/8950-2 15 - 130

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

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 131 9813/8950-2 15 - 131

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

Introduction .................................................. 15-132 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-133 bearings at the big-end of the connecting rod.
15 - 132 9813/8950-2 15 - 132

15 - Engine
33 - Connecting Rod

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

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 133 9813/8950-2 15 - 133

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

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

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear.
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
4. Install the lower bearing shell to the big-end
bearing cap. Lubricate the bearing shell with
15 - 134 9813/8950-2 15 - 134

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

to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new big end bearing cap bolts. Tighten the
new bolts in three stages to the correct torque
value.
1)
5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
5.2. The bolts are tightened using a torque and
angle method.
Figure 202.
0° +90°
Figure 203.
T3
T3 Angle gauge (obtain locally)
After Installation
1. The after installation procedure is the opposite of
the before removal procedure.

Item Torque Value Angle (de-
(Nm) grees)
2 (1st Stage) 35
2 (2nd Stage) 65
2 (Final Stage) 90
15 - 135 9813/8950-2 15 - 135

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-137

15-36-03 Piston Ring ................................................................................................................... 15-146
15 - 136 9813/8950-2 15 - 136

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-137 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-138 expanding combustion gases in the combustion
Component Identification ............................. 15-139 chamber space at the top of the cylinder. This force
Check (Condition) ........................................ 15-139 then acts downwards through the connecting rod and
on to the crankshaft.
Disassemble and Assemble ........................ 15-143 The pistons are cast from aluminium alloys for
increased strength and improved fatigue life.
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 - 137 9813/8950-2 15 - 137

15 - Engine
36 - Piston
00 - General
Technical Data
Table 52.
Engine 444 448
Gudgeon pin bore diameter
- min. 40.01 mm 42.008 mm
- max. 40.015 mm 42.013 mm
Piston ring clearance
- Top ring Full keystone ring Full keystone ring
- Middle ring 0.125 –0.08 mm 0.125 –0.08 mm
- Bottom (oil) ring 0.09 –0.05 mm 0.09 –0.05 mm
Piston ring gap
- Top ring 0.3 –0.4 mm 0.3 –0.4 mm
- Middle ring 0.55 –0.8 mm 0.55 –0.8 mm
Piston height above crankcase 0.00025 –0.36825 mm
(1)
0.00025 –0.36825 mm
(1)
(cold)
Piston groove width
- Top ring 3.114 –3.134 mm 3.114 –3.134 mm
- Middle ring 2.575 –2.595 mm 2.575 –2.595 mm
Piston skirt 102.853 –102.871 mm 105.851 –105.869 mm
Piston pin 39.994 –40 mm 41.994 –42 mm
(1) Nominal measurement is 0.03325 mm
15 - 138 9813/8950-2 15 - 138

15 - Engine
36 - Piston
00 - General
Component Identification Check (Condition)

Figure 204. 1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
diameter, piston pin bore and the clearance in
the piston ring grooves to confirm they are within
service limits.
A
2. Check the piston pin for signs of damage and
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston.
B
C The connecting rod small end bearing bush is not
D
renewable. If the small end bearing bush is damaged
E or worn the connecting rod must be renewed as a
complete assembly.
A F
F
A Piston
B Connecting rod
C Oil control ring
D Piston ring - compression No.1
E Piston ring - compression No.2
F Retaining circlips
G Piston pin
15 - 139 9813/8950-2 15 - 139

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

Before Removal 4. Disconnect and remove the fuel pipes from the
The following procedure is for one piston and injectors. Refer to (PIL 18-96).
connecting rod assembly. Note that each assembly 5. Remove the rocker cover. Refer to (PIL 15-42).
must be replaced in the same cylinder bore. Label
each piston and connecting rod assembly to make 6. Remove the fuel injectors. Refer to (PIL 18-18).
sure it is installed in the correct position on assembly.
7. Remove the cylinder head assembly. Refer to
1. This procedure requires service parts. Make sure (PIL 15-06).
that you have obtained the correct service parts
before you start. Refer to Parts Catalogue. 8. Remove the oil sump. Refer to (PIL 15-45).
2. Make sure that the engine is safe to work on. If 9. Remove the big end bearing caps. Refer to (PIL
the engine has been running, let it cool before 15-33-06).
15 - 140 9813/8950-2 15 - 140

15 - Engine
36 - Piston
00 - General
Figure 205.
X
1
1 Piston 2 Piston ring

3 Connecting rod X Longest side of connecting rod
15 - 141 9813/8950-2 15 - 141

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

the carbon deposits from around the top of the
cylinder bore. Take care not to scratch or damage
the cylinder bore.
2. Use a hammer and a short length of wood to
tap the piston from the connecting rod side. Take
care not to scratch or damage the cylinder bore
or the connecting rod bearing surface.
Install
steps.
3. If the upper big end bearing shell has been
removed replace it. Refer to (PIL 15-33-06).
4. Lubricate the cylinder bore with clean engine oil.
5. Use a suitable compressor tool to compress the
piston rings.
6. Insert the piston and connecting rod assembly
into the cylinder bore, make sure that the longest
side of the connecting rod is on the exhaust side
of the crankcase. Take care not to damage the
cooling jets when you guide the connecting rod
down the cylinder bore and over the crank pin
diameter.
After Installation
1. Install the big end bearing caps. Refer to (PIL
15-33-06).
2. Carry out the procedures listed under Before
removal in reverse order.
15 - 142 9813/8950-2 15 - 142

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

Dismantle To avoid damage or distortion to the rings, use a
suitable piston ring expander tool. Note that the
1. Clamp the connecting rod in a vice. Take care not oil control ring is installed with a spiral wire. Pull
to damage the connecting rod. the wire apart and remove it.
2. It is recommended that the piston rings are 3. Remove the circlips and push out the piston pin.
renewed. If they are to be reused, label the
rings to ensure they are installed in the correct 4. Use a suitable cleaning agent, clean the carbon
positions and the correct way up on assembly. deposits from the piston.
15 - 143 9813/8950-2 15 - 143

15 - Engine
36 - Piston
00 - General
Figure 206.
A TOP
2 X
B 3
TOP
C
4a
TOP
1
4
6
7
0°
12
12
0°
120°
1 Piston 2 Piston ring - compression No.1

3 Piston ring - compression No.2 4 Piston ring - oil control ring
4a Spiral wire - oil control ring 5 Connecting rod
6 Piston pin 7 Retaining circlip (x2)
X Connecting rod - longest side Y Cast boss - piston
Inspect
1. Inspect the pistons for signs of wear or damage.
Refer to Check (Condition) (PIL 15-36-00).
15 - 144 9813/8950-2 15 - 144

15 - Engine
36 - Piston
00 - General
Assemble
1. The assembly procedure is the opposite of
the disassemble procedure. Additionally do the
following steps.
3. Lubricate the piston pin with clean engine oil.
Assemble the connecting rod to the piston and
insert the piston pin. Make sure that the long side
of the connecting rod is on the same side as the
internal cast boss in the piston.
4. Install new circlips. Make sure that they are
installed correctly in the groove in the piston.
5. Lubricate the piston with clean engine oil. Install
the piston rings to the piston in sequence as
follows:
5.1. Install the spiral wire for the oil control ring
in the bottom groove and locate the locking
wire inside both ends of the spiral as shown.
Using a piston ring expander tool to install
the oil control ring in the bottom groove and
locate the locking wire inside both ends of
the spiral as shown. Ensure that the ring
gap is positioned 180° to the locking wire.
Note: The correct ring orientation can also
be determined from the profile shape of the
ring as shown at C.
5.2. Install the No.2 compression ring into
the middle groove. Note that new rings
have a reference number etched on one
face. Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at B.
5.3. Install the No.1 compression ring into the
top groove. Note that new rings have a
reference number etched on one face.
Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at A.
6. Rotate the piston rings so that the ring gaps are
120° apart as shown.
15 - 145 9813/8950-2 15 - 145

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 - 146 9813/8950-2 15 - 146

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-149
15 - 147 9813/8950-2 15 - 147

Notes:
15 - 148 9813/8950-2 15 - 148

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 149 9813/8950-2 15 - 149

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-151

15-42-06 Rocker Cover ............................................................................................................... 15-159
15-42-09 Push Rod ..................................................................................................................... 15-161
15-42-21 Tappet ........................................................................................................................... 15-163
15-42-24 Tappet Cover ................................................................................................................ 15-165
15 - 150 9813/8950-2 15 - 150

15 - Engine
00 - General
Introduction .................................................. 15-151 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-152 system consisting of rocker arms and a shaft.
Operation ..................................................... 15-154 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Remove and Install ..................................... 15-155 movement at the poppet valve to open it. One end is
Disassemble and Assemble ........................ 15-157 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 - 151 9813/8950-2 15 - 151

15 - Engine
00 - General
Technical Data
Table 53. Rocker Levers, Rocker Shafts and Tappets Data

Valve clearances measured at the valve bridge piece
tip of the rockers (measured cold):
- Inlet 0.19 –0.27 mm
- Exhaust 0.56 –0.64 mm
Rocker clearances measured at the adjusting screw
tip of the rockers (measured cold):
- Inlet 0.15 –0.2 mm
- Exhaust 0.43 –0.5 mm
Rocker lever bore diameter
- min 26.058 mm
- max 26.092 mm
Rocker shaft diameter
- min 26.003 mm
- max 26.021 mm
Tappets stem diameter
- min 19.975 mm
- max 19.985 mm
Tappet bore diameter
- min 20 mm
- max 20.021 mm
Tappet height (maximum) 55.25 mm
15 - 152 9813/8950-2 15 - 152

15 - Engine
00 - General
Figure 207.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 153 9813/8950-2 15 - 153

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

When the camshaft lobe raises the outside of the rotation, the inside rises to allow the valve spring to
rocker arm, the inside presses down on the valve close the valve.
stem to open the valve. When the outside of the
Figure 208.
1 Oil feed from main gallery 2 Small transfer gallery

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

where it flows by gravity along a groove to the rocker
Oil is fed from the main gallery via a drilling which tip.
passes up through the crankcase and the cylinder
head to a small transfer gallery under the rocker
shaft pedestal. The oversize rocker shaft fixing bolt
hole allows oil to pass into a drilling in the centre of
the rocker shaft. Further cross drillings transfer oil
to each of the rocker pivot bushes. A cross drilling
15 - 154 9813/8950-2 15 - 154

15 - Engine
00 - General
Remove and Install

Before Removal 3. Disconnect and remove the fuel pipes from the
1. Make sure that the engine is safe to work on. If fuel injectors, refer to Fuel pipes (PIL 18-96).
Figure 209.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 155 9813/8950-2 15 - 155

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

Item Nm
2 24
3 24
15 - 156 9813/8950-2 15 - 156

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

Before Disassembly 15-42).
1. Remove the rocker cover. Refer to (PIL 15-42).
Figure 210.
2
2
3
1
2
2
4
4
4
5
4
5
6
7
4
1 Rocker shaft 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - Oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Rockers - inlet (x4)
7 Rockers - exhaust (x4) 8 Wave washers (x8)
15 - 157 9813/8950-2 15 - 157

15 - Engine
00 - General
Disassemble
1. Lift out the rocker shaft fixing bolts, then slide
the pedestals, rockers and wave washers off the
rocker shaft as shown. Label the pedestals and
rockers to make sure that they are installed in the
correct positions on assembly.
2. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Refer to
Check (Condition) (PIL 15-42).
Assemble
the disassemble procedure. Additionally do the
following steps.
2. Lubricate the rocker shaft and rocker bearing
bushes with clean engine oil.
3. Make sure that the rockers and pedestals are
installed in their original positions along the
rocker shaft. Note the position of the oil feed
pedestal.
4. Insert the rocker shaft fixing bolts to hold the
rockers and pedestals loosely in position before
fitting the assembly into the cylinder head. Note
the position of the longer bolt.
After Assembly
1. Install the rocker assembly. Refer to (PIL 15-42).
2. Install the rocker cover. Refer to (PIL 15-42).
15 - 158 9813/8950-2 15 - 158

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

Before Removal 15-00).

Figure 211.
D
A Rocker cover B Bolts

C Gasket D Injector seals
15 - 159 9813/8950-2 15 - 159

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

Item Nm
B 24
15 - 160 9813/8950-2 15 - 160

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

Introduction .................................................. 15-161 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-162 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 - 161 9813/8950-2 15 - 161

15 - Engine
09 - Push Rod
Remove and Install

15 - 162 9813/8950-2 15 - 162

15 - Engine
21 - Tappet
21 - Tappet Figure 213.
Remove and Install

B
Before Removal
injectors. Refer to (PIL 18-96). C
B Timing pin - crankshaft
3. Remove the rocker cover. Refer to (PIL 15-42). C Blanking plug
4. Remove the fuel injection pump. Refer to (PIL 12. Remove the fuel injection pump drive gear. Refer
18-18). to (PIL 15-51).
5. Remove the rocker assembly and push rods.
Refer to (PIL 15-42). Removal
6. Remove the starter motor. Refer to (PIL 15-75). The engine must be inverted. DO NOT attempt
to remove the camshaft and its drive gears with
7. Remove the oil sump. Refer to (PIL 15-45). the engine upright. The tappets and push rods will
8. Remove the flywheel. Refer to (PIL 15-54). fall into the engine and further dismantling will be
required to retrieve them.
9. Remove the flywheel housing. Refer to (PIL
15-54). 1. Remove the camshaft timing pin.
10. Rotate the crankshaft until the camshaft timing 2. Carefully withdraw the camshaft and gear
pin can be inserted through the gear and into the assembly from the crankcase. Make sure you
aligning hole in the rear gear case. fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
Figure 212. The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
Figure 214.
A Timing pin - camshaft

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

D Camshaft and drive gear
15 - 163 9813/8950-2 15 - 163

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

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a 1. Lubricate the tappets and tappet bores inside the
suitable magnetic probe. Label the tappets to crankcase with clean engine oil.
ensure replacement in their original positions.
2. Insert the tappets in their original positions in the
Figure 215. crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
F the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
E preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
E camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear casing.
Insert the timing pin to lock the camshaft in this
position.
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
E Tappet (8 off)
F Magnetic probe
Inspection
1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting.
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the
dimensions are within service limits.
4. Inspect the cam bearing surfaces inside the
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits.
5. Inspect the bearing surfaces of the tappets for
the dimensions are within service limits.
6. Inspect the tappet bores inside the crankcase for
the dimensions are within service limits.
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries
in the crankcase and camshaft may be blocked.
Make sure all oil ways are clear and free from
debris.
15 - 164 9813/8950-2 15 - 164

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

steps.
It is not necessary to remove the tappet covers 2. Inspect the tappet cover seals for signs of
unless a new rocker cover is to be installed. It is damage. Replace any damaged seals.
necessary to remove the tappet covers to measure
and adjust the valve clearances. Refer to Valve- 3. Install the tappet covers. Tighten the screws to
Adjust, Valve Clearances (PIL 15-30). the correct torque value.
Remove Table 56. Torque Values

Item Nm
the engine has been running, let it cool before A 9
3. Clean the tappet covers and the adjacent areas
of the rocker cover. Refer to Engine - Clean.
Important: Make sure that the screws do not fall
into the engine.
4. Remove the tappet cover screws.
5. Keep the screws away from the engine.
6. Use a screwdriver in the slot to remove the tappet
covers. Make sure that dirt or debris does not fall
into the engine.
Figure 216.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 165 9813/8950-2 15 - 165

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-167
15 - 166 9813/8950-2 15 - 166

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-167 The lubrication system distributes oil around the
Component Identification ............................. 15-168 engine by a system of galleries and drillings in the
Remove and Install ..................................... 15-169 crankcase and cylinder head. The oil lubricates and
seals the moving parts of the engine, reducing friction
and wear. In addition the oil plays an important role in
cooling the engine by carrying heat from the engine
to the cooler. A piston cooling jet sprays oil onto the
underside of the pistons to keep them cool, refer to
(PIL 15-36).
Oil is drawn from the oil sump by the integral oil pump
via the suction strainer. The strainer prevents any
large particles of debris passing through, which may
damage the pump.
The oil passes from the outlet side of the pump

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

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

bearings it reverts to sump pressure and splash
lubricates the internal components such as rocker
tips, cam lobes and timing gear teeth. Gravity
drains the oil via drains into the cylinder head and
crankcase, back into the oil sump. A drain slot allows
the oil to drain from the timing case back to the oil
sump.
15 - 167 9813/8950-2 15 - 167

15 - Engine
45 - Oil Sump
00 - General
Figure 217.
1 Oil sump 2 Suction strainer

3 Oil pump 4 Oil cooler
5 Filter 6 Camshaft - high pressure oil feed
7 Crankshaft main bearings - high pressure oil 8 Rocker assembly - high pressure oil feed
feed
9 PTO (Power Take-Off) idler gear bearing/ 10 External high pressure oil feed connection
timing case - high pressure oil feed (crankcase) - Turbocharger (if installed)
11 Main high pressure oil feed gallery 12 Oil pressure switch
(crankcase)
Green- Oil at sump pressure Red- Oil at high pressure
Pink- Oil at lower pressure but higher than
sump pressure
15 - 168 9813/8950-2 15 - 168

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

Template for Sealant 892/01149 1 Removal
Oil Sump - Pressed
1. Remove the fixing bolts and remove the oil sump
Oil Sump Location 892/01150 2
from the engine. The oil sump may be difficult to
Dowel
remove due to adhesion of sealing compound.
Template for Sealant 892/12354 1 If necessary, carefully lever the mating flanges
Oil Sump (Cast) apart. Do not use excessive force, the oil sump
could be damaged. Be sure to retrieve the oil pick
Consumables up seal.
Clear Silicone Sealant 4102/0901 0.31 L 2. Use a gasket removal compound, carefully
remove all traces of sealing compound from the
oil sump and engine mating faces. Do not allow
Before Removal the sealing compound to enter the engine.
1. Make sure that the engine is safe to work on. 3. Use a suitable degreasing agent to thoroughly
If the engine has been running, make sure the clean the oil sump.
engine has cooled sufficiently before you start.
Figure 218.
1 Oil sump 1a Integral suction tube

1b Integral baffle plates 2 Oil sump fixing bolts (x20)
3 Oil pick up seal
15 - 169 9813/8950-2 15 - 169

15 - Engine
45 - Oil Sump
00 - General
Installation Figure 220.
1. Lightly smear the new oil pick up seal with oil and X
install into the bedplate as shown.
Figure 219.
3 Oil pick up seal

2. Install the two guide pins at the oil sump screw
holes in the engine.
Special Tool: Oil Sump Location Dowel (Qty.: 2)
S Hole
3. Use the fixing bolts to locate the template to T Hole
the oil sump mating face. Make sure that the T2 Guide pins
template is the correct way round (note that holes X 4mm Bead of sealant
are on different centres).
8. Position the oil sump with the suction tube outlet
Special Tool: Template for Sealant Oil Sump aligned with the oil pump inlet port on the engine.
(Cast) (Qty.: 1) Take care not to damage the oil pick up seal when
Special Tool: Template for Sealant Oil Sump - you install the oil sump. Damage to the seal could
Pressed (Qty.: 1) cause a drop in oil pressure and subsequently
damage to the engine.
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the 9. Locate the oil sump on the guide pins on the
template as a guide as shown. Note the beads engine. Avoid smudging the sealant beads. DO
around holes. NOT remove the guide pins until sufficient bolts
Length/Dimension/Distance: 4 mm have been installed to secure the oil sump.
Consumable: Clear Silicone Sealant 10. Install the bolts and tighten the bolts to the correct
5. Carefully remove the template without smudging torque value. Note that the bolts are not installed
the sealant beads. at 6 positions.
6. Apply a bead of sealant so as to join the sealant Figure 221.

beads around holes with the bead around the oil
sump flange.
7. After applying the sealing compound, the oil
sump must be installed and the bolts torque
tightened within
Duration: 5 min
2 Bolts
Y No bolts to be installed at this position (x6)
15 - 170 9813/8950-2 15 - 170

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

Item Nm
2 24
15 - 171 9813/8950-2 15 - 171

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-173

15-51-03 Crankshaft Gear ........................................................................................................... 15-176
15-51-06 Camshaft Gear ............................................................................................................. 15-179
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-180
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-183
15-51-22 Rear Case .................................................................................................................... 15-186
15 - 172 9813/8950-2 15 - 172

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-173 The timing gears are located inside a case at the
Component Identification ............................. 15-174 flywheel end of the engine.
Operation ..................................................... 15-175
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 - 173 9813/8950-2 15 - 173

15 - Engine
51 - Timing Gear
00 - General
Figure 222.
B E
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO device gear (if installed) F Heavy duty PTO device gear (if installed)
G Low duty PTO device gear (if installed)
15 - 174 9813/8950-2 15 - 174

15 - Engine
51 - Timing Gear
00 - General
Operation
All the gears are driven via the crankshaft gear as

follows.
• Camshaft gear-The camshaft is driven at half

crankshaft speed.
• High pressure fuel pump gear-The high
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
• Oil pump gear-The lubrication oil pump is driven
directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
gear via idler gear.
• Low Duty Power Take-Off (PTO) Gear (if
installed)-driven by the camshaft gear.
15 - 175 9813/8950-2 15 - 175

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

Crankshaft / 892/01148 2 15-54).
Camshaft Timing Pin
(444/448/672 Engine) 4. Rotate the crankshaft until the camshaft locking
pin can be inserted through the gear and into the
Note: The illustrations show the engine inverted. If aligning hole in the rear gear case. Note: The
the drive gear components are being removed prior camshaft and crankshaft locking pins must be
to crankshaft or camshaft removal the engine must in position to lock the crankshaft and camshaft
be inverted. If the gear components only are being before removing the crankshaft gear.
removed (for inspection/renewal) then the engine
need not be inverted. Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 2)
Before Removal 5. Remove the taper blanking plug and insert the
crankshaft locking pin.
1. Remove the starter motor. Refer to (PIL 15-75).
15 - 176 9813/8950-2 15 - 176

15 - Engine
51 - Timing Gear
Figure 223.
7 T1
T2
6
1 Drive gear and flywheel hub fixing bolt 2 Flywheel hub

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

Make sure you retrieve the location dowel.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub.
15 - 177 9813/8950-2 15 - 177

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

Item Nm
1 47
6 11
15 - 178 9813/8950-2 15 - 178

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 - 179 9813/8950-2 15 - 179

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

Note: The illustrations show the engine inverted. If fixing nut, retain the gear.
the drive gear components are being removed prior
to crankshaft or camshaft removal the engine must 3. Remove the starter motor. Refer to (PIL 15-75).
be inverted. If the gear components only are being
removed (for inspection/renewal) then the engine 4. Remove the flywheel. Refer to (PIL 15-54).
need not be inverted. 5. Remove the flywheel housing. Refer to (PIL
15-54).
Before Removal
1. Remove the high pressure fuel injection pump.
Refer to (PIL 18-18).
15 - 180 9813/8950-2 15 - 180

15 - Engine
51 - Timing Gear
Figure 224.
1 Drive gear - high pressure fuel pump 2 Fixing nut - drive gear - high pressure fuel pump
Remove Install
1. Remove the fixing nut and lift out the gear. 1. Use the fixing nut to loosely install the high
pressure fuel pump and the drive gear. DO NOT
2. If the rear timing case is to be removed, remove lock the gear to the taper on the fuel pump drive
the high pressure fuel pump. shaft.
2. Follow the procedures listed under Before
Removal in reverse order. Note that the gear
fixing nut is torque tightened as part of the
15 - 181 9813/8950-2 15 - 181

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

15 - 182 9813/8950-2 15 - 182

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
Remove and Install
Before Removal
The illustrations show the engine inverted. If the
drive gear components are being removed prior to 1. This procedure requires service parts. Make
crankshaft or camshaft removal the engine must sure you have obtained the correct service parts
be inverted. If the gear components only are being before you start, refer to Parts Catalogue.
removed (for inspection / renewal) then the engine
need not be inverted. 2. Remove the starter motor. Refer to (PIL 15-75).
3. Remove the flywheel. Refer to (PIL 15-54).
15-54-03).
15 - 183 9813/8950-2 15 - 183

15 - Engine
51 - Timing Gear
Figure 225.
1 Z
6
5 W
4 W
X
2
Y
3
1
2
1 High duty PTO idler gear 2 Idler gear hub

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

screws and lift out the hub.
the flywheel hub. DO NOT remove the crankshaft Inspect
gear.
1. Check the idler gear teeth and idler gear bearing
2. Lift the High duty PTO (Power Take-Off) idler bush for signs of damage or excessive wear.
gear from the hub.
15 - 184 9813/8950-2 15 - 184

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

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

Item Nm
3 65
5 47
15 - 185 9813/8950-2 15 - 185

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

Description Part No. Qty. device (if installed).
Template for Sealant 892/01176 1 7. Remove the low duty PTO device (if installed).
Flywheel Housing to
Gear Case (4 Cyl and 6 8. Remove the flywheel. Refer to (PIL 15-54).
Cyl Elec)
Before Removal 15-54).
1. Drain the oil from the engine. Refer to (PIL 10. Remove the fuel injection pump drive gear. Refer
15-21). to (PIL 15-51).
2. Disconnect and remove the fuel pipes from the 11. Remove the oil pump. Refer to (PIL 15-60).
injectors. Refer to (PIL 18-96). 12. Remove the high duty PTO idler drive gear (if
3. Remove the fuel injection pump. Refer to (PIL installed). Refer to (PIL 15-51).
18-18). 13. Remove the crankshaft drive gear. Refer to (PIL
4. Remove the fuel lift pump. Refer to (PIL 18-21). 15-51).
5. Remove the starter motor. Refer to (PIL 15-75). 14. Remove the camshaft. Refer to (PIL 15-15).
15 - 186 9813/8950-2 15 - 186

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 226.
2
T1
3
T1
1
Y B (T2) C (T2) X X
P1 5 A (T2)
X
P1 1
Y
Y
P1 Y
X X
Z V
1 Timing gear case - rear 2 Timing case fixing bolts (x19)

3 Crankcase/bedplate assembly 4 Dowel
5 Dowel - with flats P1 Anaerobic sealant
T1 Alignment pins (Locally manufacture) T2 Sealant template (comprises: Main template
- A, Long gallery template - B, Short gallery
template - C
15 - 187 9813/8950-2 15 - 187

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

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

whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 1. Replace all the components listed under Before
put together) it will immediately start to harden. Make removal in reverse order.
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The Table 60. Torque Values
parts must be installed and torque tightened within
Item Nm
5 minutes (with a maximum permissible time of 15
minutes). 2 37
Install
1. Carefully remove all traces of the old sealing
compound from the timing case and crankcase/
bedplate assembly mating faces. Make sure
that the mating faces are clean and free from
damage. Clean the inside of the timing case
using a suitable degreaser.
2. Install two alignment pins T1 to the crankcase/
bedplate assembly.
3. Make sure that dowels are correctly located in the
crankcase. Note: Dowel 5 has flats which must
be positioned relative to dowel 4, as shown at
W. This ensures correct alignment of the timing
cover.
4. The sealant template T2 comprises three pieces.
Locate parts B and C using the holes in the
templates and fixing bolts at positions Y as
shown.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl and 6 Cyl Elec)
(Qty.: 1)
5. Use the templates B and C as a guide apply a
continuous 1.5 mm (0.060 in.) bead of sealant
P1 to the case. Remove the bolts from positions
Y. Remove the templates make sure you do not
smudge the sealant. Discard the templates.
6. Locate part A of the template T2 using the holes
in the template and bolts at positions X as shown.
7. Use the template A as a guide apply a continuous
1.5 mm (0.060 in.) bead of sealant P1 to the case.
Do not follow the template at V, instead apply a
continuous bead Z (inboard of the fixing hole).
Remove the bolts from positions X. Remove the
template make sure you do not smudge the
sealant. Discard the template.
8. Locate the timing case on the alignment pins T1
and install the timing case fixing bolts (remove
15 - 188 9813/8950-2 15 - 188

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-191

15-54-03 Housing ........................................................................................................................ 15-194
15-54-09 Gear Ring ..................................................................................................................... 15-197
15 - 189 9813/8950-2 15 - 189

Notes:
15 - 190 9813/8950-2 15 - 190

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-191 Flywheels are used to provide continuous energy in
Remove and Install ..................................... 15-192 systems, where the energy source is not continuous.
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 - 191 9813/8950-2 15 - 191

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

Before Removal the engine has been running, let it cool before
sure you have obtained the correct service parts 3. Get access to the engine.
before you start. The flywheel is installed with a
crankshaft position sensor target disc. DO NOT Removal
remove the target disc. If the disc is defective the
flywheel must be replaced. 1. Remove the bolts and withdraw the flywheel from
the crankshaft hub. The bolts MUST NOT be
reused. Discard the bolts.
Figure 227.
3 1 2
1
T3
1 Flywheel 2 Flywheel fixing bolts (x8)

3 Flywheel location dowel Y Angle tightening mark
15 - 192 9813/8950-2 15 - 192

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

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

Item Torque Value Angle (de-
(Nm) grees)
2 (Ist Stage) 40
2 (2nd Stage) 120
2 (Final Stage) +120
15 - 193 9813/8950-2 15 - 193

15 - Engine
54 - Flywheel
03 - Housing
03 - Housing
Remove and Install
Special Tools 2. Remove the flywheel. Refer to (PIL 15-54).

3. Remove the starter motor. Refer to (PIL 15-75).
Template for Sealant 892/12349 1
Flywheel Housing to
Gear Case (4 Cyl Elec ) Removal
1. Remove the flywheel housing fixing bolts and
Before Removal then separate the flywheel housing from the gear
case.
The flywheel housing is integral with the drive gears
front case. When the housing is removed the drive 2. If required, undo the bolts and remove the access
gears will be exposed. DO NOT attempt to remove cover.
the camshaft and the drive gears. Removing the
camshaft with the engine in the upright position will 3. Remove and discard the crankshaft rear oil seal.
cause the tappets to dislodge, requiring the engine Take care not to damage the seal bore in the
block to be dismantled. housing.

before you start.
15 - 194 9813/8950-2 15 - 194

15 - Engine
54 - Flywheel
03 - Housing
Figure 228.
4 Z
3
Y Y
2
6
2 X
T4 Y
1 Flywheel housing 2 Dowel - 12 mm

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

inside of the flywheel housing.
1. Carefully remove all traces of the old sealant
compound from the flywheel housing mating 3. Carefully inspect all gears, bearings and shafts
faces. for signs of excessive wear or damage. If wear
or damage is evident, the components must be
renewed.
15 - 195 9813/8950-2 15 - 195

15 - Engine
54 - Flywheel
03 - Housing
Installation 2. Install the flywheel.
Anaerobic sealant will not start to cure whilst it 3. Install the starter motor.
is open to the atmosphere, however when air is
excluded (for instance when the two parts are put Table 62. Torque Values
together) it will immediately start to harden. Make Item Nm
sure that all the necessary tools, bolts etc. are readily 4 47
available prior to assembling the components. The
5 24
parts must be installed and torque tightened within 5
min with a maximum permissible time of 15 min 7 24

steps.
3. Make sure that the dowels are installed to the
mating face of the flywheel housing.
4. Install the sealant template T4 on the housing.
Locate the holes in the template, use the dowel
and three fixing bolts in the fixing points.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl Elec ) (Qty.: 1)
5. Use the template T4 as a guide, apply a
continuous bead of sealant around the flywheel
housing mating face
5.1. Some engines feature a flywheel housing
with a different fixing hole pattern. Use the
template to apply the sealant but apply
sealant manually in the position shown at Z.
6. Remove the three fixing bolts at positions.
Remove the template T4, make sure not to
smudge the sealant. Discard the template.
7. Locate the flywheel housing on the alignment
pins T3 on the crankcase and install the fixing
bolts. Progressively tighten the bolts to the
7.1. Remove the alignment pins to install the last
two M10 fixing bolts.
7.2. 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: 15 min
8. Install the access cover and use the bolts to
secure. Tighten the bolts to the correct torque
value. Refer to Table 62.
After Installation
1. Install a new crankshaft rear oil seal.
15 - 196 9813/8950-2 15 - 196

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an
Before Removal oven to make sure that the heat is applied
evenly around the circumference, to the specified
This procedure requires service parts. Make sure temperature.
you have obtained the correct service parts before Temperature: 280 °C ( 535.6 °F)
you start. Refer to the Parts Catalogue.
3. When the gear ring is sufficiently heated, install
1. Remove the flywheel from the crankshaft hub. the gear ring into position over the flywheel. Make
sure that the gear ring is installed the correct way
Figure 229. around.
X
4. Allow the gear ring to cool and shrink into
position.
After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 197 9813/8950-2 15 - 197

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-199
15 - 198 9813/8950-2 15 - 198

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-199 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-200 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-202 the crankshaft.
The pump consists of two rotors, one running inside
the other. The outer rotor has one more lobe than the
inner rotor and turns on a different axis.
When rotated the gap between the inner and outer

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

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

pump body. As oil pressure increases it acts on a
spool to overcome the pressure of the spring. As the
spool moves it uncovers a port allowing pressurised
oil directly back to the inlet port. In practice the
spool is continually opening and closing to maintain
the correct oil pressure value. The valve is not
adjustable.
15 - 199 9813/8950-2 15 - 199

15 - Engine
60 - Oil Pump
00 - General
Figure 230.
5
1
1 3 2 4
1 5
8 8a
7 7a
9 4
6
1 Oil pump 2 Outer rotor

3 Inner rotor 4 Inlet port
5 Outlet port 6 Relief valve assembly
7 Relief valve spring 7a Relief valve port (return to inlet port 4)
8 Relief valve spool 8a Relief valve pressure port (connected to port 5)
9 Oil pump connecting ports (engine bed plate)
15 - 200 9813/8950-2 15 - 200

15 - Engine
60 - Oil Pump
00 - General
Figure 231.
10
10 CCV Anti drain back valve
15 - 201 9813/8950-2 15 - 201

15 - Engine
60 - Oil Pump
00 - General
Check (Condition)
Before Removal
The illustrations show the engine inverted. If the
drive gear components are being removed prior to 1. This procedure requires service parts. Make
crankshaft or camshaft removal the engine must sure you have obtained the correct service parts
be inverted. If the gear components only are being before you start, refer to Parts Catalogue.
removed (for inspection / renewal) then the engine
need not be inverted. 2. Remove the starter motor. Refer to (PIL 15-75).
3. Remove the flywheel. Refer to (PIL 15-54).
15-54-03).
Figure 232.
1 Z
6
5 W
4 W
X
2
Y
3
1
2
1 High duty PTO idler gear 2 Idler gear hub

3 Idler gear hub retaining screws (x3) 4 Flywheel hub
15 - 202 9813/8950-2 15 - 202

15 - Engine
60 - Oil Pump
00 - General
5 Flywheel hub fixing bolt 6 Idler gear bearing bush

X Crankshaft gear Y Idler gear hub location dowel
Z Oil feed drilling
Remove
the flywheel hub. DO NOT remove the crankshaft
gear.
2. Lift the High duty PTO (Power Take-Off) idler
gear from the hub.
3. If required, remove the idler gear hub retaining
screws and lift out the hub.
Inspect
1. Check the idler gear teeth and idler gear bearing
bush for signs of damage or excessive wear.
2. Measure the bearing bush inside diameter
to confirm it is within service limits, refer to
Technical Data.
Install
steps.
3. Make sure the oil way in the idler gear hub is
through the oil feed drilling.
4. When you install the idler gear hub, make sure
the Idler gear hub location dowel locates into the
hole in the crankcase.
5. Lubricate the idler gear bearing bush with clean
engine oil.
6. Install the flywheel hub to the crankshaft gear,
locate on the dowel. Tighten the bolt to the
After Installation
1. Install the flywheel housing. Refer to (PIL
15-54-03)
2. Install the flywheel to the crankshaft hub. Refer
to (PIL 15-54)
3. Install the starter motor. Refer to (PIL 15-75).

Item Nm
3 65
5 47
15 - 203 9813/8950-2 15 - 203

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

Torque Wrench 993/70111 1 1. Make sure that the engine is safe to work on. If
(10-100Nm) the engine has been running, let it cool before
The illustrations show the engine inverted. If the 2. Drain the oil from the engine, refer to (PIL 15-21).
oil pump is being removed prior to crankshaft or
camshaft removal, the engine must be inverted. If 3. Remove the starter motor, refer to (PIL 15-75).
the oil pump only is being removed (for inspection or
renewal) then the engine need not be inverted. 4. Remove the flywheel, refer to (PIL 15-54).
This procedure requires service parts. Make sure 5. Remove the flywheel housing, refer to (PIL
you have obtained the correct service parts before 15-54).
you start, refer to Parts Catalogue.
Figure 233.
4 3 X
1 Oil pump 2 Oil pump fixing bolts (x4)

3 Flywheel hub 4 Flywheel hub fixing bolt
X Crankshaft gear Y Oil pump location dowel
15 - 204 9813/8950-2 15 - 204

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

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

Item Nm
2 24
4 47
15 - 205 9813/8950-2 15 - 205

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-207
15 - 206 9813/8950-2 15 - 206

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-207 Engine mounts support the engine and in some
Remove and Install ..................................... 15-208 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 - 207 9813/8950-2 15 - 207

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 - 208 9813/8950-2 15 - 208

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-211
15 - 209 9813/8950-2 15 - 209

Notes:
15 - 210 9813/8950-2 15 - 210

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-211
Oil Cooler Assembly
Operation ..................................................... 15-212 The oil cooler and filter are incorporated in a housing
Check (Condition) ........................................ 15-213 that is bolted to the side of the crankcase. The
Remove and Install ..................................... 15-213 housing allows transfer of lubricating oil from the
crankcase to the oil cooler and filter head.
Disassemble and Assemble ........................ 15-215
Some installations have a remote oil filter head. The
oil cooler housing incorporates feed and return ports
for hose connections to the filter head. A remote
oil filter head is used when access to the engine is
restricted.
Oil Cooler Matrix

The oil cooler matrix is a non-serviceable part and
must not be removed from the housing. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 211 9813/8950-2 15 - 211

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

Figure 234. The oil cooler housing allows transfer of lubricating
oil from the crankcase to the oil cooler and filter head.
The coolant also transfers to the housing and passes
1 over the oil cooler matrix causing heat to exchange
from the oil to the coolant.
The cooled and filtered oil then passes back into the
main oil gallery into the crankcase.
An engine oil filler point is also included via cap and

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

Figure 235.
1 3
2 4
8 5
7 6
1
1 Oil cooler housing

2 Oil cooler matrix
3 Sealing gasket (housing to crankcase)
4 Coolant gallery
5 Oil gallery (from cooler to filter head)
6 Oil fill port
7 Oil gallery (from filter head to main oil gallery)
8 Oil gallery (from pump to cooler)
15 - 212 9813/8950-2 15 - 212

15 - Engine
69 - Oil Cooler
00 - General

1. Inspect the sealing faces on the oil cooler matrix,
oil cooler housing and the crankcase. Make sure
Before Removal
that the faces are clean and free from scale or 1. Make sure that the engine is safe to work on. If
damage. the engine has been running, let it cool before
2. Inspect the sealing gasket and o-rings for signs
of damage. If in doubt, renew the gasket or O- 2. Drain the coolant, refer to (PIL 21-00).
rings.
3. Remove the oil filter, refer to (PIL 15-21).
Figure 236.
A B
C D
E
A Oil cooler housing (integral oil filter head)
B Oil cooler housing fixing bolts (x10)
C Oil filter head
D Oil cooler housing (remote oil filter head)
E Remote oil filter head hose ports
Remove
2. If applicable, disconnect the electrical connectors
at the oil pressure switch and the oil temperature
sensor.
3. If applicable, label and disconnect the electrical
connectors at the ECM (Engine Control Module).
Do not touch the electrical pins on the ECM.
Cap the connectors on the harnesses and the
15 - 213 9813/8950-2 15 - 213

15 - Engine
69 - Oil Cooler
00 - General
ECM to prevent ingress of oil and coolant. Tie the Table 65. Torque Values
harnesses away from the oil cooler housing.
Item Description Nm
4. If applicable disconnect the remote oil filter head B Bolts 24
hoses from the ports on the oil cooler.
5. Remove the bolts and lift the oil cooler housing
away from the crankcase. DO NOT attempt to
remove the oil cooler matrix from the oil cooler
housing.
If there is cross contamination of coolant and

lubricating oil, the oil cooler matrix may be faulty. If a
faulty matrix is suspected renew the matrix and the
seals.
Figure 237.
A
B C
A Oil cooler housing

B Oil cooler matrix
C Sealing gasket
Install
steps.
2. Make sure that sealing gasket is undamaged and
correctly located in its groove. A faulty gasket will
cause cross contamination of the lubricating oil
and coolant. If in doubt install a new gasket.
After Installation
1. If applicable, install the oil filter, refer to (PIL
15-21).
2. Refill the cooling system with the recommended
coolant mixture, refer to (PIL 21-00).
3. If applicable, make sure that the harness
connectors are connected to the correct
connectors on the ECM.
4. Start the engine and check for oil and coolant
leaks.
15 - 214 9813/8950-2 15 - 214

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

1. Locate the new O-rings. Install the oil cooler
Dismantling of the oil cooler and oil filter head matrix. Tighten the bolts to the correct torque
assembly is not necessary unless the oil cooler value.
matrix or the seals are faulty.
2. Install the sealing gasket to the oil cooler
Disassemble housing.
1. Remove the four fixing bolts and lift off the oil Table 66. Torque Values
cooler matrix. Item Nm
2. Remove and discard the two sealing O-rings. A 23
3. Remove the sealing gasket.

Figure 238.
D
C
A
B C
A
A
A
A Fixing bolts
B Oil cooler matrix
C O-rings
D Sealing gasket
E Oil cooler housing
Inspect
1. Refer to Oil Cooler - Check Condition.
15 - 215 9813/8950-2 15 - 215

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-217

15-72-03 Pulley ............................................................................................................................ 15-223
15-72-06 Voltage Regulator ......................................................................................................... 15-224
15 - 216 9813/8950-2 15 - 216

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-217 The alternator is a three phase generator having a
Health and Safety ........................................ 15-218 rotating field winding and static power windings.
Check (Operation) ....................................... 15-219 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Remove and Install ..................................... 15-221 warning light to the field winding. This creates
Disassemble and Assemble ........................ 15-222 a magnetic field which supplements the residual
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 - 217 9813/8950-2 15 - 217

15 - Engine
72 - Alternator
00 - General

• Ensure that the battery negative terminal is Figure 239.
connected to the earthing cable.
• Never make or break connections to the battery
or alternator, or any part of the charging circuit D
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. A Alternator
B Regulator and brush assembly
C Drive pulley
D Tie bolts
15 - 218 9813/8950-2 15 - 218

15 - Engine
72 - Alternator
00 - General
Check (Operation) 1. Stop the engine and turn the ignition switch to
OFF.
2. Withdraw the alternator plug and connect the
Charging Circuit Test Multimeter between the large terminals and
1. Make sure that all the battery and alternator earth. With the Multimeter set to measure,
connections are in place, secure and making Voltage: 12 V
good metal - to - metal contact, especially the
earth connections to chassis and engine. Figure 241.
2. Adjust the alternator drive belt tension if

necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If 2.1. The Multimeter should show battery
the oil pressure warning remains on stop the voltage.
engine Immediately and investigate the engine
lubrication system. 2.2. If the reading is zero, check the cables
for continuity, particularly at the starter
Check 1 terminals.
3. If the voltage is correct, check the alternator.
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
Alternator Charging Test
If they operate normally, check the warning light bulb Figure 242.
for a blown filament.
Simultaneous failure of all items indicates a fault at

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

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 240.
1. Make sure that all battery and alternator

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 alternator drive belt tension is
correctly adjusted.
3. If the battery is in a fully charged condition, before
Check 2
commencing the test switch on the working lights
The following checks should be made using an for
analogue (moving pointer) type Multimeter. Duration: 3 min
15 - 219 9813/8950-2 15 - 219

15 - Engine
72 - Alternator
00 - General
4. Alternatively, operate the starter for a few 12.6. Open or short circuited power (stator)
moments with the ESOS (Engine Shut-Off windings.
Solenoid) fuse removed.
13. To check for a fault, disconnect the capacitor and
5. Install an open type shunt between the battery repeat the charging test. Renew the capacitor if
positive lead and the battery positive terminal. necessary.
Current: 100 A 14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
6. Connect a Multimeter positive lead to machine
assembly. Check the condition of the brushes
side of the shunt and negative lead to battery side
and, if necessary, clean the slip rings using extra-
of the shunt.
fine glass paper. The regulator may only be
7. Connect the leads to the Multimeter and set the renewed.
Multimeter to the relevant range as follows.
15. Faults with the rectifier, rotor and stator may be
8. AVO 2002 checked only by removing and dismantling the
alternator for further testing.
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
8.3. Right side slider to DC (Direct Current)
voltage.
8.4. Left side slider,Refer to Figure 242.
9. AVO 2003
9.1. Red lead to amps socket (A) on the
Multimeter.
9.2. Black lead to negative on Multimeter.
9.3. Right side slider to DC voltage
9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
conditions. These are listed in the order of
probability.
12.1. Defective suppression capacitor.
12.2. Dirty slip rings or worn brushes.
12.3. Defective regulator.
12.4. Defective rectifier.
12.5. Open or short circuited field (rotor)
windings.
15 - 220 9813/8950-2 15 - 220

15 - Engine
72 - Alternator
00 - General
Remove and Install Install

Figure 243. Alternator location removal procedure. Additionally do the following
steps.
2. It is not necessary to adjust the position of the
alternator in order to tension the drive belt, as
the accessory drive belt arrangement is self-
tensioning.
3. Tighten the alternator securing bolts to the
4. Make sure you reconnect the electrical leads to
the alternator in the correct positions and tighten
Remove to the correct torque.
1. Disconnect the negative (-) lead followed by the Table 67. Alternator securing bolt torque
positive (+) lead from the battery terminals. Item Torque Value
2. Remove the alternator (accessory) drive belt. A 47 N·m
B 47 N·m
3. Disconnect the electrical leads from the
alternator terminals. Label the leads to make Figure 245.
sure that they are installed in the correct positions
on assembly.
L
4. Undo the alternator securing bolts and lift the
alternator away from the cylinder block mounting.
Figure 244.
A
Table 68. Alternator electrical connection torque

Item Torque Value
B
B+ 9 –13 N·m
L 2.7 –3.8 N·m
A Alternator
W 2.7 –3.8 N·m
B Securing bolts
Inspect
1. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 221 9813/8950-2 15 - 221

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 - 222 9813/8950-2 15 - 222

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 - 223 9813/8950-2 15 - 223

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 - 224 9813/8950-2 15 - 224

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-227

15-75-06 Brush Gear ................................................................................................................... 15-235
15 - 225 9813/8950-2 15 - 225

Notes:
15 - 226 9813/8950-2 15 - 226

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-227 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-228 magnet or a series-parallel wound direct current
Component Identification ............................. 15-229 electric motor with a starter solenoid mounted on to
Check (Operation) ....................................... 15-230 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Remove and Install ..................................... 15-232 the solenoid engages a lever that pushes out the
Disassemble and Assemble ........................ 15-233 drive pinion on the starter driveshaft and meshes the
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 - 227 9813/8950-2 15 - 227

15 - Engine
75 - Starter Motor
00 - General
Health and Safety

WARNING Make the machine safe before
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and
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 - 228 9813/8950-2 15 - 228

15 - Engine
75 - Starter Motor
00 - General
Figure 246.
1 Solenoid
2 Brush gear
3 Tie bolts
Figure 247.
A
B
A Solenoid positive terminal (From battery) B Solenoid terminal (From ignition switch)
C Negative terminal (To ground) D Solenoid positive after contact terminal (To
motor)
15 - 229 9813/8950-2 15 - 229

15 - Engine
75 - Starter Motor
00 - General
Check (Operation) Figure 249.
Before carrying out the multimeter tests, check

the battery condition and make sure that all the
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.
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 A Starter main terminal
start position (HS) and the controls set to enable the B Commutator end bracket (Starter earth
starter motor. The readings are shown for both 12 connection)
V and 24 V systems. The highest values are for
machines with 24 V systems. Identify the applicable 2.1. Minimum permissible reading in start
system before carrying out the tests. position
Do not operate the starter motor for more than 20 s Voltage: 9 V

at one time. Let the starter motor cool for at least 2 Voltage: 17 V
min between starts. 2.2. If the reading is within this limit, continue to
3. If the reading is outside the limit, proceed
1. Connect the multimeter across the battery to 4.
terminals.
3. Connect the multimeter between the solenoid
Figure 248. terminal and a good earth. Minimum permissible
reading in start position
Voltage: 8 V
Voltage: 16 V
Figure 250.
1.1. Reading in start position approximately

Voltage: 10 V
Voltage: 20 V
1.2. Minimum permissible reading in start C Solenoid terminal
position
4. If the reading is less than specified, connect
Voltage: 9.5 V
the multimeter between the start relay switched
Voltage: 18 V
output and earth. A fault is indicated with the
1.3. A low reading probably indicates a fault in wiring from the start relay to the solenoid if the
the starter motor. reading increases to
2. Connect the multimeter between the starter main Voltage: 8 V
terminal and the commutator end bracket. In the Voltage: 16 V
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5 V
Voltage: 1 V
15 - 230 9813/8950-2 15 - 230

15 - Engine
75 - Starter Motor
00 - General
Figure 251. 5.1. If the reading is above the maximum

permissible voltage, a high resistance in the
earth lead or connections is indicated.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter
switch off, the voltmeter should indicate battery
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading
Voltage: 0.25 V
Figure 253.
A Starter main terminal

B Starter earth connection
C Solenoid terminal
D Start relay feed
E Start relay switched output
H Battery positive and solenoid connection
4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
and earth.
4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage A Starter main terminal
increases to
Voltage: 8 V 7. If the reading is above the maximum permissible
Voltage: 16 V voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the
4.3. Check also the solenoid earth connection. multimeter between the battery positive and
The fault must be in either the starter switch solenoid connection. If the multimeter now reads
or in the wiring between the solenoid, starter zero with the switch closed, the fault is in the
switch, and the start relay, if the reading solenoid.
between terminal and earth is less than
Figure 254.
Voltage: 8 V
Voltage: 16 V
5. Connect the multimeter between battery
negative and starter earth connection. The
reading in the start position should be practically
zero, maximum permissible reading
Voltage: 0.25 V
Figure 252.
H Battery positive and solenoid connection

8. Finally install the engine stop fuse.
B Starter earth connection
15 - 231 9813/8950-2 15 - 231

15 - Engine
75 - Starter Motor
00 - General

Figure 255. removal procedure. Additionally do the following
steps.
A
E 2. Make sure that the flywheel housing and starter
motor mating faces are clean.
B
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
D A 15 ± 3
C D 47 ± 4
A Electrical lead (Terminal 30) E 3.6 ± .6
B Security cover
C Starter motor
D Bolt (x3)
E Electrical lead (Terminal 50)
Remove
2. Make sure the engine is safe to work on. If the
engine has been running, make sure that the
engine has cooled sufficiently before you start
work.
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.
Inspection
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 - 232 9813/8950-2 15 - 232

15 - Engine
75 - Starter Motor
00 - General
sure the wave washer is installed inside the

These parts are non-serviceable if any part fails, cover.
replace the complete starter motor. For cleaning
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 1.4. Before you install the solenoid make sure
Length/Dimension/Distance: 8 mm you engage the pinion lever arm through
the hole in the solenoid actuator rod, then
1.4. Clean the commutator. tighten the screws.
1.5. Before installing the commutator end 1.5. Reconnect the starter motor cable to the
cover, make sure that the sealing ring is solenoid connector post.
undamaged and correctly installed. Make
15 - 233 9813/8950-2 15 - 233

15 - Engine
75 - Starter Motor
00 - General
Figure 256.
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 - 234 9813/8950-2 15 - 234

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 - 235 9813/8950-2 15 - 235

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-237

15-84-03 Crankshaft Position ...................................................................................................... 15-247
15-84-06 Camshaft Position ........................................................................................................ 15-251
15-84-09 Knock ........................................................................................................................... 15-255
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-258
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-261
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-264
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-267
15-84-19 Exhaust Temperature ................................................................................................... 15-270
15-84-24 Fuel Temperature ......................................................................................................... 15-273
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-276
15-84-33 Coolant Temperature .................................................................................................... 15-279
15-84-42 Engine Oil Temperature ............................................................................................... 15-282
15-84-43 Engine Oil Level ........................................................................................................... 15-285
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-288
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-291
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15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-237 The engine sensors continually send signals to the
Technical Data ............................................. 15-238 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-240 control the smooth running of the engine and related
Fault-Finding ................................................ 15-242 components.
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 - 237 9813/8950-2 15 - 237

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

Sensor (TMAP)
Atmospheric Output voltage +/- V
pressure bar V
Table 70.
( psi)
Crankshaft Position Sensor 0.98 -0.025/ 1.84 0.05
Type Hall effect. +0.025 ( 14.2
-0.4/+0.4 )
Table 71. Table 74.

Camshaft Position Sensor Knock Sensor
Type Hall effect. Type Piezo crystal.
Fixing screw tightening 24 N·m
torque
Table 72.
Fixing screw thread di- M8
Coolant Temperature Sensor ameter
Type Temperature dependant resis-
tance. Table 75.
Tightening 22 N·m max
Throttle Position Sensor (TPS)
(1)
torque
Thread diame- M12 x 1.5. Type Two channel ratio metric
ter voltage output sensor.
Temperature v Resistance Table Supply voltage 5V
Temperature Resistance Ω +/- % Rotational range 75 °
°C ( °F) Output range Linear output voltage
25 ( 77.0 ) 2,062 5.7 over the rotational
range.
50 ( 121.9 ) 833 4.3
(1) The throttle position sensor is not supplied as part
100 ( 211.9 ) 187 2
of the engine assembly. The technical data given is
110 ( 229.8 ) 144 2.4 compatible with the specification required.
Table 76.
Table 73.
Rail Pressure Sensor
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) Type The rail pressure sensor
is integral with the com-
Fixing screw 22 N·m max mon rail.
tightening
torque
Table 77.
Fixing screw M6
thread diameter High Pressure Rail Fuel Valve
Supply voltage 5 V Type The HPV (High Pressure
Temperature Sensor Valve) is integral with
the common rail.
Type Temperature dependant resistor.
Temperature v Resistance Table Table 78.
Temperature Resistance Ω +/- %
Fuel Temperature Sensor
°C ( °F)
Type The fuel temperature
5 ( 41.0 ) 4,707 4.66
sensor is integral with
10 ( 50.0 ) 3,791 4.55 the high pressure fuel
15 ( 59.0 ) 3,075 4.44 pump.
20 ( 68.0 ) 2,510 4.33
25 ( 77.0 ) 2,062 4.22 Table 79.
30 ( 86.0 ) 1,715 4.12 Oil Pressure Switch
Pressure Sensor Set pressure 0.6 bar ( 8.7 psi) falling.
Type Piezo-resistive Switch mode Normally open.
Atmospheric Pressure v Voltage Max pressure 27.5 bar ( 398.5 psi)
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15 - Engine
84 - Sensor
00 - General
Oil Pressure Switch

Max working pressure 13.8 bar ( 200.0 psi)
Tightening torque 23 N·m max.
Thread diameter M12 x 1.5.
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15 - Engine
84 - Sensor
00 - General
Engine Sensors and Actuators
Figure 257.
B
P
F
G
H
J
K
A Coolant temperature sensor (PIL 15-84) B Turbocharger actuator (not installed on 55Kw
engines) (PIL 18-36)
D TMAP (Temperature Manifold Air Pressure) (PIL E Fuel temperature sensor (PIL 15-84)
15-84)
F Fuel inlet metering valve (PIL 18-18) G Camshaft position sensor (PIL 15-84)
H Crankshaft position sensor (PIL 15-84) J Oil temperature sensor (PIL 15-84)
K Oil pressure switch (PIL 15-84) P Inter cooler outlet temperature sensor (PIL
15-84)
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15 - Engine
84 - Sensor
00 - General
Figure 258.
M
C
C Exhaust manifold pressure sensor (PIL 15-84) L Fuel pressure relief valve (HPV) (PIL 15-84)
M EGR (Exhaust Gas Recirculation) actuator (PIL N Exhaust manifold temperature sensor (PIL
18-27) 15-84)
O Oil level switch (optional) (PIL 15-84)
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15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 80. Page 15-242
Water in Fuel Sensor Fault Table 81. Page 15-242
Knock Sensors Table 82. Page 15-243
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 83. Page 15-244
Crankshaft Position Sensor Table 84. Page 15-244
Camshaft Position Sensor Table 85. Page 15-245
TMAF (Temperature and Mass Air Flow) Sensor Table 86. Page 15-246
Table 80. 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 81. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
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15 - Engine
84 - Sensor
00 - General
Cause Remedy
If no faults is found, proceed to ECM connection
fault'.
necessary.
Wiring fault Check the harness continuity and machine and
engine earth contacts. Repair/ replace as necessary.
Table 82. Knock Sensors

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM).
Check the knock sensors connection and screw
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
ECM connection fault Disconnect ECM and inspect. Check seals are in
place, check for signs of corrosion or contamination.
necessary.
Wiring fault Check the harness continuity and electrical
installation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes fault'.
Injector calibration codes fault Check the injector calibration codes recorded in
ECM, if found fault re-enter all injector calibration
codes (read then write) in correct position to reset
learned parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the DTC (Diagnostic
Trouble Code) again with the diagnostic tool. If the
problem is still present, replace the knock sensors.
15 - 243 9813/8950-2 15 - 243

15 - Engine
84 - Sensor
00 - General
Table 83. TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure)
Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM.
If sensor supply voltage is OK, proceed to 'Air inlet
circuit fault'.
Air inlet circuit fault Check the consistency of barometric pressure
reading. Verify the conformity of air inlet circuit:– VGT
(Variable Geometry Turbocharger) / Turbo – Leakage
before VGT / Turbo – Air filter – Valve position using
ServiceMaster – Vane state.
Check all the hose connections for air leaks, repair
as necessary.
necessary.
fault'.
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM
necessary.
If no fault found, raise Techweb Helpdesk call.
Table 84. Crankshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to ECM connection fault'.
15 - 244 9813/8950-2 15 - 244

15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the crankshaft position sensor target wheel if
damaged, replace with a new crankshaft.
If no fault is found raise Techweb Helpdesk call.
Table 85. Camshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to Step 4.
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the Cam target wheel if damaged, replace
with new camshaft.
15 - 245 9813/8950-2 15 - 245

15 - Engine
84 - Sensor
00 - General
Table 86. TMAF (Temperature and Mass Air Flow) Sensor

Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM
If sensor supply voltage is OK, proceed to 'Air inlet
fault'.
Air inlet fault Check all the hose connections for air leaks, repair
as necessary.
If no fault is found proceed to 'Sensor connection
faulty'.
necessary.
Sensor failure If sensor is out of specification replace.
If no faults is found, proceed to Step 5.
necessary.
If no fault is found proceed to Step 6.
If no fault found, raise Techweb Helpdesk call.
15 - 246 9813/8950-2 15 - 246

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

Introduction .................................................. 15-247 The crankshaft position sensor is a device used
Operation ..................................................... 15-248 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-249 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-249 (Engine Control Module) to control the ignition
system timing and other engine parameters.
15 - 247 9813/8950-2 15 - 247

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 259.
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 - 248 9813/8950-2 15 - 248

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

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
2. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
2. Clean the sensor and the adjacent area of the
flywheel housing.
Figure 260.
A
D
C
A Crankshaft position sensor

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

item. If the sensor is defective it must be replaced.
Install
steps.

Item Nm
C 8
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15 - Engine
84 - Sensor
06 - Camshaft Position
06 - Camshaft Position Introduction

Introduction .................................................. 15-251 The camshaft position sensor is a device that detects
Operation ..................................................... 15-252 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-253 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-253 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
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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 261.
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)
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15 - Engine
84 - Sensor
Check (Operation) Remove and Install

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
crankcase.
Figure 262.
A
B
A Camshaft position sensor

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

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

Item Nm
C 8
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15 - Engine
84 - Sensor
09 - Knock
09 - Knock Introduction
Introduction .................................................. 15-255 There are two knock sensors fixed to the side of the
Operation ..................................................... 15-256 crankcase with a centre mounted bolt. One sensor is
Check (Operation) ....................................... 15-256 situated between cylinders 1 and 2, and the second
Remove and Install ..................................... 15-257 is situated between cylinders 3 and 4.
A knock sensor is a device that measures engine

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

the knock sensor detects pinging. At that point the
ECM retards the ignition timing just enough for the
pinging to stop. The knock sensor ensures that you
are getting as much power and fuel economy as
possible from your engine.
Figure 263. Knock sensor locations
A
B
A Knock sensor - cylinders 1 and 2

B Knock sensor - cylinders 3 and 4
15 - 255 9813/8950-2 15 - 255

15 - Engine
84 - Sensor
09 - Knock
Operation Check (Operation)
The knock sensors detect pre-ignition (knock) by 1. For the full inspection and testing procedure,
means of sensing engine vibration. The vibration refer to the help files in ServiceMaster.
signal is sent to the engine ECM (Engine Control
Module)where the ECM will adjust the fuel timing to
give optimum performance, economy and driveability
and prevent engine damage. The voltage signal is
proportional to engine vibration/acceleration.
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15 - Engine
84 - Sensor
09 - Knock
Remove and Install 3. Tighten the bolt to the correct torque value.
Torque: 22 –26 N·m
The following procedure is for one knock sensor. The
procedure for both sensors is identical.
Before Removal
Remove
2. Disconnect the electrical connector at the knock
sensor.
3. Remove the bolt and remove the knock sensor
from the crankcase.
The knock sensor is a non-serviceable item. If the

sensor is defective it must be replaced.
Figure 264.
B C
A Knock sensor
C Bolt
Install
steps.
2. Make sure that the sensor mates fully with the
adjacent face on the crankcase.
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15 - Engine
84 - Sensor
14 - Exhaust Manifold Temperature
14 - Exhaust Manifold Temperature Introduction

Introduction .................................................. 15-258 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-259 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-259 cylinder 3 and 4 exhaust outlet ports.
Figure 265. Exhaust manifold
temperature sensor location
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15 - Engine
84 - Sensor
The exhaust manifold temperature sensor measures For the full inspection and testing procedure, refer to
the exhaust gas temperature from the engine, before the help files in ServiceMaster.
it reaches the turbocharger. The analogue voltage
signal is 1 –4.5 V.
15 - 259 9813/8950-2 15 - 259

15 - Engine
84 - Sensor
Remove and Install

Special Tools
Deep Socket 892/12351 1
Before Removal
Figure 266.
A
N
A Exhaust manifold temperature sensor
Remove
2. Disconnect the electrical connector at the
exhaust manifold temperature sensor.
3. Use the special tool to remove the sensor from
the exhaust manifold.
Special Tool: Deep Socket (Qty.: 1)
4. Discard the sealing washer.
The exhaust manifold temperature sensor is a non-

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

Item Nm
N 45
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15 - Engine
84 - Sensor
16 - Exhaust Manifold Pressure
16 - Exhaust Manifold Pressure Introduction

Introduction .................................................. 15-261 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-262 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-262 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-263 (Engine Control Module) Controlled engine.
The sensor is mounted in the rear section of the

rocker cover.
Figure 267.
C Exhaust manifold pressure sensor
15 - 261 9813/8950-2 15 - 261

15 - Engine
84 - Sensor
The exhaust manifold pressure sensor informs 1. For the full inspection and testing procedure,
the ECM (Engine Control Module) of the exhaust refer to the help files in ServiceMaster.
manifold pressure. To attain an 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 in the corner of the rocker
cover where the sensor is screwed directly into the
pressure path.
The sensor produces an analogue signal from 1

–4.5 V which informs the ECM of the exhaust
manifold pressure. The voltage output proportional to
pressure is 0.5 –4.5 V.
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15 - Engine
84 - Sensor
Remove and Install 3. Use the special tool to tighten the exhaust
manifold pressure sensor to the correct torque
Special Tools value.
Item Nm
Before Removal 1 22.5

Figure 268.
P1
1 Exhaust manifold pressure sensor

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

it must be renewed.
Install
steps.
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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 .................................................. 15-264 sensor is mounted in a port on top of the inlet
Operation ..................................................... 15-265 manifold. It measures the inlet manifold boost air
Check (Operation) ....................................... 15-265 pressure and temperature. The sensor incorporates
a piezo-resistive element and resistor.
Figure 269.
D TMAPsensor
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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.
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15 - Engine
84 - Sensor
Remove and Install 3. Carefully push the sensor into its location bore in
the inlet manifold. Do not use excessive force.
Before Removal
1. Make sure that the engine is safe to work on. If Table 91. Torque Values
the engine has been running, let it cool before Item Nm
you start the service work. C 3.3
inlet manifold.
Figure 270.
A
C B
D
A TMAP (Temperature Manifold Air Pressure)
C Bolt
D O-ring seal
Remove
3. Remove the bolt.
4. Remove the sensor from the inlet manifold
together with O-ring.
The TMAP sensor is a non-serviceable item. If the

sensor is defective, it must be replaced.
Install
steps.
2. Make sure that the sealing O-ring is correctly
installed.
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15 - Engine
84 - Sensor
18 - Temperature and Mass Air Flow (TMAF)
18 - Temperature and Mass Air Introduction

Flow (TMAF)
The TMAF (Temperature and Mass Air Flow) sensor
Introduction .................................................. 15-267 measures the amount of air coming in to the engine
Operation ..................................................... 15-268 and the air temperature. It is mounted between the
Check (Operation) ....................................... 15-268 air filter and turbo charger.
Remove and Install ..................................... 15-269 Figure 271.
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15 - Engine
84 - Sensor
The TMAF (Temperature and Mass Air Flow) sensor Faults relating to the TMAF (Temperature and Mass
produces a digital signal measuring air flow, and an Air Flow) will normally be reported by the fault codes.
analogue signal measuring inlet air temperature.
1. Remove contamination from the sensor. Do not
touch the air flow sensor area or temperature
sensor area.
2. Carefully inspect the sensor. If it is defective,
replace it.
replace it.
Figure 272.
1 Air flow sensor area

2 Temperature sensor area
15 - 268 9813/8950-2 15 - 268

15 - Engine
84 - Sensor

Do not install a TMAF sensor which has been
Before Removal dropped or damaged. Replace it with a new one.
1. Make sure that the engine is safe to work on. If 1. The installation procedure is the opposite of the
the engine has been running, let it cool before removal procedure. Additionally do the following
you start the service work. step.
2. Get access to the TMAF (Temperature and Mass 2. Tighten the screws to the correct torque value.
Air Flow) sensor
3. Clean the area around the sensor to prevent
Item Nm
contamination entering the engine.
2 5
Remove
Figure 273.
1 2
3
2 Screws (x2)
3 TMAF sensor
1. Disconnect the electrical connector. Do not touch
the connector pins.
2. Remove the screws (x2) which secure the TMAF
sensor to the air intake hose.
3. Remove the TMAF sensor together with the O-
ring from the air intake hose. Do not touch the air
flow sensor area or temperature sensor area.
Figure 274.
1 Air flow temperature sensor area

2 Temperature sensor area
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15 - Engine
84 - Sensor
19 - Exhaust Temperature
19 - Exhaust Temperature Introduction

Introduction .................................................. 15-270 The exhaust temperature sensor is located in the
Operation ..................................................... 15-271 exhaust system just before the SCR (Selective
Check (Operation) ....................................... 15-271 Catalytic Reduction) catalyst.
15 - 270 9813/8950-2 15 - 270

15 - Engine
84 - Sensor
The exhaust temperature sensor measures the Make sure that the engine is safe to work on. If the
exhaust gas temperature just before it reaches the engine has been running, let it cool before you start
SCR (Selective Catalytic Reduction) catalyst. The the service work.
analogue voltage signal is 0 - 5 V
The resistance values specified are correct at 20 °C
( 68.0 °F).
1. Disconnect the electrical connector from the

exhaust temperature sensor.
2. Switch the ignition on.
3. Connect the multimeter across the harness pins.
3.1. Measure the voltage, the reading should be:
Voltage: 5 V
3.2. If the reading is correct, proceed to 4
3.3. If the reading is not correct, check the
harness between the sensor and the DCU
(Dosing Control Unit) for continuity.
3.4. Check the electrical connectors for integrity
and contamination.
4. Connect the multimeter across the sensor pins.
4.1. Measure the resistance, the reading should
be:
Resistance: 24,560 ± 1,228 Ω
4.2. If the resistance is not within tolerance, the
sensor is faulty and must be replaced.
5. Connect the electrical connector to the exhaust
temperature sensor.
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15 - Engine
84 - Sensor
Remove and Install 3. Remove the sensor from the exhaust, take care
not to damage the sensor probe.
Consumables
Description Part No. Size The exhaust temperature sensor is a non-
Graphite/Calcium 4004/7545 -
it must be replaced.
Fluoride Based Metal
Free Anti-Seize
Compound Install
Before Removal removal procedure. Additionally do the following
steps.
the engine has been running, let it cool before 2. Apply anti-seize compound to the threads of the
you start the service work. retaining nut. Make sure the correct anti-seize
compound is used to prevent damage to the SCR
2. Get access to the exhaust temperature sensor. (Selective Catalytic Reduction) system.
Remove Consumable: Graphite/Calcium Fluoride Based

Metal Free Anti-Seize Compound
Figure 275.
3. Tighten the retaining screw to the correct torque
value.

Item Nm
2 44
2
1
1 Exhaust temperature sensor

2 Retaining nut
1. Disconnect the electrical connector.
2. Undo the retaining screw.
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15 - Engine
84 - Sensor
24 - Fuel Temperature
24 - Fuel Temperature Introduction

Introduction .................................................. 15-273 The fuel temperature sensor is an integral part of
Operation ..................................................... 15-274 the fuel injection high pressure pump, refer to (PIL
Check (Operation) ....................................... 15-274 18-18).
Figure 276.
E Fuel temperature sensor
15 - 273 9813/8950-2 15 - 273

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 - 274 9813/8950-2 15 - 274

15 - Engine
84 - Sensor
Remove and Install
This part is a non-serviceable component, if it is

defective, replace the fuel injection high pressure
pump. Refer to: PIL 18-18-15.
15 - 275 9813/8950-2 15 - 275

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

Introduction .................................................. 15-276 The HPV (High Pressure Valve) is an integral part
Operation ..................................................... 15-277 of the common fuel rail assembly, If the valve
Check (Operation) ....................................... 15-277 is defective replace the complete common rail
Remove and Install ..................................... 15-278 assembly. (Refer to PIL 18-18).
Figure 277. High pressure valve location
Figure 278.
A HPV
B Solenoid coil
15 - 276 9813/8950-2 15 - 276

15 - Engine
84 - Sensor
In certain operating conditions, the HPV (High For the full inspection and testing procedure, refer to
Pressure Valve) controls the fuel pressure inside the the help files in ServiceMaster.
common rail.
When the valve opens, fuel is bled from the rail back
to the fuel tank, reducing the fuel pressure inside the
fuel rail. The valve is actuated by a solenoid coil and
features proportional control. The fuel flow through
the valve is proportional to the current supplied to
the coil. The current value is controlled by the ECM
(Engine Control Module) using PWM (Pulse Width
Modulation).
During normal engine operation, the fuel pressure is

controlled solely by the IMV (Inlet Metering Valve),
refer to (PIL 18-18).
In some operating circumstances, the IMV is unable

to alter the fuel pressure in the common rail quickly
enough. At these times, the ECM activates the HPV.
Typically the valve is used in the following conditions:
• Extreme transients, for example if the operator

goes from full throttle to no throttle quickly.
• When the fuel is cold.
In the event of an IMV failure, the ECM compensates

by altering the control of the HPV to ensure the
engine performance is sufficient to limp home.
15 - 277 9813/8950-2 15 - 277

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 - 278 9813/8950-2 15 - 278

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

Introduction .................................................. 15-279 The coolant temperature sensor is located on the
Operation ..................................................... 15-280 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-280
A
A Coolant temperature sensor
15 - 279 9813/8950-2 15 - 279

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 - 280 9813/8950-2 15 - 280

15 - Engine
84 - Sensor
Remove and Install Table 94. Torque Values

Item Nm
1 16
Before Removal
2. Drain the coolant, refer to (PIL 21-00).
Figure 280.
1
P1
1 Coolant temperature sensor

P1 Sealing washer
Remove
3. Remove the sensor from the cylinder head.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The coolant temperature sensor unit is a non-

serviceable item. If the switch is faulty or damaged it
must be renewed.
Install
steps.
3. Tighten the coolant temperature sensor to the
4. Refill the cooling system with the recommended
coolant mixture, refer to Technical Data (PIL
21-00).
5. Start the engine and check for coolant leaks.
15 - 281 9813/8950-2 15 - 281

15 - Engine
84 - Sensor
42 - Engine Oil Temperature
42 - Engine Oil Temperature Introduction

Introduction .................................................. 15-282 The engine oil temperature sensor is mounted in a
Operation ..................................................... 15-283 port on the oil cooler housing adjacent to the engine
Check (Operation) ....................................... 15-283 oil dipstick.
Figure 281. Engine oil tem-
perature sensor location
A Engine oil temperature sensor
15 - 282 9813/8950-2 15 - 282

15 - Engine
84 - Sensor
The oil temperature sensor informs the ECM (Engine 1. For the full inspection and testing procedure,
Control Module) of the engine oil temperature. The refer to the help files in ServiceMaster.
ECM processes the signal to determine the oil
temperature. The ECM adjusts the fuel delivery.
15 - 283 9813/8950-2 15 - 283

15 - Engine
84 - Sensor

Item Nm
Special Tools
Description Part No. Qty. 1 21
Before Removal
Figure 282.
B
A Sealing washer
B Engine oil temperature sensor
Remove
2. Disconnect the electrical connector at the engine
oil temperature sensor.
the oil cooler housing.
ingress of dirt.
The engine oil temperature sensor is a non-

it must be renewed.
Install
steps.
3. Use the special tool to tighten the engine oil
temperature sensor to the correct torque value.
15 - 284 9813/8950-2 15 - 284

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

Introduction .................................................. 15-285 The engine oil level sensor is used to warn the
Operation ..................................................... 15-286 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-286 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-287 mounted on the engine oil sump.
15 - 285 9813/8950-2 15 - 285

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 - 286 9813/8950-2 15 - 286

15 - Engine
84 - Sensor
Remove and Install
Before Removal
1. Ensure that the engine is safe to work on. If the
engine has been running, make sure the engine
has cooled sufficiently before you start.
Figure 283.
A
C
B
D
E
1 Engine oil level sensor 2 Oil sump
Remove
2. Disconnect the electrical connector at the engine
oil level sensor.
ingress of dirt.
The engine oil level sensor is a non-serviceable item.

If the sensor is faulty or damaged it must be renewed.
Install
1. Replacement is the reversal of the removal
procedure.
2. Install a new sealing washer.
3. Tighten the engine oil level sensor to the correct
torque value.

Item Nm
1 16
15 - 287 9813/8950-2 15 - 287

15 - Engine
84 - Sensor
48 - Intercooler Outlet Temperature
48 - Intercooler Outlet Temperature Introduction

Introduction .................................................. 15-288 The intercooler outlet sensor is located in the air
Operation ..................................................... 15-289 intake on the inlet manifold.
Check (Operation) ....................................... 15-289
P Intercooler outlet sensor
15 - 288 9813/8950-2 15 - 288

15 - Engine
84 - Sensor
The intercooler outlet sensor measures the 1. For the full inspection and testing procedure,
temperature of the air coming from the intercooler refer to the help files in ServiceMaster.
into the inlet manifold. The sensor sends an
analogue voltage signal to the ECM (Engine Control
Module).
15 - 289 9813/8950-2 15 - 289

15 - Engine
84 - Sensor
Remove and Install
Before Removal
Figure 285.
A Intercooler outlet temperature sensor
Remove
3. Remove the sensor from the air intake.
4. Cap the open port with a blanking cap to prevent
dirt ingress.
Install
step.
2. Tighten the sensor to the correct torque value.

Item Nm
A 8.5
15 - 290 9813/8950-2 15 - 290

15 - Engine
84 - Sensor
51 - Nitrogen Oxide (NOx)
51 - Nitrogen Oxide (NOx) Introduction

Introduction .................................................. 15-291
Operation ..................................................... 15-292
Introduction
Remove and Install ..................................... 15-293 Reaction of nitrogen and oxygen gases in the air
during combustion, especially at high temperatures
causes the NOx (Nitrogen Oxide) emission from the
exhaust system.
To monitor the NOx emission, two NOx sensors are

installed on the exhaust system. One is the upstream
NOx sensor and another is downstream NOx sensor.
The Upstream NOx sensor is installed before the
SCR (Selective Catalytic Reduction) catalyst and it
measures NOx level in the exhaust gases before
the after-treatment system. The downstream NOx
sensor is installed after the SCR catalyst and it
measures NOx level in the exhaust outlet.
Figure 286.
P
B
C
A D
P
F
K E L M N
G H J
A DEF (Diesel Exhaust Fluid) system control unit-
ECM (Engine Control Module) or a separate
ECU (Electronic Control Unit)
B Supply module (SM)- pump, filter and valves
C DEF tank- tank, tank level sensor and heating
device (with or without DEF quality sensor)
D Engine coolant connections – used to defrost
DEF
E Dosing module– DEF injector nozzle
F Engine coolant connections – for nozzle cooling
G Diesel Oxidation Catalyst (DOC) – Not installed
on all systems
H Mixer
J SCR
K NOx sensor - Upstream
L Upstream catalyst temperature sensor
M Downstream catalyst temperature sensor
N NOx sensor - Downstream
P DEF lines (inlet, pressure and return) – usually
heated by electric elements or engine coolant
15 - 291 9813/8950-2 15 - 291

15 - Engine
84 - Sensor
Operation
NOx (Nitrogen Oxide) sensors are similar to The NOx sensors will not work unless they are at
wideband oxygen sensors, but typically have their the correct temperature, so they have an integrated
own control module that communicates with the heater that is also module controlled. The power
SCR (Selective Catalytic Reduction) ECU (Electronic supply to the NOx sensor control module is critical
Control Unit) over a CAN (Controller Area Network) for proper sensor operation.
bus.
During a cold start, moisture in the exhaust system
Two NOx sensors are used: can interfere with the NOx sensor operation. In
this scenario, the ECU will not turn on the NOx
• Upstream sensor at the Turbocharger exhaust sensor heaters until the exhaust temperatures reach
outlet. a certain threshold and condensed moisture is
• Downstream sensor from the SCR catalyst. evaporated. This can result in a delay of up to 5 min
before both NOx sensors are fully operational.
These two signals are then compared to determine
the conversion efficiency of the catalyst.
Figure 287.
G E
C H
J
F C
K
A O2 B NOx
C O and O2 D N
E NOx sensor body F First chamber
G Nerst cell 1 H Second chamber
J Catalytic element K Nerst cell 2
Diesel NOx sensors are of dual-purpose. They are catalytic element, which breaks them into nitrogen
used to measure both the oxygen level in the and oxygen gases.
exhaust as well as NOx (NO and NO2) content.
The measurements take place in two separate A second Nerst cell is then used to pump the newly
chambers in the sensor, and the exhaust gases flow generated oxygen out of the chamber, and this
sequentially through one and then into the other. electric current is used to calculate the NOx levels in
the exhaust. The residual nitrogen gases then flow
Gases flow from the exhaust stream through a out an exit port in the second measurement chamber.
diffusion barrier to reach the first chamber, which
pumps the free oxygen out using a Nerst cell (simple When two NOx sensors are in a urea SCR system,
oxygen sensor). The electric current for operating the upstream sensor is used to estimate what
this first Nerst cell is used to measure the exhaust amount of DEF (Diesel Exhaust Fluid) needs to be
oxygen content. injected ahead of the SCR catalyst to achieve optimal
NOx conversion. The downstream (post-catalyst)
With the free oxygen removed, the NOx is then sensor is then used to check the results.
left to pass through another diffusion barrier and
into the second measurement chamber. At this
point, the NOx molecules come into contact with a
15 - 292 9813/8950-2 15 - 292

15 - Engine
84 - Sensor
Remove and Install Remove

Consumables Figure 288.
Graphite/Calcium 4004/7545 -
Fluoride Based Metal
Free Anti-Seize
Compound
NOx (Nitrogen Oxide) sensors are extremely 4

delicate. Care must be taken to avoid knocks and
impacts which can damage the sensor. Do not
touch the tip of the sensor, doing so can prevent it
from functioning correctly. The NOx sensor and the
sensor control unit are permanently connected, do
not attempt to disconnect the harness as damage will
be caused. 1
Before Removal
the engine has been running, let it cool before 2
2. Get access to the NOx sensor.
3. Ensure that the area around the NOx sensor
is clean to prevent contamination of the SCR
(Selective Catalytic Reduction) system. 3
1 NOx sensor
2 Harness support bracket
3 NOx sensor retaining nut
4 Cable tie
15 - 293 9813/8950-2 15 - 293

15 - Engine
84 - Sensor
Figure 289. Tighten the retaining nut to the correct torque

value.
7
5. Install the harness support bracket around the
NOx sensor.
6. Install the Sensor control unit.
6
6.1. Install the bolts (x2) finger tight to minimise
the strain on the harness.
6.2. Tighten the bolts to the correct torque value.
6.3. Connect the electrical connector.
7. Install the new cable ties around the harness
support brackets.
8. Install any additional supports and clips.

5
Item Nm
3 70
5 Electrical connector 7 10
6 Sensor control unit
7 Bolts
Sensor control unit.
2. Remove the cable ties from the harness support
brackets.
3. Remove the bolts (x2) that secure the Sensor
control unit to the machine.
4. Remove the harness support bracket.
5. Remove the NOx sensor retaining nut.
6. Remove any additional supports or clips.
7. Remove the NOx sensor and the Sensor control
unit from the machine.
Install
1. Inspect the sensor for signs of damage. Pay
particular attention to the mating faces of the
sensor and exhaust system. Clean off any oil
or corrosion. Make sure that the faces are flat,
smooth and free from damage.
2. Replace the NOx sensor sealing washer.
3. Apply anti-seize compound to the threads of the
retaining nut. Make sure the correct anti-seize
compound is used to prevent damage to the SCR
system.
Consumable: Graphite/Calcium Fluoride Based
Metal Free Anti-Seize Compound
4. Carefully insert the NOx sensor into the exhaust
system. Make sure that it is seated correctly.
15 - 294 9813/8950-2 15 - 294

15 - Engine
86 - Solenoid
86 - Solenoid
Contents Page No.
15-86-00 General ......................................................................................................................... 15-297
15 - 295 9813/8950-2 15 - 295

Notes:
15 - 296 9813/8950-2 15 - 296

15 - Engine
86 - Solenoid
00 - General
00 - General
Introduction
A solenoid refers to a variety of transducer devices

that convert energy into linear motion. The term also
refers to a solenoid valve, which is an integrated
device containing an electromechanical solenoid
which actuates a hydraulic valve, or a solenoid
switch.
15 - 297 9813/8950-2 15 - 297

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-00 General ......................................................................................................................... 15-299

15-87-03 Engine Oil Pressure ..................................................................................................... 15-300
15 - 298 9813/8950-2 15 - 298

15 - Engine
87 - Switch
00 - General
00 - General
Introduction
The engine electrical switches send signals to the

ECM (Engine Control Module) to help the ECM
to control the smooth running of the engine and
related components. The ECM processes signals
from the switches and its response will be based
on an evaluation of the combination of the switches
signals.
After removal from the engine, protect the switches

from knocks, dampness and any high temperature
sources. The switches are not serviceable, therefore
they must be replaced in the event of damage.
15 - 299 9813/8950-2 15 - 299

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

Introduction .................................................. 15-300 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-301 oil cooler housing.
Check (Operation) ....................................... 15-301
A
A Engine oil pressure switch
15 - 300 9813/8950-2 15 - 300

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 - 301 9813/8950-2 15 - 301

15 - Engine
87 - Switch
Remove and Install
Before Removal
Remove
engine oil pressure switch.
3. Remove the switch.
4. Discard the sealing washer. Plug all the open
ports and hoses to prevent contamination.
The engine oil pressure switch is a non-serviceable

item. If the switch is faulty or damaged it must be
renewed.
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the
Torque: 16 N·m
15 - 302 9813/8950-2 15 - 302

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-305
15 - 303 9813/8950-2 15 - 303

Notes:
15 - 304 9813/8950-2 15 - 304

15 - Engine
90 - Air Intake
00 - General
00 - General
Check (Condition)
15 - 305 9813/8950-2 15 - 305

Notes:
15 - 306 9813/8950-2 15 - 306

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-17
18-09 Filter
18-09-00 General ........................................................................................................................... 18-23
18-09-09 Pre-Filter Element .......................................................................................................... 18-28
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-31
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-33
18-18 Injection
18-18-00 General ........................................................................................................................... 18-35
18-18-03 Injector ............................................................................................................................ 18-50
18-18-07 Injector Seal ................................................................................................................... 18-55
18-18-12 Rail ................................................................................................................................. 18-57
18-18-15 Pump .............................................................................................................................. 18-59
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-67
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-75
18-24-03 Inlet Manifold .................................................................................................................. 18-77
18-24-04 Outlet Manifold ............................................................................................................... 18-81
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-87
18-27-03 Actuator .......................................................................................................................... 18-94
18-35 Turbocharger
18-35-00 General ........................................................................................................................... 18-97
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-105
18-96-03 High Pressure Pipe ...................................................................................................... 18-108
18-96-06 Low Pressure Pipe ....................................................................................................... 18-111
9813/8950-2
2018-02-21
Acronyms Glossary

DEF Diesel Exhaust Fluid
NOx Nitrogen Oxide
VGT Variable Geometry Turbocharger
WIF Water in Fuel
9813/8950-2
2018-02-21
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/8950-2 18 - 1
Notes:
18 - 2 9813/8950-2 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for
Health and Safety ........................................... 18-4 engine damage due to the use of incorrect or
Technical Data ................................................. 18-4 contaminated fuel is much greater with common
Component Identification ................................. 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Operation ......................................................... 18-6 and cleanliness requirements, refer to Consumable
Fault-Finding .................................................... 18-9 Products Refer to: PIL 75-00-00. Technical Data,
Discharge and Pressurise ............................. 18-11 Fuel, Acceptable and Unacceptable Fuels and
Clean ............................................................. 18-11 Cleanliness Requirements.
Check (Pressure) .......................................... 18-13 For information about the fuel injection system. Refer
Bleed ............................................................. 18-15 to: PIL 18-18.
Common Rail Fuel Injection

The common rail fuel injection system enables
the following advantages when compared with
mechanical direct injection systems:
• Reduced engine noise.

• Reduced polluting emissions.
• Increased engine performance, higher torque at
lower engine speeds in particular.
Unlike mechanical direct injection systems, common

rail systems employ electrically operated computer
controlled fuel injectors. The high pressure fuel
injection pump no longer controls the point of
injection but continually supplies pressurised fuel to
a common fuel rail.
The injectors are connected to the common rail and

inject fuel when supplied with electrical signals from
the ECM (Engine Control Module).
Several electrical sensors supply the ECM with

engine operating parameters such as engine speed,
engine phase (firing order), engine temperature,
inlet manifold air pressure and temperature, throttle
position etc. Software in the ECM memory is used
to interpret the data from the sensors and the fuel
injection characteristics are adjusted accordingly.
Prevention of fuel system contamination is even

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9813/8950-2 18 - 3
00 - General
Health and Safety Technical Data

Fuel Table 99. Fuel System Data
Fuel is flammable, keep naked flames away from the
High pressure pump Delphi DFP 4.2
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 Anti-clockwise
engine running. Completely wipe off any spilt fuel drive end
which could cause a fire. There could be a fire and Fuel lift pump type Electrically operated
injury if you do not follow these precautions. Fuel filter micron rating
Fluid Under Pressure Pre-filter 5 micron
Fine jets of fluid at high pressure can penetrate the Main filter 2 micron
skin. Keep face and hands well clear of fluid under Fuel filter restriction - 0.65 bar ( 9.4 psi)
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Fuel return restriction - 0.22 bar ( 3.2 psi)
leaks and then examine the cardboard for signs of maximum
fluid. If fluid penetrates your skin, get medical help Injector information Electronically controlled
immediately. solenoid actuated in-
WARNING! Do not open the high pressure fuel jectors. Each injector is
system with the engine running. Engine operation marked with a unique
causes high fuel pressure. High pressure fuel spray calibration code.
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the
system could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
accordance with local regulations. Use authorised
18 - 4 9813/8950-2 18 - 4
00 - General
Figure 291.
3
2
15
A
6 6 6 6
14
13
1 16
1 ECM (Engine Control Module)(refer to PIL 2 High pressure fuel injection pump (refer to PIL
33-45) 18-18)
3 Common fuel rail (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
13 Fuel filter (2 micron) (refer to PIL 18-09) 14 Fuel pre-filter and water separator (5 micron)
(refer to PIL 18-12)
15 Electric feed pump (refer to PIL 18-21) A Electrical sensors (refer to PIL 15-84)
B Fuel tank (refer to PIL 18-03)
18 - 5 9813/8950-2 18 - 5
00 - General
Operation
Some fuel flows through the pump at all times to

The fuel system is central to the performance and provide internal lubrication and cooling. This fuel
efficiency of the engine, distributing an accurate bleeds back to tank via the bleed-off fuel lines.
amount of fuel to each cylinder at exactly the right
time. Pressurised fuel from the high pressure pump
passes into the common fuel rail. The high pressure
Fuel is drawn from the fuel tank by the electric pump is capable of pressurising the fuel in the rail
lift pump integral via the 5 micron pre-filter/water up to 2000 bar. The ECM controlled IMV is used to
separator. (The fuel lift pump is integral with the pre- control the amount, and therefore pressure of the fuel
filter/water separator assembly.) in the common rail.
Fuel is pressurised at low pressure by the electric In some operating conditions the inlet metering valve
lift pump and passes through an engine mounted 2 is not able to reduce the rail pressure quickly enough
micron fuel filter on its way to the inlet on the high (if the operator goes from full throttle to no throttle
pressure pump. suddenly for example). In these circumstances the
rail pressure is dumped to the bleed off line using the
Important: Use of the correct fuel grade, together ECM controlled electric HPV (High Pressure Valve).
with effective filtration and decontamination of the
fuel is essential. The high pressure pump, injectors High pressure fuel pipes connect the injectors to
and engine can be damaged beyond repair by the common fuel rail. The injectors are electrically
contaminated fuel or use of incorrect fuel. controlled and incorporate a small solenoid valve.
The high pressure fuel injection pump is a rotary type Injection timing is determined by the ECM. Electrical
and is gear driven by the engine. The pump consists data from several sensors is continually monitored
of two sections, the transfer pump and high pressure and processed by the ECM to determine when, how
pump. Fuel is first pressurised to about 6 bar by the much and to which cylinder fuel must be injected.
transfer pump. A constant pressure is maintained
regardless of engine speed by the regulating valve. The injectors inject fuel in response to a supply
of electrical current from the ECM. So precise is
Fuel is transferred to the high pressure pump via the control that several injections of fuel occur
the IMV (Inlet Metering Valve). The metering valve during each firing stroke for maximum efficiency and
controls the amount of fuel transferred depending on minimum emissions. During fuel injection some fuel
the engine operating parameters (throttle position, bleeds off the injectors and back to tank via bleed off
coolant temperature etc.). The metering valve is lines.
controlled by the ECM (Engine Control Module).
18 - 6 9813/8950-2 18 - 6
00 - General
Figure 292.
2b
2e 2
2c 2d
3b
3
5 4
15
6 6 6 6
14
16
13
1 ECM 2 Fuel high pressure pump

2b IMV 2c Fuel high pressure pump (transfer section)
18 - 7 9813/8950-2 18 - 7
00 - General
2d Fuel high pressure pump (high pressure 2e Pressure regulating valve (transfer section)
section)
3 Common fuel rail 3b HPV
4 High pressure fuel lines 5 Bleed off fuel lines
6 Fuel injectors 13 Fuel filter
14 Pre-filter/water separator 15 Electric fuel lift pump
16 Fuel tank
Table 100. Colour code key

Colour Component
Green Tank pressure
Blue Transfer pressure
Red Injection rail pressure
Yellow Electrical connections
-ECM - injectors
Light Green Pump internal pressure,
injector bleed-off
18 - 8 9813/8950-2 18 - 8
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 101. Page 18-9
Fuel/Oil- Leaking from Exhaust Manifold Table 102. Page 18-9
General Fuel System Faults Table 103. Page 18-10
Exhaust Gas Recirculation Table 104. Page 18-10
Table 101. Fuel Consumption Excessive

Cause Remedy
Additional load on engine. Check/repair accessories and vehicle components.
Refer to the equipment manufacturer's procedures.
Operator technique. Review operation for correct gear shifts, deceleration
and idling.
Fuel leaks. Check for external leaks at the fuel tank, fuel lines,
filters and lift pump WARNING: Do not repair
defective fuel lines. If there is a fuel leak remove and
discard the necessary components and install new
ones.
Air intake or exhaust leaks.
ECM (Engine Control Module)or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
clearances.
Table 102. Fuel/Oil- Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Review operation for correct gear shifts, deceleration
conditions. and idling.
Air intake or exhaust leaks.
Turbocharger lubricating oil drain line obstructed. Check/clean line.
Exhaust leak at the Manifold or Turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Check for a cracked manifold.
Valve guide seals are leaking. Replace valve guide stem seals as required.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
18 - 9 9813/8950-2 18 - 9
00 - General
Table 103. General Fuel System Faults

Cause Remedy
Fuel supply fault Check the low pressure circuit connections are
secure.
Check the fuel pressure in low circuit/tank level.
Check the fuel type (EN590 Specification).
Check for the external diesel fuel leaks.
Check the filter is not blocked
Check the fuel lift pump operation (Refer to
ServiceMaster help files).
Replace/repair as necessary.
If no faults are found, proceed to "Engine does not
start," or "Engine starts," depending on symptoms
Engine does not start Complete the ‘Static Injector Leak Test’.
If the injector back leak is above the limit, replace
injector(s) as necessary.
If the injector back leak is OK check the rail pressure
is above 300 bar, if not, replace the high pressure
pump.
If the rail pressure is OK and back leak is within
limits, raise Techweb Helpdesk Call.
Engine starts Complete the ‘Dynamic IMV (Inlet Metering Valve)
Test’.
If the IMV is faulty replace the high pressure pump.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
injector(s).
If the back leak is OK complete the ‘Dynamic HPV
(High Pressure Valve) test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 104. Exhaust Gas Recirculation

Cause Remedy
Air inlet circuit fault Check the air inlet circuit: – Valve position using
ServiceMaster – Check the EGR (Exhaust Gas
Recirculation) linkage – Vane state
If no fault is found proceed to 'EGR valve connection
fault'.
EGR valve connection fault Check the EGR valve connection. Check that the
supply voltage is correct. Repair as necessary.
Check that the EGR valve position can reach MIN
(0%) to MAX position (100%). Use ServiceMaster to
launch the learning procedure of the EGR position.
18 - 10 9813/8950-2 18 - 10
00 - General
Discharge and Pressurise Clean

Notice: Running the engine with air in the
system could damage the fuel injection pump. Cleanliness Requirements
After maintenance, the system must be bled to
remove any air. Important: Additional cleaning must be carried out
prior to working on the high pressure fuel system.
Obey all fuel system health and safety information. It is extremely important the high pressure fuel
Refer to (PIL 18-00). components and the adjacent parts of the engine
are meticulously cleaned before any components are
The entry of air into the fuel system can cause removed. Refer to: Effects of Contamination.
problems such as difficult engine starting and
unstable engine running. Air can enter the system if Before starting work on the high pressure fuel
the following occurs: system, make sure that the working environment
is suitable. Refer to: Maintenance Environment,
• A fuel system component has been Common Rail Fuel Injection.
disconnected. For example, a fuel filter renewal.
• A leak in the low pressure side of the fuel 1. Obey all fuel system health and safety
system during engine operation, or the low information.
pressure pipes have been disconnected. Refer Refer to: PIL 18-00-00.
to Fuel System - General (PIL 18-00) for a more
detailed description of the fuel circuit. 2. Clean the machine, prior to completing any
• The fuel tank is allowed to drain fully during maintenance work.
normal operation.
3. Clean the engine.
The engine installation features an electrically Refer to: PIL 15-00-00.
operated fuel lift pump. The system is designed to
bleed automatically when the lift pump is operated. 4. Remove the hoses, electrical harnesses and
Make sure that as much air is removed from the fuel ancillaries to improve access and expose any
as possible before you start the engine. Bleed the remaining trapped dirt close to the relevant high
system as follows: pressure components.
Important: DO NOT attempt to bleed the high 5. Wash away any remaining dirt or debris and then
pressure fuel system by loosening the high pressure dry the area using a compressed air jet. When
pipe connections even when the engine is not the area is dry use a soft clean brush to remove
running. To bleed the fuel system follow the correct sand or grit particles that remain.
procedure.
Effects of Contamination
1. Turn on the machine ignition switch to start the
fuel lift pump. DO NOT start the engine. Allow the Whist the requirement for a good level of cleanliness
pump to run for 30 seconds. is well known and common practice, the introduction
of high pressure common rail fuel injection
2. Turn off the machine ignition switch to stop the
necessitates working to new levels of cleanliness.
fuel lift pump. Wait 10 seconds and then turn the
ignition switch to start the pump. DO NOT start Once inside the system, fuel circuit contaminants
the engine. Allow the pump to run for 30 seconds. greatly affect the performance and life of the fuel
3. Repeat step 2 twice more before you start the injection equipment. For example, contaminants in
engine. the fuel pump will develop internal wear to cause
internal leakage and hence lower discharges. Use
4. Start the engine and make sure it runs smoothly. of poor quality fuels and poor maintenance could
also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment
failure if debris should prevent the injectors from fully
closing. The main contaminants can be classified as
follows:
• Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 11 9813/8950-2 18 - 11
00 - General
• Gases - Air, sulphur dioxide etc. which can Maintenance Environment, Common
create corrosive compounds if dissolved in the Rail Fuel Injection
fluid.
Depending on circumstances engine maintenance
These contaminants can appear during may be required in various working environments.
manufacture, assembly, operation and maintenance. Obviously procedures are best carried out in a
dedicated workshop equipped with a suitable clean
The main filter is rated at 2 micron = 0.002 mm
room, but in practice this is not always possible.
(0.0007874 in). The pre-filter is rated at 5 micron.
Listed are a few typical comparisons of micron size: Maintenance procedures requiring removal or
replacement of fuel system components, particularly
Figure 293.
high pressure components, require special
precautions to make the working environment
suitable, reducing the risk of contamination to an
absolute minimum.
Use the following guidelines to make sure you reduce

the chances of fuel system contamination when
C working in different environments:
B
Worksite - Open to weather
This repair site is not an acceptable location. Only
A
in extreme circumstances should a machine be
repaired on an open site. Use the guidelines below:
A 8 Microns • Clean the engine, Refer to: PIL 15-00-00. If
B 70 Microns the machine is on hard standing, clean away the
C 100 Microns material washed from the engine.
• Red Blood Cell = 8 microns (0.008 mm, • Place suitable clean boards on the ground
0.000315 in). around the machine.
• Human Hair = 70 microns (0.07 mm, 0.00275 • Erect clean plastic sheeting to shelter the
in). engine from wind and rain.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 • Wear a new disposable environmental type suit
in). when working on the fuel system. If the suit
• The smallest particle visible to the naked eye is becomes contaminated with mud, move away
40 microns (0.00157in) approximately. from the engine and change into a new suit.
• Use clean latex gloves (non-powdered).
The main filter and pre-filter must be changed in • Before you start work make sure that all the
accordance with the applicable service schedule required replacement parts and tools are on
and procedures. The water in fuel sensor must be site. Make sure that the replacement parts are
maintained to ensure correct operation at all times. still sealed inside their packaging.
• Cap all exposed ports and orifices immediately.
The potential for engine damage due to fuel Do not leave them open.
contamination is much greater when using common • High pressure fuel pipes MUST BE REPLACED
rail injection technology than with mechanical if any pipe joint is loosened or disconnected. DO
injection systems. This is because common rail NOT re-use the original pipe.
requires components with smaller manufacturing
tolerances, especially the fuel injectors. In addition, Worksite - Closed to weather from above
common rail operates at much higher fuel pressures,
over five times that of mechanical systems. This repair site is the least acceptable condition,
if possible move the machine to a more suitable
Similar pressures are used by commercial water environment. Use the guidelines below:
jet cutting machines to cut metal. Fortunately clean
diesel fuel has lubricating qualities that prevents • Clean the engine, Refer to: PIL 15-00-00.
erosion of components but it is obvious that Clean the floor of all material washed from the
contaminated fuel will cause serious damage at such engine.
high pressures. • Place suitable clean boards on the ground
around the machine.
18 - 12 9813/8950-2 18 - 12
00 - General
• Erect clean plastic sheeting to shelter the Check (Pressure)

engine from the wind and the possibility of
debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit When it is necessary to check the fuel rail pressure
when working on the fuel system. If it becomes function on a faulty vehicle, it is often difficult to
contaminated with mud, move away from the decide which component of the system has failed.
engine and change into a new suit. It is essential to keep in mind the principles of the
• Use clean latex gloves (non-powdered). function of the Common Rail Fuel system:
• Before you start work make sure that all the
required replacement parts and tools are on Table 105.
site. Make sure that the replacement parts are Principle Function
still sealed inside their packaging.
• Cap all exposed ports and orifices immediately. Pressure production The pump compresses
Do not leave them open. the fuel at high pressure
• High pressure fuel pipes MUST BE REPLACED Pressure regulation The pressure thus pro-
if any pipe joint is loosened or disconnected. DO duced is accumulated in
NOT re-use the original pipe. a rail and measured and
regulated (the rail pres-
Vehicle Maintenance Workshop sure sensor, the ECU
(Electronic Control Unit)
Unless the workshop has a dedicated `sealable and the IMV (Inlet Me-
clean room' work bay, precautions must still be taken. tering Valve) function in
a closed loop, excess
• Clean the engine, Refer to: PIL 15-00-00. pressure is drained to
Clean the engine in the dedicated area and tank by the HPV (High
then move it to the workshop. Pressure Valve)
• Clean the floor area around the machine. Pressure consumption This pressure is finally
• Erect clean plastic sheeting to shelter the consumed by the injec-
engine from any wind and the possibility of tors (injection into the
debris such as dirt and dust falling from above. engine cylinders and in-
• Ensure that workshop doors to the outside are jector management)
kept closed. A gust of wind through an open
door will easily blow sand particles into the air. This means that a pressure fault may come from
• Make sure your work wear is clean, non-flocking the producer, the regulator or the consumers. Simply
and lint free. If in doubt wear a new disposable studying the physical parameters of the rail pressure
environmental type suit. does not allow the disassociation of the producer and
the consumer.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the Symptoms
required replacement parts and tools are on • The engine won’t start or is difficult to start.
site. Make sure that the replacement parts are • The engine stalls while running.
still sealed inside their packaging • Lack of power and dashboard warning lamps
• Cap all exposed ports and orifices immediately. light: the recovery mode may lead to engine
Do not leave them open. stop.
• High pressure fuel pipes MUST BE REPLACED
if any pipe joint is loosened or disconnected. DO Hydraulic System Status Analysis
NOT re-use the original pipe.
Hydraulic flow balance is established as follows:
Injected flow + Back leaks flow (Flow consumed)

= Capacity of the HP pump to supply the flow
requested for a given diesel fuel temperature
Hydraulic flow balance is upset if:

• The Injector back leak flow increases sharply,
exceeding the pump capacity.
• This can happen when particles disturb the
internal injector sealing, increasing the back
leak flow from one/several injectors or HPV
18 - 13 9813/8950-2 18 - 13
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 295. Reduction in HP Pump Capacity
• Mechanical wear in the injector.
• HPV stuck open.
100 100
The capacity of the pump to supply the required
pressure is reduced due to internal pump wear,
pressure is reduced due to internal pump wear or a
fuel feed problem.
Figure 294. Increased Back Leak Flow
C
F
C
100 100
E D
0 0
B A
A Production
B Consumption
C Reduction in HP pump capacity
D Pressure deficit
E Pump capacity
E F Injected flow
G Back Leak flow
0 0
B A
A Production
B Consumption
C Increased back leak flow
D Pressure deficit
E Pump capacity
F Injected flow
Example
• Presence of air in the low pressure circuit.
18 - 14 9813/8950-2 18 - 14
00 - General
Bleed
1. Make sure that there is enough fuel in the fuel
tank.
2. Turn the ignition key to position 1 (Accessories).
3. Let the pump run for the specified duration.
Duration: 20 s
4. Crank the engine for the specified duration.
Duration: 10 –15 s
4.1. If the engine fails to start repeat the bleeding
process.
18 - 15 9813/8950-2 18 - 15
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-17
18 - 16 9813/8950-2 18 - 16
03 - Tank
00 - General
Introduction .................................................... 18-17 The fuel tank is a safe container for storing flammable
Remove and Install ....................................... 18-18 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel

tank. Therefore, you must fill the fuel tank after you
operate the engine.
Drain the water and sediment from any fuel storage

tank at the recommended service intervals.
18 - 17 9813/8950-2 18 - 17
03 - Tank
00 - General

Front Tip [Hi-Viz] ....................... Page 18-18
For: 9T-1 Front Tip .................... Page 18-19
C
B
Front Tip [Hi-Viz])
Obey all fuel system health and safety information.
Remove
B Hoses
1. Make the machine safe. C Fuel filter assembly
Refer to: PIL 01-03-27. 8. Remove the P-clips.
2. Isolate the battery. Figure 298.
machine. D
4. Remove the rear upper crossmember. D
5. Remove the drain plug.
6. Drain the fuel tank.
Figure 296.
D P-clips
Figure 299.
D
A Drain plug
7. Disconnect the hoses from the fuel filter
assembly. D P-clips
9. Disconnect the fuel return hose.
18 - 18 9813/8950-2 18 - 18
03 - Tank
00 - General
Figure 300. Table 106. Torque Values

Item Description Nm
F Bolts 105
(For: 9T-1 Front Tip)

E Refer to: PIL 18-00-00.
Remove
E Fuel return hose Refer to: PIL 01-03-27.
10. Remove the bolts. 2. Isolate the battery.
Figure 301. Refer to: PIL 33-03-00.
machine.
4. Remove the rear upper crossmember.
F
6. Drain the fuel tank.
F Bolts Figure 303.
11. Remove the fuel tank from the machine.
11.1. Position the fuel tank forwards.
11.2. Raise the rear of the fuel tank.
Figure 302.
A
A Drain plug
7. Disconnect the hoses from the fuel filter
assembly.
G Fuel tank
Install
step.
18 - 19 9813/8950-2 18 - 19
03 - Tank
00 - General
C
B
E
B Hoses E Fuel return hose

C Fuel filter assembly
10. Put a label on the hoses to help installation.
8. Remove the P-clips.
11. Plug all the open ports and hoses to prevent
Figure 305. contamination.
12. Disconnect the gas strut from the access door.
Figure 308.
D
D
G
D P-clips
Figure 306. G Gas strut
14. Remove the gas strut and the bracket assembly.
Figure 309.
D
J
D P-clips
9. Disconnect the fuel return hose.
J Bolts 2
K Bracket assembly
18 - 20 9813/8950-2 18 - 20
03 - Tank
00 - General
Figure 310.
H H
H Bolts 3
16. Remove the fuel tank from the machine.
16.1. Position the fuel tank forwards.
16.2. Raise the rear of the fuel tank.
Figure 311.
G Fuel tank
Install
step.

Item Description Nm
H Bolts 105
18 - 21 9813/8950-2 18 - 21
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-23

18-09-09 Pre-Filter Element .......................................................................................................... 18-28
18 - 22 9813/8950-2 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 9813/8950-2 18 - 23
09 - Filter
00 - General
Figure 312.
1e 1
1f
1d
2a
2b 1a
2c 1b 1c
1 Fuel pre-filter/ water separator 1a Water bowl

1b Drain screw 1c Water level probe
1d Fuel filter element 1e Electric lift pump
1f Air bleed to tank 2 Fuel filter
2a Paper element 2b Sediment bowl
2c Drain screw
18 - 24 9813/8950-2 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 9813/8950-2 18 - 25
09 - Filter
00 - General
Remove and Install Remove - Disposable Type

Special Tools Figure 314.
Description Part No. Qty. E
Spanner - HP Fuel 334/G5933 1 C
Filter
Fuel Filter Removal 892/01383 1
Tool (4 cyl)
D
Before Removal
2. Get access to the filter.
A
2.1. On some machines the filter is located on
the engine. Other machines have remotely
located filters. There may be more than
one filter. Refer to the relevant service point
information for details.
2.2. There are different types of filters. Refer to B
the correct procedure. A Filter
B Drain tap
3. Thoroughly clean the outside of the filter housing C Low pressure fuel line
and around the filter head. D Screw
E Low pressure fuel line
4. Loosen the drain tap and allow the water / fuel to
drain into a suitable container. 1. Remove the low pressure fuel lines.
5. On machines with a fuel shut-off valve, set the 1.1. Put a label on the hoses to help installation.
valve to isolate the fuel supply.
1.2. Plug all the open ports and hoses to prevent
Figure 313. contamination.
A
2. Release the filter strap retaining screw and lift the
filter upward.
Install - Disposable Type

1. Make sure that the filter is in the correct position
B to enable connection of the fuel lines.
2. Install the filter strap.
2.1. Tighten the filter strap to the correct torque
value.
A Fuel filter element
B Drain tap Torque: 24 N·m
3. Install the low pressure fuel lines.
3.1. Make sure they are installed at the correct
ports.
4. Open the fuel shut-off valve (if applicable).
5. Bleed the fuel system. Refer to Fuel System-
General, Discharge and Pressurise.
18 - 26 9813/8950-2 18 - 26
09 - Filter
00 - General
Remove - Element Type

Figure 315.
C
A Filter head
B Filter element
C Drain tap
1. Use the applicable service tool to unscrew the
filter element from the filter head (anticlockwise).
Special Tool: Fuel Filter Removal Tool (4 cyl)
(Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.: 1)
Install - Element Type

1. Lubricate the element seals with clean fuel and
install a new filter element.
1.1. Make sure that the filter flange touches the
filter head.
1.2. Use the applicable service tool to tighten to
the correct torque value.
Torque: 35 N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
2. Open the fuel shut-off valve (if applicable).
3. Bleed the fuel system. Refer to Fuel System-
General, Discharge and Pressurise.
18 - 27 9813/8950-2 18 - 27
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element
Introduction
The fuel pre-filter with water separator is installed on

to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 28 9813/8950-2 18 - 28
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-31

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-33
18 - 29 9813/8950-2 18 - 29
Notes:
18 - 30 9813/8950-2 18 - 30
00 - General
Introduction .................................................... 18-31 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-32 lift pump is a sealed integral electrical unit. The
Remove and Install ....................................... 18-32 assembly is a non-serviceable component. If any
part is defective, replace the complete pump, filter
and separator assembly.
Figure 316.
A Fuel lift pump

B Fuel pre- filter
C Water separator
The pre-filter/water separator is designed to separate

water and dirt from the fuel using a special chemically
treated paper filter element. A bowl installed in the
bottom of the trap collects the water removed from
the fuel.
The bowl is installed with an electric probe which

senses when the water is above a preset level.
The probe enables a suitable alarm/indicator device.
Water can be drained off by means of the drain screw
installed in the base of the bowl. It is essential that
the water trap is drained regularly. Water must be
drained immediately if the probe signals an alarm.
Refer to fuel and exhaust system, filter, component

identification, (PIL 18-09).
18 - 31 9813/8950-2 18 - 31
00 - General
Drain and Fill Remove and Install

1. Obey all fuel system health and safety Refer to Fuel and Exhaust system - Filter - Pre-Filter
information. Element. Refer to: PIL 18-09.
3. Drain off any water in the filter element by turning
the 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).
5. If there is sediment in the bowl after draining,
support the bowl and release the locking ring.
6. Wash the bowl in clean fuel.
7. Install the bowl, secure in position with the
locking ring.
8. Make sure that the water in fuel electrical
connector is correctly installed.
Figure 317. Typical Engine
A
A Fuel filter
B Drain tap
18 - 32 9813/8950-2 18 - 32
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor
Remove and Install
Remove
2. Remove the ignition key.
3. Get access to the fuel filter.
4. Disconnect the electrical connections.
5. Remove the sensor fixing screw.
6. Remove the sensor.
Figure 318.
A 1
1 Fixing screw
2 Electrical connections
A Water in fuel sensor
Install
removal procedure.
18 - 33 9813/8950-2 18 - 33
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-35

18-18-03 Injector ............................................................................................................................ 18-50
18-18-07 Injector Seal ................................................................................................................... 18-55
18-18-12 Rail ................................................................................................................................. 18-57
18-18-15 Pump .............................................................................................................................. 18-59
18 - 34 9813/8950-2 18 - 34
18 - Injection
00 - General
Introduction .................................................... 18-35 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-36 injectors via high pressure fuel pipes.
Operation ....................................................... 18-37
Fault-Finding .................................................. 18-40 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
Check (Operation) ......................................... 18-47 the tubes are formed with conical nipples for sealing
Calibrate ........................................................ 18-49 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 - 35 9813/8950-2 18 - 35
18 - Injection
00 - General
Figure 319.
N
H
G
D F
M
E
C
J
A Multi-point injector nozzle

B Needle
C Spacer
D Nut
E Valve
F Solenoid coil
G Valve spring
H Calibration dowel
J Injector spring
L Electrical connector
M Return port (bleed off)
N High pressure port and filter element
18 - 36 9813/8950-2 18 - 36
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 320.
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 - 37 9813/8950-2 18 - 37
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 322.
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 321. 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 - 38 9813/8950-2 18 - 38
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 - 39 9813/8950-2 18 - 39
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 108. Page 18-40
Injector Trim Codes Table 109. Page 18-40
Open Circuit Injector Table 110. Page 18-41
Injection Bank Table 111. Page 18-41
Short Circuit Injector Table 112. Page 18-42
Engine Low on Power Table 113. Page 18-42
Injector Calibration Table 114. Page 18-43
Open Circuit Injector Table 115. Page 18-43
High Pressure Injection Diagnostics Table 116. Page 18-44
Fuel Rail Pressure Calibration Table 117. Page 18-44
IMV Table 118. Page 18-45
HPV Table 119. Page 18-45
Table 108. Injector Calibration

Cause Remedy
Old/incorrect software version Check if the software is up to date or new software
that will solve this problem is available. Upgrade as
necessary. Re-flash the injector calibration codes,
respecting power down and up delay and taking care
of injector position; erase all the faults.
If no fault is found proceed to 'Injector cylinder
position and value fault'
Injector cylinder position and value fault Check that ‘individual injector corrections’ are
correctly entered in ECM (Engine Control Module).
Check the cylinder position and value.
If no faults is found, proceed to 'Injector program
fault'.
Injector program fault Re-flash the injector calibration codes, respecting
power down and up delay and taking care of injector
position; erase all the faults.
Electrical connection faulty Check the knock sensor connection and screw
torque, repair as necessary. Note: Check the ground
shield connection of knock sensor.
If no knock sensor is installed, raise Techweb
Helpdesk call.
Table 109. Injector Trim Codes

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM.
Check the knock sensors connection and screwing
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
18 - 40 9813/8950-2 18 - 40
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECMpins are damaged, replace ECM and re-flash
necessary.
insulation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes faulty'.
Injector calibration codes faulty Check the injector calibration codes recorded inECM,
if found fault re-enter all injector calibration codes
(read then write) in correct position to reset learned
parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the Defect Trouble Code
(DTC) again with the diagnostic tool. If the problem is
still present change the knock sensor.
Table 110. Open Circuit Injector

Cause Remedy
Fuel injector fault Perform the injector buzz test, if the injector is faulty
it will not produce a buzzing sound. In such instances
raise Techweb Helpdesk call.
If no fault is found proceed to 'Injector connection
fault'.
Injector connection fault Check the resistance of injector – For solenoid, it
should be less than 1 ohm.
If the resistance is incorrect, change the injector and
calibrate it.
If no fault is found proceed to 'Electrical/ECM
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
necessary.
Table 111. 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 - 41 9813/8950-2 18 - 41
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 112. 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 113. 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 - 42 9813/8950-2 18 - 42
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 114. 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 115. 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 - 43 9813/8950-2 18 - 43
18 - Injection
00 - General
Table 116. High Pressure Injection Diagnostics

Cause Remedy
Pressure diagnostics fault Check the fault of type IMV (Inlet Metering Valve)
or HPV (High Pressure Valve) (if applicable) or rail
pressure sensor, repair the corresponding fault.
If no fault is found proceed to 'High pressure system
fault'.
High pressure system fault Read the Diagnostic Trouble Code (DTC).
Connect the battery booster.
If the DTC links to high pressure control: – Check
the fuel feed circuit is in good condition – Check the
diesel fuel is present in the system – Check there is
no air bubbles or emulsion in the pipes – Check there
is enough fuel pressure in the inlet pump – Check
there are no high pressure circuit leaks – Check the
quality and type of the diesel fuel.
If the low pressure circuit is faulty, repair the low
pressure circuit.
If no faults are found, proceed to 'Engine does not
start' or 'Engine starts' depending on symptoms,
replace the corresponding injectors.
Engine does not start Perform the ‘Dynamic IMV Test’.
If the IMV is faulty replace the IMV.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
corresponding injector(s).
If the back leak is OK complete the ‘Pump Pressure
Build Capacity Test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 117. 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 - 44 9813/8950-2 18 - 44
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from engine ECU (Electronic
Control Unit) and inspect. Check seals are in place,
check for signs of corrosion or contamination.
necessary.
If no fault is found proceed to 'Rail pressure sensor
and rail fault'.
Rail pressure sensor and rail fault Replace the rail pressure sensor and rail.
If the problem still not solved, raise Techweb
Helpdesk call.
Table 118. IMV

Cause Remedy
IMV (Inlet Metering Valve) connection fault Check the connection to IMV
If the IMV connection is faulty, replace the high
Pressure fuel injection pump.
If no fault is found proceed to 'ECM connection fault'.
ECMconnection fault Disconnect the harness from engine ECM and
If ECM pins are damaged, replace ECMand re-flash
necessary.
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the IMV electrical resistance around 5.3
ohms at 20 degrees C.
replace the high Pressure fuel injection pump if the
resistance fault occurs.
If no fault is found proceed to IMV buzz fault'.
IMV buzz fault Perform the IMV buzz test. If the IMV is not buzzing
replace the high Pressure fuel injection pump.
If the IMV buzzes, raise Techweb Helpdesk call.
Table 119. HPV

Cause Remedy
HPV (High Pressure Fuel Valve) connection fault Check the connection of HPV
If the HPV connection is faulty, repair or replace as
necessary.
If no fault is found proceed to ECMconnection fault'.
ECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
necessary.
18 - 45 9813/8950-2 18 - 45
18 - Injection
00 - General
Cause Remedy
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the HPVelectrical resistance, it should be
around 2.2 ohms at 25 degrees C.
If the electrical resistance is OK, replace the rail and
HPV.
If no fault is found proceed to 'HPV buzzing fault'.
HPV buzzing fault Perform the HPV buzz test. If theHPV is not buzzing
replace the rail and HPV.
If the HPV buzzes, raise Techweb Helpdesk call.
18 - 46 9813/8950-2 18 - 46
18 - Injection
00 - General
Check (Operation) Figure 325. Injector leak off test kit
Special Tools
Servicemaster 721/10855 1
Electronic Test Cable
Servicemaster 892/01033 1*
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
Injector Leak-off Test 892/12350 1
Kit ((Electronic Engine))
Injector Cap Kit 892/12359 1
*Unless otherwise stated, you can use any of the
tools shown.
To test the fuel injection system, there are two test

options available. Actuator tests, which supply a
voltage signal to the actuators and diagnostic tests Fuel System Diagnostic Test (Cranking only)
which require the engine to be cranked or started.
This test can be found in the fuel system diagnostic
Static Actuator Tests test (cranking) tab in the EcoMax engine test section
on the engine diagnostic tool within Servicemaster.
The IMV (Inlet Metering Valve), HPV (High Pressure This test closes the injectors, opens the IMV and
Valve) and the injectors can each be tested using the controls the rail pressure using the HPV.
engine diagnostic tool within Servicemaster.
1. Connect the fuel leak off test kit, ensure all open
The IMV test can be found under the fuel system tab fuel pipes are capped.
in EcoMax actuators section. The test sends a signal
to theIMV, normally the IMV can be heard operating Special Tool: Injector Leak-off Test Kit
and the test results will be displayed. ((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
The HPV test can be found under the fuel system
2. Use Servicemaster to control the tests and follow
tab in EcoMax actuators section. The test sends a
the on screen instructions in Servicemaster.
signal to the HPV, normally the HPV can be heard
operating. Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
The injector test can be found under the injector test Special Tool: Servicemaster Electronic Test
tab in EcoMax actuators section. The test sends a Cable (Qty.: 1)
signal to each individual injector, normally the injector
can be heard operating. 3. Measure the quantity of diesel fuel obtained in
the leak off kit.
Diagnostic Tests 4. Replace the injectors whose back leak exceeds
the value given in the Servicemaster reference
To diagnose fuel system faults the return flow from table.
the fuel system must be measured using the fuel
Injector leak off test kit. Refer to Injector-Check 5. Replace the fuel rail if the HPV return volume
Operation (PIL 18-18). exceeds the value given in the Servicemaster
help file. Note: The HPV is a non-serviceable
There are two sets of dynamic tests, one for when part.
the engine does not start (Cranking only) and one for
when the engine does start (Engine running). 6. After each replacement confirm the results by re-
testing.
7. If the leak off volumes are within limits and the
maximum rail pressure during the test is below
500 bar this indicates the high pressure pump
capacity may be low.
18 - 47 9813/8950-2 18 - 47
18 - Injection
00 - General
Fuel System Diagnostic Tests (Engine 1. Warm the engine to over 60°C (depending on
Running) the application) and the fuel temperature to over
20°C to be able to start the cycle.
These tests can be found in the fuel system
diagnostic test (engine running) tab in the ecomax 2. Connect the HPV leak off bottle, make sure all
engine test section on the engine diagnostic tool open fuel pipes are capped.
within Servicemaster. 3. Use Servicemaster to control the tests and follow
IMV Dynamic test
4. Measure the quantity of diesel fuel obtained in
1. Warm the engine to over 60°C (depending on
the HPV leak off bottle.
the application) and the fuel temperature to over
20°C to be able to start the cycle. 5. Replace the fuel rail if the HPV return volume
exceeds the value given in the Servicemaster
part.
3. Check status. If test OK, it should report
6. After each replacement confirm the results by re-
Diagnosis finished and no problem detected.
testing.
If the test indicates it is not OK (status
report Diagnosis finished and problem detected).
Replace the High pressure pump. Note: The IMV
is a non-serviceable part.
High Pressure IMV Diagnostic test
This test is designed to check the fuel system by

controlling the rail pressure using the IMV only.
Excessive HPV. Leak off indicates a leaking HPV,
excessive leak off from the injectors indicates a faulty
injector.
1. Warm the engine to over 60°C (depending on

the application) and the fuel temperature to over
20°C to be able to start the cycle.
2. Connect the fuel leak off test kit, make sure all
open fuel pipes are capped.
4. Measure the quantity of diesel fuel obtained in
the leak off kit.
5. Replace the injectors whose back leak exceeds
the value given in the Servicemaster reference
table.
6. Replace the fuel rail if the HPV. return volume
exceeds the value given in the Servicemaster
part. Make sure you replace the high pressure
fuel pipes at the same time.
7. After each replacement confirm the results by re-
testing.
High Pressure FIE HPV Test
This test is designed to check the fuel pump capacity

by opening the IMV fully and controlling the rail
pressure using the HPV. Leak off flow from the HPV
indicates the high pressure pump capacity.
18 - 48 9813/8950-2 18 - 48
18 - Injection
00 - General
Calibrate
recorded in code form and attached to the injector

Since the injector operating components are by body.
necessity very small, even the most advanced
manufacturing techniques do not ensure consistent The codes for each injector installed to the engine are
injection cycle characteristics between injectors. programmed into the ECM (Engine Control Module).
The operating software in the ECM uses the data
For example, small variations in the metering orifice to adjust the control of the injector solenoid coil
sizes will alter the time durations for the start and accordingly. The injector is therefore effectively re-
stop of fuel injection. The small dimensions involved calibrated by the ECM.
mean that only a tiny variation will alter the orifice
area by a relatively large percentage. It follows that if injectors are removed they must
always be installed in their original positions. If
For this reason it is necessary to individually test and new injectors are installed the ECM must be
record the operating characteristics of each injector reprogrammed with the new injector codes.
assembly at the factory. The results of the test are
Figure 326.
18 - 49 9813/8950-2 18 - 49
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-50 The fuel Injectors are electronically controlled and
Check (Operation) ......................................... 18-51 incorporate a small solenoid valve. The injectors are
Remove and Install ....................................... 18-52 supplied with pressurised fuel by the high pressure
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 327.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 50 9813/8950-2 18 - 50
18 - Injection
03 - Injector
Check (Operation) Figure 328.

B
Special Tools
A
Injector Leak-off Test 892/12350 1
Kit ((Electronic Engine))
Injector Cap Kit 892/12359 1
A
The injectors can be tested using Servicemaster
diagnostics and by means of a leak off test. To test
for a defective injector first use Servicemaster to
diagnose the problems with the high pressure fuel
injection equipment, specifically when the engine A
does not start.
Leak Off Test

The leak off test kit must be installed on the engine
and the ServiceMaster must be used to test the
engine. A
1. Operate the engine until it reaches its normal

operating temperature.
2. Stop the engine. Remove the bleed off pipe at
each injector. Refer to (PIL 18-96). 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 Cap Kit (Qty.: 1)
3. Connect the test pipes to the leak off ports on the
four injectors.
4. Position the four plastic bottles as upright as
possible. Keep the test equipment clear of
components that get hot when the engine is
operated.
5. Connect a test pipe to the leak off ports on the
High Pressure valve outlet. Cap the open pipe.
6. Make sure it is safe to start the engine.
7. Use ServiceMaster to control the tests. Refer to A Injectors (x4)
Fuel Injection - Check Operation (PIL 18-18). B HP valve
7.1. Fuel System Diagnostic Test (Cranking

Only).
7.2. Fuel System Diagnostic Tests (Engine
Running).
8. Examine the fuel levels in the test bottles. If the
difference between any of the levels is more than
10 ml. this indicates that there are one or more
defective injectors.
9. Remove the test equipment and replace the
bleed off pipes. Refer to (PIL 18-96).
18 - 51 9813/8950-2 18 - 51
18 - Injection
03 - Injector
4 X 1
The following procedure is for one injector, the
procedures are identical for all injectors.
Note: The original injector calibration codes are

located on a label on the rocker cover.
Before Removal
4. Remove the fuel bleed off fuel pipes. Refer to
6. Record which injector is for which cylinder. The 3
injectors must be installed in the same positions.
Note: If a fuel injector is defective, it must be 2

replaced. 1 Injector
2 Injector clamp
Remove 3 Retaining bolt
4 Injector sleeve
1. Remove the injector clamp retaining bolt and lift X Injector bleed-off port
the clamp away.
2. Remove and discard the sealing washer. Label
the injector to make sure it is installed in its
original cylinder. Put a clean protective cap over
the nozzle of the injector.
3. Remove and discard the O-ring.
18 - 52 9813/8950-2 18 - 52
18 - Injection
03 - Injector
5 A
D
C
A Correction factor (20 characters)

B Manufacturers reference
C JCB part number
D Injector serial number
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
6 or surface contamination will cause the injector
sealing O-ring to fail.
3. Install a new O-ring.
4. Install a new sealing washer.
7
5. Make sure that the injector is installed in the
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the
5 Protective cap engine. Make sure the injector is pushed fully into
6 Protective cap the cylinder head.
7 Sealing washer 6. Tighten the injector clamp bolt to the correct
torque value.
Install
After Installation
Important: The fuel injectors are not interchangeable
between cylinders or other engines. Make sure you 1. Replace the rocker cover, refer to (PIL 15-42).
install the injectors in the same positions. If a new
or different injector is installed, the engine electronic 2. Renew the high pressure fuel pipes, Refer to Fuel
control unit (ECU) must be re-programmed. Refer to Pipes (PIL 18-96).
(PIL 33-45), Engine Electronic Control Unit, Vehicle
Set Up Data. 3. Replace the low pressure fuel pipes, Refer to
When new or different injectors are installed, record
the calibration code. Record which cylinder the 4. Start the engine and check for fuel leaks.
injector is installed into. Refer to (PIL 33-45), Engine
Electronic Control Unit, Vehicle Set Up Data.
18 - 53 9813/8950-2 18 - 53
18 - Injection
03 - Injector

Item Nm
3 28
4 39
18 - 54 9813/8950-2 18 - 54
18 - Injection
07 - Injector Seal
07 - Injector Seal
Remove and Install
Special Tools Before Removal

Injector Seal 892/12346 1 1. Make sure that the engine is safe to work on. If
Installation Tool the engine has been running, let it cool before
(Electronic Engine) you start the service work.
Injector Sleeve 892/12348 1 2. Clean the engine. Refer to Engine- Clean (PIL
Installation/Removal 15-00).
Tool
Figure 332.
D
A Rocker cover B Bolts

C Gasket D Injector seals
18 - 55 9813/8950-2 18 - 55
18 - Injection
07 - Injector Seal
Remove Figure 334.
1. Get access to the engine. E

Fuel Pipes (PIL 18-96). F
3. Remove the rocker cover from the cylinder head.

4. Put wooden supports under the rocker cover and
tap out the injector seals using the special tool.
Discard the seals. G
Special Tool: Injector Seal Installation Tool E Injector seal installation tool
(Electronic Engine) (Qty.: 1) F Injector seals
G Wooden supports
Figure 333.
4. Renew the rocker cover gasket.
F E
5. Prevent damage to the seals. Put sleeves/covers
on the injectors. Apply a rubber lubricant to the
seals.
Special Tool: Injector Sleeve Installation/
Removal Tool (Qty.: 1)
6. Install the rocker cover. Refer to (PIL 15-42).
G
After Installation
E Injector seal installation tool
F Injector seals 1. The high pressure fuel pipes must be replaced
G Wooden supports with new parts. Refer to Fuel Pipes (PIL 18-96).
Install 2. Start the engine and check for oil and fuel leaks.

steps.
2. Remove all oil and sludge contamination from
inside the valve chamber.
3. Renew the injector seals. Put supports under the
rocker cover and tap in the new seals using the
special tool.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
18 - 56 9813/8950-2 18 - 56
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-57 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-58 pipe resembling a rail that is used to deliver fuel
to individual fuel injectors on internal combustion
engines. It is designed to have an outlet for each
injector, an inlet for a fuel supply and an outlet for a
fuel bleed off.
The fuel rail also incorporates an attached fuel

pressure sensor and a fuel valve. DO NOT
remove the high pressure fuel valve or the fuel
pressure sensor from the rail. If these components
are defective replace the complete common rail
assembly.
Figure 335.
A B
F
E
D
A Fuel pressure sensor

B Outlet
C Bleed off
D High pressure fuel valve
E Inlet
F Rail assembly
18 - 57 9813/8950-2 18 - 57
18 - Injection
12 - Rail

A B
Before Removal
C
1. Obey all fuel system health and safety
information. Refer to (PIL 18-00).
E F
2. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine E
has been running, wait at least one hour before D
you start work.
A Fuel pressure sensor
3. Clean the engine. Refer to Engine-Clean (PIL B High pressure fuel pipe
15-00). C Fuel bleed off pipe
4. Remove the high pressure fuel pipes. Refer to D High pressure fuel valve
Fuel Pipes (high pressure) - Remove and Install E Bolts
(PIL 18-96). F Rail assembly
5. Remove the fuel bleed off pipe at the rail. Refer to Table 121. Torque Values
Fuel Pipes (low pressure) - Remove and Install Item Nm
(PIL 18-96). C 24
Remove
1. Disconnect the electrical connector at the high
pressure fuel valve.
2. Disconnect the electrical connector at the fuel
pressure sensor.
3. Remove the bolts and lift off the common rail
assembly.
Seal the common rail assembly inside a clean plastic

bag until it is ready for use. If the assembly is
defective discard it and get a new one.
Install
steps.
When renewing the rail assembly make sure to

replace all of the high pressure fuel pipes. Refer to
(PIL 18-96).
18 - 58 9813/8950-2 18 - 58
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-59 The high pressure fuel injection pump is a rotary
Component Identification ............................... 18-60 type device that pumps fuel into the cylinders of
Operation ....................................................... 18-60 the engine. The pump is driven indirectly from the
Remove and Install ....................................... 18-62 crankshaft by gears.
18 - 59 9813/8950-2 18 - 59
18 - Injection
15 - Pump

Figure 337. The high pressure fuel injection pump is driven via a
7 8 2 10 gear on the engine and rotates at half engine speed.
The pump comprises of two sections, the transfer
pump and the high pressure pump.
1
9 Although the pump does not control fuel injection
timing, it is still timed in relation to engine phasing.
12 3 By timing the pump pressure pulses, the load on the
engine timing gears is reduced together with reduced
mechanical noise.
Transfer Pump Operation

The integral transfer pump is a vane type. An engine
driven rotor houses four vanes in slots. The rotor
13 rotates inside an eccentric liner. The vanes are
6 held in contact with the liner by springs. Fuel is
5 drawn into the pump chamber at port X, pressurised
by the decreasing volume inside the chamber and
expelled at port Y. Fuel pressure generated by the
4 2 11 transfer pump is limited to a specified pressure by an
1 Fuel injection pump integral pressure regulating valve. This pressure is
2 Pump fixing nuts (x3) maintained regardless of engine speed. 6 bar ( 87.0
3 Injection pump gear cover psi)
4 Inlet metering valve electrical connector
5 Fuel temperature sensor electrical connector Figure 338.
6 Fuel pipe connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector, injector bleed off
9 Drive shaft nut E
10 Drive gear A
11 Injection pump O-ring oil seal
12 High pressure fuel outlet port B
13 Gear cover O-ring oil seal
D
X Y
A Rotor
B Vanes (x4)
C Eccentric liner
D Springs
E Regulating valve
X Port X
Y Port Y
High Pressure Pump Operation

Fuel passes to the high pressure pump via the IMV
(Inlet Metering Valve). The ECM (Engine Control
18 - 60 9813/8950-2 18 - 60
18 - Injection
15 - Pump
Module) controlled IMV determines the amount of Fuel pressure in the chamber rises and forces the
fuel transferred to the high pressure pump. The inlet valve on to its seat. As the plunger is pushed
plunger actuator block is located on the engine driven further up its chamber the fuel pressure exceeds that
eccentric shaft. When the shaft rotates the actuator of the rail pressure and the delivery valve is forced off
block operates the two plungers. As one plunger is its seat. Fuel is forced into the rail at high pressure.
pushed up its chamber the other is pushed down by
its spring. Figure 340.
State 1 - Charging E
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries. D
When the eccentric shaft is in the position shown
force from spring moves the plunger down its C
chamber. Pressure in the chamber falls below the
rail pressure and the delivery valve closes. Transfer
pressure is now sufficient to force inlet valve off its
seat and allow the fuel to fill the chamber.
Figure 339.
E B
D
A Eccentric shaft
C B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F
A Eccentric shaft
B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F Spring
State 2 - Pumping
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries.
When the eccentric shaft is in the position shown the

actuator block moves the plunger up its chamber.
18 - 61 9813/8950-2 18 - 61
18 - Injection
15 - Pump

7 8 2 10
Special Tools
1
Crankshaft Turning Tool 892/01147 1
(95.25mm PCD)- JCB 9
4 Cylinder Ecomax and 3
Dieselmax 12
Crankshaft / 892/01148 1
Camshaft Timing Pin
(444/448/672 Engine)
Tamper proof Cover 892/01154 1
Removal Tool
Pump Gear Removal 892/01155 1
Tool 13
C-Shaped Ring 892/01179 1 6
Spanner 5
(10-100Nm) 4 2 11
Important: The following procedures include removal 1 Fuel injection pump
and replacement of fuel system components. Before 2 Pump fixing nuts (x3)
starting the procedures the engine assembly must be 3 Injection pump gear cover
cleaned. Clean the engine. Refer to Engine- Clean 4 IMV (Inlet Metering Valve) electrical connector
(PIL 15-00). 5 Fuel temperature sensor electrical connector
Important: Service procedures on the high pressure 7 Fuel bleed-off connector
fuel pump can only be carried out by specialist 8 Fuel bleed-off connector, injector bleed off
personnel with the relevant training and equipment. 9 Drive shaft nut
10 Drive gear
11 Injection pump O-ring oil seal
Before Removal 12 High pressure fuel outlet port
1. Make sure that the engine is safe to work on. If 13 Gear cover O-ring oil seal
you start the service work. Remove
2. Get access to the engine. 1. Release the fuel pipe couplings at the inlet
connection 6 and bleed-off connections 7 and 8
3. Remove the high pressure fuel pipe at port 12, on the pump. Cap all open ports and pipes.
refer to Fuel Pipes- Remove and Install. Cap all
open ports and pipes, refer to (PIL 18-96). 2. Uncouple the electrical connectors at the IMV
and the fuel temperature sensor.
4. To improve access to the pump, remove the fuel
filter, refer to (PIL 18-09). 3. Remove the bedplate plug.
Important: When removing components dirt and

debris may become exposed or dislodged. Stop the
removal procedures and clean away the exposed
deposits. Refer to Engine- Clean (PIL 15-00).
18 - 62 9813/8950-2 18 - 62
18 - Injection
15 - Pump
11
3
B
A
1
F G
1 Bedplate plug H
A Crankshaft / Camshaft timing pin
C Crankshaft turning tool
4. Use the crankshaft turning tool to turn the E
crankshaft until the timing pin engages in the
crankshaft timing hole.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax 3 Gear cover
(Qty.: 1) 11 Drive shaft nut
Special Tool: Crankshaft / Camshaft Timing Pin B Gear removal tool
(444/448/672 Engine) (Qty.: 1) E Pump gear removal tool, comprises:
F Pump gear removal tool (Reaction cap)
5. Use the gear removal tool and a suitable ratchet G Pump gear removal tool (Body)
drive to remove the fuel injection pump gear H Pump gear removal tool (Bolt)
cover.
Special Tool: Pump Gear Removal Tool (Qty.: 1) 7. Remove the nuts. Use the special C shaped
ring spanner to remove the nut closest to the
6. Remove the drive shaft nut. crankcase. Make sure you remove all nuts (X3).
8. Install the reaction cap over the pump shaft.
Screw the body to the housing. Use a suitable
ratchet drive and socket to screw the bolt in until
you feel a slight resistance.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
Special Tool: Pump Gear Removal Tool (Qty.: 1)
18 - 63 9813/8950-2 18 - 63
18 - Injection
15 - Pump

2 10
2 10
9
F
G
2 12
2 Fixing nuts
9 Gear pump nut
2 Fixing nuts
10 Drive gear
10 Injection pump drive gear
12 Drive shaft
F Pump gear removal tool (Reaction cap)
G Pump gear removal tool (Body) 2. Make sure that the oil seal is correctly located on
H Pump gear removal tool (Bolt) the pump mounting face.
9. The injection pump drive gear is located on a Figure 346.
taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel pump. Tap the end of the bolt H with a
soft faced hammer. When the taper breaks there
will be an audible sound. Note: The pump drive 16
gear connects to the injection pump drive shaft by
means of taper lock alone, there is no mechanical
locking key.
10. Remove the service tools. Withdraw the pump
from the flywheel housing.
Install
1. Make sure that the taper surfaces on the injection 16 Oil seal
pump drive shaft and gear are clean and free 3. Locate the pump on to the mounting studs.
from oil and damage. Locate the drive gear over the pump drive shaft.
4. Install the fixing nuts and tighten to the correct
torque value.
5. Install the gear pump nut and tighten to the
correct torque value. Note: If a washer is supplied
with a replacement pump, Do not install the
washer. Secure the gear with the gear pump nut
only.
6. Use the tamperproof cover removal tool to install
the gear cover. Make sure its sealing O-ring is
correctly installed. Tighten the gear cover to the
1)
Special Tool: Tamper proof Cover Removal Tool
(Qty.: 1)
18 - 64 9813/8950-2 18 - 64
18 - Injection
15 - Pump
7 8
12
3
B
6
3 Gear cover 5
B Tamperproof cover removal tool
4
After Installation 4 IMV electrical connector
1. Remove the crankshaft turning tool. 5 Fuel temperature sensor electrical connector
2. Remove the crankshaft timing pin and install the 7 Fuel pump bleed-off connection
bedplate plug. 8 Fuel pump bleed-off connection
12 High pressure fuel outlet port
3. Reconnect the fuel pipe couplings at the inlet
connection, reconnect the bleed-off connections Table 122. Torque Values
on the pump.
Item Nm
4. Install a new high pressure fuel pipe, remove 2 24
the protective caps from the ports, refer to Fuel 3 70
Pipes- Remove and Install, refer to (PIL 18-96). 9 65
5. Connect the electrical connectors at the IMV and
the fuel temperature sensor.
6. Replace the fuel filter, refer to (PIL 18-09).
7. Start the engine and check for fuel leaks.
18 - 65 9813/8950-2 18 - 65
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-67
18 - 66 9813/8950-2 18 - 66
21 - Fuel Pump
00 - General
Introduction .................................................... 18-67 The fuel lift pump is a sealed electrical unit integral
Technical Data ............................................... 18-69 with the fuel pre-filter and water separator.
Operation ....................................................... 18-70
Check (Operation) ......................................... 18-70 The fuel lift pump is a non-serviceable component.
If any part is defective, replace the complete pump,
Remove and Install ....................................... 18-71 filter and separator assembly.
Figure 349.
A Fuel lift pump

B Fuel pre- filter
C Water separator
Some lift pump installations are modified to operate

from a 24 V supply by means of an in-line voltage
reducer.
18 - 67 9813/8950-2 18 - 67
21 - Fuel Pump
00 - General
Figure 350.
A
A Lift pump motor

B Voltage reducer
C In-line electrical connector
D Harness electrical connector
18 - 68 9813/8950-2 18 - 68
21 - Fuel Pump
00 - General
Technical Data
Table 123.
Component Value
Operating pressure 0.8 bar ( 11.6 psi)
Expected minimum free 2.5 L/min
flow delivery
Table 124. Expected electrical values

Machine Minimum Maximum Minimum Maximum Minimum Maximum
Voltage V Voltage V Voltage V Resistance Resistance Current Draw Current Draw
Ohms Ohms A A
12 8 16 0.8 1.5 4 8
24 20 30 4.9 5.7 4 5.5
18 - 69 9813/8950-2 18 - 69
21 - Fuel Pump
00 - General
The pump draws fuel from the tank, through the water If the fuel lift pump is suspect, measure the delivery
separator, pumping it through the fuel filter and into flow rate.
the fuel injection pump. The pump has a built in
protection against running dry and will shut down Flow Test
after 2 min if no fuel is present.
2. Disconnect the fuel hose from the outlet of the
pump/ filter assembly.
3. Connect a length of fuel hose from the pump
outlet to a suitable fuel container.
Volume: 5 L
4. Activate the fuel pump. Do not attempt to start
the engine.
5. Run the pump. The fuel flow must be equal to or
greater than the value shown.
Duration: 1 min
Flowrate: 2.5 L/min
Machines with Electronic Control Fuel

Injection
When the ignition is set to ON the ECM (Engine
Control Module) energises the fuel lift pump. If the
engine is not started the pump is de-energised after
a period of 24 s. A fuel pump flow test can be carried
out during this period of time. Minimum expected fuel
flow. 1 L in 24 s.
Alternatively use the JCB engine diagnostic tool

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5 s delay the pump runs for
a period of 24 s.
18 - 70 9813/8950-2 18 - 70
21 - Fuel Pump
00 - General
Remove and Install
4. Disconnect the WIF (Water in Fuel) sensor

Remove harness connector.
Refer to Figure 351. 5. Make sure to mark label on the fuel pipes to aid
in the installation.
The fuel lift pump is installed on the loader tower. 6. Disconnect the fuel pipes at the fuel lift pump by
This procedure is also similar for the machines with means of the quick release connectors.
lift pumps installed on the side of the fuel tank.
7. Disconnect the drain hose at drain tube.
Refer to: PIL 01-03-27. 8. Support the fuel lift pump and remove the bolts.
2. Disconnect the battery. 9. Remove the fuel lift pump together with its pre-
filter/separator from the machine.
3. Disconnect the fuel lift pump harness connector.
Figure 351.
G
K
J
D
C
H G A
E
G
F
B
M
N
A WIF sensor harness connector B Fuel pipe

C Fuel lift pump harness connector D Fuel lift pump
18 - 71 9813/8950-2 18 - 71
21 - Fuel Pump
00 - General
E Fuel pipe F Bolt

G Washers H Deutsch clip
J Locknut K Screw
L Drain tube M Pre-filter/Separator
N Fuel pipe
Install
removal procedure.
18 - 72 9813/8950-2 18 - 72
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-75

18-24-03 Inlet Manifold .................................................................................................................. 18-77
18-24-04 Outlet Manifold ............................................................................................................... 18-81
18 - 73 9813/8950-2 18 - 73
Notes:
18 - 74 9813/8950-2 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 may flow
through the following components:
• Cylinder head and exhaust manifold.

• Turbocharger to increase the engine power (if
installed).
• A catalytic converter or EGR (Exhaust Gas
Recirculation) system to reduce air pollution (if
installed).
• SCR (Selective Catalytic Reduction) (if
installed). In SCR system exhaust gases
pass through the DEF (Diesel Exhaust Fluid)
injection chamber to lower the NOx (Nitrogen
Oxide) concentration in the exhaust gases.
• A silencer or muffler to reduce noise (if
installed).
The exhaust pipe carries the toxic and noxious gases

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 75 9813/8950-2 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
Switch off the engine before working in the engine
engine cover open.
18 - 76 9813/8950-2 18 - 76
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-77 The inlet manifold (or intake manifold) supplies
Component Identification ............................... 18-78 combustion air to the cylinders in compression
Check (Condition) .......................................... 18-78 ignition engines or the air/fuel mixture for spark
Remove and Install ....................................... 18-79 ignition engines (except most direct injection spark
ignition engines). Even distribution of the air or
air/fuel is important to optimize the efficiency and
performance of the engine.
The manifold is required to be air tight under pressure

and vacuum conditions and can be required to
provide mounting points for sensors, grid heaters,
throttle bodies and other components depending on
the engine type and specification.
18 - 77 9813/8950-2 18 - 77
24 - Exhaust
03 - Inlet Manifold

Figure 352. 1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
1
1 Inlet Manifold
18 - 78 9813/8950-2 18 - 78
24 - Exhaust
03 - Inlet Manifold
Remove and Install

4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 353.
6
12 11 10
8
13
9
3
4
5
1 Inlet manifold 2 Manifold gasket

3 Flanged hexagon bolt (x8) 4 Fuel rail mount
5 Screw (x4) 6 EGR (Exhaust Gas Recirculation) mixer tube
7 EGR Plug 8 Inlet manifold adaptor / throttle valve (not
shown)
9 Throttle O-ring 10 Flanged hexagon bolt (x4)
11 Inlet manifold bracket 12 Bolt M6 x 16mm (x1)
13 Bolt M8 x 25mm (x1)
Remove 4. Cap the inlet ports with blanking caps to prevent

ingress of dirt.
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector. 5. Inspect the manifold, refer to Check Condition
(PIL 18-24).
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
18 - 79 9813/8950-2 18 - 79
24 - Exhaust
03 - Inlet Manifold
Install
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.

Item Nm
3 43
18 - 80 9813/8950-2 18 - 80
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-81 The exhaust outlet manifold collects the exhaust
Component Identification ............................... 18-82 gases from the multiple cylinders and delivers it to
Check (Condition) .......................................... 18-82 the turbocharger or the exhaust pipe.
18 - 81 9813/8950-2 18 - 81
24 - Exhaust

Figure 354. 1. Check the manifold mating faces for signs of
A B damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
A Exhaust manifold
B Manifold gasket and heat shield
18 - 82 9813/8950-2 18 - 82
24 - Exhaust
Remove and Install

4. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 355.
1 Exhaust manifold 2 Fixing bolts M10 x 57mm (x8)

3 Manifold gasket
Remove 2. Renew the manifold gasket.
1. Remove the upper four bolts. 3. Install the lower four bolts, together with the new
exhaust gasket to the cylinder head (screw in the
2. Loosen the lower four bolts and lift the exhaust bolts approximately to a length of 8 mm).
manifold from the cylinder head. Remove the
bolts and discard the gasket. 4. Rest the manifold in position on the row of
lower bolts by locating the slots, then install the
3. Cap the exhaust ports to prevent ingress of dirt. remaining four upper bolts.
4. Inspect the manifold, refer to Check Condition 5. Tighten the bolts to the correct torque value.
(PIL 18-24). Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
Install
After Installation
removal procedure. Additionally do the following 1. Reconnect the oil pipes to the turbocharger (if
steps. installed).
18 - 83 9813/8950-2 18 - 83
24 - Exhaust
2. Install the exhaust pipe and the silencer box.

3. Start the engine and check for exhaust leaks.

Item Torque Value Torque Angle
(Nm) (Degrees)
2 (First Stage) 25
2 (Final Stage) +90
18 - 84 9813/8950-2 18 - 84
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-87

18-27-03 Actuator .......................................................................................................................... 18-94
18 - 85 9813/8950-2 18 - 85
Notes:
18 - 86 9813/8950-2 18 - 86
00 - General
Introduction .................................................... 18-87 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................... 18-88 a technique that re-circulates a portion of the
Operation ....................................................... 18-89 exhaust gases back into the combustion chamber.
Check (Condition) .......................................... 18-90 The system cools and controls the quantity of re-
circulated exhaust gas.
The EGR valve is controlled by the CAN (Controller
Area Network)bus system (PIL 33-45), the valve
opens and closes to allow the exhaust gases to
flow back into the intake system via the EGR cooler.
This has the effect of lowering the combustion
temperature and reducing the formation of NOx
(Nitrogen Oxide).
In order to ensure full power is always available when

it is needed, the EGR valve will close when full power
is needed or when the engine is cold and inherently
inefficient this means that the engine is running as
lean and efficiently as possible at all times.
The EGR valve system comprises an actuator with

a feedback position sensor, linkage and a valve
mechanism. The valve actuator, which is controlled
by the CANbus system, position sensor and linkage,
drives the valve to the demanded position.
18 - 87 9813/8950-2 18 - 87
00 - General
Figure 356.
B
C
D
A E
F
G
A VGT (Variable Geometry Turbocharger) actuator B VGT

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
Table 127. Colour Code Key

Colour System
Blue Coolant Flow 1
Red Recirculated Gas Flow
Green Air Flow
Yellow Coolant flow 2
18 - 88 9813/8950-2 18 - 88
00 - General
Operation Figure 359.
1. Exhaust gases enter the exhaust manifold.

Figure 357.
4. Exhaust gases enter the mixer tube.

Figure 360.
2. The exhaust gases travel through the
intermediate EGR (Exhaust Gas Recirculation)
cooler.
Figure 358.
5. The exhaust gases are mixed with new air and

re-enter the engine.
Figure 361.
3. The exhaust gases enter the main cooler which
reduces the heat.
18 - 89 9813/8950-2 18 - 89
00 - General
Check (Condition)
1. Check that the EGR (Exhaust Gas Recirculation)
for excessive carbon build up. Visually inspect for
leaks at the EGR. Make sure all gaskets are in
good condition, replace as required.
18 - 90 9813/8950-2 18 - 90
00 - General
Remove and Install
Before Removal 2. Get access to the engine.

Figure 362.
C
B D
E
A
F
G
A VGT (Variable Geometry Turbocharger) actuator B VGT

C EGR (Exhaust Gas Recirculation) actuator D EGR valve
E EGR Intermediate Cooler F Main Plate Cooler
G Mixer Tube
18 - 91 9813/8950-2 18 - 91
00 - General
Remove 8. Remove the bolts (x4) that retain the heat shield
to the EGR control module.
1. Remove the EGR cooler hose (Left side viewed
from the rear of the engine). 9. Remove the bolt from the cooler pipe.
2. Remove the EGR cooler bracket assembly bolts 10. Remove the cooler connections (banjo fittings
(x2). (x4) and copper washers) from the EGR control
module and electrical harness connector.
3. Carefully remove the main EGR cooler.
11. Remove the small bolts (x3) that fix the control
4. Remove the EGR cooler hose (Right side viewed module to the EGR valve.
from the rear of the engine).
12. Remove the bolts (x2) that fix the EGR bracket
5. Remove the nuts (x4) fixing the EGR tube in tube to the W-clip that clamp the cooler pipes together
cooler pipe assembly to the EGR valve. (captive nuts).
6. Remove the EGR actuator control rod pivot pin 13. Remove the EGR valve body from the mounting
fixing clips and the EGR control rod. studs fixed to the manifold with a steel gasket
both sides.
7. Remove the bolt fixing the EGR tube in tube
cooler to the rear of the cylinder head.
Figure 363.
19
22
41
42 41
45
5 41 35
25 20
17 41
10
29
38
32
19 41
3 20
22 15
7
37
4 13
20 20 6
42
12
27 8 40
1
26 39
20 42
42 14
43
23 16
9 21
34
2 28
23
24 31
1 Main EGR cooler 2 Intermediate EGR cooler

3 EGR valve 5 Pipe (Coolant return to header)
6 Pipe (Under actuator to coolant return) 7 Pipe (EGR actuator feed)
18 - 92 9813/8950-2 18 - 92
00 - General
8 Pipe (EGR cooler out) 9 Pipe (rear of head feed)

10 Pipe (Turbo actuator feed) 11 Pipe (Turbo actuator return)
12 Hose (EGR cooler in) 13 Hose (EGR cooler out)
14 Hose (EGR in, intermediate cooler) 15 Hose (EGR cooler out, intermediate cooler)
16 Hose (EGR actuator feed) 17 Hose (EGR cooler return)
18 Hose (Turbo actuator feed) 19 Hose (Turbo actuator feed/return)
20 Spring-band clamp form B (24mm Diameter) 21 Spring-band clamp form B (20mm Diameter)
22 Spring-band clamp (14mm Diameter) 23 Laminar seal ring (Large)
24 Laminar seal ring (Small) 25 O-ring (I.D.17.0mm x 3.5mm)
26 Gasket (EGR to Manifold) 27 Outlet lobe seal
28 Copper washer (M16) 29 Copper washer (M12)
30 Copper washer (M10) 31 Banjo bolt (M16)
32 Banjo bolt (M12) 33 Banjo bolt (M10 long)
34 EGR Cooler strap 35 EGR Valve heat-shield
36 W-Clip for 8mm O.D. pipe 37 Coolant pipe clamp
38 Pipe clamp strap 39 Locknut (M8 Special)
40 Stud (M8 x 80mm) 41 Bolt flange hexagon head (M6 x 16mm)
42 Bolt flange hexagon head (M8 x 16mm) 43 Screw hexagon head (M8 x 30mm)
Install 3. The EGR actuator is a CAN (Controller Area

Network) driven device and can only be
1. The installation procedure is the opposite of the evaluated with the use of Servicemaster. Refer
removal procedure. Additionally do the following to EGR Actuator (PIL 18-27).
steps.
4. All conditions of the EGR are reported by the fault
2. Renew all O-rings, sealing washers and gaskets. codes. Test the turbocharger boost pressure,
refer to Check Operation (PIL 18-36).
3. Tighten the fixings to the correct torque value.
Note: Tighten the EGR cross over tube bolts in Table 128. Torque Values
the correct order, 1 to 4 as shown in 2 stages.
Item Nm
Figure 364. 31 50
32 27
2
33 16
39 24
40 24
4
41 10.5
42 24
43 24
44 24
3
1
After Installation
1. Complete the actuator learn procedure, Refer to
Servicemaster, JCB Engine > Diagnostic Tool >
Ecomax Actuators > Actuator Learn > EGR Valve
Position Learn.
2. Start the engine and check for exhaust leaks and
coolant leaks.
18 - 93 9813/8950-2 18 - 93
03 - Actuator
03 - Actuator Introduction
Introduction .................................................... 18-94 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ....................................... 18-95 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 - 94 9813/8950-2 18 - 94
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 - 95 9813/8950-2 18 - 95
35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ........................................................................................................................... 18-97
18 - 96 9813/8950-2 18 - 96
35 - Turbocharger
00 - General
Introduction .................................................... 18-97 The turbocharger (turbo) is a turbine driven forced
Component Identification ............................... 18-98 induction device that makes an engine more efficient
Check (Condition) .......................................... 18-99 and helps to produce more power for its size.
Check (Operation) ....................................... 18-100
Engine exhaust gasses drive a turbine, which in turn
Remove and Install ..................................... 18-101 drives a compressor via a common shaft. The shaft
bearings are lubricated by a feed from the engine
lubrication system.
A turbocharged engine is more powerful and efficient

than a naturally aspirated engine because the turbine
forces more air, and proportionately more fuel, into
the combustion chamber than atmospheric pressure
alone.
Some variants incorporate a wastegate assembly. A

flap type valve is housed in the turbocharger body.
The valve is actuated by a diaphragm type actuator
via an actuator rod. When the pressure generated
by the turbocharger compressor reaches a pre-set
value the actuator opens the valve, some exhaust
gas is diverted back to the exhaust manifold and
the turbocharger turbine speed reduces. In this way
the pre-set maximum boost pressure from the turbo
charger is not exceeded, regardless of engine speed.
18 - 97 9813/8950-2 18 - 97
35 - Turbocharger
00 - General
Figure 365.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
18 - 98 9813/8950-2 18 - 98
35 - Turbocharger
00 - General
Check (Condition) Figure 367.
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 366. 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 - 99 9813/8950-2 18 - 99
35 - Turbocharger
00 - General
Check (Operation)
To maximise the duration of the turbocharger follow

the rules described below.
Start-up
Start the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached within
a few seconds, but it is useful to allow the moving
parts to warm up in good lubrication conditions.
Immediately increasing the engine speed after start
up will result in the turbocharger running at high rpm
with less than optimal lubrication. This may lead to
premature failure of the turbocharger.
After maintenance
When carrying out maintenance on the engine
or turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it is
completely full. After pre-lubrication, let the engine
run via the starter motor without firing (engine /
fuel pump stop out) to allow the oil to circulate
through the complete system under pressure. Upon
engine start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to work
satisfactorily.
Low temperature air or engine inactivity

If the engine has been inactive for a certain period
of time or the air temperature is very low, start
the engine and then let it run at idle speed. This
enables the oil to go into the lubrication system
before applying high loads and speeds to the engine
and turbocharger.
Engine shutdown
Before switching the engine off after intense activity,
you must allow the turbocharger to cool down, let the
engine run at idle speed for at least 2 minutes to allow
the turbocharger to cool.
Engine at idle speed

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 100 9813/8950-2 18 - 100

35 - Turbocharger
00 - General
Remove and Install
Figure 368.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
Before Removal 4. Get access to the engine.
1. This procedure requires service parts. Make sure 5. Drain the cooling system.
you have obtained the correct parts before you
start, refer to Parts Catalogue. Remove
2. Make sure that the engine is safe to work on. 1. Disconnect the air induction hose at the inlet
If the engine has been running, make sure the manifold and turbocharger. Remove the hose.
engine has cooled sufficiently before you start.
2. Remove the pipe clip. Undo fixing bolts and
3. Remove the ignition key. remove the oil drain pipe. Note that the pipe pulls
18 - 101 9813/8950-2 18 - 101

35 - Turbocharger
00 - General
off the pipe adaptor, leaving the adaptor in place.

Cap the open ports to prevent ingress of dirt.
Discard the O-ring and the gasket.
3. Undo the banjo bolts at each end of the oil
feed pipe, remove the pipe. Cap the open ports
to prevent ingress of dirt. Discard the sealing
washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold-Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket.
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard the gasket.
Install
steps.
2. Check the condition of the turbocharger (PIL
18-35)
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all `O' rings, sealing washers and
gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat shield. Be sure to position the
gasket the correct way round.
6. Tighten the nuts, bolts and banjo bolts to the

Item Nm
4 21
6 24
8 24
13 36
18 - 102 9813/8950-2 18 - 102

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-105

18-96-03 High Pressure Pipe ...................................................................................................... 18-108
18-96-06 Low Pressure Pipe ....................................................................................................... 18-111
18 - 103 9813/8950-2 18 - 103

Notes:
18 - 104 9813/8950-2 18 - 104

96 - Fuel Pipe
00 - General
Introduction .................................................. 18-105 Fuel at rail pressure is continuously supplied to
Health and Safety ........................................ 18-106 the injectors via high pressure fuel pipes. The high
Component Identification ............................. 18-106 pressure fuel injector pipes consist of thick walled,
Preparation .................................................. 18-107 seamless steel tubing. The ends of the tubes are
formed with conical nipples for sealing in the sealing
cones on the common rail and on the injector at port.
It is essential that the pipes are maintained and

installed correctly for safe and effective engine
operation.
The high pressure fuel pipes connect the injectors to

the common rail. The injectors inject fuel in response
to a supply of electrical current from the ECM (Engine
Control Module). During fuel injection some fuel
bleeds off the injectors and back to tank via the low
pressure bleed off pipes.
Important: If the high pressure fuel pipes are

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
18 - 105 9813/8950-2 18 - 105

96 - Fuel Pipe
00 - General

WARNING Do not open the high pressure fuel
system with the engine running. Engine operation Figure 369.
causes high fuel pressure. High pressure fuel A
spray can cause serious injury or death. A A A
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system, B
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and H
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously C
damage the fuel injection equipment and could be
expensive to repair. G
E
D
A Pipe assembly high pressure - fuel rail to

injector (x4)
B Injector
C Pipe assembly high pressure - injection pump to
fuel rail
D Pipe low pressure - return to tank
E Injection pump
F Pipe assembly low pressure - Fuel injectors to
tank
G Pipe assembly low pressure - fuel rail to tank
H Fuel rail
18 - 106 9813/8950-2 18 - 106

96 - Fuel Pipe
00 - General
Preparation
must decay before you start work. If the engine

Important: Before you disconnect or remove fuel has been running, wait at least one hour before
pipes make sure that you have the correct new parts. you start work.
The high pressure fuel pipes MUST BE REPLACED
with new ones. The new fuel pipes must remain 2. Clean the engine. Refer to Engine-Clean (PIL
sealed inside their bags before use. If a bag is open 15-00).
DO NOT USE the fuel pipe, get a new one.
3. Remove the protective cover. Push out the four
Obey all fuel system health and safety information. plastic segments. Remove the screws and lift off
Refer to (PIL 18-00). the cover.
1. Make sure that the engine is safe to work on. The 4. Remove any dirt or debris that is exposed. Refer
engine must cool and pressure in the fuel system to Engine-Clean (PIL 15-00).
Figure 370.
A Protective cover B Plastic segments (x4)

C Screws
18 - 107 9813/8950-2 18 - 107

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe 5.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00-00).
Remove and Install 6. Always use a spanner at the top of the fuel pipe
nut (this will prevent damage to the nut).
Special Tools
Description Part No. Qty. Figure 372.
Socket 17MM Offset - 331/27987 1
(HP Fuel pipes)
(10-100Nm)
Important. Before disconnecting or removing fuel

pipes proceed as follows.
1. Make sure that you have the correct new parts.

1.1. The high pressure fuel pipes MUST BE
REPLACED with new ones.
1.2. The new fuel pipes must remain sealed
inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one.
2. Obey all fuel system health and safety Injector Fuel Pipes
information. Refer to (PIL 18-00).
Remove
3. Make sure that the engine is safe to work on.
The procedure describes how to remove one fuel
3.1. The engine must cool and pressure in the pipe.
fuel system must decay before you start
work. Figure 373.
3.2. If the engine has been running, wait at least B
one hour before you start work.
A
4. Clean the engine. Refer to Engine, Clean (PIL C
15-00-00).
5. Remove the protective cover as follows.
E
Figure 371.
B
A Fuel pipe
A B Nut 1
C Fuel injector
D Fuel rail
E Nut 2
C
1. Remove the fuel pipes one at a time as follows.
A Screw
B Plastic segment 1.1. Loosen the nut 2 at the fuel rail. Do not
C Protective cover remove the nut at this step.
1.2. Use the 17mm deep socket special tool at
5.1. Push out the plastic segments. the top of nut. This will prevent damage to
5.2. Remove the screws and lift off the cover. the nut.
18 - 108 9813/8950-2 18 - 108

96 - Fuel Pipe
Special Tool: Socket 17MM Offset - (HP Injection Pump to Rail Fuel Pipe
Fuel pipes) (Qty.: 1)
Special Tool: Torque Wrench (10-100Nm) Remove
(Qty.: 1)
Figure 374.
1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1. A
B
1.4. Push the fuel pipe against the fuel rail cone
and at the same time remove the nut 2.
1.5. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Repeat step 1 to remove the other fuel pipes.
3. Discard the old fuel pipes.
Install
Important: The high pressure fuel pipes must be E
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the D
fuel pipe.
1. Make sure that the bleed-off adaptors are C

assembled on the injectors before you install the A Nut 1
high pressure pipes. B Fuel rail
C Injection pump
2. Assemble the fuel pipes one at a time. The D Nut 2
procedure describes how to assemble one fuel E Fuel pipe
pipe.
1. Remove the fuel pipe as follows.
2.1. Put the correct end of the fuel pipe against
the correct injector cone. 1.1. Loosen the nut 2. Do not remove the nut at
this step.
2.2. Tighten the nut 1 with your hand.
1.2. Use the 17mm deep socket special tool at
2.3. Put the other end of the fuel pipe against the
the top of nut. This will prevent damage to
correct fuel rail cone.
the nut.
2.4. Tighten the nut 2 with your hand. Special Tool: Socket 17MM Offset - (HP
2.5. Nuts must be tightened in the correct Fuel pipes) (Qty.: 1)
sequence. Tighten nut 1 and then nut 2. Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
2.6. Use the special tool at the top of nut 1 and
tighten it to the correct torque value. 1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1.
Torque: 27 N·m
Special Tool: Socket 17MM Offset - (HP 1.4. Push the fuel pipe against the rail cone and
Fuel pipes) (Qty.: 1) at the same time remove the nut 2.
2.7. Put the spanner at the top of nut 2 and 1.5. Make sure that there is no dirt or debris on
tighten it to the correct torque value. the fuel pipe or the connectors.
Torque: 27 N·m 1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Discard the old fuel pipe.
18 - 109 9813/8950-2 18 - 109

96 - Fuel Pipe
Install
Important: The high pressure fuel pipes must be

replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the
fuel pipe.
1. To assemble the fuel pipe.

1.1. Put the correct end of the fuel pipe against
the correct pump cone at the injection
pump.
1.3. Put the other end of the fuel pipe against the
correct fuel rail cone.
1.5. Nuts must be tightened in the correct
sequence. Tighten nut 2 and then nut 1.
1.6. Use the special tool at the top of nut 2 and
tighten it to the correct torque value.
Torque: 27 N·m
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
1.7. Put the spanner at the top of nut 1 and
tighten it to the correct torque value.
Torque: 27 N·m
After Installation
1. Ensure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced or renewed
18 - 110 9813/8950-2 18 - 110

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 375.

B
Remove and Install
A
Before Removal A
Refer to Fuel System, Health and Safety (PIL 18-00). C
Low Pressure Fuel Pipes

Remove
The low pressure fuel pipes have a nylon fitting
attached to the pipe that replaces the nut and olive.
The fittings are part of the pipe and not a separate
item.
1. To release the fuel pipe, first press and hold the

release buttons (one each side of the coupler).
Push the coupler towards the connector spigot
and then withdraw.
2. Cap all open ports to prevent ingress of dirt and
debris.
Assemble
1. To install the fuel pipe, press and hold the release
buttons. Push the coupler over the connector A Release Buttons
spigot and release the button. The connector will B Coupler
be heard to click when it is fully home and locked C Spigot
in place.
After Assembly
2. To check that the connection has been fully
made, attempt to pull the connector from the 1. Make sure that all the fuel pipes are correctly
connector spigot without releasing the lock installed and located in the retaining clips as
mechanism. (A gentle pull is all that is required, applicable. If retaining clips are missing or
if the connection is not correct the connector will damaged, they must be replaced or renewed.
release very easily.)
Injector Bleed-off Pipes

Before Removal
1. Make sure that the engine is safe to work on. The

engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine, Clean (PIL
15-00).
3. Remove the protective cover as follows.
18 - 111 9813/8950-2 18 - 111

96 - Fuel Pipe
06 - Low Pressure Pipe
3.1. Push out the plastic segments. Figure 377.

3.2. Remove the screws and lift off the cover.
Figure 376.
D
C
B
A B
C
A Screw A Location tabs
B Plastic segment B Bleed pipe connector
C Protective cover C Bleed pipe clip
D High pressure fuel pipe
3.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00). After Assembly
4. To remove the bleed pipe clips, remove the high 1. Make sure that all pipes are correctly installed
pressure fuel pipes first. Refer to (PIL 18-96-03). and located in retaining clips as applicable. If the
retaining clips are missing or damaged they must
5. DO NOT try to repair fuel pipes or connectors. be replaced or renewed.
Defective fuel pipe assemblies must be replaced.
Remove
3. Install the protective cover. Refer to Figure 376.
The following details the removal and replacement
of one bleed-off connector. The procedure for the
remaining connectors is identical.
1. Gently spring the location tabs apart and pull out

the bleed pipe connector. DO NOT use excessive
force on the tabs.
2. Remove and discard the O-ring.
3. If it is necessary to remove the bleed off pipe
assembly, remove the nylon fitting at the high
pressure pump.
4. Cap all open ports to prevent ingress of dirt and
debris.
Install
1. Install a new O-ring.
2. Push in the bleed pipe connector until the
location tabs snap over the connector.
3. If applicable, replace the high pressure fuel pipes
with new ones. DO NOT use a high pressure fuel
pipe that was removed. Refer to (PIL 18-96-03)
18 - 112 9813/8950-2 18 - 112

21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-13
21-03-03 Radiator .......................................................................................................................... 21-16
21-03-06 Charge Air Cooler (CAC) ............................................................................................... 21-18
21-03-09 Transmission Oil Cooler ................................................................................................. 21-20
21-03-12 Hydraulic Oil Cooler ....................................................................................................... 21-22
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-25
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-31
21-93 Hose
21-93-00 General ........................................................................................................................... 21-37
9813/8950-2
2018-03-09
Acronyms Glossary
CAC Charge Air Cooler

9813/8950-2
2018-03-09
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/8950-2 21 - 1
Notes:
21 - 2 9813/8950-2 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Component Identification ................................. 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Operation ......................................................... 21-6 quickly and then maintain it.
Fault-Finding .................................................... 21-7
Drain and Fill ................................................... 21-9
Check (Level) .................................................. 21-9
Bleed ............................................................. 21-10
21 - 3 9813/8950-2 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 130.
cap, hot coolant can spray out and burn you. Data Description
Make sure that the engine is cool before you work
on the cooling system. Radiator test pressure 1.2 bar ( 17.4 psi)
CAC (Charge Air Cool- 3 bar ( 43.5 psi)
CAUTION Antifreeze can be harmful. Obey the er) test pressure
manufacturer's instructions when handling full
strength or diluted antifreeze. Hydraulic oil cooler test 10 bar ( 144.9 psi)
pressure
21 - 4 9813/8950-2 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 378.
K
B
G
A H
A Radiator B CAC (Charge Air Cooler)

C Hydraulic oil cooler D Filler cap
E Expansion tank F Hose - CAC, Cold side
G Hose - CAC, Hot side H Hose - Radiator top
J Hose - Radiator bottom K Hose - Breather
21 - 5 9813/8950-2 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
Operation
The coolant pump is driven via a pulley and front end

accessory drive belt, the pump draws coolant from
the pump cavity.
The coolant is pumped through the outlet gallery

to the oil cooler cavity in the left-hand side of the
crankcase. As the coolant flows past the oil cooler
matrix, heat is exchanged from the oil to the coolant.
This enables the oil to function as a coolant as well
as a lubricant. Refer to Oil Cooler (PIL 15-69) and Oil
Filter (PIL 15-21).
The coolant leaves the oil cooler cavity and passes

into the main crankcase gallery. The gallery is
connected to the cylinder water jackets. Coolant
flows around and up the jackets and then passes into
the cylinder head via the link galleries. The coolant
circulates around the cylinder head where it conducts
heat away from the combustion chambers and also
the fuel injector tips, refer to (PIL 18-18). The coolant
then passes to the thermostat housing.
When the engine is below normal operating

temperature the thermostat is closed, preventing
coolant flowing to the machine radiator via the top
hose connection port. Instead coolant is directed
through the by-pass gallery back to the pump
cavity and is again drawn into the pump. Refer to
Thermostat (PIL 21-12).
When the engine is at operating temperature the

thermostat opens, closing the by-pass gallery to the
pump and opening the top hose connection port to
the machine radiator. The coolant passes through
the radiator matrix and is cooled. The coolant flows
back to the engine via the bottom hose connection
port and is again drawn into the pump. Refer to
Thermostat (PIL 21-12).
A coolant temperature gauge and warning light

sender unit is installed at port 14. Refer to Engine
Sensors (PIL 15-84).
A cab heater hose can be installed at port 15. This

enables coolant to circulate through a heater matrix
when the thermostat is open or closed, ensuring fast
heater warm up.
21 - 6 9813/8950-2 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 131. Page 21-7
Coolant - Over Temperature. Table 132. Page 21-7
Coolant - Under Temperature. Table 133. Page 21-8
Coolant - Contaminated. Table 134. Page 21-8
Table 131. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting See Also: Table 132. Coolant - Over Temperature.
in loss through the radiator overflow.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
EGR (Exhaust Gas Recirculation) cooler leak (if Check/replace the EGR cooler. Check for signs of
applicable). coolant leaking into combustion chamber.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
Table 132. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 131. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level overfilled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of anti-freeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
21 - 7 9813/8950-2 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
Leak between the top tank and the auxiliary tank Check for coolant leakage between radiator auxiliary
(sudden overheating). tank and radiator top tank.
Cooling passages in radiator, cylinder head, head Flush the system and fill with clean coolant.
gasket or crankcase blocked.
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault (if applicable). connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
Table 133. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, (open - not sealing). Check/replace the thermostat.
Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss
may result in the gauge showing low temperature
initially. In which case, check the level.
Table 134. Coolant - Contaminated.

Cause Remedy
Coolant rusty, operation without correct mixture of Drain and flush the cooling system. Fill with correct
antifreeze and water. mixture of antifreeze and water. Review the coolant
change interval.
Engine oil cooler, or cooler housing allowing cross Remove the oil cooler assembly and check relevant
contamination of coolant with engine oil. sealing elements for damage.
Transmission lubricating oil cooler leaking (if Check/replace lubricating oil cooler. Refer to
applicable). equipment manufacturer's procedures.
Lubricating oil leaks from lubricating oil cooler, head See Also: Table 131. Coolant - Loss.
gasket, head and crankcase.
21 - 8 9813/8950-2 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Level)

Consumables
Description Part No. Size 1. Make the machine safe.
Antifreeze HP/ 4006/1101 5L Refer to: PIL 01-03.
Coolant ASTM D6210 4006/1120 20 L
Concentrate 2. Get access to the coolant expansion tank.
4006/1103 200 L
3. Check the level of coolant in the coolant
The graphic shows a typical engine cooling system, expansion tank. If necessary remove the filler
the system you are working on may look slightly cap and top up to the level indicated.
different.
4. Install the filler cap and make sure it is tight.
1. Make the machine safe. Refer to (PIL 01-03).
5. Run the engine for a while to raise the coolant to
2. Stop the engine and let it cool down. working temperature and pressure.
3. Get access to the engine. 6. Stop the engine and check for leaks.
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 379.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 9 9813/8950-2 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Bleed 3. Install the radiator cap.

4. Fill the coolant expansion tank to the full mark.
Observe all the health and safety information. Refer
to: Cooling System - Health and Safety. Refer to: PIL 5. Start the engine and run until the normal engine
21-00-00. operating temperature is achieved.
6. Check for leaks.
Drain
7. Allow to cool then re-check the coolant level.
1. Slowly turn the coolant expansion tank cap a
quarter of a turn to discharge the cooling system
pressure.
2. Connect a suitable hose to the drain tap on the
left side of the crankcase.
3. Connect a pressure bleed kit to the radiator.
Figure 380.
A
A Pressure bleed kit
B Radiator
4. Open the coolant drain tap on the left side of
the engine and drain the cooling system into a
suitable container.
Figure 381.
C Drain tap
Fill
1. Make sure that the correct grade and quality of
antifreeze is added to the water.
1.1. The recommended content mixture is 50%
water, with 50% antifreeze.
2. Fill the cooling system through the radiator cap
until completely full.
21 - 10 9813/8950-2 21 - 10
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-13

21-03-03 Radiator .......................................................................................................................... 21-16
21-03-06 Charge Air Cooler (CAC) ............................................................................................... 21-18
21-03-09 Transmission Oil Cooler ................................................................................................. 21-20
21-03-12 Hydraulic Oil Cooler ....................................................................................................... 21-22
21 - 11 9813/8950-2 21 - 11
Notes:
21 - 12 9813/8950-2 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-13 The cooling pack contains the following major
Remove and Install ....................................... 21-14 components:
• Radiator.
• Cooling fan.
• CAC (Charge Air Cooler).
• Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 13 9813/8950-2 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install 10. Remove the expansion tank from the machine.
Remove 11. Loosen the clamp 2 (x2).
1. Make the machine safe. 12. Remove the right side radiator hose.
Refer to: PIL 01-03-27. 13. Remove the right side CAC hose.
2. Isolate the battery. Figure 383.
3. Drain the cooling system.
Refer to: PIL 21-00-00. B

D
5. Remove the rear lower crossmember.
8. Remove the left side radiator hose.
D
9. Remove the left side CAC (Charge Air Cooler)
hose.
Figure 382.
C
B CAC hose
C Radiator hose
D Clamp 2
14. Support the cooling pack with suitable lifting
equipment at the lifting points.
15. Remove the bolt 1 (x5) and washer 1 (x5).
A 16. Remove the rear bumper to access the bottom
mounting bolt 2 to remove the cooling pack.
B 17. Remove the bolt 2 (x4) and washer 2 (x4).
A C 18. Remove the cooling pack from the machine
carefully.
A Clamp
B CAC hose
C Radiator hose
21 - 14 9813/8950-2 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 384.
K
F
E
E Bolt 1 (x5)
F Washer 1 (x5)
G Bolt 2 (x4)
H Washer 2 (x4)
J Cooling pack
K Lifting point
Install
removal procedure.
21 - 15 9813/8950-2 21 - 15
21 - Cooling System
03 - Cooling Pack
03 - Radiator
03 - Radiator Introduction
Introduction .................................................... 21-16 Radiators are used for cooling internal combustion
Remove and Install ....................................... 21-17 engines.
To cool down the engine, a coolant is passed through

the crankcase, where it absorbs heat from the
engine. The hot coolant is then fed into the inlet tank
of the radiator from which it is distributed across the
radiator core through tubes to another tank on the
opposite end of the radiator. As the coolant passes
through the radiator tubes on its way to the opposite
tank, it transfers much of its heat to the tubes which,
in turn, transfer the heat to the fins that are lodged
between each row of tubes. The fins then release
the heat to the ambient air. Fins are used to greatly
increase the contact surface of the tubes to the air,
thus increasing the exchange efficiency.
The cooled coolant is fed back to the engine, and the

cycle repeats. Normally, the radiator does not reduce
the temperature of the coolant back to ambient air
temperature, but it is still sufficiently cooled to keep
the engine from overheating.
21 - 16 9813/8950-2 21 - 16
21 - Cooling System
03 - Cooling Pack
03 - Radiator
Remove and Install

method and device.
Remove
2. Install the articulation lock.
3. Remove the hydraulic oil cooler from the cooling
pack.
4. Remove the cooling pack from the machine.
5. Remove the CAC (Charge Air Cooler) from the
cooling pack.
6. Remove the radiator. Make sure that you do not
damage the cooling fins.
Install
removal procedure.
21 - 17 9813/8950-2 21 - 17
21 - Cooling System
03 - Cooling Pack
06 - Charge Air Cooler (CAC)
06 - Charge Air Cooler (CAC) Introduction

Introduction .................................................... 21-18 The CAC (Charge Air Cooler) is used to cool
Remove and Install ....................................... 21-19 the engine air after it has passed through the
turbocharger, but before it enters the engine. This
lowers the temperature of compressed air, optimizing
the power for the combustion process within the
turbocharged engine.
The CAC is the part of the main cooling pack. Refer

to: PIL 21-03-00.
21 - 18 9813/8950-2 21 - 18
21 - Cooling System
03 - Cooling Pack
06 - Charge Air Cooler (CAC)

Remove removal procedure.

2. Remove the cooling pack from the machine.
3. Place the cooling pack on a clean workbench.
4. Disconnect the CAC (Charge Air Cooler) hoses.
5. Remove the setscrew 1 (x9) and washers 1 (x9)
from the bend plate.
6. Remove the bend plate from the CAC.
7. Remove the setscrew 2 (x4) and washer 2 (x4).
8. Remove the CAC from the radiator.
Figure 385.
D
B
C
G
A
E,F
A CAC
B Setscrew 1 (x9)
C Washer 1 (x9)
D Bend plate
E Setscrew 2 (x4)
F Washer 2 (x4)
G Radiator
21 - 19 9813/8950-2 21 - 19
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Introduction

Introduction .................................................... 21-20 The transmission oil cooler is used to cool the
Remove and Install ....................................... 21-21 transmission oil. It is combined with the hydraulic oil
cooler, but functions individually.
21 - 20 9813/8950-2 21 - 20
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
Remove and Install
The transmission oil cooler is part of the hydraulic oil

cooler. Refer to: PIL 21-03-12.
21 - 21 9813/8950-2 21 - 21
21 - Cooling System
03 - Cooling Pack
12 - Hydraulic Oil Cooler
12 - Hydraulic Oil Cooler Figure 387.
Remove and Install
Remove E,F

Refer to: PIL 01-03-27. G
2. Install the articulation lock. D

D
3. Remove the engine compartment cover.
4. Drain the hydraulic system.
D Hoses
Refer to: PIL 30-00-00. E Nuts (x4)
F Screw (x4)
5. Drain the gearbox. D Oil cooler
Install
6. Remove the setscrew 1 (x5) and washer (x5).
7. Remove the fan cowl. removal procedure.
Figure 386.
A,B
A Setscrew (x5)
B Washer (x5)
C Fan cowl
9. Disconnect the hoses from the cooler.
contamination.
11. Remove the nuts (x4) and screws (x4).
12. Remove the oil cooler from the machine.
21 - 22 9813/8950-2 21 - 22
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-25
21 - 23 9813/8950-2 21 - 23
Notes:
21 - 24 9813/8950-2 21 - 24
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-25 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-26 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 - 25 9813/8950-2 21 - 25
21 - Cooling System
06 - Expansion Tank
00 - General
Remove and Install
Consumables Refer to: PIL 21-00-00.

5. Get access to the coolant expansion tank.
JCB Threadlocker 4101/0250 0.01 L
and Sealer (Medium 4101/0251 0.05 L 6. Put a label on the hoses to help installation.
Strength)
7. Loosen the clips that attach the hoses to the
Remove coolant expansion tank.
1. Make the machine safe. 8. Disconnect the hoses from the coolant
expansion tank.
2. Make sure that the engine is safe to work on. If contamination.
you start the service work. 10. Remove the screws (x3).
3. Open the engine compartment cover. 11. Remove the expansion tank cover.
Refer to: PIL 06-06-06. 12. Remove the coolant expansion tank from the
bracket.
4. Drain the cooling system.
21 - 26 9813/8950-2 21 - 26
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 388.
A B
F
A
A Clips B Hoses
C Tank cover D Expansion tank
E Screws (x3) F Bracket
Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
removal procedure. Additionally do the following 3. Check the coolant level and top up to the correct
steps. level.
2. Apply specified locking fluid to the screws.
21 - 27 9813/8950-2 21 - 27
21 - Cooling System
06 - Expansion Tank
00 - General
4. Check the cooling system for leaks.

21 - 28 9813/8950-2 21 - 28
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-31
21 - 29 9813/8950-2 21 - 29
Notes:
21 - 30 9813/8950-2 21 - 30
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-31 The thermostat is located between the engine and
Component Identification ............................... 21-32 the radiator. The function of the thermostat is to block
Operation ....................................................... 21-32 the flow of coolant to the radiator until the engine has
Check (Condition) .......................................... 21-33 warmed up to a sufficient temperature.
Check (Operation) ......................................... 21-34 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 - 31 9813/8950-2 21 - 31
21 - Cooling System
12 - Thermostat
00 - General

Figure 389. The thermostat is a wax element type and is
configured for by-pass blanking. The thermostat
functions as follows:
State A - Closed (Engine Cold)

When the engine is cold the wax pellet has
contracted into its housing. This allows the spring to
act against the thermostat body and move the valve
A plate up against its seat, closing the outlet port to the
radiator. Since the bottom valve plate is connected
to the top valve plate it also moves up, opening the
bypass port. The coolant flows from the thermostat
housing inlet port into the bypass gallery.
Figure 390.
7 3
8 11
6
10
5
A Thermostat
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1 mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1
21 - 32 9813/8950-2 21 - 32
21 - Cooling System
12 - Thermostat
00 - General
mm diameter orifice allows trapped air to be expelled Check (Condition)

from the system.
Figure 391. 1. If the thermostat is suspected of being faulty,

7 3 perform a thermostat test, refer to Thermostat
- Check Operation to confirm its serviceability.
Note that the thermostat is a non-serviceable
8 11 item. If the thermostat is faulty or damaged it
must be renewed.
2. Inspect the seal for damage or splits. If necessary
renew the seal. Make sure that the seal is
correctly located.
9
6
10
5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1 mm diameter orifice
21 - 33 9813/8950-2 21 - 33
21 - Cooling System
12 - Thermostat
00 - General
Check (Operation)
A period of 3 –5 min before the thermostat valve

starts to operate is normal because of the time
required to heat soak the thermostat.

2. Remove the thermostat housing and the
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 392.
Figure 392.
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 - 34 9813/8950-2 21 - 34
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-37
21 - 35 9813/8950-2 21 - 35
Notes:
21 - 36 9813/8950-2 21 - 36
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-37 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-38 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-38 between the engine and the radiator/cooling pack.
21 - 37 9813/8950-2 21 - 37
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 - 38 9813/8950-2 21 - 38
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-01 Master Cylinder ................................................................................................................ 24-9
24-18 Park Brake
24-18-06 Cable .............................................................................................................................. 24-13
9813/8950-2
2018-01-21
Notes:
9813/8950-2
2018-01-21
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/8950-2 24 - 1
Notes:
24 - 2 9813/8950-2 24 - 2
24 - Brake System
00 - Brake System
00 - General
Introduction ...................................................... 24-3 Under no circumstances allow conventional brake
Health and Safety ........................................... 24-4 fluid to be added to the system, never purge the
Component Identification ................................. 24-5 system and refill with brake fluid. Otherwise damage
Fault-Finding .................................................... 24-6 will occur to all the rubber sealing components within
the brake system. Use only mineral based hydraulic
oil.
The machine uses axles with oil immersed totally

enclosed multi plate brakes. The machines have
front and rear brakes, operating on independent
circuits that gives dual circuit safety.
The brake system uses a tandem master cylinder

and is filled with mineral oil through a remotely
mounted fluid reservoir located behind the access
panel on the front of the seat support.
Normally adjustment of the brakes is not necessary

as they adjust automatically by design. Bleeding of
the system may be necessary if the system pipework
is damaged causing system leakage.
The dumper has a park brake system which is

integral with the disc and caliper installed to the
gearbox output shaft and is operated by a park brake
located to the right of the operator seat.
24 - 3 9813/8950-2 24 - 3
24 - Brake System
00 - Brake System
00 - General
Health and Safety the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
Brake Fluid WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Use of incorrect brake fluid will cause serious
Put blocks on all wheels to prevent the machine
damage to the seals of the braking system. This will
rolling.
result in brake failure.
WARNING! Do not use the machine with any part of
Accumulators
its brake system disconnected or inoperative. When
The accumulators contain hydraulic fluid and gas at the test has been completed, make sure all brake
high pressure. Prior to any work being carried out system components are installed and the system is
on systems incorporating accumulators, the system operating correctly.
pressure must be discharged by a JCB dealer, as
WARNING! Before testing the park brake make sure
the sudden release of the hydraulic fluid or gas may
the area around the machine is clear of people.
cause serious injury or death.
WARNING! If the machine starts to move during the
Service Brake Bleeding
park brake test, immediately apply the foot brake and
Before bleeding the service brake system, park on reduce the engine speed.
level ground and set the park brake to on. Put blocks
WARNING! If the machine starts to move during the
on both sides of the wheels on one axle to prevent
service brake test, immediately reduce the engine
the machine rolling. Stop the engine and disconnect
speed and apply the park brake.
the battery so that the engine cannot be started. If
you do not take these precautions the machine could WARNING! Do not use a machine with a faulty park
run over you. brake.
Park Brake Maintenance WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
Before working on the park brake, park on level
adversely affect the performance of the park brake.
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and WARNING! Oil on the brake disc will reduce brake
disconnect the battery so that the engine cannot be effectiveness. Keep oil away from the brake disc.
started. If you do not take these precautions the Remove any oil from the disc with a suitable solvent.
machine could run over you. Read and understand the solvent manufacturer's
safety instructions. If the pads are oily, install with the
new pads.
WARNING! Faulty brakes can kill. If you have to top
up the brake oil reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
movement. WARNING! The park brake must not be used to
slow the machine from travelling speed, except in an
Brake Dust
emergency, otherwise the efficiency of the brake will
Brake pads generate dust, which if inhaled may be reduced. Whenever the park brake has been used
endanger health. Wash off the caliper assemblies in an emergency the brake friction components must
before commencing work. Clean hands thoroughly be renewed and the other components inspected.
after completing the work.
Notice: Over adjustment or failure to disengage the
Brake Dust park brake properly will cause excessive wear of the
Brake shoes generate dust, which if inhaled park brake mechanism.
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
24 - 4 9813/8950-2 24 - 4
24 - Brake System
00 - Brake System
00 - General
Figure 393.
C
F
B
A
A Front axle B Front axle brake bleed nipple

C Remote brake fluid tank D Master cylinder
E Rear axle brake bleed nipple F Rear axle
24 - 5 9813/8950-2 24 - 5
24 - Brake System
00 - Brake System
00 - General
Fault-Finding
Fault
Insufficient braking Table 135. Page 24-6
Brake pedal is soft Table 136. Page 24-6
Overheating of the brake system Table 137. Page 24-6
Table 135. Insufficient braking

Cause Remedy
Incorrect adjustment Check the brake disc thickness. Adjust the brakes.
Worn out brake disc Check the brake disc thickness. Replace the brake
discs.
Incorrect brake fluid Drain the incorrect brake fluid. Replace all the seals
and hoses from the brake system. Fill the correct oil.
Loss of brake fluid Check the outside circuit and the master cylinder
for leaks. Repair as necessary. If the leak is to the
outside, replace the O-rings between the center and
the intermediate housings. If the leak is to the inside,
replace the all the O-rings.
Overheated axle causing brake fluid to vaporize Refer to overheating fault remedy.
See Also: Table 137. Overheating of the brake
system
Table 136. Brake pedal is soft

Cause Remedy
Air in the brake system Bleed the brake system.
Table 137. Overheating of the brake system

Cause Remedy
Wrong oil level Drain, flush and fill the brake oil to the correct level.
Too small brake gap Adjust the brakes.
Incorrect brake fluid in the system Drain the incorrect brake fluid. Replace all the seals
and hoses from the brake system. Fill the correct oil.
No free play of brake pedal at master cylinder Adjust the brake pedal free play.
Restrictions in the brake lines Check the condition of the brake lines. Replace as
necessary.
24 - 6 9813/8950-2 24 - 6
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-01 Master Cylinder ................................................................................................................ 24-9
24 - 7 9813/8950-2 24 - 7
Notes:
24 - 8 9813/8950-2 24 - 8
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Introduction

Introduction ...................................................... 24-9 The brake master cylinder contains brake fluid and
Remove and Install ....................................... 24-10 is connected to the brakes through the brake pipes.
When you step on the brake pedal, brake fluid flows
from the master cylinder to the brake unit at each
wheel, creating enough friction to slow down and/or
stop the machine.
The brake master cylinder has internal and external

seals that can wear out over time. If the external seals
have worn out, they will leak brake fluid, reducing the
amount of fluid in the brake system and cause the
brakes to malfunction.
24 - 9 9813/8950-2 24 - 9
24 - Brake System
03 - Service Brake
01 - Master Cylinder
Remove and Install 2. Tighten the bolts to the correct torque value.

Remove Item Description Nm
E Bolts 60
3. Remove the floorplate.
4. Disconnect the front brake pipe, rear brake pipe
and the brake fluid tank from the master cylinder.
Figure 394.
B C A C
A Front brake pipe

B Rear brake pipe
C Brake fluid tank
D Master cylinder
5. Remove the bolts.
6. Remove the master cylinder from the machine.
Figure 395.
D Master cylinder
E Bolts
Install
step.
24 - 10 9813/8950-2 24 - 10
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-06 Cable .............................................................................................................................. 24-13
24 - 11 9813/8950-2 24 - 11
Notes:
24 - 12 9813/8950-2 24 - 12
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-13 1. Make the machine safe.
Remove and Install ....................................... 24-15 Refer to: PIL 01-03-27.
2. Remove the floorplate.
4. Remove the plastic hand grip from the park brake
lever.
Figure 396.
A Plastic hand grip

5. Loosen the locking grub screw.
6. Rotate the adjusting nut in an anticlockwise
direction to give free play in the cable.
Figure 397.
C
B
B Grub screw
C Adjusting nut
7. Adjust the cable so that the specified length of
thread protrudes through the locknut.
Dimension: 5 mm
8. Tighten the nut against the back of the bracket.
24 - 13 9813/8950-2 24 - 13
24 - Brake System
18 - Park Brake
06 - Cable
Figure 398.
E
F
D Park brake cable

E Locknut
F Nut
9. Rotate the adjusting nut on the park brake lever
in a clockwise direction until the free play in the
cable has been taken up. Correct adjustment is
achieved when there is no free play in the cable
and no pressure on the brake lever.
10. Tighten the locking grub screw.
11. Install the plastic hand grip to the park brake
lever.
24 - 14 9813/8950-2 24 - 14
24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
4. Disconnect the park brake cable from the hand

Remove brake lever.
1. Make the machine safe. 5. Remove the cable tie (x3) securing the park
brake cable to the chassis.
6. Remove the nut and washer at the front axle.
Refer to: PIL 33-03-00. 7. Disconnect the park brake cable at the front axle.
3. Remove the cable locknut (x3) and bolt (x3) from 8. Make a note of the route and the position of the
the hand brake lever. cable to help installation.
9. Remove the park brake cable from the chassis.
Figure 399.
A Hand brake lever B Locknut

C Nut D Cable tie
24 - 15 9813/8950-2 24 - 15
24 - Brake System
18 - Park Brake
06 - Cable
Install
step.
2. Adjust the park brake.
24 - 16 9813/8950-2 24 - 16
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-06 Steer Unit/Valve
25-06-00 General ............................................................................................................................. 25-9
25-12 Column
25-12-00 General ........................................................................................................................... 25-15
25-12-06 Cover .............................................................................................................................. 25-19
9813/8950-2
2018-02-21
Notes:
9813/8950-2
2018-02-21
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3
25 - 1 9813/8950-2 25 - 1
Notes:
25 - 2 9813/8950-2 25 - 2
00 - General
Introduction ...................................................... 25-3 The site dumpers have a chassis which incorporates
Health and Safety ........................................... 25-4 a design known as centre pivot articulated steering.
Diagram ........................................................... 25-6 The chassis is in two parts, a front and a rear section
which are joined together in the middle by a vertical
pivot pin and a link. This link provides movement in
the horizontal and the lateral planes between the two
chassis sections. The combined movement of the
chassis sections allow the front frame to be moved
relative to the rear frame, by means of a single
double acting steering ram.
The link in the system enables the front and rear

frames to articulate relative to each other and thus
provide the ability to maintain maximum adhesion
with the ground at all times.
The steering system is controlled through the

steering wheel acting on an orbitrol hydrostatic
steering unit. The hydraulic power is supplied
through an engine driven pump to the steering unit,
which on turning the steering wheel meters the oil
to the steering ram and thus provides movement in
either direction of the dumper.
In the event of a hydraulic failure the dumper can

still be steered. Under these circumstances steering
loads are high and the dumper should only be driven
at slow speeds.
25 - 3 9813/8950-2 25 - 3
00 - General
Health and Safety

Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
the fault has been corrected.
movement.
Fluid Under Pressure
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.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
hose line must be vented. Make sure the hose
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
WARNING! When getting access for maintenance
work, make sure no-one is in a position to be caught
and/or crushed by the wheels when the steering
wheel is turned.
25 - 4 9813/8950-2 25 - 4
00 - General
Figure 400.
T L
P LS
A Steer unit B Priority valve

L L Port, steer unit - To steering cylinder ram R R Port, steer unit - To steering cylinder ram
P P Port, steer unit - To priority valve T T Port, steer unit - To hydraulic tank
LS LS Port, steer unit - To priority valve (LS Port)
25 - 5 9813/8950-2 25 - 5
00 - General
Diagram
Refer to Hydraulic System- General- Schematic

Diagram. Refer to: PIL 30-00-50.
25 - 6 9813/8950-2 25 - 6
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ............................................................................................................................. 25-9
25 - 7 9813/8950-2 25 - 7
Notes:
25 - 8 9813/8950-2 25 - 8
00 - General
Introduction ...................................................... 25-9 The steer unit valve controls the amount of hydraulic
Technical Data ............................................... 25-10 fluid flow in the steering system.
Check (Condition) .......................................... 25-10
25 - 9 9813/8950-2 25 - 9
00 - General
Technical Data Check (Condition)

Consumables
Table 139. Description Part No. Size
Description Data Surface Cleaning Fluid 4103/1204 1L
Type Load sensing dynamic
1. Examine all contact surfaces and replace any
Displacement 400 cm³ per rev
parts that have scratches, wear or other damage
Pump flow supply 12 –50 L/min that could cause leakage.
Maximum back pressure 40 bar ( 579.7 psi)
Relief valve pressure 170 –175 bar ( 2,463.8 – 2. Do not use abrasive or try to file or grind the
2,536.2 psi) surfaces.
Shock valve set pres- 240 –260 bar ( 3,478.2 – 3. Clean all metal parts with a solvent and blow dry
sure 3,768.1 psi) with an air line.
Maximum steering pres- 170 –175 bar ( 2,463.8 – Consumable: Surface Cleaning Fluid
sure 2,536.2 psi)
25 - 10 9813/8950-2 25 - 10
00 - General
Remove B
B Hoses
10. Remove the grease nipple.
5. Remove the steering column cover.
12. Disconnect the steer valve from the steering
6. Remove the cable ties. column.
J Grease nipple
K Steer valve
L Bolts 2
13. Rotate the steer valve anti-clockwise and remove
the steer valve from the machine.
A
Figure 404.
A Cable ties
7. Disconnect the hoses from the steer unit.
8. Put a label on the hoses to help installation. K
contamination. K Steer valve
25 - 11 9813/8950-2 25 - 11
00 - General
Install
steps.
2. Align the steering column splines to the steer
unit.
4. Check the hydraulic oil level and top up as
required.

Item Description Nm
L Bolts 2 60
25 - 12 9813/8950-2 25 - 12
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-15

25-12-06 Cover .............................................................................................................................. 25-19
25 - 13 9813/8950-2 25 - 13
Notes:
25 - 14 9813/8950-2 25 - 14
12 - Column
00 - General
Introduction .................................................... 25-15 The steering column connects the steering wheel to
Remove and Install ....................................... 25-16 the steering mechanism.
25 - 15 9813/8950-2 25 - 15
12 - Column
00 - General
Remove and Install
6. Remove the screw 3 (x8).

Remove 6.1. Remove the control leg guard.
7.1. Remove the control mounting block.
2. Remove the cap.
3. Remove the locknut.
8.1. Remove the control leg guard cover.
4. Remove the steering wheel.
9. Remove the bolt (x4) and washer from the
5. Remove the screw 1 (x4). steering column.
5.1. Remove the column cover. 10. Remove the steering column.
Figure 405.
A
B
C
K
D
E
H N
A Cap B Locknut
C Steering wheel D Column cover
25 - 16 9813/8950-2 25 - 16
12 - Column
00 - General
E Screw 1 (x4) F Screw 2 (x6)

G Control leg guard cover H Control leg guard
J Screw 3 (x8) K Control mounting block
L Screw 4 (x2) M Steering column
N Bolt (x4)
25 - 17 9813/8950-2 25 - 17
12 - Column
00 - General
Install
step.
25 - 18 9813/8950-2 25 - 18
12 - Column
06 - Cover
06 - Cover
Remove and Install
Refer to Steering, Column - Remove and Install PIL

25-12-00 .
25 - 19 9813/8950-2 25 - 19
Notes:
25 - 20 9813/8950-2 25 - 20
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-03 Manual Gearbox
27-03-00 General ............................................................................................................................. 27-9
27-03-06 Clutch - Forward/Reverse .............................................................................................. 27-64
27-03-15 Solenoid Control Valve ................................................................................................... 27-73
27-03-16 Check Valve ................................................................................................................... 27-76
27-03-24 Oil Pump ........................................................................................................................ 27-78
27-03-39 Filter ............................................................................................................................... 27-80
27-03-40 Suction Strainer .............................................................................................................. 27-82
27-03-45 Piston Ring Seal ............................................................................................................ 27-84
27-03-47 Oil Seal .......................................................................................................................... 27-86
27-03-74 Synchromesh Gear 1 and 2 ........................................................................................... 27-88
27-03-90 Front Case ..................................................................................................................... 27-98
27-03-91 Rear Case .................................................................................................................... 27-100
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-103
27-20 Axle
27-20-00 General ......................................................................................................................... 27-117
27-24 Differential
27-24-00 General ......................................................................................................................... 27-137
27-27 Hub
27-27-00 General ......................................................................................................................... 27-141
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-145
27-29-15 Wheel Nuts ................................................................................................................... 27-148
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-151
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-155
9813/8950-2
2018-02-21
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
PMV Pressure Maintenance Valve
PTFE Polytetrafluoroethylene
9813/8950-2
2018-02-21
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/8950-2 27 - 1
Notes:
27 - 2 9813/8950-2 27 - 2
27 - Driveline
00 - Driveline
00 - General
Introduction ...................................................... 27-3 The Synchro Shuttle Gearbox consists of a torque
Health and Safety ........................................... 27-6 converter, hydraulic reverser unit, and an integral
Technical Data ................................................. 27-6 manual 4–speed transmission.
The reverser unit has a pair of hydraulically operated
clutches giving forward - neutral - reverse drive.
Oil pressure is provided by a crescent type pump
driven at engine speed by the drive lugs of the
torque converter. The oil pressure is controlled by a
pressure maintenance valve and clutch selection is
achieved by means of an electric solenoid valve.
Drive is transferred from the reverser unit by helical

gears to the main shaft, which carries the 3rd/4th
synchromesh unit and to the layshaft, which carries
the 1st/2nd synchromesh unit. The synchromesh
units are of the 'Blocking Pin' type. Drive is
transmitted finally via the output shaft to the transfer
box.
Oil from the pump is fed through an internal passage

via the filter to the pressure maintenance valve,
which maintains pressure to the solenoid valve for
clutch selection. Excess oil from the maintenance
valve flows back through the gearbox case to the
torque converter between the converter hub and the
stator support and leaves between the stator and
the input shaft. Pressure in the torque converter is
controlled by a relief valve which dumps oil from the
torque converter line back into the sump.
Oil from the torque converter flows out of the gearbox

to the external oil cooler, returning at the rear of
the gearbox unit to pass through the centre of the
reverser shaft for clutch lubrication. In neutral the
flow of the pressurised oil is blocked at the solenoid
valve.
When either forward or reverse is selected, the

solenoid valve diverts pressurised oil via the reverser
shaft to the appropriate clutch in the reverser unit.
A restrictor orifice in the feed to the solenoid valve
modulates the pressure to the clutch to give a smooth
engagement. Pressure from the clutch is vented
back to the sump via the solenoid valve spool.
27 - 3 9813/8950-2 27 - 3
27 - Driveline
00 - Driveline
00 - General
Figure 406. SS620 Synchro Shuttle
Q
D
R
B A
C
L H
S U G
K N
M
V
A Forward and reverse clutch unit B Oil pump

C Oil pressure maintenance valve D Oil pressure maintenance valve
E Main shaft F Synchromesh unit (3rd and 4th gears)
27 - 4 9813/8950-2 27 - 4
27 - Driveline
00 - Driveline
00 - General
G Layshaft H Synchromesh unit (1st and 2nd gears)

J Transfer gear, output shaft and yoke K 4WD (Four Wheel Drive) output yoke (if
installed)
L 2WD (Two Wheel Drive) and 4WD clutch unit (if M 4WD solenoid control valve (if installed)
installed)
N Oil strainer P Oil filter
Q Gear selection turret assembly R Torque converter
S Torque converter relief valve U Hose connection (to oil cooler)
V Hose connection (from oil cooler)
27 - 5 9813/8950-2 27 - 5
27 - Driveline
00 - Driveline
00 - General

Working Under the Machine Table 141.
Description Data
correctly attached. Engage the park brake, remove Axle
the ignition key, disconnect the battery. If the machine Type JCB PD70
has wheels use blocks to prevent unintentional Ratio (For: 6T) 15.785:1
movement. (For: 9T) 18.16:1
WARNING! A raised and badly supported machine Transfer gearbox
can fall on you. Position the machine on a firm, level Type JCB TG300
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the Ratio 1:1
machine hydraulics or jacks to support the machine Transmission
when working under it. Disconnect the battery, to Type GA SS600 G/BOX 2WD S/R,
prevent the machine being started while you are Manual gearbox
beneath it. Gear ratio (For- 1st 5.558:1
WARNING! Before disconnecting any propshaft, ward) 2nd 3.445:1
make sure you block both sides of all wheels to 3rd 1.834:1
prevent machine movement. The park brake will
4th 1:1
become ineffective or may only operate on 2 wheels
(depending on machine specification). Gear ratio (Re- 1st 5.558:1
verse) 2nd 3.445:1
WARNING! If a 4 wheel drive machine is to be
raised and the engine/transmission run, make sure 3rd 1.834:1
all four wheels are raised off the ground. Make sure 4th 1:1
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 - 6 9813/8950-2 27 - 6
27 - Driveline
00 - Driveline
00 - General
Figure 407.
B
A
E
D
A Front axle B Rear axle

D Transfer gearbox E Propshaft
27 - 7 9813/8950-2 27 - 7
27 - Driveline
03 - Manual Gearbox
03 - Manual Gearbox
Contents Page No.
27-03-00 General ............................................................................................................................. 27-9

27-03-06 Clutch - Forward/Reverse .............................................................................................. 27-64
27-03-15 Solenoid Control Valve ................................................................................................... 27-73
27-03-16 Check Valve ................................................................................................................... 27-76
27-03-24 Oil Pump ........................................................................................................................ 27-78
27-03-39 Filter ............................................................................................................................... 27-80
27-03-45 Piston Ring Seal ............................................................................................................ 27-84
27-03-47 Oil Seal .......................................................................................................................... 27-86
27-03-90 Front Case ..................................................................................................................... 27-98
27-03-91 Rear Case .................................................................................................................... 27-100
27 - 8 9813/8950-2 27 - 8
27 - Driveline
03 - Manual Gearbox
00 - General
Introduction ...................................................... 27-9 A manual gearbox is a type of transmission used in
Component Identification ............................... 27-10 motor vehicle applications. It uses a driver operated
Fault-Finding .................................................. 27-15 clutch, engaged and disengaged by a foot pedal,
Drain and Fill ................................................. 27-24 for regulating torque transfer from the engine to the
transmission and a gear lever operated by hand.
Clean ............................................................. 27-25
Check (Condition) .......................................... 27-26 A typical JCB manual transmission is called Synchro
Check (Pressure) .......................................... 27-27 Shuttle, of which the following types exist:
Calibrate ........................................................ 27-30
• SS500
Remove and Install ....................................... 27-34 • SS600
Disassemble and Assemble .......................... 27-37 • SS620
• SS700
• SS750
27 - 9 9813/8950-2 27 - 9
27 - Driveline
03 - Manual Gearbox
00 - General
order for parts replacement, always give the details

Unit Identification mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
The gearbox serial number is stamped on the unit stamped on the gear, and the number of teeth.
identification plate as shown. When you make an
27 - 10 9813/8950-2 27 - 10
27 - Driveline
03 - Manual Gearbox
00 - General
Main Component Identification
Q
D
R
B A
C
L H
S U G
K N
M
V
A Forward and reverse clutch unit B Transmission oil pump
27 - 11 9813/8950-2 27 - 11
27 - Driveline
03 - Manual Gearbox
00 - General
C Oil pressure maintenance valve D Oil pressure maintenance valve

E Main shaft F Synchromesh unit (3rd and 4th gears)
G Layshaft H Synchromesh unit (1st and 2nd gears)
J Transfer gear, output shaft and yoke K 4 Wheel drive output yoke (if installed)
L 2 and 4 Wheel drive clutch unit (if installed) M 4 Wheel drive solenoid control valve (if installed)
N Oil strainer P Oil filter
Q Gear selection turret assembly R Torque converter
S Torque converter relief valve U Hose connection (to oil cooler)
V Hose connection (from oil cooler)
27 - 12 9813/8950-2 27 - 12
27 - Driveline
03 - Manual Gearbox
00 - General
Sectional Drawing
35
43
42
41
40
44
39
38
37
36
32 33 34
31
29 44
30
28
23 24
45
26
27
18 48 19 20 21 22
25 46
10
8
7
6
14
13
15
17
16
9
47
12
11
4
3
2
5
27 - 13 9813/8950-2 27 - 13
27 - Driveline
03 - Manual Gearbox
00 - General
1 Park brake disc (Gearboxes may be installed 2 Washer

with a coupling yoke in place of the park brake
disc where applicable.)
3 Stake nut 4 Transfer gear output shaft
5 Oil seal 6 Bearing (taper roller)
7 Bearing (taper roller) 8 Seal
9 Spacer 10 Synchromesh unit (3rd and 4th gears)
11 Bearing (taper roller) 12 Spacer
13 Cover plate 14 Gasket
15 Spacer 16 Bearing (taper roller)
17 Shims 18 Lay shaft
19 Synchro hub 20 Bearing (needle roller)
21 2nd Gear 22 Bearing track ring
23 Synchromesh unit (1st and 2nd gears) 24 1st Gear
25 3rd Gear 26 Main shaft
27 Gearbox case (rear) 28 Forward and reverse clutch
29 Gearbox case (front) 30 4 Wheel drive gear (if installed)
31 2 and 4 Wheel drive clutch (if installed) 32 4 Wheel drive housing (if installed)
33 Oil seal 34 Coupling yoke (4 Wheel drive)
35 Flanged bolt 36 Bearing taper roller
37 Transfer gear (4 Wheel drive) 2 Wheel drive 38 Dowel
gearboxes are installed with a spacer in place
of the 4 wheel drive gear.
39 Spacer 40 Bearing (taper roller)
41 Oil pump 42 Sealing ring
43 Torque converter housing 44 Shims
45 4 Wheel drive solenoid control valve (if 46 Forward/reverse solenoid control valve
installed)
47 Park brake calliper (if installed) 48 Bearings (needle roller) (if installed) 2011 on
only (not low ratio variants)
27 - 14 9813/8950-2 27 - 14
27 - Driveline
03 - Manual Gearbox
00 - General
Fault-Finding
Fault
The transmission is noisy Table 142. Page 27-15
The transmission is overheating Table 143. Page 27-17
The transmission will not pull Table 144. Page 27-19
There is no drive in one or both directions Table 145. Page 27-21
The transmission is jumping out of gear Table 146. Page 27-22
The transmission is sticking in gear Table 147. Page 27-23
The gear ratios are crash changing Table 148. Page 27-23
Before you do the following checks, make sure that For fault-finding of the transmission hydraulic
you operate the machine to determine the fault area. system, refer to Hydraulic System, General, Fault
Make sure that the system is at its normal working Finding- (PIL 30-00).
temperature. For fault-finding of the transmission oil cooling
Make sure that the you use the correct quantity and system, refer to Manual Gearbox, Check
grade of oil. (Operation)- (PIL 27-03).
Make sure that there are no leaks in the system.
Table 142. The transmission is noisy

Check Action
1 Is there noise when selecting direction? Yes Check 3.
No Check 2.
2 Is there noise when running with direction Yes Check 9.
selector in neutral and ratio selector in first? No Check 19.
3 Is there air in the hydraulic system? Yes Continue to run the engine to expel air.
No Check 4.
4 Is the fluid level correct? Yes Check 5.
No Allow machine to cool down. Check the oil
level. If necessary, top up as required.
5 Are the oil passages restricted? Yes Clear the restrictions.
No Check 6.
6 Is the suction strainer restricted? Yes Remove and clean the strainers.
No Check 7.
7 Is pump pressure as specified? Yes Check 9.
No Check the condition of the clutch PMV
(Pressure Maintenance Valve). Make sure
that it is free to operate.
8 When flow testing pump, is output low? Yes Replace the pump.
No Check the condition of the converter sprag
clutch for wear or slip.
9 Does the noise continue when direction Yes Check 10.
selector is in forward or reverse? No Check 11.
10 Is transmission misaligned? Yes Replace the mounting. Check the position
of the transmission.
No Check the converter out pressure and flow.
11 Are the pump bushes worn? Yes Replace the bushes.
No Check the converter for wear or cooler for
restriction to flow.
12 Is the transmission not pulling in one Yes Check 16.
direction only? No Check 13.
13 Is the transmission not pulling in both Yes Stall test the machine.
forward and reverse? Check 14.
27 - 15 9813/8950-2 27 - 15
27 - Driveline
03 - Manual Gearbox
00 - General
Check Action
No Check 16.
14 Is the converter in pressure is as specified? Yes Check 15.
No Inspect the converter relief valve for
damage.
15 Is pump being driven by converter? Yes Check the pump pressure.
No Replace the damaged components.
16 Are clutch sealing rings damaged? Yes Tap the pressure gauge into clutch feed
lines to monitor pressure.
No Check the clutch plates for damage.
17 Is there drive in one direction only? Yes Check 19.
No Check 18.
18 Is the start switch in the run position and Yes Check 19.
supplying current to the neutral start relay? No Repair as necessary.
19 Is the fault only when the transmission is Yes Disassemble the solenoid. Check the
hot? condition of the components.
No Check the condition of the microswitches,
relay and wiring loom.
20 Is the noise a growl, hum or grinding? Yes Check the condition of the gears for
damage or wear.
No Check 21.
21 Is the noise a hiss, thump or bumping? Yes Check the condition of the bearings for
damage or wear.
No Check 22.
22 Is the noise a squeal? Yes Check the free running gears for seizure.
No Check 23.
23 Is the noise present when in neutral? Yes Check 25.
No
24 Is the noise present when in gear? Yes Check 28.
No
25 Is the countershaft or its bearings worn or Yes Replace the damaged parts.
damaged? No Check 26.
26 Is there excessive backlash in the gears? Yes Check the shaft end float. Adjust as
necessary.
No Check 27.
27 Is the mainshaft pilot bearing worn? Yes Replace as necessary.
No Check the gear teeth for scuffing.
28 Is the mainshaft rear bearing worn? Yes Replace as necessary.
No Check 29.
29 Are the sliding gear teeth worn or Yes Replace the gears as necessary.
30 Are the selector forks loose? Yes Tighten the screws.
No Check 31.
31 Are the selector fork pads or grooves in Yes replace the worn parts.
gears worn? No Check 32.
32 Are the dog gear teeth worn? Yes Replace as necessary.
No Check 33.
33 Are the selector rod detent springs broken? Yes Replace as necessary.
No Check 34.
34 Are the selector rods worn or damaged? Yes Replace as necessary.
No Check 35.
27 - 16 9813/8950-2 27 - 16
27 - Driveline
03 - Manual Gearbox
00 - General
Check Action
35 Are the selector fork pads out of position? Yes Reposition the selector fork pads. Replace
as necessary.
No Check 36.
36 Is there excessive end float in gears or Yes Adjust the end float.
shafts? No Check the thrust washers and mating faces.
37 Is the synchroniser bronze worn? Yes Replace the synchro pack.
No Check 38.
38 Are steel chips embedded in the bronze? Yes Continue using, chips will either embed
below bronze or be rejected.
No Check 39.
39 Are the synchroniser components Yes Replace as necessary.
damaged? No Check the free running gears for seizure or
damage.
40 Are the sliding gears tight on the splines? Yes Replace as necessary.
No Check 41.
41 Are chips wedged between splines of shaft Yes Remove the chips.
or gear? No Make sure that the clutch is disengaged
when dump pedal is pressed.
No Check 43.
43 Are the synchroniser spring pins damaged? Yes Replace the synchro pack.
No Check 44.
No Check the blocker pins.
Table 143. The transmission is overheating

Check Action
1 Is the fluid level correct? Yes Check 2.
No Allow machine to cool down. Check the oil
level. If necessary, top up as required.
2 Are the oil passages restricted? Yes Clear the restrictions.
No Check 3.
3 Is the suction strainer restricted? Yes Remove and clean the strainers.
No Check 4.
4 Is pump pressure as specified? Yes Check 6.
No Check the condition of the clutch PMV.
Make sure that it is free to operate.
5 When flow testing pump, is output low? Yes Replace the pump.
No Check the condition of the converter sprag
clutch for wear or slip.
6 Does the noise continue when direction Yes Check 7.
selector is in forward or reverse? No Check 8.
7 Is transmission misaligned? Yes Replace the mounting. Check the position
of the transmission.
No Check the converter out pressure and flow.
8 Are the pump bushes worn? Yes Replace the bushes.
No Check the converter for wear or cooler for
restriction to flow.
27 - 17 9813/8950-2 27 - 17
27 - Driveline
03 - Manual Gearbox
00 - General
Check Action
No Check 13.
damage.
No Check 15.
damage or wear.
No Check 18.
damage or wear.
No Check 19.
No Check 20.
No
No
necessary.
No Check 24.
No Check 26.
No Check 28.
No Check 30.
No Check 31.
27 - 18 9813/8950-2 27 - 18
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00 - General
Check Action
No Check 32.
as necessary.
No Check 33.
No Check 35.
No Check 36.
damage.
No Check 38.
No Check 40.
No Check 41.
Table 144. The transmission will not pull

Check Action
No Check 5.
damage.
No Check 7.
27 - 19 9813/8950-2 27 - 19
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00 - General
Check Action
damage or wear.
No Check 10.
damage or wear.
No Check 11.
No Check 12.
No
No
necessary.
No Check 16.
No Check 18.
No Check 20.
No Check 22.
No Check 23.
No Check 24.
as necessary.
No Check 25.
No Check 27.
No Check 28.
damage.
No Check 30.
27 - 20 9813/8950-2 27 - 20
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Check Action
No Check 32.
No Check 33.
Table 145. There is no drive in one or both directions

Check Action
No Check 2.
damage or wear.
No Check 5.
damage or wear.
No Check 6.
No Check 7.
No
No
necessary.
No Check 11.
No Check 13.
No Check 15.
No Check 17.
27 - 21 9813/8950-2 27 - 21
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Check Action
No Check 18.
No Check 19.
as necessary.
No Check 20.
No Check 22.
No Check 23.
damage.
No Check 25.
No Check 27.
No Check 28.
Table 146. The transmission is jumping out of gear

Check Action
No Check 2.
No Check 4.
No Check 5.
No Check 6.
as necessary.
No Check 7.
No Check 9.
No Check 10.
27 - 22 9813/8950-2 27 - 22
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00 - General
Check Action
damage.
No Check 12.
No Check 14.
No Check 15.
Table 147. The transmission is sticking in gear

Check Action
No Check 2.
No Check 4.
No Check 5.
Table 148. The gear ratios are crash changing

Check Action
No Check 2.
No Check 3.
27 - 23 9813/8950-2 27 - 23
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00 - General
Drain and Fill Figure 412.
Drain
1. Make sure that all oil has been drained from
the gearbox case by removing the bolts and the
suction strainer. Discard the gasket. Refer to
Manual Gearbox, Suction Strainer - Remove and
Install (PIL 27-03-40).
2. Remove the drain plug. Discard the sealing
washer.
Figure 411.
Fill
1. Install a new gasket to a clean suction strainer
and insert into the gear case. Refer to Manual
Gearbox, Suction Strainer - Remove and Install
(PIL 27-03-40).
2. Install the drain plug with a new sealing washer.
Tighten to the correct torque value.
1 Drain plug
2 Sealing washer
3 Bolts
4 Suction strainer
5 Gasket
3. Remove and discard the oil filter. Refer to
Manual Gearbox, Filter - Remove and Install (PIL
27-03-39).
27 - 24 9813/8950-2 27 - 24
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00 - General
Figure 413. Clean

Consumables
Cleaner/Degreaser 4104/1557 0.4 L
- General purpose
solvent based parts
cleaner
Clean the exterior of the gearbox assembly as

follows:
1. Make sure that all open ports and orifices are

effectively plugged.
2. Remove any deposits of dirt, grit and oil from
the outer cases using a suitable degreaser and
water.
3. Dry the cases.
1 Drain plug
2 Sealing washer
3 Bolts
4 Suction strainer
5 Gasket
3. Install a new oil filter. Refer to Manual Gearbox,
Filter - Remove and Install (PIL 27-03-39).
Figure 414.

Item Nm
1 102
27 - 25 9813/8950-2 27 - 25
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00 - General
Check (Condition)
Before assembling the gearbox make sure that a

thorough inspection of all components is carried out.
Remember that although a failed component may
be easy to identify, the cause of that failure may be
less easy to trace. It is also possible that a failed
component may have caused damage to other areas
of the gearbox.
1. Carefully remove all traces of gasket compound

from components as follows:
1.1. Front and rear case mating faces.
1.2. Front case and torque converter housing
mating faces.
2. Clean the inside of the case using a suitable
degreasing agent.
3. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
renewed.
4. Make sure that all oil way cross drillings in the
cases, shafts and gears are clear and free from
debris. Blocked oil ways are a common cause of
bearing failure. Use an air line to blow through
cross drillings.
If failure of the forward and reverser clutch or

power take-off clutch is suspected, see the relevant
dismantling and assembly procedure.
27 - 26 9813/8950-2 27 - 26
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Check (Pressure)
Special Tools 11. Connect the pressure gauge and flow meter to
Description Part No. Qty. the out line from the converter.
Flow Test Adaptor 892/00237 1 12. Start the engine and run at 1000 RPM.
Assembly
Hydraulic Flow Test Kit 998/11046 1 13. Check the flow meter and the pressure gauge
Digital Hydraulic 998/11051 1 readings. Refer to (PIL 27-03).
Pressure Test Kit
13.1. A high pressure together with low flow
could be caused by blocked oil cooler.
Make sure the engine and transmission are at normal
operating temperature. 14. Apply the parking brake and foot brake firmly and
select forward.
The tests must be carried out only in the following
order, step by step. 15. Check make sure that the flow meter reading is
not less than the specified value.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot. Flowrate: 4.5 L/min
1. Make the machine safe. Refer to (PIL 01-03). 15.1. If the flow meter reading is low, it could be
due to a high leakage rate in that particular
2. Stop the engine. clutch caused by worn or broken piston
seals or shaft sealing rings.
3. Remove the transmission filter and the filter head
adaptor. Refer to (PIL 27-03). 16. Do the leakage rate check again after you select
reverse. See 14.
4. Install the adaptor 1 or adaptor 2 into the gearbox
casing depending on the filter head adaptor. 17. If the clutch leakage rate is high, check the clutch
pressures as follows:
Special Tool: Flow Test Adaptor Assembly (Qty.:
1) 17.1. Connect the pressure gauge to the port 1
and port 2.
5. Install the test adaptor and secure with the
adaptor 3. 17.2. Do the leakage rate check again. See 14.
6. Connect the flow meter and pressure gauge of 17.3. If the reading is lower than the specified
the specified value to the test connector. value, the leakage rate is high in the
selected clutch.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Digital Hydraulic Pressure Test Kit 18. Stop the engine.
(Qty.: 1)
Special Tool: Hydraulic Flow Test Kit (Qty.: 1) 19. Connect the pressure gauge to the port 3 in the
transmission.
7. Start the engine and run at 1000 RPM
(Revolutions Per Minute). 20. Connect the load valve to the out line from the
converter.
8. Check the flow meter and the pressure gauge
readings. Refer to (PIL 27-03). 20.1. Make sure that the load valve is screwed
out fully before you start the engine.
8.1. A low reading can be caused by either Otherwise the converter seals will be
a faulty pressure maintenance valve or a damaged.
worn pump.
21. Start the engine and run at 1000 RPM.
8.2. A high reading indicates a faulty pressure
maintenance valve. 22. Slowly screw down the load valve while checking
the gauge reading.
8.3. If the pump flow is low, the oil cooler may
be blocked. 23. Make sure that the gauge reading is as per the
converter relief (safety) valve setting. Refer to
9. Stop the engine.
(PIL 27-03).
10. Remove the flow test adaptors and reinstall the
filter.
27 - 27 9813/8950-2 27 - 27
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03 - Manual Gearbox
00 - General
24. Make sure that the pressure is not more than the 26. Connect the pressure gauge and the flow meter
specified value or else, the converter seals may to the return line from oil cooler to transmission.
be damaged.
27. Start the engine.
Pressure: 10.3 bar ( 149.3 psi)
28. Put the transmission in neutral and make sure
24.1. If the reading is higher, the relief valve the flow rate indicated on the flow meter is as per
might be faulty. the specified value. Refer to (PIL 27-03).
24.2. A low reading can be caused due to
a faulty relief valve, a leaking converter 29. Make sure that the lubrication pressure indicated
'piston ring' type seal or a leaking pump on the pressure gauge is as per the specified
seal. value. Refer to (PIL 27-03).
25. Stop the engine. 29.1. A low flow and pressure readings might be
due to a blocked oil filter.
27 - 28 9813/8950-2 27 - 28
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03 - Manual Gearbox
00 - General
Figure 415.
C
B E
A
A1 B
D G
F L
A Adaptor 1 A1 Adaptor 2
B Test adaptor C Adaptor 3
D Flow meter E Test connector
F Converter out line G Port 1
H Port 2 J Port 3
K Oil cooler return line L Load valve
27 - 29 9813/8950-2 27 - 29
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03 - Manual Gearbox
00 - General
Calibrate
Special Tools End float adjustment - Layshaft.

1. Remove the layshaft bearing cap and in that
Shim Kit 445/04700 1
place put an end float setting tool together with
Shim Kit 921/02200 1 a new gasket.
End Float Setting Tool 990/00083 1
Special Tool: End Float Setting Tool (Qty.: 1)
Consumables 2. Secure the end float setting tool with the bolt.
JCB Threadlocker 4101/0250 0.01 L 3. Tighten the fixing bolt to the correct torque value.
and Sealer (Medium 4101/0251 0.05 L 4. Make sure that the gasket is not damaged as
Strength)
it will be used at the end of the assembly
procedure.
Shafts - End Float Measurement
5. Measure the layshaft end float and it should be
After replacement of the gearbox shafts, check within the specified limit.
the end float measurements. The component Dimension: 0.03 –0.08 mm
manufacturing system makes sure that the end
float is controlled within specified limits. To check 6. Rotate the layshaft when you take the
for correct assembly and installation of the shafts, measurement to install the bearings fully.
measure the end float dimensions as follows:
Figure 416.
CG
CH
CF
CD
CE
CD End float setting tool CE Gasket

CF Bolt CG Spacer
CH Shim
7. Calculate the correct seam thickness. Remove 10. Apply sealant to the bolt 7 and then attach the
the end float setting tool and put the shims layshaft cover with the bolt.
between the bearing outer cup and the spacer. Consumable: JCB Threadlocker and Sealer
Special Tool: Shim Kit (Qty.: 1) (Medium Strength)
8. Again install the end float setting tool and make 11. Tighten the bolt 7 to the correct torque value.
sure that the end float is within the limits given.
Refer step 5. End float adjustment - Main shaft
9. Remove the end float setting tool. Make sure that 1. Remove the torque converter housing.
gasket is correctly located.
27 - 30 9813/8950-2 27 - 30
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00 - General
2. Install an end float setting tool over the main shaft 4. Measure the main shaft end float and it should
end bearing. Secure the tool with the bolt. be within the specified limit.
Special Tool: End Float Setting Tool (Qty.: 1) Dimension: 0.03 –0.08 mm
3. Tighten the fixing bolt to the correct torque value.
Figure 417.
CF
CD
CJ
CK
5. Rotate the main shaft when you take the 8. Remove the end float setting tool.
measurement to install the bearings fully.
End float adjustment - Forward and reverse
6. Calculate the correct seam thickness. Remove shaft
the end float setting tool and put the shims
between the bearing outer cup and the spacer. 1. To check the end float it is necessary to
Special Tool: Shim Kit (Qty.: 1) temporarily assemble the front and rear cases of
the gearbox.
7. Calculate the correct seam thickness. Remove
the end float setting tool and put the shims 2. Make sure that the forward reverse shaft rear
between the bearing outer cup and the spacer. bearing outer cup and shims are installed to the
Refer step 4 rear cover.
27 - 31 9813/8950-2 27 - 31
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00 - General
Figure 418.
V U
V Output end case U Bolt
3. Shims are installed behind the front bearing outer 7. Set the pointer of the DTI on the chamfer of the
cup at the factory. For service assembly it is shaft, not on the end face. This will make sure
preferable to install them behind the rear bearing that a constant reading is given.
outer cup.
8. Remove the output end case.
4. Carefully lower the output end case into position
and install the bolt. Do not use sealant on the bolt. 9. If the end float measurement is more than the
Tighten the bolt to the correct torque value. specified limit, mentioned in the step 5, then
remove the bearing cup and shims from the
5. Use a DTI (Dial Test Indicator) to measure the rear case. Measure the shims and calculate the
shaft end float and it must be within the specified correct shim thickness. Select all the necessary
limit. shims from the shim kit. Do the steps from step
Dimension: 0.03 –0.08 mm 1 to step 8.
Special Tool: Shim Kit (Qty.: 1)
6. Rotate the shaft when you take the measurement
to install the bearings fully.
27 - 32 9813/8950-2 27 - 32
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03 - Manual Gearbox
00 - General
Figure 419.
BX
BX DTI
10. Remove the forward reverse assembly.
27 - 33 9813/8950-2 27 - 33
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00 - General
CAUTION This component is heavy. It must only D

be removed or handled using a suitable lifting C
method and device.
Remove
2. Isolate the battery. Refer to (PIL 33-03).
3. Remove the floorplate. Refer to (PIL 09-78).
4. Open the engine compartment cover. Refer to C Electrical connectors
(PIL 06-06). D Gearbox
5. Remove the operator seat base. Refer to (PIL 9. Remove the gearbox oil filter.
09-12).
9.1. Be prepared for some fluid loss.
9.2. Collect the fluid in a suitable container.
7. Move the steering column forwards to get access
to the dumper body. 9.3. Dispose of the fluid in an appropriate
manner.
Figure 420.
Figure 422.
A E Gearbox oil filter

10. Disconnect the breather tube and the gearbox oil
supply hose.
11. Discard the O-ring seals.
Figure 423.
A Bolts 1
B Dumper body F
8. Disconnect the electrical connectors from the G

gearbox.
F Breather tube
G Gearbox oil supply hose
27 - 34 9813/8950-2 27 - 34
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03 - Manual Gearbox
00 - General
12. Remove the clamp and the nut 1. Figure 427.

13. Remove the dipstick tube assembly.
Figure 424.
H P
Q
K
J P Bolts 3
Q Propshaft
H Clamp
J Nut 1 20. Remove the propshaft from the machine.
K Dipstick tube assembly
Figure 428.
14. Disconnect the gearbox oil return hose.
Figure 425.
R
L
Q Propshaft
R Bolts 4
L Gearbox oil return hose 21. Support the gearbox with suitable lifting
15. Remove the bolts 2. equipment.
16. Disconnect the park brake caliper. Figure 429.

S
Figure 426.
M
D
D Gearbox
S Lifting equipment
M Bolts 2
N Park brake caliper 22. Remove the bolts 5.
17. Remove the bolts 3. 22.1. Be prepared for some fluid loss.
18. Disconnect the propshaft from the gearbox. 22.2. Collect the fluid in a suitable container.
27 - 35 9813/8950-2 27 - 35
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03 - Manual Gearbox
00 - General
22.3. Dispose of the fluid in an appropriate

manner.
Figure 430.
T Bolts 5
23. Remove the gearbox from the machine.
23.1. When you remove the gearbox, lift and
rotate it to allow the park brake disc to
clear the chassis.
Figure 431.
D Gearbox
S Lifting equipment
Install
step.
2. Make sure that the drive gears on the gearbox
pump and the torque converter are the specified
degrees apart.
Angle: 180 °
3. Tighten the nuts to the correct torque value.

Item Description Nm
M Bolts 2 230
P Bolts 3 140
R Bolts 4 43
T Bolts 5 60
27 - 36 9813/8950-2 27 - 36
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03 - Manual Gearbox
00 - General
Special Tools Lifting Equipment

Description Part No. Qty. You can be injured if you use incorrect or faulty lifting
Bearing Press 892/00179 1 equipment. You must identify the weight of the item to
Drive Coupling 892/00812 1 be lifted then choose lifting equipment that is strong
Spanner enough and suitable for the job. Make sure that lifting
Support Bracket 892/01076 1 equipment is in good condition and complies with all
local regulations.
Spacer Kit 921/52600 1
End Float Setting Tool 990/00083 1 When the gearbox is removed from the machine,
Flange Spanner 992/04800 1 put suitable wooden blocks to securely support the
Bearing Adaptor 992/06300 1 assembly.
Torque Wrench 993/70111 1 Cleanliness is of the utmost importance when
(10-100Nm) servicing the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken.
Consumables
Description Part No. Size Clean the exterior of the gearbox assembly. Refer to
JCB Multi-Gasket 4102/1212 0.05 L Manual Gearbox - Clean. Refer to (PIL 27-03).
JCB Threadlocker 4101/0250 0.01 L
and Sealer (Medium 4101/0251 0.05 L Disassemble
Strength)
1. Drain the oil from the gearbox. Refer to (PIL
27-03).
Figure 432.
CV
A Suction strainer B Oil filter

CV Bolt 1
2. Remove and discard the oil filter. 3. If installed, remove the 2 and 4 wheel drive
clutch. Refer to (PIL 27-03-07).
27 - 37 9813/8950-2 27 - 37
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03 - Manual Gearbox
00 - General
Figure 433.
C 2 and 4 wheel drive clutch
4. Remove the bolt 2 and the then remove the 5. Remove and discard the pump sealing ring.
pump. Refer to Figure 434. Refer to Figure 434.
Figure 434.
D Bolt 2 E Pump
F Sealing ring G Oil seal
6. Remove and discard the oil seal from the pump 9. Undo the capscrews and remove the solenoid
housing. Refer to Figure 434. control valve. Refer to Figure 435.
7. Put the transmission in a vertical position with the 10. Remove the O-rings installed around the ports on
torque converter housing facing down. Refer to the mating face of the solenoid valve body. Refer
Figure 434. to Figure 435.
8. On some gearbox variants the input shaft 11. On 4WD (Four Wheel Drive) transmissions
protrudes beyond the face of the torque remove the 4WD hydraulic pipe and control
converter housing. Use wooden blocks under the valve. Refer to Figure 435.
housing to ensure clearance of the input shaft.
27 - 38 9813/8950-2 27 - 38
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03 - Manual Gearbox
00 - General
Figure 435.
CU
H Capscrew J Hydraulic pipe

K Control valve L Gear lever turret
CU Bolt 3
12. Remove the bolt 3 and then remove the gear 13.1. The short single lever type must not
lever turret.Refer to Figure 435. be disassembled, the only replaceable
component is the rubber gaiter. Refer to
13. The gearbox can be installed with different types Figure 436.
of gear lever turret assemblies.
Figure 436.
M Rubber gaiter
13.2. The larger two-piece gear lever turrets careful about the spring pressure, behind
can be disassembled. Push the bottom the lever and circlip. Refer to Figure 437.
lever and remove the circlip. You must be
27 - 39 9813/8950-2 27 - 39
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03 - Manual Gearbox
00 - General
Figure 437.
P
N P
P Circlip N Bottom lever
14. Remove the plug 1 and then remove the

pressure maintenance valve spool and spring1.
27 - 40 9813/8950-2 27 - 40
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03 - Manual Gearbox
00 - General
Figure 438.
CS Q
CT
Q Plug 1 R Bolt 4
S Pressure maintenance valve body CS Pressure maintenance valve spool
CT Spring 1
15. Remove all the bolt 4 and then remove the 16. Remove the plug 2 with the washer 1. Refer to
pressure maintenance valve body with the Figure 439.
gasket and discard the gasket. Refer to Figure
438. 17. Remove the torque converter pressure relief
valve ball and spring 2. Refer to Figure 439.
Figure 439.
V U
CP T
CQ CR
27 - 41 9813/8950-2 27 - 41
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03 - Manual Gearbox
00 - General
T Spring 2 U Bolt 5
V Output end case CP Torque converter pressure relief valve ball
CQ Washer 1 CR Plug 2
18. Remove the bolt 5 and then lift off the output end 19. Remove the plug 3. Refer to Figure 440.
case. Make sure that you take out the bearing
outer cups from inside the case. Keep the cups 20. Remove the gear selector detent balls and spring
together with their associated bearing. Refer to 3. Refer to Figure 440.
Figure 439.
Figure 440.
Z
AA
X W
W Plug 3 X Detent ball

Y Spring 3 Z Retaining screw
AA Selector forks
21. Remove the selector fork retaining screws and correctly at the time of assembly. Remove the
lift off the selector rods. Refer to Figure 440. selector forks. Refer to Figure 440.
22. The selector forks are not interchangeable. Mark 23. Push out the interlock plunger. Refer to Figure
the forks to make sure that they are placed 441.
27 - 42 9813/8950-2 27 - 42
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03 - Manual Gearbox
00 - General
Figure 441.
AC
AB
AD
AB Interlock plunger AC Synchromesh gear (3rd and 4th)

AD Layshaft
24. Lift off the 3rd and 4th synchromesh gear. Mark 27. Tilt the main shaft to one side and lift off the
the positions of the synchro hubs to make sure idler gear together with the needle roller bearing.
that they are installed correctly with mating cups Refer to Figure 442.
at the time of assembly. Refer to Figure 441.
28. Remove the idler gear lower thrust washers and
25. Lift off the layshaft assembly. Refer to Figure 441. bearing. Keep the thrust washers and bearing
together. Refer to Figure 442.
26. Remove the idler gear upper thrust washers and
bearing. Keep the thrust washers and bearing 29. Remove the idler gear spacer. Refer to Figure
together .Refer to Figure 442. 442.
27 - 43 9813/8950-2 27 - 43
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03 - Manual Gearbox
00 - General
Figure 442.
AE
AG
AM
AH
AF AJ
AK
AL
AE Upper thrust washers and bearing assembly AF Main shaft

AG Idler gear AH Needle roller bearing
AJ Lower thrust washers and bearing assembly AK Idler gear spacer
AL Forward and reverse clutch AM Idler gear spindle
30. Tilt the main shaft to one side and lift off the 34. Remove the stake nut. Whilst holding the output
forward and reverse clutch. Discard the sealing yoke with the drive coupling spanner tool or
rings. Refer to Figure 442. brake disc with the flange spanner tool as
applicable, remove the output shaft nut and the
31. Remove the main shaft. Refer to Figure 442. washer below it. From below support the output
shaft and lift off the yoke. Refer to Figure 443.
32. The idler gear spindle is a press fit in the case.
Use a suitable puller, screwed into the 1/2 in. Special Tool: Drive Coupling Spanner (Qty.: 1)
B.S.P. hole in the end of the spindle for extraction. Special Tool: Flange Spanner (Qty.: 1)
35. Remove the output shaft assembly and take out
33. The spindle should only be removed if it is the outer bearing. Remove the spacer and keep
damaged, and need to be replaced. Refer to it for assembly. Refer to Figure 443.
Figure 442.
27 - 44 9813/8950-2 27 - 44
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03 - Manual Gearbox
00 - General
Figure 443.
AN
AP
AQ
AU
AS
AT
AR
AV
AN Nut 1 AP Washer 2
AQ Yoke AR Output shaft assembly
AS Outer bearing AT Spacer
AU Oil seal AV Output shaft inner bearing
36. Prise out the oil seal and discard it. Refer to 38.1. Using a bearing press and a bearing
Figure 443. adaptor to pull out the 3rd gear with the
synchro cup, hub, spacer, seal and the
37. Make sure that you use a suitable puller to bearing. Keep the synchro hubs and cups
remove the output shaft inner bearing. Refer to in their original relationship.
Figure 443.
Special Tool: Bearing Press (Qty.: 1)
38. Disassemble the main shaft. Refer to Figure 444. Special Tool: Bearing Adaptor (Qty.: 1)
27 - 45 9813/8950-2 27 - 45
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00 - General
Figure 444.
BB BA AZ AY AX AW
BC
AW 3rd gear AX Synchro cup

AY Hub AZ Spacer
BA Seal BB Bearing
BC Bearing 1
38.2. Remove the bearing1 from the converter layshaft. On 2WD (Two Wheel Drive)
end of the main shaft using a press tool. machines a spacer is installed in place of
the transfer gear.
Special Tool: Bearing Press (Qty.: 1)
39.2. Lift off the 1st gear.
39. Disassemble the layshaft. Refer to Figure 445.
39.3. Remove the 1st gear needle roller
39.1. Remove the bearing 2. Remove the bearings.
4WD transfer gear and bearing from the
Figure 445.
BD BN BP BK
BM BL BJ BH BG BE BF
BD Bearing 2 BE 4WD transfer gear

BF Layshaft bearing BJ 1st and 2nd synchro unit
BK 2nd gear BL 1st gear needle roller track ring
BM Synchro hub BN 2nd gear needle roller bearing (if installed)
BP 2nd gear needle roller bearing BG 1st gear
BH 1st gear needle roller bearing
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39.4. Remove the 1st or 2nd synchro unit. 1.6. Tighten the fixing bolts to the correct torque
value.
39.5. Use a press to push off the 2nd gear, the
synchro hub and the 1st gear needle roller Torque: 166 N·m
track ring. 1.7. New plugs may be supplied with a sealant
39.6. Remove the 2nd gear needle roller 'patch', in which case sealant need not be
bearing and if installed then remove the applied. Torque tighten plugs
other 2nd gear needle roller bearing that 1.8. If the new plugs are supplied with a sealant
is located after the 2nd gear needle roller 'patch', there case sealant is not necessary.
bearing. Tighten the plugs to the correct torque
value.
Before assembly inspect the gearbox, refer to
Gearbox - Check condition (PIL 27-03). Torque: 25 –28 N·m
All bearings must be lightly oiled before assembly. 2. If the torque converter housing has been
Make sure all components are thoroughly clean and removed, temporarily replace it. The gearbox can
renew all O-rings. again be positioned standing on the face of the
housing ready for assembly.
Assemble 3. The layshaft assembly. Refer to Figure 446.
1. Gearbox case replacement. 3.1. Lubricate the bearing surface of the shaft.
1.1. If the gearbox cases are to be replaced, 3.2. Move the 2nd gear needle roller bearing
make sure that you put the blanking plugs and if installed move the needle roller
and adaptors where it is necessary. bearing1. Make sure that both the bearings
1.2. Check the original cases and identify the are installed in the correct sequence on the
blanking plugs and adaptor positions. layshaft as both the bearings are not the
same size.
1.3. Move the plugs and adaptors to the new
cases. 3.3. Apply oil to the needle roller bearings.
1.4. Apply JCB Threadlocker and Sealer to the 3.4. Move the 2nd gear followed by the synchro
threads of the plugs. hub and press fit the bearing hub.
Consumable: JCB Threadlocker and Sealer 3.5. Install the 1st and 2nd gear synchro unit.
(Medium Strength) Make sure that the unit is installed in the
correct orientation.
1.5. If applicable move the park brake calliper
mounting bracket from the rear case.
Figure 446.
BD BN BP BK
BM BL BJ BH BG BE BF
BD Bearing 2 BE 4WD transfer gear

BF Layshaft bearing BG 1st gear
BH 1st gear needle roller bearing BJ 1st and 2nd synchro unit
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03 - Manual Gearbox
00 - General
BK 2nd gear BL 1st gear needle roller track ring

BM Synchro hub BN 2nd gear needle roller bearing (if installed)
BP 2nd gear needle roller bearing
3.6. Move the 1st gear needle roller bearing 3.9. Put the bearing 2 on the assembled
across the track. Apply oil to the bearings. layshaft. Lubricate the bearings.
3.7. Install the 1st gear over the needle roller 4. The main shaft assembly. Refer to Figure 447.
bearing.
4.1. Lubricate the bearing surface of the main
3.8. Assemble the 4WD transfer gear over
shaft.
the splines. On 2WD machines move the
spacer over the splines. 4.2. Assemble the 3rd gear and the synchro cup.
Install the synchro hub.
Figure 447.
BB BA AZ AY AX AW
BC
AW 3rd gear AX Synchro cup

AY Hub AZ Spacer
BA Seal BB Bearing
BC Bearing 1
4.3. Install the spacer followed by the seal. Push 6. The transfer gear - output shaft assembly. Refer
the bearing on to the shaft and lubricate. to Figure 448.
4.4. Lubricate the bearing 1 and push the 6.1. Before installing the output shaft inner
bearing 1 onto the assembled main shaft. bearing, lubricate the bearing.
5. Make sure that the layshaft bearing outer cup is 6.2. Install the service solid spacer (13.70 mm)
installed on the rear case before installing the over the output shaft and assemble into the
transfer gear or the output shaft. Refer to Figure case.
447. Special Tool: Spacer Kit (Qty.: 1)
27 - 48 9813/8950-2 27 - 48
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03 - Manual Gearbox
00 - General
Figure 448.
AN
AP
AQ
AU
AS
AT
AR
AV
AQ Yoke AR Output shaft assembly
AS Outer bearing AT Spacer
AU Oil seal AV Output shaft inner bearing
6.3. Lightly apply oil on the output shaft outer Special Tool: Support Bracket (Qty.: 1)
bearing and on the cup, then attach them to
7.5. Install a DTI (Dial Test Indicator). Refer to
the output shaft. Do not install the oil seal
Figure 449.
at this stage.
7.6. Set the torque wrench to the specified
7. Install the special tool sleeve which temporarily value and then measure the end float while
replace the output yoke and attached with special rotating the output shaft.
tool nut and tighten the nut to the correct torque
value. Refer to Figure 449. Torque: 35 N·m
Special Tool: Torque Wrench (10-100Nm)
7.1. Check for the end float while tightening nut. (Qty.: 1)
7.2. If there is no end float then check that the 7.7. To select the right size spacer do the steps
bearing cups are pushed fully into the case. 7.8 to 7.10.
7.3. Refer to the parts catalogue for correct 7.8. Subtract the end float obtained in step 7.6
bearing installation. from the solid spacer thickness value (13.70
mm).
7.4. Install the special tool so that the fork end
can engage in the special tool nut and then
tighten the bolt 6.
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03 - Manual Gearbox
00 - General
Figure 449.
BR
BU
BQ
BV
BT
BS
BQ Special tool sleeve BR Special tool nut

BS Support pillar BT Bolt 6
BU DTI BV Torque wrench
7.9. Subtract 0.120mm to allow for theoretical 7.14. If the rolling torque is too high, install the
bearing tolerance and pre-load. next larger size spacer. If there is end float,
install the next smaller size spacer
7.10. If the there is no spacer of the thickness
valued derived in step 7.9 use the next 7.15. Remove the special nut and sleeve.
smallest spacer.
8. Install the new oil seal and lubricate the seal
7.11. Remove the special nut and sleeve, also lips before installing. The seal is not attached
remove the rear bearing and the 13.70 mm to the back of the housing. Use the service tool
spacer. to locate the seal and install the brake disc or
7.12. Install the correct size spacer. Do not the output yoke whichever is applicable. Refer to
install the oil seal at this stage. Make sure Figure 450.
that the outer bearing is not damaged.
9. At the time of assembly, do not hammer on
7.13. Install the sleeve and initially tighten the the brake disc, the bearings will be damaged.
nut to the correct torque value. Check that If necessary use a press to assemble. Refer to
there is no end float and rolling torque less Figure 450.
than 1.5 Nm (1.0 lb-ft). If the rolling torque
exceeds 1.5 Nm (1.0 lb-ft), check that the 10. Install the washer 2 on the output yoke or on the
output shaft is assembled correctly. brake disc. Refer to Figure 450.
27 - 50 9813/8950-2 27 - 50
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03 - Manual Gearbox
00 - General
Figure 450.
AQ
AN
AP
AU
AQ Output yoke AU Oil seal
11. Gearboxes with the output yoke are installed with 13. If the correct size spacer is selected the rolling
a stepped washer. Make sure that the washer is torque should be the specified value when the
installed in the correct orientation. Refer to Figure nut 1 is fully tightened. Refer to Figure 450.
450. Torque: 2 N·m
12. Install a new nut 2 and tighten the nut to the 14. Use a square-ended staking tool to carefully
correct torque value. Refer to Figure 450. stake the nut into the slot. Refer to Figure 450.
15. Push the idler gear spindle into the front gear
case. Refer to Figure 451.
Figure 451.
AM
AL
BW
AM Idler gear spindle AL Forward and reverse clutch

BW Gear case (Front)
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03 - Manual Gearbox
00 - General
16. Make sure that the forward reverse shaft front 19.2. Make sure that the forward reverse shaft
bearing outer cup is correctly located inside the rear bearing outer cup and shims are
front case. Refer to Figure 451. installed to the rear cover. Refer to Figure
452.
17. Lubricate the forward reverse shaft front bearing.
Refer to Figure 451. 19.3. Shims are installed behind the front
bearing outer cup at the factory. For
18. Carefully lower the forward reverse shaft unit into service assembly it is preferable to install
the case and do not install the shaft sealing ring them behind the rear bearing outer cup.
at this stage. Refer to Figure 451. Refer to Figure 452.
19. The forward reverse shaft end float check. 19.4. Carefully lower the output end case into
position and install the bolt 5. Do not use
19.1. To check the end float it is necessary to sealant on the bolt 5. Tighten the bolt 5 to
temporarily assemble the front and rear the correct torque value. Refer to Figure
cases of the gearbox. Refer to Figure 452. 452.
Figure 452.
V U
V Output end case U Bolt 5
19.5. Use a DTI to measure the shaft end float

and it must be within the specified limit.
Dimension: 0.03 –0.08 mm
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Figure 453.
BX
BX DTI
19.6. Rotate the shaft when you take the 19.10. Remove the forward reverse assembly.
Refer to Figure 453. 20. At the time of disassembly, if the idler gear
spindle was removed then install it again on the
19.7. Set the pointer of the DTI on the chamfer main shaft. Refer to Figure 454.
of the shaft, not on the end face. This will
make sure that constant reading is given. 21. Refer to Figure 454. Lubricate the main shaft
Refer to Figure 453. output end bearing and put the main shaft in
the correct position against the forward reverse
19.8. Remove the output end case. Refer to
assembly. Refer to Figure 454.
Figure 452.
19.9. If the end float measurement is more 22. Install the idler gear spacer. Refer to Figure 454.
than the specified limit mentioned in the
step 19.5 then remove the bearing cup 23. Install the lower thrust washers and bearing
and shims from the rear case. Measure assembly. Then lubricate and install the needle
the shims and calculate the correct shim roller bearing. Refer to Figure 454.
thickness. Select all the necessary shims 24. Install the idler gear to the spindle, while tilting
from the shim kit. Do the steps from step the main shaft to one side. Refer to Figure 454.
19.1 to step 19.8 again. Refer to Figure
453.
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Figure 454.
AE
AG
AM
AH
AF AJ
AK
AL
AE Upper thrust washers and bearing assembly AF Main shaft

AG Idler gear AH Needle roller bearing
AJ Lower thrust washers and bearing assembly AK Idler gear spacer
AL Forward and reverse clutch AM Idler gear spindle
25. Install the upper thrust washers and bearing 27. Install the remaining synchronising components
assembly. Refer to Figure 454. to the main shaft. Make sure that you install all of
the synchronising components into there original
26. Lubricate the front end bearing of the layshaft. location. Refer to Figure 455.
Then carefully lower then layshaft into the correct
position. Refer to Figure 455.
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Figure 455.
AC
AB
AD
AB Interlock plunger AC Synchro hub (3rd and 4th)

AD Layshaft
28. Use a suitable wire support to locate the interlock Consumable: JCB Threadlocker and Sealer
plunger into its bore. Lubricate the plunger to hold (Medium Strength)
the plunger in position. If necessary, access is
available through a 1/4 BSP side drilling. Refer 31. Install the gear selector detent ball and spring 3
to Figure 455. into the position on the case. Apply sealant to the
plug 3 and then tighten the plug 3 correctly. Refer
29. Install the selector forks into their original location to Figure 456.
as they are not interchangeable. Refer to Figure Consumable: JCB Threadlocker and Sealer
456. (Medium Strength)
30. Move the selector rods into the position, make 32. Make sure that the each gear is engaged
sure that the interlock plunger is not moved. correctly. Refer to Figure 456.
Apply sealant to the selector fork retaining
screws and tighten the retaining screws to the
correct torque value. Refer to Figure 456.
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Figure 456.
BY
Z
AA
X W
W Plug 3 X Detent ball

Y Spring 3 Z Retaining screw
AA Selector forks BY Selector rods
33. Make sure that the interlock plunger does not let 35. Apply a bead of JCB Multi-gasket to the mating
two gear ratios engage at the same time. Refer surfaces of the case. Put the O-rings on the
to Figure 456. mating surface of the front case. Lubricate
the reverser shaft ring seals, and lubricate the
34. Install the forward reverse shaft sealing rings. bearings when installing into the output end case.
Refer to Piston Sealing Ring - Remove and Refer to Figure 457.
Install, refer to (PIL 27-03-45).
Consumable: JCB Multi-Gasket
Figure 457.
BZ BW
BW Gear case (Front) BZ O-ring
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00 - General
36. Make sure that the forward reverse shaft ring correctly located together with its shims. Refer to
seals are in good condition before installing into Figure 458.
the output end case.
38. Carefully lower the output end case into its
37. Make sure that the two bearing outer cups are position. Make sure that the forward reverse unit
correctly located. one is located inside the case shaft engages with the case first, followed by 3rd
and the other one is located in the centre of and 4th gear selector rod. Do not apply too much
the output shaft transfer gear. Make sure that force when installing the case. Refer to Figure
the forward reverse shaft bearing outer cup is 459.
Figure 458.
CA
CC
CA
CB
CA Bearing outer cup CB Output shaft transfer gear

CC Forward reverse shaft bearing outer cup
39. Apply sealant to the bolt 5 and tighten the bolt 5 Consumable: JCB Threadlocker and Sealer
to the correct torque value. Refer to Figure 459. (Medium Strength)
Figure 459.
V U
V Output end case U bolt 5
40. End float adjustment - layshaft. Refer to Figure 40.1. Remove the layshaft bearing cap and in
460. that place put an end float setting tool
together with a new gasket.
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00 - General
Special Tool: End Float Setting Tool (Qty.: 40.4. Make sure that the gasket is not damaged
1) as it will be used at the end of the assembly
procedure.
40.2. Secure the end float setting tool with the
bolt 7. 40.5. Measure the layshaft end float and it
should be within the specified limit.
40.3. Tighten the fixing bolt 7 to the correct
torque value. Dimension: 0.03 –0.08 mm
40.6. Rotate the layshaft when you take the
Figure 460.
CG
CH
CF
CD
CE
CD End float setting tool CE

CF Bolt 7 CG Spacer
CH Shim
40.7. Calculate the correct seam thickness. 40.11. Tighten the bolt 7 to the correct torque
Remove the end float setting tool and put value.
the shims between the bearing outer cup
and the spacer. 41. End float adjustment - main shaft. Refer to Figure
461.
40.8. Again install the end float setting tool and
make sure that the end float is within the 41.1. Remove the torque converter housing.
limits given. Refer step40.5.
41.2. Install an end float setting tool over the
40.9. Remove the end float setting tool. Make main shaft end bearing. Secure the tool
sure that gasket is correctly located. with the bolt 7.
40.10. Apply sealant to the bolt 7 and then Special Tool: End Float Setting Tool (Qty.:
attach the layshaft cover with the bolt 7. 1)
Consumable: JCB Threadlocker and 41.3. Tighten the fixing bolt 7 to the correct
Sealer (Medium Strength) torque value.
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00 - General
Figure 461.
CF
CD
CJ
CK
CD End float setting tool CF Bolt 7

CJ Shim CK Spacer
41.4. Measure the main shaft end float and it 41.7. Again install the end float setting tool and
should be within the specified limit. make sure that the end float is within the
limits given. Refer step41.4
Dimension: 0.03 –0.08 mm
41.8. Remove the end float setting tool.
41.5. Rotate the main shaft when you take the
measurement to install the bearings fully. 42. Apply a bead of JCB Multi-gasket to the mating
41.6. Calculate the correct seam thickness. face of the gearbox cover. Refer to Figure 462.
Remove the end float setting tool and put Consumable: JCB Multi-Gasket
the shims between the bearing outer cup
and the spacer.
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00 - General
Figure 462.
CL
CL Gearbox cover mating surface
43. Install the torque converter housing. Apply the Consumable: JCB Threadlocker and Sealer
sealant to all the bolt 8. Refer to Figure 463. (Medium Strength)
Figure 463.
CM
CN
CM Bolt 8 CN Torque converter housing
44. Tighten bolt 8 to the correct torque value. 46. Install the pump carefully and make sure that it is
aligned with all the mounting holes. Put the new
45. Put a new pump sealing ring in its correct sealing washers and the bolt 2. Refer to Figure
position. Make sure that the charge pump drain 464.
hole is clear before installing a new oil seal to the
pump housing. Refer to Figure 464.
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00 - General
Figure 464.
D Bolt 2 E Pump
F Sealing ring G Oil seal
47. Tighten the bolt 2 to the correct torque value. 49. Make sure that a larger diameter of spring 2 is
Refer to Figure 464. located correctly over the spigot on the plug 2.
48. Install the torque converter pressure relief valve
assembly. Install the valve ball and the spring 2.
Figure 465.
Q
CT
CS
CP CQ
T CR
Q Plug 1 R Bolt 4
S Pressure maintenance valve body T Spring 2
CP Torque converter pressure relief valve ball CQ Washer 1
CR Plug 2 CS Pressure maintenance valve spool
CT Spring 1
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00 - General
50. Refer to Figure 465. Use a new sealing washer contamination of the sealant applied on the
1 and apply sealant to the plug 2. Refer to Figure gasket. Refer to Figure 465.
465.
56. Install the pressure maintenance valve spool and
Consumable: JCB Threadlocker and Sealer spring 1 into the adaptor block. Refer to Figure
(Medium Strength) 465.
51. Tighten the plug 2 correctly. Refer to Figure 465. 57. Apply the sealant on the plug 1 and then install
and tighten the plug 1 correctly. Refer to Figure
52. Use a new gasket mount pressure maintenance
465.
valve body on the case. Refer to Figure 465.
Consumable: JCB Threadlocker and Sealer
53. Apply sealant to the bolt 4. Refer to Figure 465. (Medium Strength)
58. Put the new O-rings around the ports on the
(Medium Strength)
mating surface of the solenoid valve. Refer to
54. Tighten the bolt 4 to the correct torque value. Figure 466.
59. Install the solenoid valve onto the pressure
55. Do not remove the protective cover of the maintenance valve and make sure that the port
gasket until it is required. This is to prevent P aligns with the metering orifice in the pressure
maintenance valve body. Refer to Figure 466.
Figure 466.
CU
H Capscrew J Hydraulic pipe

K Control valve L Gear lever turret
CU Bolt 3
60. Refer to Figure 466. Apply sealant to the 63. Put a new gasket on the case and then install the
capscrews. Refer to Figure 466. turret assembly. Refer to Figure 466.
Consumable: JCB Threadlocker and Sealer 64. Apply sealant on the bolt 3. Refer to Figure 466.
(Medium Strength)
61. Tighten the capscrews to the correct torque (Medium Strength)
value. Refer to Figure 466.
65. Tighten the bolt 3 to the correct torque value.
62. Install the 4 wheel drive solenoid valve and if Refer to Figure 466.
applicable attach the hydraulic pipe. Refer to
Figure 466. 66. Check the gear selection. Refer to Figure 466.
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03 - Manual Gearbox
00 - General
67. It is recommended that a 75 micron (0.075mm)

service suction strainer is installed to clean the
system after a major overhaul.
68. After the first 100 hours of operation remove the
service strainer and install a production strainer.
69. Put a new gasket and install the suction strainer.
Refer to Manual Gearbox, Suction Strainer -
Remove and Install (PIL 27-03-04).
70. Install a new filter. Refer to Manual Gearbox,
Filter - Remove and Install (PIL 27-03-03).
71. Install the dipstick or oil filler tube.
71.1. Install the nut to the tube followed by the
seal.
71.2. Insert the tube fully down bore in the case.
Engage the nut and tighten down loosely
onto the seal.
71.3. Tighten the nut fully after the tube has
been correctly routed.
72. Refer to Figure 433. If applicable install the 2 and
4 wheel drive clutch. Refer to (PIL 27-03-07).
73. Fill the gearbox with the correct oil to the correct
level. Refer to (PIL 27-03).

Item Description Nm
BR Nut 50
AN Nut1 300
U Bolt 5 56
Z Screw 35
CF Bolt 7 56
CM Bolt 8 56
D Bolt2 28
R Bolt 4 10
H Capscrew 5
CU Bolt 3 56
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03 - Manual Gearbox
06 - Clutch - Forward/Reverse
06 - Clutch - Forward/Reverse Introduction

Introduction .................................................... 27-64 The clutch is a mechanical device that engages
Component Identification ............................... 27-65 and disengages the transmission, from driving shaft
Check (Condition) .......................................... 27-66 to driven shaft. The clutch is located between the
Calibrate ........................................................ 27-66 engine and the gearbox, as disengaging it is required
to change gear.
Disassemble and Assemble .......................... 27-67
The clutch is operated by a pedal using a hydraulic
or cable connection from the pedal to the clutch
mechanism.
The default state of the clutch is engaged, that is

the connection between the engine and gearbox is
always on unless the driver presses the pedal and
disengages it.
If the engine is running with the clutch engaged

and the transmission in neutral, the engine spins
the input shaft of the transmission, but no power
is transmitted to the wheels. Although the gearbox
does not stop rotating during a gear change, there
is no torque transmitted through it, thus less friction
between gears and their engagement gears.
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03 - Manual Gearbox
Figure 467.
Item Description
Table 152. 20 Pressure plate 2 (if in-
Item Description stalled)
1 Clutch shaft 21 Needle roller bearing
2 Sealing ring 23 Shim plate (if installed)
3 Bearing 1 25 Thrust washer 3
4 Gear 1 26 Thrust bearing
5 Circlip 1
6 Pressure plate 1
7 Disc spring
8 O-ring 1
9 Spring
10 Circlip 2
11 Thrust washer 1
12 Thrust washer 2
13 Gear 2
14 Spring retainer
15 Oil baffle plate
16 Piston
17 Friction plate
18 Counter plate
19 O-ring 2
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Check (Condition) Calibrate
Carry out a visual inspection of the friction and Calibration(For: SS600)

counter plates:
1. Use a DTI (Dial Test Indicator) to measure the
Counter plates end float of the pressure end plate.
1. Light scoring or polishing is permissible, plates 2. The pressure end plate end float should be within
that are not flat, worn or heavily marked or scored 3.2 to 4.4 mm (0.126 to 0.173 in), or 2.5 to 4.4
must be replaced with a new set. mm (0.1 to 0.173 in) for assemblies with a 4mm
thick pressure plate.
Friction plates Figure 468.
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material H
damage or scoring must be replaced with a new
set.
2. DO NOT mix old and new plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
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
H Friction and counter plates retaining circlip

J Pressure end plate
3. If it is necessary to adjust the end float, to bring it
within specified limit mentioned in step 2, install
shim between the retaining circlip and pressure
end plate.
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03 - Manual Gearbox
Disassemble and Assemble Figure 470.
Special Tools
D
Description Part No. Qty. C
Hand Pump Pressure 892/00223 1 D
Test
Disassembly
E
1. Carefully remove the piston ring seals. Refer to
Manual Gearbox, Piston Ring Seal, Remove and
Install (PIL 27-03-45). Refer to Figure 469.
Figure 469.
A
C Thrust bearing 1
A D Thrust washer 1
E Gear and splined hub assembly
A
B 5. Some clutch assemblies may have a different
type of thrust washer combination, to make
sure that they are correctly installed at the time
of assembly, mark them to help the assembly
procedure. Refer to Figure 470.
6. Remove the gear and the splined hub assembly
with the needle roller bearing and the spacer.
7. Make sure that you note the location of the
spacer for its correct assembly. Refer to Figure
470.
A Piston ring seal 8. Remove the thrust bearing 2 and the thrust
B Clutch end bearing washer 2. Refer to Figure 471.
2. If the piston ring seals are excessively worn then
check for burrs or damage on the shaft grooves.
If necessary remove burrs with a fine grade
abrasion paper and oil. Refer to Figure 469.
3. Use a puller to remove the clutch end bearing.
4. Remove the thrust bearing 1 and the thrust
washer 1. Refer to Figure 470.
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03 - Manual Gearbox
G
K
F
G
L
H
J M
K Friction plate
L Counter plate
M Disc spring
F Thrust bearing 2
G Thrust washer 2 14. Some clutch assemblies are installed with a 4
H Friction and counter plates retaining circlip mm thick pressure plate next to the disc spring.
J Pressure end plate Refer to Figure 472.
9. Some clutch assemblies may have a different 15. Remove the disc spring. Refer to Figure 472.
type of thrust washer combination, to make
sure that they are correctly installed at the time 16. Put the clutch assembly in a suitable press to
of assembly, mark them to help the assembly compress the piston spring then remove the
procedure. Refer to Figure 471. circlip. Refer to Figure 473.
10. Remove the friction and counter plate retaining Figure 473.
circlip. Refer to Figure 471.
11. Remove the pressure end plate. Refer to Figure
471.
12. Remove the friction plates and the counter
plates. Keep them together in a set. Refer to
Figure 472.
13. Do not mix the plates with those from other
clutches assemblies. Refer to Figure 472.
17. Lift off the spring retaining plate. Refer to Figure

474.
18. Remove the spring. Refer to Figure 474.
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03 - Manual Gearbox
S
N
P R
T
Q
R Piston
S Piston O-ring
T Shaft O-ring
23. Remove and discard the piston O-ring and the
shaft O-ring. Refer to Figure 476.
24. Do the step from 3 to 23 again, to disassemble
the opposite side clutch.
N Spring retaining plate
P Spring Before you assemble the clutch assembly check
Q Oil baffle the condition of the clutch assembly. Refer to
19. If installed, remove the oil baffle plate. Refer to Manual Gearbox, Clutch- Forward/Reverse, Check
Figure 474. Condition (PIL 27-03-06).
20. Turn the assembly over and hit the clutch shaft Assembly
gently on a piece of aluminium (or wooden) block
to loosen the piston. Refer to Figure 475. 1. Install new O-rings to the piston and shaft.
Lubricate the piston with hydraulic oil and push
Figure 475. fully into the bore of the clutch housing. Refer to
Figure 477.
Figure 477.
21. If the piston does not loosen when you hit the R Piston
clutch shaft then hand pump air down the shaft S Piston O-ring
oil inlet hole. Refer to Figure 475. T Shaft O-ring
Special Tool: Hand Pump Pressure Test (Qty.: 1)
2. Install the oil baffle (if applicable) and the piston
22. Remove the piston. Refer to Figure 476. spring. Refer to Figure 478.
3. Make sure that the spring seats in the piston.
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03 - Manual Gearbox
N K
P
L
Q
N Spring retaining plate

P Spring K Friction plate
Q Oil baffle L Counter plate
M Disc spring
4. Install the spring retaining plate. Refer to Figure
478. 7. Install the counter plates and friction plates
alternately, starting with a counter plate and finish
5. Compress the spring and install the circlip. Refer with a friction plate. Refer to Figure 480.
to Figure 479.
8. Some assemblies are installed with a 4mm thick
Figure 479. pressure plate next to the disc spring.
9. If applicable, install the pressure plate first and
then refer to step7.
10. Install the pressure end plate. Refer to Figure
481.
11. Make sure that the chamfered face is installed,
facing the clutch pack. Refer to Figure 481.
6. Install the disc spring and then install the

assembly so that the outer diameter curves are
away from the clutch piston. Refer to Figure 480.
27 - 70 9813/8950-2 27 - 70
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03 - Manual Gearbox
H H
J

15. Install the thrust washer2 and thrust bearing 2.
Figure 483.
G
12. Make sure that the teeth are not aligned with the
lubrication slots in the housing. Refer to Figure F
481. G
13. Install the clutch friction and counter plate
retaining circlip. Use an air line to blow air down
the shaft oil inlet hole and check the piston and
clutch pack is free to operate smoothly. Refer to
Figure 481.
14. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate, refer to
Forward/Reverse Clutch- Calibrate (PIL 27-03).
F Thrust bearing 2
G Thrust washer 2
16. Thrust washer configurations may vary to that
shown. Make sure that components are installed
in the correct order.
17. Carefully use a thin rod (or screwdriver) to align
the teeth of the clutch plates. Install the gear and
splined hub. Refer to Figure 484.
18. Install the thrust washer 1 and thrust bearing 1.
27 - 71 9813/8950-2 27 - 71
27 - Driveline
03 - Manual Gearbox
Figure 484.
D
C
D
C Thrust bearing 1
D Thrust washer 1
E Gear and splined hub assembly
19. Thrust washer configurations may vary to that
shown. Make sure that components are installed
in the correct order. Refer to Figure 484.
20. Lubricate the clutch end bearing and push the
bearing onto the shaft. Refer to Figure 485.
Figure 485.
A
A
A
B
A Piston ring seal

B Clutch end bearing
21. Install new piston ring seals. Refer to Manual
Gearbox, Piston Ring Seal, Remove and Install
(PIL 27-03-45). Refer to Figure 485.
22. Do the step from 1 to 21 again, to assemble the
opposite side clutch.
27 - 72 9813/8950-2 27 - 72
27 - Driveline
03 - Manual Gearbox
15 - Solenoid Control Valve
15 - Solenoid Control Valve Introduction

Introduction .................................................... 27-73 The solenoid control valve provides the switching for
Check (Condition) .......................................... 27-74 forward drive and reverse drive to select the direction
Disassemble and Assemble .......................... 27-74 of travel.
27 - 73 9813/8950-2 27 - 73
27 - Driveline
03 - Manual Gearbox
Check (Condition) Disassemble and Assemble

Consumables
If damage to any component or distortion of the Description Part No. Size
spool is evident the complete valve assembly must JCB Threadlocker 4101/0250 0.01 L
be renewed. Great care should be taken when and Sealer (Medium
dismantling and assembling the valve to avoid the 4101/0251 0.05 L
Strength)
following:
It is not normally recommended to remove the spool
• Contamination
from the valve body. None of the component parts
• Damage to spools
of the valve assembly can be renewed individually.
• Damage to seal grooves
The extent of permissible servicing is cleaning and
Any of the above may result in possible problems the consequential renewal of O-ring seals. Refer to
with the operation of the valve. Check Condition.
Disassemble
1. Remove the surface mounted O-rings 1.
2. Unscrew the knurled nut and remove O-ring 3,
withdraw the solenoid and O-ring 5.
3. Hold the solenoid valve body in a vice, using the
spanner flats, remove spindle and O-ring 8.
4. Pull out the actuating pin, spring, spring retainer
and spool.
5. Dismantle the opposite solenoid in the same
sequence as described above.
6. Inspect the spool and spool bore for signs of
wear, nicks scratches etc.
27 - 74 9813/8950-2 27 - 74
27 - Driveline
03 - Manual Gearbox
Figure 486. 2. Lightly lubricate all parts with clean transmission

fluid before assembling.
3. Apply a small quantity of JCB Threadlocker and
Sealer to the threads in the knurled nut before
installation.
(Medium Strength)

Item Nm
2 12.5
1 O-rings
2 Knurled nut
3 O-ring
4 Solenoid
5 O-ring
6 Solenoid valve body
7 Spindle
8 O-ring
9 Actuating pin
10 Spring
11 Spring retainer
12 Spool
A Spanner flats
Assemble
1. Renew all O-rings.
27 - 75 9813/8950-2 27 - 75
27 - Driveline
03 - Manual Gearbox
16 - Check Valve
16 - Check Valve Introduction

Introduction .................................................... 27-76 Check Valves are unidirectional flow devices used
Remove and Install ....................................... 27-77 primarily in hydraulic systems to eliminate potential
damage caused by fluid back pressure.
27 - 76 9813/8950-2 27 - 76
27 - Driveline
03 - Manual Gearbox
16 - Check Valve
Remove and Install
Remove
1. Clean the area around the check valve and the
gearbox case. Do not allow particles of grit to fall
into the gearbox.
2. Unscrew and remove the check valve.
Figure 487.
A Check valve
B O-ring seal
C O-ring seal
Replacement is the opposite of the removal

procedure. During the replacement procedure do the
following work:
Install
1. Make sure that the O-ring seals are undamaged
and free from damage.
2. Tighten the check valve to the correct torque
value.

Item Nm
A 27
27 - 77 9813/8950-2 27 - 77
27 - Driveline
03 - Manual Gearbox
24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) .......................................... 27-78 Note: A pump which is worn or damaged may have
Remove and Install ....................................... 27-79 caused further damage to the gearbox.
If the existing pump is to be re-installed proceed as

follows:
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).
2. Carefully remove and discard the oil seal. Take
care not to damage the seal housing.
3. Install a new oil seal. Install the seal the correct
way around. Push the seal flush with the front of
the housing.
4. Re-assemble the pump.
5. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.
Figure 488.
A
B
C
A Security screw
B Oil seal
C Housing
27 - 78 9813/8950-2 27 - 78
27 - Driveline
03 - Manual Gearbox
24 - Oil Pump
Remove and Install
Remove
1. Clean the area around the pump. Do not allow
particles of grit to fall into the gearbox.
2. Remove the four fixing bolts and lift the pump
assembly off the input shaft.
3. Remove the four sealing washers and the pump
sealing ring. Discard the washers and sealing
ring.
Figure 489.
C
B
A Fixing bolts
B Pump assembly
C Sealing ring
Inspect the pump for signs of damage, refer to

Manual Gearbox, Pump - Check Condition (PIL
27-03).
Install
1. Install a new sealing ring. Locate the pump over
the input shaft and align the bolt holes. Install
the bolts together with new sealing washers.
Progressively tighten the bolts to the correct
torque value.
2. Pour some clean, new oil into the pump.

Item Nm
A 28
27 - 79 9813/8950-2 27 - 79
27 - Driveline
03 - Manual Gearbox
39 - Filter
39 - Filter Introduction
Introduction .................................................... 27-80 The transmission filter is designed to filter all the
Remove and Install ....................................... 27-81 contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.
27 - 80 9813/8950-2 27 - 80
27 - Driveline
03 - Manual Gearbox
39 - Filter
Remove and Install Consumable: JCB Transmission Fluid EP SAE

30
Special Tools
Description Part No. Qty. 2. Screw the filter on until it just contacts the filter
head.
Oil Filter Removal Tool 892/00292 1
3. Turn the filter at least another 3/4 of a turn.
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20 L
4000/2603 200 L
For draining the gearbox, refer to Manual Gearbox,

Drain and Fill (PIL 27-03).
Remove
1. Clean the area around the filter. Do not allow
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 490.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
27 - 81 9813/8950-2 27 - 81
27 - Driveline
03 - Manual Gearbox
40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................... 27-82 The suction strainer is a component used for trapping
Remove and Install ....................................... 27-83 large and coarse particles entering the transmission
system.
27 - 82 9813/8950-2 27 - 82
27 - Driveline
03 - Manual Gearbox
Remove and Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
Consumables
Description Part No. Size Table 156. Torque Values
JCB Threadlocker 4101/0250 0.01 L Item Nm
and Sealer (Medium 4101/0251 0.05 L B 10
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 Manual Gearbox, Drain and Fill (PIL
27-03).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 491.
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
27 - 83 9813/8950-2 27 - 83
27 - Driveline
03 - Manual Gearbox
45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................... 27-84 A piston ring is a split ring that fits into a groove on
Remove and Install ....................................... 27-85 the outer diameter of a piston.
27 - 84 9813/8950-2 27 - 84
27 - Driveline
03 - Manual Gearbox
45 - Piston Ring Seal
Remove and Install
Remove
1. Refer to the relevant Clutch- Disassemble and
Assemble procedure (PIL 27-03).
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 492.
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 493.
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 - 85 9813/8950-2 27 - 85
27 - Driveline
03 - Manual Gearbox
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................... 27-86 Oil seals close spaces between components in
Remove and Install ....................................... 27-87 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 - 86 9813/8950-2 27 - 86
27 - Driveline
03 - Manual Gearbox
47 - Oil Seal
Remove and Install
2. Remove the oil seal. Do not damage the seal

Remove housing.
1. Remove the drive yoke, refer to Drive Yoke -

Remove and Install (PIL 27-03).
Figure 494.
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. 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. refer to Drive Yoke- Remove and
Install (PIL 27-03).
27 - 87 9813/8950-2 27 - 87
27 - Driveline
03 - Manual Gearbox
74 - Synchromesh Gear 1 and 2
74 - Synchromesh Gear 1 and 2 Introduction

Introduction .................................................... 27-88 In a synchronised gearbox the gears are always
Component Identification ............................... 27-89 in mesh and rotating, but gears on one shaft can
Operation ....................................................... 27-90 freely rotate or be locked to the shaft. The locking
Check (Condition) .......................................... 27-93 mechanism for a gear consists of a collar on the shaft
which is able to slide sideways so that teeth on its
Disassemble and Assemble .......................... 27-93 inner surface bridge two circular rings with teeth on
their outer circumference, one attached to the gear,
one to the shaft. When the rings are bridged by the
collar, that particular gear is rotationally locked to
the shaft and determines the output speed of the
transmission.
The gearshift lever manipulates the collars using a

set of linkages, so arranged so that one collar may
be permitted to lock only one gear at any one time.
When shifting gears, the locking collar from one gear

is disengaged before that of another is engaged.
One collar often serves for two gears, sliding in one
direction selects one transmission speed, in the other
direction selects another.
In a synchromesh gearbox, to correctly match the

speed of the gear to that of the shaft as the gear is
engaged the collar initially applies a force to a cone-
shaped clutch attached to the gear, which brings the
speeds to match prior to the collar locking into place.
The collar is prevented from bridging the locking
rings when the speeds are mismatched by synchro
rings. The synchro ring rotates slightly due to the
frictional torque from the cone clutch. In this position,
the dog clutch is prevented from engaging. The brass
clutch ring gradually causes parts to spin at the same
speed. When they do spin at the same speed, there
is no more torque from the cone clutch and the dog
clutch is allowed to fall into engagement.
27 - 88 9813/8950-2 27 - 88
27 - Driveline
03 - Manual Gearbox
Component Identification Figure 497.
Figure 495.
B C
E E Sleeve
F Ball
D G Poppet
H Spring
A Synchro hub J Wear indicator grooves
B Synchro rings
C Blocker pins
D Split energiser pins
E Synchro cups
Figure 496.
A Cone
B Cone
C Ring
D Ring
E Sleeve
J Wear indicator grooves
27 - 89 9813/8950-2 27 - 89
27 - Driveline
03 - Manual Gearbox
Operation Figure 498.
A
The gearbox is installed with a Blocking Pin
synchromesh, comprising the following parts.
B
Synchro hub
Controls the operation of the synchromesh unit and
gear selection, the selector fork installed into the B C
outer groove. Internal splines link the selected gear
to the drive shaft. Through the synchro hub centre
are two sets of holes for the blocker pins and the split
energiser pins, spaced alternately.
Synchro rings
Synchro rings are rigidly joined by the blocker pins,
with the split energiser pins held, in counter bores,
between the two synchro rings.
Blocker pins
E
Blocker pins have a narrow neck in the centre,
against which the synchro hub transmits radial drive
during gear changes. The edges of the blocker
E
pin neck and their mating synchro hub holes are D
designed so that, as the radial loads are reduced,
the synchro hub can slide over the shoulder of the
A Synchro hub
blocker pin.
B Synchro rings
C Blocker pins
Split energiser pins D Split energiser pins
E Synchro cups
Split energiser pins take the initial axial load of the
synchro hub on the shoulder of the split energiser pin The diagram shows the gearbox with first gear
neck. As the axial load reaches approximately 40.8 engaged. The synchro ring is in contact with the
kg the internal springs allow the split energiser pin to synchro cup and the synchro hub splines are linking
collapse and the synchro hub to move axially. first gear to the shaft gear. In this position the split
energiser pins are collapsed. Refer to Figure 499.
Synchro cups
Synchro cups take the frictional drive from the
synchro ring on their inner faces. The synchro cups
are splined to drive their respective gears whilst
synchronisation is taking place.
27 - 90 9813/8950-2 27 - 90
27 - Driveline
03 - Manual Gearbox
A
C
B
As the axial load on the synchro hub increases, the

split energiser pin collapses and the conical faces
of the blocking pin and synchro hub hole come into
E contact. Refer to Figure 501.
F
A Synchro hub
B Synchro rings
C Blocker pins
D Split energiser pins
E Synchro cups
When selecting second gear the synchro hub slides

along the split energiser pins until the pin recess
and the synchro hub flange are in line. At this point
the split energiser pins open and the synchro rings
are moved by the synchro hub pushing on the split
energiser pin shoulder.
Initial contact between the synchro ring and the

synchro cup starts to synchronise the speed of the
shaft and second gear. The rotational force of the
synchro ring is taken by the blocker pin against the
edge of the synchro hub hole. Refer to Figure 500.
27 - 91 9813/8950-2 27 - 91
27 - Driveline
03 - Manual Gearbox
H
Further increases in the axial loads increase the
frictional grip of the synchro ring and the synchro
cup, causing the shaft and the gear speeds to
synchronise.
As the speeds are synchronised the radial load on

the blocker pin and the synchro hub is reduced.
This allows the synchro hub to slide freely along the
blocker pin and engage its splines with the second
gear. Refer to Figure 502.
27 - 92 9813/8950-2 27 - 92
27 - Driveline
03 - Manual Gearbox
Check (Condition) Disassemble and Assemble
Ring and cone type synchroniser units must be Disassemble

checked for wear before assembly as follows:
1. Before dismantling the unit be aware that on re-
1. Inspect the mating faces of the cones and rings. assembly, the components must be kept in their
The wear indicator grooves must still be visible. original relationships.
2. Inspect the teeth on all cones and rings for 2. Dismantle the synchromesh unit by removing the
excessive wear or damage. If wear or damage is cones and rings. Push off the sleeve, take care
evident the synchromesh unit must be renewed. to retrieve the sets of balls, poppets and springs.
Figure 503.
A Cone
B Cone
C Ring
D Ring
E Sleeve
27 - 93 9813/8950-2 27 - 93
27 - Driveline
03 - Manual Gearbox
Figure 504. 4. Inspect the teeth on all cones and rings for
excessive wear or damage. If wear or damage is
evident the unit must be renewed.
Assemble
1. Assemble the parts in the reverse order, make
sure that the components are kept in their original
relationships.
E Sleeve
F Ball
G Poppet
H Spring
3. Inspect the mating faces of the cones and
rings. The wear indicator grooves must still be
visible. As a further check, locate the cones
and rings together as shown and measure the
clearance between them using feeler gauges.
The clearance should be between the given
tolerance for both pairs. If either is outside these
limits then the complete synchromesh unit must
be renewed.
Length/Dimension/Distance: 0.5 –1.9 mm
Figure 505.
K Cone and ring clearance
27 - 94 9813/8950-2 27 - 94
27 - Driveline
03 - Manual Gearbox
76 - Synchromesh Gear 3 and 4 Introduction

Introduction .................................................... 27-95 Refer to Synchromesh Gear 1 and 2 - Introduction
Component Identification ............................... 27-96 (PIL 27-03-74).
Check (Condition) .......................................... 27-96
Disassemble and Assemble .......................... 27-97
27 - 95 9813/8950-2 27 - 95
27 - Driveline
03 - Manual Gearbox
Refer to Synchromesh Gear 1 and 2 - Component Refer to Synchromesh Gear 1 and 2 - Check
Identification (PIL 27-03-74). Condition (PIL 27-03-74).
27 - 96 9813/8950-2 27 - 96
27 - Driveline
03 - Manual Gearbox
Refer to Synchromesh Gear 1 and 2 - Disassemble

and Assemble (PIL 27-03-74).
27 - 97 9813/8950-2 27 - 97
27 - Driveline
03 - Manual Gearbox
90 - Front Case
90 - Front Case Clean

Consumables
Clean ............................................................. 27-98
Check (Condition) .......................................... 27-99
Cleaner/Degreaser 4104/1557 0.4 L
- General purpose
solvent based parts
cleaner
Cleanliness is of the utmost importance when

servicing the gearbox. Observe the following:
1. Remove deposits of dirt, grit and oil from the

outer cases and components.
2. Prevent dirt, grit and debris falling into the
gearbox.
3. Cap all open ports, hoses, pipes and orifices.
27 - 98 9813/8950-2 27 - 98
27 - Driveline
03 - Manual Gearbox
90 - Front Case
Check (Condition)
Before you assemble the gearbox make sure that a

thorough inspection of all components is carried out.
Remember that although a failed component may
be easy to identify, the cause of that failure may be
less easy to trace. It is also possible that a failed
component may have caused damage to other areas
of the gearbox.
1. If the output shaft and bearing are removed they

must be installed.
2. Make sure that the shaft assemblies are correctly
assembled and free from defects.
3. Install new shaft piston ring seals. Make sure that
they are installed correctly on the groove.
4. Carefully remove all traces of gasket compound
from components as follows:
4.1. Front and rear case mating faces.
4.2. Front case and torque converter housing
mating faces.
5. Clean the inside of the case using a suitable
degreasing agent.
6. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
replaced.
7. Make sure that all oil way cross drillings in the
cases, shafts and gears are clear and free from
debris. Blocked oil ways are a common cause of
bearing failure. Use an air line to blow through
cross drillings.
8. Make sure that new cases are installed with the
correct adaptors, plugs and orifice restrictors.
27 - 99 9813/8950-2 27 - 99
27 - Driveline
03 - Manual Gearbox
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-100 Refer to Front Case - Clean (PIL 27-03-90).
Check (Condition) ........................................ 27-101
27 - 100 9813/8950-2 27 - 100

27 - Driveline
03 - Manual Gearbox
91 - Rear Case
Check (Condition)
Refer to Front Case - Check Condition (PIL

27-03-90).
27 - 101 9813/8950-2 27 - 101

27 - Driveline
12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-103
27 - 102 9813/8950-2 27 - 102

27 - Driveline
00 - General
Introduction .................................................. 27-103 The transfer gearbox is a system of gears used in
Technical Data ............................................. 27-104 4WD (Four Wheel Drive) vehicles, which transfers
Component Identification ............................. 27-105 torque from the transmission to the front and rear
Fault-Finding ................................................ 27-107 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Drain and Fill ............................................... 27-107 wheels.
Clean ........................................................... 27-108
Check (Condition) ........................................ 27-108 Transfer gearboxes typically have two gear ranges,
Calibrate ...................................................... 27-109 High and Low.
Remove and Install ..................................... 27-109 • High Range is used for typical road use.
Disassemble and Assemble ........................ 27-111 • Low Range is used for off-road conditions.
27 - 103 9813/8950-2 27 - 103

27 - Driveline
00 - General
Technical Data
Refer to Driveline - Technical Data. Refer to: PIL

27-00-00.
27 - 104 9813/8950-2 27 - 104

27 - Driveline
00 - General
Figure 506.
Unit Identification
The drop box assembly serial number is stamped
on the unit identification plate as shown. When you
make an order for parts replacement, always give
the details mentioned 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.
27 - 105 9813/8950-2 27 - 105

27 - Driveline
00 - General
Figure 507.
Item Description
Table 157. 10 Idler gear
Item Description 11 Nuts
1 Gear case front half 12 Washers
2 Ball bearing 13 Yokes
3 Input gear 14 Oil seals
4 Input shaft 15 Oil drain plug
5 Dowel 16 Oil level plug
6 Gear case rear half 17 Removing plug
7 Retaining bolt 18 Bolt
8 Roller bearing
9 Output shaft
27 - 106 9813/8950-2 27 - 106

27 - Driveline
00 - General
Fault-Finding
Most of the problems in the transfer gearbox are Drain and Fill
identified by a noisy unit.
The only tests that can be carried out without
removing the transfer gearbox from the machine are: Refer to the relevant Transfer Gearbox- Disassemble
- Checking the oil level in the drop box. and Assemble (PIL 27-12).
- Checking the gearbox case for signs of damage.
27 - 107 9813/8950-2 27 - 107

27 - Driveline
00 - General
Clean Check (Condition)

Consumables
Description Part No. Size Before you assemble the gearbox, do a full
Cleaner/Degreaser 4104/1557 0.4 L inspection of all the components. It may be easy to
- General purpose find out a component failure but the cause behind
solvent based parts the failure may not be as easy to find out. It is also
cleaner possible that a failed component may have caused
damage to other areas of the gearbox.
Surface Cleaning Fluid 4103/1204 1L
1. General inspection.
1. Carefully remove all traces of the gasket
or gasket compound from the dropbox case 1.1. Carefully inspect all of the gears, bearings
mating faces. Note: When removing the gasket and shafts for any signs of excessive
compound use a gasket removal product such wear or damage. If you find any damage
as Loctite Chisel. Take care not to damage the during the inspection, components must be
mating faces. replaced.
2. Clean the faces with a fine carborundum paper. 1.2. Make sure that all oil way cross drillings
Use a solvent cleaner and a clean cloth to finally are clear and free from contamination and
remove all traces of oil or debris. foreign particles. Blocked oil ways are
a common cause of bearing failure. If
Consumable: Surface Cleaning Fluid necessary use an air line to blow through
the oil ways.
3. Clean the inside of the dropbox case using a
suitable degreasing agent.
27 - 108 9813/8950-2 27 - 108

27 - Driveline
00 - General
Calibrate Remove and Install
Refer to the relevant disassembly-assembly (For: 6T-1 Swivel Tip, 9T-1 Front Tip)
procedure. Refer to (PIL 27-12).
Remove
4. Disconnect the front propshaft.
Figure 508.
A
B
A Front propshaft
B Bolts 1
6. Disconnect the rear propshaft.
Figure 509.
C Rear propshaft
D Bolts 2
7. Support the transfer gearbox with a suitable
lifting jack.
27 - 109 9813/8950-2 27 - 109

27 - Driveline
00 - General
Figure 510.
E Transfer gearbox
9. Remove the transfer gearbox from the machine.
Figure 511.
E Transfer gearbox
F Bolts 3
Install
step.

Item Description Nm
B Bolts 1 115
D Bolts 2 49
F Bolts 3 230
27 - 110 9813/8950-2 27 - 110

27 - Driveline
00 - General
Figure 514.
Disassemble
The gearbox can be disassembled while it is installed
to the axle. If the rear case is to be replaced, or the
axle is to be disassembled then the gearbox must
be removed from the axle. Place suitable wooden T
blocks to securely support the assembly.
1. Remove the drain plug and the bonded seal.

2. Drain the oil from the gearbox into a suitable
container.
3. Install the drain plug with a new bonded seal.
T Bolts 2
4. Tighten the drain plug to the correct torque value.
8. Install the bolt 2 in the extraction holes.
Figure 512.
9. Tighten the bolt 2 to split the front half case and
the rear half case.
Q Figure 515.
Q Drain plug
5. Remove the nuts, washers and the yokes. T
6. Remove the coupling.
Figure 513. T Bolts 2
10. Remove the front case.
M
L
L Nuts
M Washer
N Yokes
27 - 111 9813/8950-2 27 - 111

27 - Driveline
00 - General
H
K
A
C
H
C H Roller bearing
K Idler gear
12. Remove the input gear.
K
13. If necessary, remove the bearing races from the
gear case.
A Front half case
C Input gear Figure 518.
K Idler gear C
11. Remove the idler gear complete with the roller C
bearings.
11.1. The roller bearing inner race will remain on
the shaft and the roller bearing outer race
will remain in the gear case.
C Input gear
14. Remove and discard the oils seals (x3).
27 - 112 9813/8950-2 27 - 112

27 - Driveline
00 - General
Figure 519.
P
N
F G
M
L
E
D
B
C
B
A
T J
K
H
B E
S
C
N
B
M L
M
L P
R Q
A Front half case B Ball bearing

C Input gear D Input shaft
E Dowel F Rear half case
G Bolt 1 H Roller bearing
J Output shaft K Idler gear
L Nuts M Washer
N Yokes P Oil seals
Q Drain plug R Oil level plug
S Plug T Bolts 2
27 - 113 9813/8950-2 27 - 113

27 - Driveline
00 - General
Assemble
1. Assembly is the opposite of the disassemble
procedure.
2. Install the oil seals (x3).
3. Install the bearings into the gear cases and onto
the idler shaft.
4. Use small pieces (x2) of timber to support the
rear half case clear of the workbench to allow for
the protrusion of the output shaft.
5. Position the rear half case with the joint face
uppermost.
6. Install the input gear into the bearing in the gear
case.
7. Take care not to damage the oil seals.
8. Install the input gears into the bearing in the rear
half case.
9. Install the idler gear complete with the ball
bearings on both sides into the rear half case.
10. Apply Loctite 275 to seal the case halves.
11. Fill in the lips of the seals with grease before
installation.
12. Take care not to damage the oil seals.
13. Install the front half case, locating it to the dowels.
14. Install the bolts 2.
16. Apply grease to the oil seals before the coupling
installation.
17. Make sure that the yokes are aligned with each
other.
18. Install the output yoke, washer and the nuts.
19. Tighten the nuts to the correct torque value.
20. Fill the unit with the correct grade and quantity
of oil.

Item Description Nm
Q Drain plug 102
L Nuts 300
T Bolts 2 56
27 - 114 9813/8950-2 27 - 114

27 - Driveline
20 - Axle
20 - Axle
Contents Page No.
27-20-00 General ......................................................................................................................... 27-117
27 - 115 9813/8950-2 27 - 115

Notes:
27 - 116 9813/8950-2 27 - 116

27 - Driveline
20 - Axle
00 - General
Introduction .................................................. 27-117 The axle consists of a differential housing. The
Technical Data ............................................. 27-118 differential housing carries the differential in the
Component Identification ............................. 27-119 centre and an axle arm on the sides with a wheel
Fault-Finding ................................................ 27-123 hub unit at each end. The axle arm carries the oil
immersed multi-plate braking system, planetary drive
Drain and Fill ............................................... 27-125 and the axle shaft.
Disassemble and Assemble ........................ 27-131 The ring bevel gear is adjusted with two ring nuts
located opposite to each other. The position of the
bevel pinion, supported by two bearings, is adjusted
by installing adjusting shims. The wheel hubs are
supported by two tapered roller bearings.
The axle shafts are fully floating, carrying none of the

wheel loads which are supported on tapered roller
bearings.
The axle can have braking system with a hydraulic

actuation for service braking and mechanical control
for the park brake.
27 - 117 9813/8950-2 27 - 117

27 - Driveline
20 - Axle
00 - General
Technical Data
Refer to Driveline - Technical Data. Refer to: PIL

27-00-00.
27 - 118 9813/8950-2 27 - 118

27 - Driveline
20 - Axle
00 - General
Figure 521.
Unit Identification
The axle 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.
Figure 520.
27 - 119 9813/8950-2 27 - 119

27 - Driveline
20 - Axle
00 - General
Figure 522.
10
9A
Item Description
Table 160.
4 Driveshaft
Item Description 5 Stub axle arm
1 Counter plates 6 Brake piston
2 Friction plates 7 Reaction pin
3 Brake carrier
27 - 120 9813/8950-2 27 - 120

27 - Driveline
20 - Axle
00 - General
Item Description This type of piston back off is installed for servo brake
8 Brake piston housing applications.
(2) Positive piston back off retracts the piston to
9 Controlled piston back the same position. As the friction plates wear the
off spring assembly
(1)
retraction distance will increase. This type of piston
A Positive piston back off back off is installed for hydraulic power brake
spring assembly
(2)
applications.
10 Drive head housing
(1) Controlled piston back off maintains the same
piston retraction distance as the friction plates wear.
Sectional Drawing
Figure 523.
6 7 8 10
1
2
5 9 11
Item Description
Table 161. 3 Brake carrier
Item Description 4 Driveshaft
1 Counter plates 5 Stub axle arm
2 Friction plates
27 - 121 9813/8950-2 27 - 121

27 - Driveline
20 - Axle
00 - General
Item Description
6 Brake piston
7 Reaction pin
8 Brake piston housing
9 Back off pin
10 Drive head housing
11 Differential unit
27 - 122 9813/8950-2 27 - 122

27 - Driveline
20 - Axle
00 - General
Fault-Finding
Fault
Noise while driving Table 162. Page 27-123
Noise while driving in neutral Table 163. Page 27-123
Intermittent noise Table 164. Page 27-123
Constant noise Table 165. Page 27-123
Noise while steering Table 166. Page 27-124
Noise under power greater than during coast Table 167. Page 27-124
Noise during coast greater than under power Table 168. Page 27-124
Table 162. Noise while driving

Cause Remedy
Excessive backlash between the pinion and the ring Adjust the backlash between the pinion and the ring
gear gear.
Worn out pinion and gear ring Replace the pinion and the gear ring.
Worn out pinion bearings Replace the pinion bearings.
Loosened pinion bearings Adjust the pinion bearings.
Excessive axial pinion backlash Adjust the axial pinion backlash.
Worn out differential bearings Replace the differential bearings.
Loosened differential bearings Adjust the differential bearings.
Ring gear out of roundness Replace the ring gear.
Low Lubricant level Check the oil level and top up as required.
Poor or wrong lubricant Flush the system and fill again with the correct grade
of oil.
Bent half shaft Replace the half shaft.
Table 163. Noise while driving in neutral

Cause Remedy
Noise from the axle is usually heard when the Check the condition of the axle and repair as
machine moves in neutral gear but are not loud required.
See Also: Table 162. Noise while driving
Incorrect backlash between the pinion and the ring Replace the pinion and the ring.
(sound heard while decelerating disappears while
increasing the speed).
Worn out pinion or input flange Adjust the pinion and the input flange.
Table 164. Intermittent noise

Cause Remedy
Damaged ring gear Replace the ring gear.
Loosened differential box bolts Tighten differential box bolts.
Table 165. Constant noise

Cause Remedy
Damaged ring gear teeth and pinion Replace the ring gear teeth and pinion.
Worn out bearings Replace the bearings.
Worn out pinion spline Replace the pinion spline.
Bent half shaft Replace the half shaft.
27 - 123 9813/8950-2 27 - 123

27 - Driveline
20 - Axle
00 - General
Table 166. Noise while steering

Cause Remedy
Worn out differential gears Replace the differential gears.
Worn out differential box and spider Replace the differential box and spider.
Worn out differential thrust washers Replace the differential thrust washers.
Worn out half shaft spline Replace the half shaft spline.
Table 167. Noise under power greater than during coast

Cause Remedy
Low Lubricant level Check the oil level and top up as required.
Poor or wrong lubricant Flush the system and fill again with the correct grade
of oil.
Worn out ring and pinion Check the condition of the ring and pinion through
the top cover. Adjust or replace as required.
Worn out ring and pinion bearings Adjust or replace the ring and pinion bearings as
required.
Worn out planetary gears or bearings Replace the planetary gears or bearings.
Table 168. Noise during coast greater than under power

Cause Remedy
Loosened pinion nut Tighten the pinion nut.
Only pinion bearing is damaged Replace the pinion bearing.
27 - 124 9813/8950-2 27 - 124

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 524.
machine level, otherwise a false indication of the and Refer to Figure 525.
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 169. and Refer
Remove to Table 170.
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 524.
and Refer to Figure 525.
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 169. and
Refer to Table 170.
Figure 524. JCB Axle (Inboard Brakes)
C
A
B
C
A Axle fill/level plug B Axle drain plug

C Hub drain plug
27 - 125 9813/8950-2 27 - 125

27 - Driveline
20 - Axle
00 - General
Figure 525. JCB Axle (Braked Hubs)

F
D
E
D Axle fill/level plug E Axle drain plug

F Hub drain plug
Figure 526. Hexagonal Plug and Seal- Figure 527. Taper Plug (January 2011 Onwards)
ing Washer (Prior to January 2011)
Table 169. 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 170. 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
27 - 126 9813/8950-2 27 - 126

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).
27 - 127 9813/8950-2 27 - 127

27 - Driveline
20 - Axle
00 - General
Remove and Install 8. Remove the front wheels from the machine.
Front Tip [Hi-Viz], 9T-1 Front Tip, Front 9. Raise the front of the machine with a suitable
................................................. Page 27-128 jack.
For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 10. Support the machine chassis on a suitable axle
Front Tip [Hi-Viz], 9T-1 Front Tip, Rear stand.
................................................. Page 27-129
Figure 530.
Front Tip [Hi-Viz], 9T-1 Front Tip, Front)
Remove
3. Install the articulation lock. Refer to (PIL 06-27).
4. Remove the bolts 1. E
5. Disconnect the propshaft from the front axle. E Axle stand
6. Collect the retaining straps. 11. Support the front axle with suitable lifting
equipment.
Figure 528.
Figure 531.
C A
F
A Bolts 1 F Lifting equipment

B Propshaft
C Retaining strap 12. Remove the nuts (x8) and the bolts 2 (x8).
7. Disconnect the brake pipes. 13. Collect the washers and the plate.
Figure 529.
D Brake pipes
27 - 128 9813/8950-2 27 - 128

27 - Driveline
20 - Axle
00 - General
H J
A B
K
L G
C
G Front axle A Bolts 1
H Nuts B Propshaft
J Bolts 2 C Retaining strap
K Washers
L Plate 8. Disconnect the brake pipes.
14. Remove the front axle from the machine. Figure 534.
Install
D
step.
3. Bleed the brake system. Refer to (PIL 24-00). D

Item Description Nm
D Brake pipes
A Bolts 1 84
H Nuts 230 9. Raise the rear of the machine with a suitable jack.
10. Support the machine chassis on a suitable axle
stand.
Front Tip [Hi-Viz], 9T-1 Front Tip, Rear) Figure 535.
Remove
3. Remove the floorplate. Refer to (PIL 09-78).
E
4. Install the articulation strut. Refer to (PIL 06-27).
5. Remove the bolts 1 (x4).
6. Disconnect the propshaft from the rear axle.
E Axle stand
7. Collect the retaining straps.
11. Remove the rear wheels from the machine. Refer
to (PIL 27-30).
12. Support the rear axle with suitable lifting
equipment.
27 - 129 9813/8950-2 27 - 129

27 - Driveline
20 - Axle
00 - General
Figure 536.
F Rear axle
G Lifting equipment
13. Remove the nuts (x8) and the bolts 2 (x8).
14. Collect the washers and the plates.
15. Remove the rear axle from the machine.
Figure 537.
F J
K
G
F Rear axle
G Nuts
H Bolts 2
J Washers
K Plates
Install
step.
3. Bleed the brake system. Refer to (PIL 24-00).

Item Description Nm
A Bolts 1 84
B Nuts 230
27 - 130 9813/8950-2 27 - 130

27 - Driveline
20 - Axle
00 - General
Consumables 13. Remove all the three reaction pins and check
Description Part No. Size them for damage.
JCB Gear Oil HP 4000/0505 20 L 14. In the controlled retraction piston type, If new
4000/0503 200 L brake and friction plates are installed then a new
JCB Multi-Gasket 4102/1212 0.05 L brake back off pin 1 and tension bushes also
JCB Threadlocker 4101/0250 0.01 L need to be installed. Failure to do so could result
and Sealer (Medium in the brake being permanently on.
4101/0251 0.05 L
Strength)
Brake piston and seals- Controlled
Disassembly retraction type
It is recommended that axle must be removed from Make sure that only one side at a time is
the machine while you disassemble the rear axle disassembled to prevent damage to the bearings and
brake. preserve the crownwheel and the backlash settings.
Before you disassemble the rear axle brakes, it is Before you remove the brake housing and the piston
mandatory to mark the components for alignment assembly make sure that you support the differential
and to identify the right hand and left hand side, to with the driveshaft or any other suitable support.
make sure that it is correctly assembled at the time
1. Mark the brake piston housing and the
of assembly.
drivehead.
Brake pack 2. Remove the capscrews.
1. Use a heavy duty (6 point) socket to remove the 3. Remove the brake housing and the piston
bolt 1. assembly.
2. Carefully remove the axle arm from the 4. Make sure that you do not turn the nut, if it is
drivehead. turned then the bearing pre-load needs to be
reset.
3. If necessary, tap the case with a soft faced
hammer and remove all traces of the old sealant 5. Remove the six reaction pin assemblies.
from the mating faces.
5.1. Remove the circlip 2.
4. The brake pack consist of five friction plates and
six counter plates. There are two counter plates, 5.2. Remove the back off pins 1.
one at each end of the brake pack, which are not 5.3. Remove the tension bushes and the spring
attached to the plate carrier. 1.
5. If it is necessary to install the plates again 6. Remove the brake piston from the brake housing.
then make a note of their position and correct
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 9. Nicks or cuts in the seals may be the reason for
then make a note of their original position before loss of brake fluid.
you remove them.
Brake Piston and Seals- Positive retraction
8. The wear limit of friction plates is to the depth of type
the cross hatching.
Make sure that only one side at a time is
9. Check all plates for flatness and damage.
disassembled to prevent damage to the bearings and
10. Scoring of the counter plates to a certain limit is do the preservation procedure for the crownwheel
permissible. and the backlash settings.
11. Install a new brake pack, if it is damaged. Before you remove the brake housing and the piston
assembly make sure that you support the differential
12. Make sure that you do not install new plates with the driveshaft or any other suitable support.
individually.
27 - 131 9813/8950-2 27 - 131

27 - Driveline
20 - Axle
00 - General
1. Mark the brake piston housing and the 5.1. Remove the back off pins 2.
drivehead.
5.2. Remove the spring 2.
2. Remove the capscrews.
6. Remove the brake piston from the brake housing.
3. Remove the brake housing and the piston
7. Remove and discard both the seal 1 and seal 2.
assembly.
8. Check the housing bore for damage and scoring.
4. Make sure that you do not turn the nut, if it is
turned then the bearing pre-load needs to be 9. Nicks or cuts in the seals may be the reason for
reset. loss of brake fluid.
5. Remove the six reaction pin assemblies.
27 - 132 9813/8950-2 27 - 132

27 - Driveline
20 - Axle
00 - General
Figure 538.
E J
L
K
M
N Q R
T
B
B
C D
Item Description
Table 173. 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
27 - 133 9813/8950-2 27 - 133

27 - Driveline
20 - Axle
00 - General
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
the correct torque value.
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 174. 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.
27 - 134 9813/8950-2 27 - 134

27 - Driveline
20 - Axle
00 - General
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 174.
Table 174. 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
27 - 135 9813/8950-2 27 - 135

27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-137
27 - 136 9813/8950-2 27 - 136

27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-137 The front differential is part of the front axle assembly.
Remove and Install ..................................... 27-138 Refer to: PIL 27-20-00.
27 - 137 9813/8950-2 27 - 137

27 - Driveline
24 - Differential
00 - General
Remove and Install
Refer to Front axle- Disassemble and Assemble.

27 - 138 9813/8950-2 27 - 138

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-141
27 - 139 9813/8950-2 27 - 139

Notes:
27 - 140 9813/8950-2 27 - 140

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-141 The front hub is part of the front axle assembly. Refer
Remove and Install ..................................... 27-142 to: PIL 27-20-00.
27 - 141 9813/8950-2 27 - 141

27 - Driveline
27 - Hub
00 - General
Remove and Install
Refer to Front axle- Disassemble and Assemble.

27 - 142 9813/8950-2 27 - 142

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-145

27-29-15 Wheel Nuts ................................................................................................................... 27-148
27 - 143 9813/8950-2 27 - 143

Notes:
27 - 144 9813/8950-2 27 - 144

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-145 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-146 removed, check the wheel nut torques every two
Check (Condition) ........................................ 27-146 hours until they stay correct. Every day, before
Remove and Install ..................................... 27-147 starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value. Refer to: PIL 27-29-00.
27 - 145 9813/8950-2 27 - 145

27 - Driveline
29 - Wheel
00 - General

WARNING If, for whatever reason, a wheel stud
is renewed, all the studs for that wheel must be Wheels and Tyres
changed as a set, since the remaining studs may
have been damaged. 1. If the tyre has been run flat or seriously under
WARNING Wheels and tyres are heavy. Take inflated, do not inflate it without removing and
care when lifting or moving them. Store with care checking the tyre, tube or rim for damage.
to ensure that they cannot fall and cause injury. 2. Do not rework, weld, heat or braze the rims.
WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated. 3. Do not install the tubes that are buckled or
Follow the instructions given when inflating the creased.
tyres. Do not cut or weld the rims. Use a tyre/
4. Do not use a tube in a casing larger or smaller
wheel specialist for all repair work.
than that for which the tube was designed by the
WARNING Deflate the tyre you wish to change manufacturer.
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and 5. Do not hit the tyre or rim with a hammer.
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner 6. Do not mount a tyre on a rim where any parts
and outer wheel halves together when there is air show cracks, damage or have been repaired by
pressure in the tyre. Always wear safety glasses. welding or brazing.
WARNING Wheels installed with semi-solid tyres 7. Inspect the inside of the tyres for loose
are heavy. Removing and installing them requires cords, cuts, penetrating objects or other carcass
special equipment and training. Have the work damage.
carried out by your JCB dealer or a tyre specialist.
8. Make sure that you repair any damage before
WARNING Do not install pneumatic tyres on a installation of the tube.
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If 9. Discard any tyres with irreparable damage.
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a 10. Clean and inspect the rims regularly.
trained specialist.
11. Check the rim diameter to make sure that it
DANGER Run flat inserts may be installed in the exactly matches the rim diameter moulded on the
rear wheels. These must remain installed to the tyre.
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre. 12. Inspect the inside of the tyre for dirt, liquids or
foreign material.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required. 13. Make sure that you inflate the tyre to the tyre
Where run flat inserts have been specified for use, manufacturer's recommended cold operating
ensure that replacement wheels also have run flat pressure.
inserts to ensure the machine stability.
14. If removed, install the wheel nuts to the correct
torque value, refer to technical data..
14.1. Make a note that many machines use
special wheel nuts and washers, which
must never be substituted by a standard
wheel nut. When installed, always use the
special washers under wheel nuts. If the
wheel nuts or washers are lost they must
only be replaced with genuine parts.
27 - 146 9813/8950-2 27 - 146

27 - Driveline
29 - Wheel
00 - General
Remove and Install 2. Tighten the wheel nuts to the correct torque
value.
WARNING A machine can roll off jacks and
crush you unless the wheels have been blocked. 3. Check the wheel nut torque values daily until
Always block the wheels at the opposite end of stabilized.
the machine that is to be jacked. Do not work
underneath a machine supported only by jacks. Table 175. Torque Values
Always support a jacked-up machine on axle Item Description Nm
stands before working underneath it. B Wheel nut 630
method and device.
Remove
3. Loosen the wheel nuts.
4. Jack up the machine with a suitable jack.
5. Remove the wheel nut.
5.1. Make a note that the quantity of the wheel
nuts may change for different machine
models.
6. Remove the wheel with suitable lifting
equipment.
Figure 539.
B A
A Wheel
B Wheel nut
Install
Important: If the wheel nuts or washers are lost they
must only be replaced with genuine parts.

step.
27 - 147 9813/8950-2 27 - 147

27 - Driveline
29 - Wheel
15 - Wheel Nuts
15 - Wheel Nuts
Introduction
If the wheel nuts or washers are lost they must only

be replaced with genuine parts.
If a wheel is removed and replaced for puncture

repair or any other reason, the wheel nuts must be
tightened to the correct torque values and the torque
must be checked daily until stabilised.
Make a note that many machines use special wheel

nuts and washers, which must never be substituted
by a standard wheel nut. When installed, always use
the special washers under wheel nuts.
27 - 148 9813/8950-2 27 - 148

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-151
27 - 149 9813/8950-2 27 - 149

Notes:
27 - 150 9813/8950-2 27 - 150

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-151 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-152 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-152 ground.
Tyre materials are usually synthetic rubber, natural
rubber, fabric and wire, along with other compound
chemicals. They consist of a tread and a body.
The tread provides traction while the body ensures
support.
Make sure that the tyres are kept in good condition.
27 - 151 9813/8950-2 27 - 151

27 - Driveline
33 - Tyre
00 - General

DANGER Make sure that all tyres are inflated
to the correct pressure. Refer to the machine Refer to: PIL 27-29-00.
operator manual.
WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/
wheel specialist for all repair work.
WARNING Wheels and tyres are heavy. Take
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury.
WARNING Do not use the machine with
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed
limitation of the tyres installed and do not operate
at more than their recommended maximum
speed.
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which
at high speeds may endanger life.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a
trained specialist.
WARNING When ordering tyres, you must
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are
shown in the Operator's Manual. On no account
should you use tyres of other designations
without first gaining approval from the machine
manufacturer.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode.
27 - 152 9813/8950-2 27 - 152

27 - Driveline
33 - Tyre
00 - General
Remove
1. Take care not to damage the rim or tyre.
A
2. Remove the wheel from the machine.
3. Lubricate the rim, tyre and the base of the tube
with a solution of soap and water or similar rubber
lubricant.
4. Use suitable tyre levers to pry the tyre off the rim
with small bites of the tyre levers. A Tyre levers
Figure 540.
A Tyre levers
Install
1. If any damage to the tyre is found, consult a
qualified technician to make sure if it is safe to
install the tyre.
2. Place the rim on the ground.
3. Lubricate the bead and rim.
4. Place the tyre on the rim.
5. Install the tyre with the long tyre levers.
6. Centre the tyre on the rim and inflate.
7. Remove the valve core and completely deflate
the tyre.
8. Install the valve core again and inflate to the
recommended pressure.
27 - 153 9813/8950-2 27 - 153

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-155
27 - 154 9813/8950-2 27 - 154

27 - Driveline
47 - Propshaft
00 - General
Introduction .................................................. 27-155 The propeller shaft or propshaft is usually the shaft
Remove and Install ..................................... 27-156 that connects the gearbox to the differential or
drivehead.
The propshaft is a mechanical component for

transmitting torque and rotation, usually used to
connect components of a drivetrain that cannot be
connected directly because of distance or the need
to allow for relative movement between them.
27 - 155 9813/8950-2 27 - 155

27 - Driveline
47 - Propshaft
00 - General

Item Description Nm
A Bolts 1 140
Remove
R Bolts 2 43
4. Disconnect the propshaft from the gearbox
output flange.
Figure 542.
A Bolts 1
Q Propshaft
5. Support the propshaft with suitable equipment.
6. Remove the bolts 2 and the nuts 2.
Figure 543.
Q Propshaft
R Bolts 2
7. Remove the propshaft from the machine.
Install
step.
27 - 156 9813/8950-2 27 - 156

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-49 Schematic Symbols ........................................................................................................ 30-17
30-00-50 Schematic Circuit ........................................................................................................... 30-21
30-03 Tank
30-03-00 General ........................................................................................................................... 30-27
30-03-24 Breather .......................................................................................................................... 30-32
30-04 Filter
30-04-00 General ........................................................................................................................... 30-35
30-04-03 Main ................................................................................................................................ 30-36
30-11 Gear Pump
30-11-00 General ........................................................................................................................... 30-39
30-15 Cylinder / Ram
30-15-00 General ........................................................................................................................... 30-45
30-15-22 Slew ................................................................................................................................ 30-48
30-15-34 Steering .......................................................................................................................... 30-50
30-15-90 Dumper Tip .................................................................................................................... 30-54
30-56 Main Control Valve Block
30-56-00 General ........................................................................................................................... 30-57
30-93 Hose
30-93-00 General ........................................................................................................................... 30-67
30-97 Connectors
30-97-03 Quick Release Coupling ................................................................................................ 30-71
9813/8950-2
2018-03-15
Acronyms Glossary
MRV Main Relief Valve

QRC Quick Release Coupling
9813/8950-2
2018-03-15
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-49 Schematic Symbols ........................................................................................................ 30-17
30-00-50 Schematic Circuit ........................................................................................................... 30-21
30 - 1 9813/8950-2 30 - 1
Notes:
30 - 2 9813/8950-2 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3 The hydraulic system is a power transmission system
Health and Safety ........................................... 30-4 that uses the force of flowing liquids to transmit power
Technical Data ................................................. 30-5 to specific components in a machine.
Operation ......................................................... 30-7
To help you trace specific hydraulic problems to a
Diagram ........................................................... 30-7 faulty unit (valve, actuator, ram etc.), refer to Fault
Fault-Finding .................................................... 30-8 finding. Refer to: PIL 30-00-00.
Discharge and Pressurise ............................. 30-10
Drain and Fill ................................................. 30-10 Once you have traced the faulty unit, refer to
the relevant section for removal, disassembly and
Clean ............................................................. 30-11 checking instructions.
Check (Condition) .......................................... 30-12
Check (Leaks) ............................................... 30-13 To help identify circuits, valves, rams etc. mentioned
Check (Level) ................................................ 30-14 in the fault finding procedures. Refer to the hydraulic
schematic diagrams. Refer to: PIL 30-00-50.
Check (Pressure) .......................................... 30-16
• 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 - 3 9813/8950-2 30 - 3
00 - General
00 - General
and leakage and can lead to major problems. The Health and Safety
main contaminants can be classified as follows:
1. Solid Particles - Sand, fibres, metallic particles, Hydraulic Pressure

welding scale, sealing materials and wear Hydraulic fluid at system pressure can injure you.
particles etc. Before connecting or removing any hydraulic hose,
2. Liquid - Usually water and incompatible oils and hose line must be vented. Make sure the hose
greases. service line has been vented before connecting or
removing hoses. Make sure the machine cannot be
3. Gases - Air, sulphur dioxide etc. which can create
started while the hoses are open.
corrosive compounds if dissolved in the fluid.
WARNING! Fine jets of fluid at high pressure can
These contaminants can appear during penetrate the skin. Keep face and hands well clear of
manufacture, assembly and operation. 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.
the correct fluid. The fluid can harm your skin. Wear
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.
the correct fluid. The fluid can harm your skin. Wear
30 - 4 9813/8950-2 30 - 4
00 - General
00 - General
Technical Data Description Data

Temperature range -20 –80 °C ( -4.0 –175.9
For: 6T-1 Front Tip, 6T-1 Swivel Tip °F)
..................................................... Page 30-5 MRV 210 bar ( 3,043.5 psi)
For: 9T-1 Front Tip ...................... Page 30-5 Port connections
For: 7T-1 Front Tip [Hi-Viz] .......... Page 30-6 Port P To priority valve EF port
Port T To tank/oil cooler
(For: 6T-1 Front Tip, 6T-1 Swivel Tip) through check valve
Port A1 To dumper tip ram, head
Table 177. end
Description Data Port B1 To dumper tip ram, rod
Maximum system flow 60 L/min end
Maximum system pres- 175 bar ( 2,536.2 psi) Port A2 To slew ram through port
sure (Swivel Tip) A1 of cross relief valve
Maximum system pres- 210 bar ( 3,043.5 psi) Port B2 To slew ram through port
sure (Front Tip) B1 of cross relief valve
Main hydraulic filter Cross line relief valve
Filtration 10 micron Nominal working pres- 240 bar ( 3,478.2 psi)
sure
Maximum flow 150 L/min
Relief valve setting pres- 230 bar ( 3,333.3 psi)
Operating pressure 10 bar ( 144.9 psi)
sure
Bypass pressure setting 3 bar ( 43.5 psi)
Check valve cracking 0.7 bar ( 10.1 psi)
Suction filter pressure
Filtration 125 micron
Table 181. Priority Valve
Table 178. Hydraulic Pump Description Data
Rated flow 80 L/min
Description Data
Control spring pressure 10 bar ( 144.9 psi)
Main pump
Type Gear pump
Table 179. Control valve (For: FT machines)
Description Data Table 182.
Type Single spool, manual Description Data
control valve Maximum system flow 60 L/min
Maximum flow 80 L/min Maximum system pres- 210 bar ( 3,043.5 psi)
Temperature range -20 –80 °C ( -4.0 –175.9 sure
°F) Main hydraulic filter
MRV (Main Relief Valve) 175 bar ( 2,536.2 psi) Filtration 10 micron
Port connections Maximum flow 150 L/min
Port P To priority valve EF port Operating pressure 10 bar ( 144.9 psi)
Port T To priority valve By pass pressure setting 3 bar ( 43.5 psi)
Port A1 To dumper tip ram, head Suction filter
end Filtration 125 micron
Port B1 To dumper tip ram, rod Maximum flow 110 L/min
end
Table 180. Control valve (For: ST machines) Table 183. Hydraulic Pump
Description Data Description Data
Type 2 spool, manual control Main pump
valve Type Gear pump
Maximum flow 80 L/min Displacement 21 cm³ per rev
30 - 5 9813/8950-2 30 - 5
00 - General
00 - General
Table 184. Control valve Description Data

Description Data Temperature range -20 –80 °C ( -4.0 –175.9
Type Single spool, manual °F)
control valve MRV 175 bar ( 2,536.2 psi)
Maximum flow 80 L/min Port connections
Temperature range -20 –80 °C ( -4.0 –175.9 Port P To priority valve EF port
°F) Port T To priority valve
MRV 210 bar ( 3,043.5 psi) Port A1 To dumper tip ram, head
Port connections end
Port P To priority valve EF port Port B1 To dumper tip ram, rod
Port T To priority valve end
Port A1 To dumper tip ram, rod Table 189. Priority Valve
end
Port B1 To dumper tip ram, head Description Data
end Rated flow 80 L/min
Table 185. Priority Valve
Description Data
Rated flow 80 L/min
(For: 7T-1 Front Tip [Hi-Viz])

Table 186.
Description Data
Maximum system flow 60 L/min
Maximum system pres- 210 bar ( 3,043.5 psi)
sure
Main hydraulic filter
Operating pressure 10 bar ( 144.9 psi)
Bypass pressure setting 3 bar ( 43.5 psi)
Suction filter
Table 187. Hydraulic Pump

Description Data
Main pump
Type Gear pump
Minimum speed 1075 RPM (Revolutions
Per Minute)
Maximum speed 3005 RPM
Table 188. Control valve (For: FT machines)

Description Data
Type Single spool, manual
control valve
30 - 6 9813/8950-2 30 - 6
00 - General
00 - General
Operation Diagram
The hydraulic system provides power to operate the Hydraulic State Colour Codes
machine steering and to power the dumper elevation.
In the case of the turntable dumpers, additional rams Some diagrams in this section use colours to
are required to swing the dumper to the left or right represent the different hydraulic system states. Refer
positions. to Figure 544.
The system comprises an engine driven hydraulic Figure 544.
pump drawing oil from the hydraulic tank located
inside the chassis. The tank is installed with a suction
strainer, an oil level gauge and a filler/breather cap.
The system is protected by a relief valve in the lift arm 1 2 3 4 5 6 7

control valve block which is set at the same pressure. 1 Lock up
A return line filter is installed to the circuit and is either 2 Cavitation
of the replaceable cartridge type (Steel Tanks) or the 3 Exhaust
replaceable element type (Plastic Tanks). 4 Neutral
5 Servo
The steering of the site dumper is done by means 6 Pressure
of a single hydraulic ram connecting the front and 7 Maximum pressure
rear chassis frames. The oil supply to the ram is
controlled by a hydrostatic steering unit. The unit
receives oil through a carry over port in the 3 way
steer control valve and meters oil to the steering ram
as the steering wheel is turned, at all times.
30 - 7 9813/8950-2 30 - 7
00 - General
00 - General
Fault-Finding
Fault
Low pressure at all hydraulic cylinder rams Table 190. Page 30-8
Low pressure at one hydraulic cylinder ram Table 191. Page 30-8
Hydraulic cylinder operates slowly Table 192. Page 30-8
Erratic hydraulic cylinder ram operation Table 193. Page 30-8
Lack of load hold Table 194. Page 30-8
Increased force required to operate the controls Table 195. Page 30-8
Hydraulic system overheating Table 196. Page 30-9
Cavitation in hydraulic pump Table 197. Page 30-9
Table 190. Low pressure at all hydraulic cylinder rams

Cause Remedy
Pressure relief valve set to low pressure Adjust the pressure relief valve.
Faulty pressure relief valve Replace the pressure relief valve.
Faulty hydraulic pump Check the output flow and condition of the hydraulic
pump.
Table 191. Low pressure at one hydraulic cylinder ram

Cause Remedy
Pressure relief valve set to low pressure Adjust the pressure relief valve.
Table 192. Hydraulic cylinder operates slowly

Cause Remedy
Control valve spool sticking Loosen and then tighten the tie-rod bolt to the correct
torque value.
Torque: 42 N·m
Incorrect control valve spool stroke Adjust the control valve spool stroke
Table 193. Erratic hydraulic cylinder ram operation

Cause Remedy
Hydraulic cylinder ram oil seal(s) worn or damaged Replace the damaged oil seals.
Hydraulic cylinder ram worn or damaged Replace the hydraulic cylinder ram.
Cavitation in hydraulic pump Check and correct the cavitation in hydraulic pump.
Table 194. Lack of load hold

Cause Remedy
Excessive clearance between the spool and the Replace the control valve.
control valve
Table 195. Increased force required to operate the controls

Cause Remedy
Tie-rod bolts to tight Loosen and then tighten the tie-rod bolt to the correct
torque value.
Torque: 42 N·m
Control linkage worn or damaged Replace the control linkage.
Control valve spool oil seal damaged Replace the spool oil seal.
30 - 8 9813/8950-2 30 - 8
00 - General
00 - General
Table 196. Hydraulic system overheating

Cause Remedy
Oil cooler blocked Clean the oil cooler.
Pressure relief valve set incorrectly Adjust the pressure relief valve.
Worn out or damaged pressure relief valve Replace the pressure relief valve.
Worn out or damaged control valve spool or housing Replace the control valve.
Control valve spool not centering Check the control valve spool stroke.
Hydraulic cylinder ram oil seals too tight causing Replace the oil seals.
partial flow through pressure relief valve
Hydraulic cylinder ram worn or damaged Replace the hydraulic cylinder ram.
Cavitation in hydraulic pump Check and correct the cavitation in hydraulic pump
Table 197. Cavitation in hydraulic pump

Cause Remedy
Vacuum in hydraulic oil Check and replace the hydraulic tank filler cap.
Air entering through hydraulic pump shaft oil seal Check the hydraulic pump for inlet restrictions.
Replace the hydraulic pump shaft oil seal.
Air entering at hydraulic pump inlet Check the oil seals, replace as required. Tighten the
bolts to the correct torque value.
Suction screen blocked Clean the suction screen. If necessary, replace the
suction screen.
Incorrect specification of hydraulic oil used Replace the hydraulic oil with correct specification of
oil.
30 - 9 9813/8950-2 30 - 9
00 - General
00 - General
Discharge and Pressurise Drain and Fill

Special Tools
1. Make the machine safe. Description Part No. Qty.
Refer to: PIL 01-03-27. Spanner 335/Y9489 1
2. Switch off the engine. 1. Make the machine safe with the dumper body
3. Turn the ignition switch on. Do not start the lowered.
engine. Refer to: PIL 01-03-27.
4. Release the hydraulic pressure, as follows: 2. Install the articulation strut.
4.1. Operate the hand control lever in all Refer to: PIL 06-27-15.
directions several times to release the drive
3. Disconnect the battery.
pressure.
4.2. Operate the dumper control switches until
the pressure is fully released. 4. Open the engine compartment cover.
5. Remove the filler cap from the hydraulic tank.
5.1. Turn the filler cap anticlockwise a quarter
turn with the specified spanner.
Special Tool: Spanner (Qty.: 1)
5.2. Loosen and remove the filler cap.
5.3. Make sure that no foreign objects or
contamination can enter the hydraulic tank.
6. Put a suitable container below the drain plug of
the hydraulic tank.
Figure 545.
A
D
B
C
A Hydraulic oil filler cap
B Drain plug
C Washer
D Hydraulic tank
30 - 10 9813/8950-2 30 - 10
00 - General
00 - General
8. When the hydraulic tank is empty, check the drain Clean

plug.
Special Tools
8.1. Clean the drain plug. Description Part No. Qty.
8.2. Install the drain plug. Hydraulic Flushing Rig 892/01255 1
8.3. If the drain plug is damaged, replace it.
Cleaning Operation
9. Tighten the drain plug to the correct torque value.
The purpose of cleaning oil is to remove
10. Fill the hydraulic tank with clean fluid through the contaminants of all types and sludge by filtering
filler neck. hydraulic fluid through a cleaning unit. Follow the
11. Check the hydraulic oil level. instructions in the Hydraulic flushing rig instruction
manual.
Procedure
12. Install the filler cap.
1. Connect the Hydraulic flushing rig in place of the
12.1. Tighten the filler cap. hydraulic filter.
12.2. Turn the filler cap clockwise a quarter turn Special Tool: Hydraulic Flushing Rig (Qty.: 1)
with a suitable spanner.
2. Run the system for sufficient time to pump all the
Table 198. Torque Values hydraulic fluid through the unit.
Item Nm
3. Disconnect the cleaning unit and reconnect the
B 180 filter.
4. Top up the system with clean hydraulic fluid as
required.
Figure 546.
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 - 11 9813/8950-2 30 - 11
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Condition)

0.000315 in)
• Human Hair = 70 microns (0.07 mm, 0.00275
in) Hydraulic Oil Contamination
• Grain of Salt = 100 microns (0.1 mm, 0.00394
in) The contamination in the hydraulic system is a major
cause of malfunction of hydraulic components. The
The smallest particle visible to the naked eye is contamination is any foreign material in the hydraulic
40 microns (0.00157) approximately. Standards will oil. It can enter the hydraulic system in several ways:
often be quoted to ISO (International Standards
Organisation) for which literature can be obtained. • When the oil is drained or any line
disconnected.
• When a component is disassembled.
• From normal wear of the hydraulic components.
• From damaged or worn seals.
• From a damaged component in the hydraulic
system.
All hydraulic systems operate with some

contamination. The design of the components in this
hydraulic system permits efficient operation with a
small amount of contamination. An increase in the
amount of contamination can cause problems in the
hydraulic system. The following list includes some of
these problems:
• Cylinder rod seals leak.

• Control valve spools do not return to neutral.
• Movement of control valve spools is difficult.
• Hydraulic oil becomes too hot.
• Pump gears, housing and other parts wear
rapidly.
• Relief valves or check valves held open by dirt.
• Quick failure of components that have been
repaired
• Cycle times are slow, machine does not have
enough power.
If any of the above problems are found on the

machine, check the hydraulic oil for contamination.
Types of Contamination
There are two types of contaminations:
1. Microscopic
2. Visible
Microscopic Contaminations
Microscopic contamination occurs when very fine
particles of foreign material are in suspension in the
hydraulic oil.
The microscopic particles are too small to see or

feel. The microscopic contamination can be found by
identification of the following problems or by testing
in a laboratory.
• Cylinder rod seal leak.

• Control valve spools do not return to neutral.
30 - 12 9813/8950-2 30 - 12
00 - General
00 - General
• The hydraulic system has a high operating Check (Leaks)

temperature.
Notice: If the fluid is cloudy, then water or air
Visible Contaminations has contaminated the system. This could damage
the hydraulic pump. Contact your JCB dealer
Visible contamination is foreign material that can be immediately.
found by sight, touch or odour. Visible contamination
can cause a sudden failure of components. 1. Make the machine safe.
• Particles of metal or dirt in the oil. Refer to: PIL 01-03-27.
• Air in the oil.
• The oil is dark and thick. 2. Open the access covers.
• The oil has the odour of burnt oil. Refer to: PIL 06-06.
• Water in the oil.
3. Check the hydraulic hoses for damage.
If water is present in the hydraulic oil, flush the water
from the hydraulic system. Refer to: PIL 30-00-00. 4. Close the access covers.
5. Replace any damaged hoses or components.
30 - 13 9813/8950-2 30 - 13
00 - General
00 - General
Check (Level)
CAUTION Do not run the machine with the should be in the middle of the inspection window.
hydraulic tank filler cap removed. Refer to Figure 547.
3. If necessary, add the recommended hydraulic
fluid:
2. Check the level of hydraulic fluid from the
inspection window. The level of hydraulic fluid
Figure 547.
A Inspection window
3.1. Release the pressure from the hydraulic Figure 548.

tank.
3.2. Open the hydraulic filler cap.
3.3. Use a suitable container to add the
hydraulic fluid through the filler port.
3.4. Check the level of hydraulic fluid.
Hydraulic Tank Filler Cap

The hydraulic tank breather (and filter) forms an
integral part of the hydraulic tank filler cap. Replace
the cap (and breather filter) with a new one at the
recommended interval. Refer to Figure 548. A Hydraulic tank filler cap
Remove the Cap

1. Turn the filler cap anticlockwise with the
recommended tool.
2. Unscrew the filler cap slowly to release any
residual pressure.
Install the Cap

1. Turn the filler cap by hand until you feel the
resistance.
30 - 14 9813/8950-2 30 - 14
00 - General
00 - General
2. Turn a further one fourth (1/4) turn with the

recommended tool.
30 - 15 9813/8950-2 30 - 15
00 - General
00 - General
Check (Pressure) 12. If the pressure exceeds the specified data, adjust
the pressure relief valve.
Special Tools
Description Part No. Qty. 12.1. Make a note that when you turn the
adjusting screw clockwise, it increases the
Pressure Gauge (0-400 892/00279 1 pressure and when you turn the adjusting
Bar) screw anti-clockwise, it decreases the
pressure.
Refer to: PIL 01-03-27. 13. Discharge the hydraulic pressure.
Refer to: PIL 33-03. 14. Remove the diagnostic equipment and install the
removed items.
15. Start the engine and check for oil leaks.
4. Remove the pressure test port plug and install a
suitable adaptor.
Figure 549.
A Test port
5. Connect the specified pressure gauge.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
1)
6. Connect the battery.
7. Start the engine.
8. Check the diagnostic equipment connectors for
oil leaks.
9. Allow the system to warm up to the specified
temperature.
Temperature: 50 –60 °C ( 121.9 –139.9 °F)
10. Set the engine speed to 1800 RPM (Revolutions
Per Minute).
11. Make sure that the pressure reading is as
specified.
30 - 16 9813/8950-2 30 - 16
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-17 Complex hydraulic components and circuits can
Diagram ......................................................... 30-18 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 - 17 9813/8950-2 30 - 17
00 - General
Diagram Table 202. Directional control valves

Symbol Description
Used to enclose sever-
Table 199. 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 200. 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 201. 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 - 18 9813/8950-2 30 - 18
00 - General
Table 203. 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 204. 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 - 19 9813/8950-2 30 - 19
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 - 20 9813/8950-2 30 - 20
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-21 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-22 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 - 21 9813/8950-2 30 - 21
00 - General
Diagram

For: 7T-1 Front Tip [Hi-Viz] ........ Page 30-24
Figure 550. Hydraulic Schematic - 336/Y1376-2 (Sheet 1 of 1)
30 - 22 9813/8950-2 30 - 22
00 - General
Figure 551. Hydraulic Schematic - 400/E9193-2 (Sheet 1 of 1)
30 - 23 9813/8950-2 30 - 23
00 - General
Figure 552. Hydraulic Schematic - 400/P4523-2 (Sheet 1 of 1)
30 - 24 9813/8950-2 30 - 24
00 - General
Figure 553. Hydraulic Schematic - 400/E9182-2 (Sheet 1 of 1)
30 - 25 9813/8950-2 30 - 25
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-27

30-03-24 Breather .......................................................................................................................... 30-32
30 - 26 9813/8950-2 30 - 26
03 - Tank
00 - General
Introduction .................................................... 30-27 The hydraulic tank holds excess hydraulic oil to
Remove and Install ....................................... 30-28 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 - 27 9813/8950-2 30 - 27
03 - Tank
00 - General
Lifting Equipment
You can be injured if you use incorrect or faulty lifting B
local regulations.
and device.
Remove B Hose clamps

1. Make the machine safe. 10. Disconnect the hydraulic return hose 1.
Refer to: PIL 01-03-27. Figure 556.
C
5. Remove the lower crossmember.
C Return hose 1
11. Loosen the clamp.
6. Remove the operator seat base.
Refer to: PIL 09-12-00. 12. Disconnect the hydraulic feed hose.
7. Remove the drain plug. Figure 557.
8. Drain the hydraulic tank.

8.1. Be prepared for some fluid loss. D
manner.
Figure 554. E
D Clamp
E Feed hose
13. Disconnect the hydraulic return hose 2.
A Drain plug
9. Remove the hydraulic hose clamps.
30 - 28 9813/8950-2 30 - 28
03 - Tank
00 - General
H Hydraulic tank
F Return hose 2 L Bolts 2 (x4)
14. Put a label on the hoses to help installation. 20. Remove the hydraulic tank.
15. Plug all the open ports and hoses to prevent 20.1. Position the hydraulic tank forwards.
contamination.
20.2. Raise the rear of the hydraulic tank.
16. Disconnect the gas strut from the access door.
Figure 562.
Figure 559.
H
G Gas strut H Hydraulic tank
Install
18. Remove the gas strut and the bracket assembly.
Figure 560. removal procedure. Additionally do the following
step.
K 2. Tighten the bolts to the correct torque value.
J 3. Check the hydraulic oil level and top up as
required.
4. Check the operation of all the hydraulic services.

J Bolts 1
Item Description Nm
K Bracket assembly
A Drain plug 180
19. Remove the bolts 2 (x4) from the rear of the
hydraulic tank.
30 - 29 9813/8950-2 30 - 29
03 - Tank
12 - Suction Strainer Introduction

Introduction .................................................... 30-30 The suction strainer is a component used for trapping
Remove and Install ....................................... 30-31 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 - 30 9813/8950-2 30 - 30
03 - Tank
Remove and Install
Remove
3. Remove the hydraulic tank from the machine.
4. Remove the suction strainer from the hydraulic
tank.
Figure 563.
A Hydraulic tank
B Suction strainer
Install
step.
2. Tighten the suction strainer to the correct torque
value.

Item Nm
B 15
30 - 31 9813/8950-2 30 - 31
03 - Tank
24 - Breather
24 - Breather
Introduction
The hydraulic tank breather allows air in and out of

the tank. This smooths out the pressure fluctuations
in the hydraulic tank as hydraulic fluid is rapidly
drawn out from, or returned to the tank.
The breather also prevents contaminants like

moisture and particles from entering the tank when
air is drawn in. Contaminates can easily corrode,
wear out or otherwise reduce the fluid performance
of a hydraulic system.
When air is expelled from the tank the breather

prevents hydraulic fluid spillage.
30 - 32 9813/8950-2 30 - 32
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-35

30-04-03 Main ................................................................................................................................ 30-36
30 - 33 9813/8950-2 30 - 33
Notes:
30 - 34 9813/8950-2 30 - 34
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 - 35 9813/8950-2 30 - 35
04 - Filter
03 - Main
03 - Main Introduction
Introduction .................................................... 30-36 The main hydraulic filter is usually located in the main
Remove and Install ....................................... 30-37 hydraulic return line close to, or inside the hydraulic
tank.
Most filters incorporate a bypass valve. If the

filter becomes blocked, the bypass valve opens
and allows fluid to bypass the filter. This prevents
excessive back pressure which can damage the
hydraulic system. The filter is not effective when the
bypass valve is open.
30 - 36 9813/8950-2 30 - 36
04 - Filter
03 - Main

Remove removal procedure. Additionally do the following
step.
2. Tighten the screws to the correct torque value.
2. Isolate the battery. required.
Refer to: PIL 33-03. Refer to: PIL 30-00-00.
3. Discharge the hydraulic pressure. Table 207. Torque Values
Refer to: PIL 30-00-00. Item Nm
4. Open the engine compartment cover. B 8 -/+1
5. Remove the hydraulic filler cap.
Figure 564.
A
B
A Filler cap
B Screws
6. Remove the main filter element.
Figure 565.
C Main filter element
30 - 37 9813/8950-2 30 - 37
11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ........................................................................................................................... 30-39
30 - 38 9813/8950-2 30 - 38
11 - Gear Pump
00 - General
Introduction .................................................... 30-39 The hydraulic gear pump is mounted directly onto the
Remove and Install ....................................... 30-40 rear of the engine. The pump is directly driven by the
Disassemble and Assemble .......................... 30-41 engine.
The speed at which the pump is driven governs the

speed at which the system will operate.
30 - 39 9813/8950-2 30 - 39
11 - Gear Pump
00 - General
Remove
C
D
Refer to: PIL 30-00-00. C Clamp
D Supply hose
contamination.
manner. 11. Remove the gear pump from the machine.
Figure 566. 12. Discard the gasket.

Figure 569.
A F
A Drain plug
6. Disconnect the hydraulic oil pressure hose from E Bolts 1
gear pump. F Gear pump
Figure 567. 13. Hold the gear pump in a soft jaw suitable vice.
B 15. Remove the hydraulic oil supply tube from the

gear pump.
B Pressure hose
7. Loosen the clamp.
8. Disconnect the hydraulic oil supply hose.
30 - 40 9813/8950-2 30 - 40
11 - Gear Pump
00 - General
Figure 570. Disassemble and Assemble

H
Disassemble
1. Remove the gear pump from the machine.
2. Hold the gear pump in a suitable vice.
G 3. Remove the adaptor from the gear pump.
Figure 571.
B
G Bolts 2 A
H Supply tube
Install
steps.
2. Tighten the bolts to the correct torque value. A Gear pump
B Adaptor
required. 4. Remove the bolts.
Refer to: PIL 30-00-00. Figure 572.
C
Item Description Nm
E Bolts 1 77
C Bolts
5. Remove the gear pump outer body.
Figure 573.
D
D Outer body
6. Remove the gear pump rotor 1.
30 - 41 9813/8950-2 30 - 41
11 - Gear Pump
00 - General

H
H Rotor 2
E Rotor 1
11. Remove and discard the seal.
7. Remove the nut.
Figure 578.
Figure 575.
J Seal
Assemble
the disassembly procedure. Additionally do the
F Nut
following step.
8. Collect the drive key.
9. Press the input shaft out of the drive gear with
suitable hydraulic press. Table 209. Torque Values
Item Description Nm
Figure 576.
C Bolts 42
G Input shaft
10. Remove the gear pump rotor 2.
30 - 42 9813/8950-2 30 - 42
15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ........................................................................................................................... 30-45

30-15-22 Slew ................................................................................................................................ 30-48
30-15-34 Steering .......................................................................................................................... 30-50
30-15-90 Dumper Tip .................................................................................................................... 30-54
30 - 43 9813/8950-2 30 - 43
Notes:
30 - 44 9813/8950-2 30 - 44
15 - Cylinder / Ram
00 - General
Introduction .................................................... 30-45 A hydraulic cylinder ram is a mechanical actuator
Health and Safety .......................................... 30-46 that is used to give a single directional force
Check (Condition) .......................................... 30-47 through a single action stroke. It is used in many
applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
consists of a cylinder barrel, in which a piston
connected to a piston rod moves back and forth.
The barrel is closed on one end by the cylinder

cap and the other end by the cylinder head where
the piston rod comes out of the cylinder. The piston
has sliding rings and seals. The piston divides the
inside of the cylinder into two chambers, the bottom
chamber (cap end) and the piston rod side chamber
(rod end / head end).
30 - 45 9813/8950-2 30 - 45
15 - Cylinder / Ram
00 - General
Health and Safety Caution During Use

1. Use only under designated conditions.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 1.1. If hydraulic oil other than the designated oil
Before connecting or removing any hydraulic hose, is used, the seals quickly degenerate and
residual hydraulic pressure trapped in the service become damaged. If the relief valve is set at
hose line must be vented. Make sure the hose a value higher than specified, it may cause
service line has been vented before connecting or ram damage and is dangerous.
removing hoses. Make sure the engine cannot be 1.2. In high temperature environments (approx.
started while the hoses are open. 90°C and above) or low temperature
Lifting Equipment environments (below -20°C), seals quickly
become damaged. Special seal materials
You can be injured if you use incorrect or faulty lifting are necessary so check to see if the ram
equipment. You must identify the weight of the item to that you are using is suitable or not.
enough and suitable for the job. Make sure that lifting 1.3. The number one cause of ram oil leakage is
equipment is in good condition and complies with all rod damage. Be careful not to damage the
local regulations. rod.
WARNING! A raised and badly supported machine 2. Warm up sufficiently before beginning work.
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other 2.1. In cold conditions the rod seals may
end is securely chocked. Do not rely solely on the be frozen, so if the ram is operated at
machine hydraulics or jacks to support the machine maximum pressure and maximum speed,
when working under it. Disconnect the battery, to the seals will be damaged.
prevent the machine being started while you are
2.2. There is a large amount of air in a new
beneath it.
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Precautions for Installation Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
1. Precautions when installing the ram on the
generated due to adiabatic compression
machine.
and the seals may burn.
1.1. When installing and removing from the 2.3. Before beginning work, always move the
machine, suspend the ram safely. ram at full stroke with no load and expel air
1.2. Suspending the ram by the piping is not only from the cylinder.
dangerous, but can also cause damage to
3. When stopping or storing, do it at a safe and fixed
the cylinder.
position.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. 3.1. The installed ram cannot maintain the same
Also, the rod can be damaged and become position for a long period of time, because
unusable. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
2. Welding after installing the ram may result in Stop or store the machine in a safe and
damage. fixed position.
2.1. If electric welding is done even at a point Maintenance, Inspection Points

away from the ram, there may be sparking
inside the ram and it will become necessary 1. Carry out daily maintenance and inspection.
to replace the ram with a new one.
1.1. The key point for correct long-term
3. When painting the machine, mask the ram. If ram function is daily maintenance and
paint adheres to the rod surface or to the wiper inspection. Carry out maintenance and
ring and the ram is operated, the wiper ring will inspection so that the ram functions fully at
not function properly and foreign matter and paint all times. Always remove any mud, water,
can easily enter the ram. This will cause damage dust or oil film adhering to the rod and
to the seals, drastically shortening the life of the keep it in normal condition. However, when
ram. cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
4. Install the ram only when it is clean.
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 46 9813/8950-2 30 - 46
15 - Cylinder / Ram
00 - General
should be kept to a minimum. If leaving for Check (Condition)

more than one week, apply a light coating
of suitable grease or petroleum jelly to the Consumables
exposed part of the ram piston rod. Description Part No. Size
2. Use genuine JCB parts when replacing parts. Surface Cleaning Fluid 4103/1204 1L
2.1. If parts other than genuine JCB parts 1. Make the machine safe.
are used, the desired results may not be Refer to: PIL 01-03-27.
obtained. Use only genuine JCB parts.
2. Extend each ram fully.
3. Caution during dismantling and reassembly.
3. Clean the piston, gland, piston rod and tube with
3.1. Dismantling the ram while it is still installed cleaning solvent.
on the machine can be dangerous as
unexpected movements of the machine can Consumable: Surface Cleaning Fluid
occur. Remove the ram from the machine
4. Visually examine each ram for score marks,
and then dismantle.
dents, leaks or similar defects.
3.2. If reassembled with dirty hands, foreign
matter can enter the ram causing a shorter 5. Check the condition of the tube as follows.
life span and also the other hydraulic
equipment may be damaged. Reassemble 5.1. Illuminate the inside of the tube.
in a clean state. 5.2. Inspect the inside of the tube for deep
3.3. Follow the instructions in the diagrams grooves and other damage. If damaged,
regarding torque tightening for screwed replace the tube.
parts. If the torque is too high or too low, it 5.3. Remove small scratches on the inside of the
can cause damage. tube with a medium grain emery cloth. Use
the emery cloth with a rotary motion.
5.4. Inspect the gland end of the tube for sharp
edges that will cut the gland O-ring.
5.5. Remove the sharp edges from the tube as
required.
6. Check the condition of the piston rod as follows.
6.1. Make sure that the piston rod is straight.
6.2. If the piston rod is not straight, install a new
piston rod.
6.3. Inspect the piston for damage and wear.
6.4. If the piston is damaged or worn, replace it.
7. Check the condition of the gland as follows.
7.1. Inspect the gland for rust.
7.2. Remove rust and clean as required.
30 - 47 9813/8950-2 30 - 47
15 - Cylinder / Ram
22 - Slew
22 - Slew Introduction
Introduction .................................................... 30-48
The slew cylinder ram is a hydraulic cylinder ram
used to give swivel movement of the dumper body.
This machine is installed with two slew cylinder rams.

They allow the dumper body to rotate through 180 °.
30 - 48 9813/8950-2 30 - 48
15 - Cylinder / Ram
22 - Slew
Remove and Install
(For: 6T-1 Swivel Tip, Swivel Tip)
Remove
2. Remove the slew ring from the machine.
3. Remove the slew rams (x2) from the machine.
Figure 579.
A Slew rams
Install
removal procedure.
30 - 49 9813/8950-2 30 - 49
15 - Cylinder / Ram
34 - Steering
34 - Steering Introduction
Introduction .................................................... 30-50 The steering cylinder ram is a hydraulic cylinder ram
Remove and Install ....................................... 30-51 used to steer the machine.
This machine is installed with one steering cylinder

ram on the right side of the machine. This cylinder
ram is a double acting single end type.
30 - 50 9813/8950-2 30 - 50
15 - Cylinder / Ram
34 - Steering

Front Tip [Hi-Viz] ....................... Page 30-51
(For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 B

Front Tip [Hi-Viz]) C
Remove
Refer to: PIL 01-03-27. A

3. Remove the R-clip and the pin 1 from the locking A R-clip
arm. B Pin 1
C Locking arm
4. Swing the locking arm into position.
Figure 580.
8. Remove the cable tie.
9. Disconnect the hose 1.
C B Figure 582.
A D
A R-clip
B Pin 1
C Locking arm E
5. Locate the locking arm onto the rear chassis. D Cable tie
E Hose 1
6. Install the pin 1 and the R clip.
contamination.
13. Remove the pin 2 from the steering ram.
30 - 51 9813/8950-2 30 - 51
15 - Cylinder / Ram
34 - Steering
Figure 583. (For: 9T-1 Front Tip)
Remove
G F Refer to: PIL 33-03.
H 3. Remove the R-clip and the pin 1 from the locking
arm.
F Hose 2
G Pin 2 4. Swing the locking arm into position.
H Steering ram
Figure 585.
14. Remove the nut.
Figure 584. B
K
C
A
H
A R-clip
J B Pin 1
C Locking arm
5. Locate the locking arm onto the rear chassis.
H Steering ram
J Nut 6. Install the pin 1 and the R clip.
K Pin 3
Figure 586.
16. Remove the steering ram.
Install
B
steps.
C
A
required.
Refer to: PIL 30-00-00. A R-clip
B Pin 1
Table 210. Torque Values C Locking arm
Item Description Nm
G Pin 2 283
J Nut 283 Refer to: PIL 30-00-00.
8. Remove the cable tie.
30 - 52 9813/8950-2 30 - 52
15 - Cylinder / Ram
34 - Steering
Figure 587. Install

steps.
D
required.
E
D Cable tie Table 211. Torque Values
E Hose 1 Item Description Nm
10. Disconnect the hose 2. G Pin 2 490
J Nut 490
contamination.
Figure 588.
G F
H
F Hose 2
G Pin 2
H Steering ram
14. Remove the nut.
Figure 589.
K
H
J
H Steering ram
J Nut
K Pin 3
16. Remove the steering ram.
30 - 53 9813/8950-2 30 - 53
15 - Cylinder / Ram
90 - Dumper Tip
90 - Dumper Tip Introduction

Introduction .................................................... 30-54 For: 6T-1 Front Tip, 9T-1 Front Tip
................................................... Page 30-54
(For: 6T-1 Front Tip, 9T-1 Front Tip)

The dumper tip cylinder ram is a hydraulic cylinder
ram used to dump the load out of the dumper body.
This machine is installed with two dumper tip cylinder

rams.

The dumper tip cylinder ram is a hydraulic cylinder
ram used to dump the payload out off the dumper
body.
This machine is installed with one dumper tip cylinder

ram.
30 - 54 9813/8950-2 30 - 54
15 - Cylinder / Ram
90 - Dumper Tip

B
Remove
C
B
A
A Cable tie
Refer to: PIL 30-00-00. B Banjo bolt
5. Isolate the battery. C Hoses
Refer to: PIL 33-03. 12. Remove the bolt from the pivot pin 2.
6. Remove the split pin from the pivot pin 1. 13. Remove the pivot pin 2.
7. Remove the pivot pin 1. Figure 592.
Figure 590.
G
E
F Bolt
D Split pin G Pivot pin 2
E Pivot pin 1
14. Remove the dumper tip ram from the machine.
8. Lower the dumper tip ram onto the slew base.
9. Remove the cable tie. Install
10. Remove the banjo bolt. 1. The installation procedure is the opposite of the
11. Disconnect the hydraulic hose from the dumper steps.
tip ram.
required.

Item Description Nm
F Bolt 60
30 - 55 9813/8950-2 30 - 55
56 - Main Control Valve Block
Contents Page No.
30-56-00 General ........................................................................................................................... 30-57
30 - 56 9813/8950-2 30 - 56
00 - General
Introduction .................................................... 30-57 The valve block consists of hydraulic servo operated
Component Identification ............................... 30-58 spools that control the lift arm and dumper tip
Diagram ......................................................... 30-61 functions.
A MRV (Main Relief Valve) controls the maximum
pressure generated in the loader circuits.
30 - 57 9813/8950-2 30 - 57
00 - General

For: 7T-1 Front Tip [Hi-Viz], 9T-1 Front Tip
................................................... Page 30-60
Figure 593.
A1
P T
B1
P To priority valve EF port T To priority valve

A1 To dumper tip ram, head end B1 To dumper tip ram, rod end
30 - 58 9813/8950-2 30 - 58
00 - General
Figure 594.
A1 A2
P T
B1 B2
B1
B1+A2 B1+B2
A2 B2
A1+A2 A1+B2
A1
P To priority valve EF port T To tank/oil cooler through check valve

A1 To dumper tip ram, head end B1 To dumper tip ram, rod end
A2 To slew ram through port A1 of cross relief B2 To slew ram through port B1 of cross relief
valve valve
30 - 59 9813/8950-2 30 - 59
00 - General
(For: 7T-1 Front Tip [Hi-Viz], 9T-1 Front Tip)
Figure 595.
A1
T
P T
B1
P To priority valve EF port T To priority valve

A1 To dumper tip ram, rod end B1 To dumper tip ram, head end
30 - 60 9813/8950-2 30 - 60
00 - General
Diagram

For: 7T-1 Front Tip [Hi-Viz], 9T-1 Front Tip
................................................... Page 30-62
Figure 596.
A1 B1 T
P
175 bar
30 - 61 9813/8950-2 30 - 61
00 - General
Figure 597.
P
T
A1 B1 A2 B2
175
bar
(For: 7T-1 Front Tip [Hi-Viz], 9T-1 Front Tip)
Figure 598.
T
A1 B1
P
175
bar
30 - 62 9813/8950-2 30 - 62
00 - General
Remove and Install Figure 599. Front Tip Machine
Remove
Refer to: PIL 33-03. B
A
6. Remove the gaiter.
7. Disconnect the hydraulic hoses.
A Control valve
8. Put a label on the hoses to help installation. B Bolt (x4)
9. Plug all the open ports and hoses to prevent Figure 600. Swivel Tip Machine
contamination.
10. Collect the adaptors and discard the seals.
11. Support the control valve.
12. Remove the bolt and washers.
13. Remove the control valve from the machine.
B
C
A
A Control valve
B Washer
C Bolt (x4)
Install
steps.
30 - 63 9813/8950-2 30 - 63
00 - General

required.
30 - 64 9813/8950-2 30 - 64
93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ........................................................................................................................... 30-67
30 - 65 9813/8950-2 30 - 65
Notes:
30 - 66 9813/8950-2 30 - 66
93 - Hose
00 - General
Introduction .................................................... 30-67 Hydraulic hoses are used to connect different
Disconnect and Connect ............................... 30-68 components in the hydraulic circuit. The hoses
Check (Condition) .......................................... 30-69 are graded by pressure, temperature, and fluid
compatibility. Hoses are built up with rubber and steel
layers. A rubber interior is surrounded by multiple
layers of woven wire and rubber. The exterior is
designed for abrasion resistance. The bend radius
of a hydraulic hose is carefully designed into the
machine, since hose failures can be deadly, and
violating the hose's minimum bend radius will cause
failure. Hydraulic hoses generally have steel fittings
swaged on the ends.
30 - 67 9813/8950-2 30 - 67
93 - Hose
00 - General
Disconnect and Connect Figure 603.
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 601. 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 602. 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 - 68 9813/8950-2 30 - 68
93 - Hose
00 - General
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
use the machine if a hose or hose fixture is
damaged.
WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
clear of fluid under pressure and wear personal
protective equipment. Hold a piece of cardboard
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 69 9813/8950-2 30 - 69
97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling ................................................................................................ 30-71
30 - 70 9813/8950-2 30 - 70
97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................... 30-71 The flat face quick release couplings allow the
Disconnect and Connect ............................... 30-72 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 604.
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 - 71 9813/8950-2 30 - 71
97 - Connectors
03 - Quick Release Coupling
• Periodically lubricate the internal locking balls Disconnect and Connect

on the female half of the coupling with silicone
grease.
Some attachments are hydraulically powered. The
Essential Don'ts following procedures show how to connect and
disconnect the hydraulic hoses safely.
• Never try to reconnect using a damaged half
coupling as this will destroy the seals in the
mating half and necessitate replacement of Connect
both halves. 1. Make the machine safe.
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this Refer to: PIL 01-03.
will distort the sleeve and prevent connection
and disconnection. 2. Discharge the hydraulic pressure.
• Never try to turn the sleeve when the coupling is Refer to: PIL 30-00-00.
disconnected as this will cause the locking ball
to jam under the locking sleeve and damage the 3. Wipe the two faces of the male and female
coupling. couplings and make sure they are clean.
• Never try to strip the coupling down, there are
no user serviceable parts. If the coupling is 4. Make sure that the ball in the female coupling is
damaged it must be replaced with a new one. located in one of its slots.
• Never hit the centre poppet of the coupling to 5. Connect the male coupling into the female
try and release the locked in pressure. This can coupling.
cause irreparable damage to the coupling and
serious injury. 6. Where applicable, rotate the sleeve half a turn
• When connecting the couplings, never clamp and make sure that the locking ball does not align
on the sleeve of the female or nose of the male, with the slot.
this will cause distortion and/or damage.
• Never subject the couplings to external forces, Disconnect
especially side load. This can decrease the life
of the coupling or cause failure. 1. Make the machine safe.
• Never allow the torsional forces transmitted
from the hoses to unscrew/screw together the Refer to: PIL 01-03.
couplings.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in Refer to: PIL 30-00-00.
the line unless the coupling type is specifically
designed to do so. 3. Where applicable, align the slot with the ball.
4. Pull back the sleeve to release the coupling.
Figure 605.
C D E
C Ball
D Slot
E Sleeve
30 - 72 9813/8950-2 30 - 72
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 ..................................................................................................................... 33-76
33-03 Battery
33-03-00 General ........................................................................................................................... 33-79
33-03-03 Isolator Switch ................................................................................................................ 33-88
33-09 Power Distribution
33-09-00 General ........................................................................................................................... 33-91
33-09-03 Fuse ............................................................................................................................... 33-93
33-09-06 Relay .............................................................................................................................. 33-96
33-09-09 Primary Fusebox ............................................................................................................ 33-97
33-12 Harness
33-12-00 General ........................................................................................................................... 33-99
33-12-04 Chassis ......................................................................................................................... 33-109
33-12-05 Rear Chassis ................................................................................................................ 33-130
33-12-12 Operator Station ........................................................................................................... 33-170
33-12-15 Front Console ............................................................................................................... 33-188
33-12-36 Work Lights .................................................................................................................. 33-200
33-18 Exterior View System
33-18-03 Camera ......................................................................................................................... 33-209
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-213
33-24-36 Service Reset ............................................................................................................... 33-216
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-219
33-42 Exterior Light
33-42-00 General ......................................................................................................................... 33-221
33-42-02 Front Road Light .......................................................................................................... 33-222
33-42-15 Front Work Light .......................................................................................................... 33-226
33-42-18 Rear Road Light ........................................................................................................... 33-227
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-229
33-45-06 Engine .......................................................................................................................... 33-231
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-243
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-247
33-57-03 Servicemaster .............................................................................................................. 33-249
33-57-90 Fault Codes .................................................................................................................. 33-280
9813/8950-2
2018-03-14
Acronyms Glossary

DLA Data Link Adaptor
DTC Diagnostic Trouble Code
DVD Digital Versatile Disc
HVAC Heating Ventilation Air Conditioning
LCD Liquid Crystal Display
LED Light Emitting Diode
MIL Malfunction Indicator Lamp
SPP Service Parts Pro
TMAF Temperature and Mass Air Flow
USB Universal Serial Bus
9813/8950-2
2018-03-14
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ..................................................................................................................... 33-76
33 - 1 9813/8950-2 33 - 1
Notes:
33 - 2 9813/8950-2 33 - 2
00 - General
Introduction ...................................................... 33-3 It is important that the electrical system on the
Health and Safety ........................................... 33-4 machine is in a sound state of repair.
Technical Data ................................................. 33-4
Fault-Finding .................................................... 33-5 Make sure that all the health and safety warnings
in this section are followed. The machine must be
Check (Condition) ............................................ 33-7 safe with the battery isolated before you attempt to
Check (Operation) ........................................... 33-7 disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/8950-2 33 - 3
00 - General

Arc Welding Table 213.
To prevent the possibility of damage to electronic
Item Specification
components, disconnect the battery and the
alternator before arc-welding on the machine or System voltage 12 V negative earth
attached implements. Alternator With Multi function regu-
lator
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control Alternator output 95 A
units (ECUs), monitor displays, etc., then disconnect Battery voltage 110Ah 12 V
them before welding. Failure to disconnect the Battery cold cranking 900 A
sensitive electrical equipment could result in amps
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 0.6 m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9813/8950-2 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 214. Page 33-5
General Relay Fault Table 215. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 216. Page 33-6
ECM Faults Table 217. Page 33-6
Table 214. Battery Fault

Cause Remedy
Battery Voltage Switch on the ignition key and check the battery
voltage with a multimeter. If the terminal voltage of
the battery is below 9 Volt or above 16 Volt, charge
or replace the battery.
Battery Connection Fault Disconnect the electrical connection from the battery.
Check for signs of corrosion or contamination in the
battery terminals, clean the terminals. Repair as
necessary.
If no fault is found proceed to ECM (Engine Control
Module) Connection Faulty.
ECM Connection Faulty Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
necessary.
Check the resistance between the vehicle chassis
ground and ECM ground, if the resistance is high
repair the ECM ground.
If no fault is found proceed to 'Battery Charge Circuit
Fault'.
Battery Charge Circuit Fault Check the battery charge circuit, if the circuit is found
faulty repair as necessary.
If no fault is found raise a Techweb Helpdesk call.
Table 215. 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 9813/8950-2 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 216. 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 217. 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 9813/8950-2 33 - 6
00 - General
Check (Condition) Check (Operation)
Examine the electrical circuits regularly for: Make sure that all the electrical equipment listed
below operate correctly.
• Damaged connectors.
• Loose connections. • Switches
• Chafing on the wiring harnesses. • Warning lights
• Corrosion. • Beacon
• Missing insulation. • Alarms
• Incorrect routing of the wiring harnesses. • Horn
• Wipers
Do not use the machine if one or more of these faults • Hourmeter
are found. You must make sure that the electrical • Battery
circuit is repaired immediately. • Lights
• Cameras (If installed)
All defective equipment must be repaired before the

machine is used.
33 - 7 9813/8950-2 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 9813/8950-2 33 - 8
Figure 606.
/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 9813/8950-2 33 - 9
Figure 607. 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 9813/8950-2 33 - 10
Diagram
Figure 608. Charge Circuit (400/M1730 Sheet 1 of 16) ........................................................ Page 33-13
Figure 609. Fusebox A and Fusebox B Circuit (400/M1730 Sheet 2 of 16) ..........................Page 33-17
Figure 610. Fusebox C Circuit (400/M1730 Sheet 3 of 16) .................................................. Page 33-21
Figure 611. Right Side Column Switch Circuit (400/M1730 Sheet 4 of 16) ........................... Page 33-25
Figure 612. Beacon and Work Light Circuit (400/M1730 Sheet 5 of 16) ...............................Page 33-29
Figure 613. Road Light Circuit (400/M1730 Sheet 6 of 16) .................................................. Page 33-33
Figure 614. Instrument Panel Circuit (400/M1730 Sheet 7 of 16) .........................................Page 33-37
Figure 615. Engine Dressed Circuit (400/M1730 Sheet 8 of 16) .......................................... Page 33-41
Figure 616. Engine ECU Circuit (400/M1730 Sheet 9 of 16) ................................................ Page 33-45
Figure 617. CANbus Circuit (400/M1730 Sheet 10 of 16) .................................................... Page 33-49
Figure 618. HVAC Circuit (400/M1730 Sheet 11 of 16) ........................................................ Page 33-53
Figure 619. Speakers Circuit (400/M1730 Sheet 12 of 16) ...................................................Page 33-57
Figure 620. F n R Circuit (400/M1730 Sheet 13 of 16) .........................................................Page 33-61
Figure 621. LiveLink Circuit (400/M1730 Sheet 14 of 16) .....................................................Page 33-65
Figure 622. Handbrake Circuit (400/M1730 Sheet 15 of 16) ................................................ Page 33-69
Figure 623. Earthing Circuit (400/M1730 Sheet 16 of 16) .................................................... Page 33-73
33 - 11 9813/8950-2 33 - 11
Notes:
33 - 12 9813/8950-2 33 - 12
Page 33-14 Figure 608. Charge Circuit

(400/M1730 Sheet 1 of 16) Page 33-15
1 2 3 4 5 6 7 8
F
F
1.00 mm² 6011 TO LIVELINK FUSE FA10

TO
/2.D2
Battery
7208/1007 -VE +VE
-T01 -T01 7207/1419
LUG LUG
M10 M8
70.00 mm² 6009 -VE +VE
16.00 mm² 2001
M8 7207/1405 -T01
+VE 16.00 mm² 2000
M8 -T01
+VE 7208/1002
E 332/F3103
-C_RC21
M5 7207/1211 -C_RC03 -C_OP24
ALT D+ TO INSTRUMENT PANEL
E
D+ 0.75 mm² 4023 1/62 1/62 0.75 mm² 4023 TO
/7.E2
-C_RC01
7207/1513
-T01
B+ 7207/1514
7208/1018
M10
W
POS
-T02
V
M10
M10
70.00 mm²
320/08610
1
D-
REGULATOR
ISOLATOR
701/47400
+ G -
-E3
-SW26
DF
-T02
D+
2002
-E1 M6 7207/1304
16.00 mm²
7232/0009 -C_RC19 TO FUSEBOX A/B &
7232/0008
2
Starter Motor -C_RC18 -PF1 -PF3 POWER HOLD RELAY

-T02 FB42-8 2 4
1
-T02 A/2
M10
4.00 mm² 200 30A 50A 4.00 mm² 3002

/2.B2 FROM TO
/2.F2
30 M10 M10 7207/1514
-PF2 -PF4 A/2 4.00 mm² 0100C
V-Batt
TO IGN RELA Y /3.E1
TO
3 5
-T01
-C_RC22
7208/1018
4.00 mm² 201A 6.00 mm² 200B 60A 60A

FROM START RELAY /2.F2 TO
TO IGN3 RELAY / FUSEBOX C

50 7207/1213 3.00 mm² 842
START SOL -S_SRC24 B/2 B/2
FROM
/2.A7
D
Start
Control M5 TO FUSEBOX A 3.00 mm² 200A -PFB
/2.E2
M 716/30077 D
TO
31
-IC02 -C_RC02
GND
M10
7208/1018
M10 7208/1018
-T02
-T3 6.00 mm² 3003

1/2 1/2
-SW01
70.00 mm² 6008
332/F6178
IGNITION SWITCH
II START
7234/0003
7236/0003
0 OFF
I ON
70.00 mm² 6007 -C_OP04 -C_OP03 7219/0075 -C_OP24 -C_RC03 TO FUSEBOX C
6.00 mm² 3003 1/4 1 5 5/6 1.00 mm² 010 39/62 39/62 1.50 mm² 010 TO
/3.D1
2 6
-IC02 -C_RC02 TO START RELAYS
8 8/6 3.00 mm² 0101 2/2 2/2 3.00 mm² 0101 TO
/2.B2
9
C
C
7208/1018
-T4
M10
-GND4
REAR CHASSIS GROUND
B
B
-E1 -R1
320/05693 716/30252
GRID HEATER GRID HEATER RELAY -FB1
7207/1316 -T01 -T04 7207/1419
716/21900 7207/1419
12V 1 M6 -T02 7207/1316 M6 4 3 M6 7207/1316 -T03 M8 2 1 M8 -T02
8001 16.00 mm² 3004 16.00 mm² 125A
0.00A 0.00A
0.00V 0.00V TO ENGINE ECU #2581 2 1 FROM FUSE FB6 -FU1
6010 0.75 mm² 2/2 1/2 3020 0.75 mm²
/9.C1 TO FROM
/2.C5 GRID HEATER FUSE
-C_RC34
7212/0044
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 13 9813/8950-2 33 - 13
Page Page
33-14 33-15
Figure 608. 1(Part 1 of 2) 2 3 4
1.00 mm² 6011 TO LIVELINK FUSE FA10

TO
/2.D2
Battery
7208/1007 -VE +VE
-T01 -T01 7207/1419
LUG LUG
M10 M8
70.00 mm² 6009 -VE +VE
M8 7207/1405 -T01
+VE 16.00 mm² 2000
M8 -T01
+VE 7208/1002
E 332/F3103
-C_RC21
M5 7207/1211 -C_RC03 -C_OP24
D+ 0.75 mm² 4023 1/62 1/62 0.75 mm² 4023 ALT D+ TO INSTRUMENT PANEL
TO
/7.E2
-C_RC01
7207/1513
-T01
B+ 7207/1514
7208/1018
M10
POS W
-T02
V
M10
M10
70.00 mm²
320/08610
1
D-
REGULATOR
ISOLATOR
701/47400
+ G -
-E3
-SW26
DF
D+
2002
-E1
16.00 mm²
2
Starter Motor -T02

-T02
M10
30 M10 M10 7207/1514

V-Batt
TO IGN RELA Y
-T01
-C_RC22
7208/1018
50 7207/1213 START SOL FROM START RELAY

3.00 mm² 842 FROM
/2.A7
D
Start
Control M5 TO FUSEBOX A
M
31
-IC02
GND
M10
7208/1018
M10 7208/1018
-T02
-T3
1/2
70.00 mm² 6008
70.00 mm² 6007
Page 33-15
6.00 mm²
C
7208/1018
-T4
M10
-GND4
REAR CHASSIS GROUND
-E1
320/05693
GRID HEATER
7207/1316
12V 1 M6 -T02
0.00A 0.00A
0.00V 0.00V TO ENGINE ECU #2581
/9.C1 TO
1 2 3 4
33 - 14 9813/8950-2 33 - 14
Page Page
33-14 33-15
Figure 608. (Part

5 2 of 2) 6 7 8
16.00 mm² 2001
TO INSTRUMENT PANEL
E
/7.E2
-T02
M6 7207/1304
7232/0009 -C_RC19 TO FUSEBOX A/B &
-C_RC18 -PF1 -PF3 7232/0008
FB42-8 2 4 POWER HOLD RELAY
1
4.00 mm² 200 A/2 30A 50A 4.00 mm² 3002

/2.B2 FROM TO
/2.F2
-PF2 -PF4 A/2 4.00 mm² 0100C
TO IGN RELA Y /3.E1
TO
4.00 mm² 201A 6.00 mm² 200B 3 60A 60A 5

/2.F2 TO
TO IGN3 RELAY / FUSEBOX C

-S_SRC24 B/2 B/2
TO FUSEBOX A 3.00 mm² 200A -PFB
/2.E2 716/30077 D
TO
-IC02 -C_RC02
6.00 mm² 3003
1/2 1/2
-SW01
332/F6178
IGNITION SWITCH
II START
7234/0003
7236/0003
0 OFF
I ON
-C_OP04 -C_OP03 7219/0075 -C_OP24 -C_RC03 TO FUSEBOX C

Page 33-14
6.00 mm² 3003 1/4 1 5 5/6 1.00 mm² 010 39/62 39/62 1.50 mm² 010 TO
/3.D1
2 6
-IC02 -C_RC02 TO START RELAYS
8 8/6 3.00 mm² 0101 2/2 2/2 3.00 mm² 0101 TO
/2.B2
9
-R1
716/30252
GRID HEATER RELAY -FB1
-T01 -T04 7207/1419
716/21900 7207/1419
8001 16.00 mm²
7207/1316 M6 4 3 M6 7207/1316 3004 16.00 mm² -T03 M8 2 125A 1 M8 -T02
2 1 FROM FUSE FB6 -FU1

6010 0.75 mm² 2/2 1/2 3020 0.75 mm² FROM
/2.C5 GRID HEATER FUSE
-C_RC34
7212/0044
400/M1730-6
5 6 7 8
33 - 15 9813/8950-2 33 - 15
33 - 16 9813/8950-2 33 - 16
Page 33-18 Figure 609. Fusebox A and Fusebox

B Circuit (400/M1730 Sheet 2 of 16) Page 33-19
1 2 3 4 5 6 7 8
-FB-A-41
F FUSEBOX A
7241/0001 F
FROM PRI FUSE PF3 -S_SRC16 -FA1
4.00 mm² 3002 1.50 mm² 3002A 1 15A 2 1.50 mm² 3008
TO HAZARD SWITCH
/1.D7 FROM TO
/4.C2
4.00 mm² 3002B -FA2 -C_RC44 -C_C01

3 4
-S008
15A 2.00 mm² 1804 M/14 M/14 2.00 mm² 1804 1.00 mm² 1804A TO
/12.C5 TO FRONT WASH WIPE SWITCH
1.00 mm² 1804C
-R4
TO
/12.C5 TO FRONT WIPER MOTOR
716/G3600 1.00 mm² 1804E TO
/12.B4 TO REAR WASH WIPE SWITCH
IGN RELAY 1.00 mm² 1804F TO
/12.B5 TO REAR WIPER MOTOR
4
-FA3
FROM PRI FUSE PF2 4.00 mm² 201A 1 2 4.00 mm² 3080 5 15A 6 1.50 mm² 312 SUPPLY TO RH COL. SWITCH
/1.D5 FROM TO
/4.E4 HIGH BEAM
FROM FUSE FC8 (IGN) 0.75 mm² 133A 3 5 0.75 mm² 6001M GROUND TO RC GROUND 7216/0018 7216/0017
/3.C7 FROM TO
/16.D1 -FA4 -C041 TO FRONT W.LIGHT SW
7 7.5A 8 1.00 mm² 1800
-C_RC40 1.00 mm² 1800
1/6 1/6
TO
/5.E1
-RB03
7241/0003
-FA5 TO REAR W.LIGHT SW
9 7.5A 10 1.00 mm² 1801
-C_RC40 -C041 1.00 mm² 1801
/5.E1
E accessory socket
TO
2/6 2/6
7232/0028 7232/0028 E
-FA6 -C_RC03 -C_OP24 -C_OP19 GND -C_OP19
FROM PRI FUSE PF2 11 12 57/62 57/62 1/2 GROUND
/1.D5 FROM 3.00 mm² 200A 10A 1.50 mm² 3808 1.50 mm² 3808
2/2
1.50 mm² 6005H TO
/16.E1 TO OP GND
2 1
-FA7 715/08100
13 7.5A 14 1.00 mm² 300 -S_SRC10 1.00 mm² 300A TO
/10.F7 TO DIAG CONN
1.00 mm² 300B TO
/14.D2 TO LIVELINK (BATT)
-FA8 7219/0187 -C_RC44 -C_C01 7219/0086
15 16 1.00 mm² 302 L/14 L/14 1.00 mm² 302 TO INT LIGHT / RADIO
7.5A
TO
/12.E2
-FA9 TO ROADLIGHT SWITCH

17 7.5A 18 1.50 mm² 306 TO
/4.F2
FROM BATT -VE -FA10

1.00 mm² 6011 19 3A 20 1.00 mm² 6015 TO LIVELINK
/1.F4 FROM TO
/14.C7
D
-R3 -FB-B-42 D
POWER HOLD RELAY FUSEBOX B
716/09800 7241/0001
-S_SRC21 5
-FB1
4.00 mm² 3002B 4.00 mm² 3002BA 8 2 4.00 mm² 3012 1 10A 2 1.00 mm² 3013 PWR HOLD SUPPLY TO EGR ACTUATOR
TO
/8.F1
6 4 TO ENGINE ECU
1.00 mm² 3002BB 1.00 mm² 8007 TO
/9.D1 -FB2
3 9 POWER HOLD-ECU O/P 3 10A 4 1.00 mm² 3014
PWR HOLD SUPPLY TO VGT
TO
/8.D2
1 7
-RB07 -FB3 -R8

5 6 TO ENG ECU FEEDS #1-4 -E1
7241/0005 10A 1.00 mm² 3015B TO
/9.D1 716/G3600
PWR HOLD RLY LIFT PUMP RLY 333/C3351
9 FUEL PUMP
-FB4 -S_SRC17 7212/0052 -C_RC08 -C_RC08 7212/0052
6 7 1 2
TO RC GND
7 10A 8 1.50 mm² 3021 1.50 mm² 3021A 1.50 mm² 8009 1/2 M 2/2 2.00 mm² 6000NGROUND TO
/16.C5
0.50 mm² 3021B 8 100.50 mm² 8022

FROM ENG ECU
FUEL PUMP
C /9.E1
FROM
-FB5 -RB05
9 10A 10 1.00 3019 TO WIF 7241/0003 C
TO
/9.D1 LIFT PUMP RLY
0.75 mm² 3021C
-FB6
11 5A 12 0.75 mm² 3020
/1.A6
TO
TO GRID HEATER RELAY

1.00 mm² 1708C TO BRAKE LIGHT RELAY
TO
/15.D5
-FB7
FROM IGN FEED 4.00 mm² 134C 13 5A 14 1.00 mm² 1708A TO PARK / FOOT BRAKE
/3.F2 FROM TO
/15.D1
-FB8
RC18-PF1 4.00 mm² 200 15 3A 16 1.00 mm² 3008B
/1.D5 TO TO
/13.D1 TO SEAT SWITCH
Direction Inhibit Ecu
TO IGNITION 2 / HEATER
B -FB9 7211/0005 7211/0007
-C_RC43 -C_C02 BLOWER RELAYS
17 30A 18 6.00 mm² 3000
1/1 1/1
6.00 mm² 3000 TO
/11.D1 B
-FB10 TO ENG ECU

FROM IGN SWITCH 3.00 mm² 0101 19 5A 20 0.75 mm² 8020
/1.C7 FROM TO
/9.E1
-R2
-R12
STARTER RELAY 716/G3600
716/09800 START INTERLOCK RLY
5 9
8 2 6 7
TO START SOL
3.00 mm² 010A 3.00 mm² 800 3.00 mm² 800 3.00 mm² 842 START SOL TO
/1.D3
FROM COL. SW NEUTRAL
6 4
TO ENG ECU 8 10 GROUND TO RC GND
0.75 mm² 3021C 1.00 mm² 8006 START RELAY GND 0.75 mm² 810A 0.75 mm² 6140
TO
/9.E1 /13.F6 FROM TO
/16.D1
3 9
1 7 DIE ECU 0.75 mm² 810B -RB03
/13.D2 TO
7241/0003
A -RB08 START INTERLOCK RLY
7241/0005 A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 17 9813/8950-2 33 - 17
Page Page
33-18 33-19
Figure 609. 1(Part 1 of 2) 2 3 4
-FB-A-41
F FUSEBOX A
7241/0001
FROM PRI FUSE PF3 -S_SRC16 -FA1

4.00 mm² 3002 1.50 mm² 3002A 1 15A 2 1.50 mm² 3008
/1.D7 FROM
4.00 mm² 3002B -FA2 -C_RC44 -C_C01

3 15A 4 2.00 mm² 1804 M/14 M/14 2.00 mm²
-R4
716/G3600
IGN RELAY
4
-FA3
FROM PRI FUSE PF2 4.00 mm² 201A 1 2 4.00 mm² 3080 5 15A 6 1.50 mm² 312
/1.D5 FROM
FROM FUSE FC8 (IGN) 0.75 mm² 133A 3 5 0.75 mm² 6001M GROUND TO RC GROUND 7216/0018 7216/0017
/3.C7 FROM TO
/16.D1 -FA4 -C041
7 7.5A 8 1.00 mm² 1800
-C_RC40
1/6 1/6
-RB03
7241/0003
-FA5
9 7.5A 10 1.00 mm² 1801
-C_RC40 -C041
E 2/6 2/6
-FA6 -C_RC03 -C_OP24

FROM PRI FUSE PF2 3.00 mm² 200A 11 10A 12 1.50 mm² 3808 57/62 57/62
/1.D5 FROM
-FA7
13 7.5A 14 1.00 mm² 300 -S_SRC10
-FA8 7219/0187 -C_RC44 -C_C01

15 16 1.00 mm² 302 L/14 L/14
7.5A
-FA9
17 7.5A 18 1.50 mm² 306
FROM BATT -VE -FA10

1.00 mm² 6011 19 3A 20 1.00 mm² 6015
/1.F4 FROM
D
-R3 -FB-B-42
POWER HOLD RELAY FUSEBOX B
716/09800 7241/0001
-S_SRC21 5
-FB1
4.00 mm² 3002B 4.00 mm² 3002BA 8 2 4.00 mm² 3012 1 10A 2 1.00 mm² 3013
6 4 TO ENGINE ECU
1.00 mm² 3002BB 1.00 mm² 8007 TO
/9.D1 -FB2
3 9 POWER HOLD-ECU O/P 3 10A 4 1.00 mm² 3014
1 7
Page 33-19
-RB07 -FB3
5 10A 6 1.00 mm² 3015B
7241/0005
PWR HOLD RLY
-FB4
7 10A 8 1.50 mm² 3021
C -FB5
9 10A 10 1.00 3019
-FB6
11 5A 12 0.75 mm² 3020

1.00 mm² 1708C
-FB7
FROM IGN FEED 4.00 mm² 134C 13 5A 14 1.00 mm² 1708A
/3.F2 FROM
-FB8
RC18-PF1 4.00 mm² 200 15 3A 16 1.00 mm² 3008B
/1.D5 TO
B -FB9 7211/0005 7211/0007

-C_RC43 -C_C02
17 30A 18 6.00 mm² 3000 6.00 mm² 3000
1/1 1/1
-FB10
FROM IGN SWITCH 3.00 mm² 0101 19 5A 20 0.75 mm² 8020
/1.C7 FROM
-R2
STARTER RELAY
716/09800
5
3.00 mm² 010A 8 2 3.00 mm²
0.75 mm² 3021C 6 4 1.00 mm²

3 9
1 7
A -RB08
7241/0005
1 2 3 4
33 - 18 9813/8950-2 33 - 18
Page Page
33-18 33-19
Figure 609. (Part

5 2 of 2) 6 7 8
F
TO HAZARD SWITCH
TO
/4.C2
-C_C01 -S008
M/14 2.00 mm² 1804 1.00 mm² 1804A TO
/12.C5 TO FRONT WASH WIPE SWITCH
1.00 mm² 1804C TO
/12.C5 TO FRONT WIPER MOTOR
1.00 mm² 1804E TO
/12.B4 TO REAR WASH WIPE SWITCH
1.00 mm² 1804F TO
/12.B5 TO REAR WIPER MOTOR
SUPPLY TO RH COL. SWITCH
TO
/4.E4 HIGH BEAM
7216/0017
-C041 TO FRONT W.LIGHT SW
1.00 mm² 1800
1/6
TO
/5.E1
-C041 TO REAR W.LIGHT SW

1.00 mm² 1801
2/6
TO
/5.E1 accessory socket
7232/0028 7232/0028 E
-C_OP24 -C_OP19 GND -C_OP19
57/62 1/2 GROUND
1.50 mm² 3808
2/2
1.50 mm² 6005H TO
/16.E1 TO OP GND
2 1
715/08100
1.00 mm² 300A TO
/10.F7 TO DIAG CONN
1.00 mm² 300B TO
/14.D2 TO LIVELINK (BATT)
-C_C01 7219/0086
L/14 1.00 mm² 302 TO INT LIGHT / RADIO
TO
/12.E2
TO ROADLIGHT SWITCH
TO
/4.F2
TO LIVELINK
TO
/14.C7
PWR HOLD SUPPLY TO EGR ACTUATOR

TO
/8.F1
PWR HOLD SUPPLY TO VGT

TO
/8.D2
Page 33-18
TO ENG ECU FEEDS #1-4 -R8

TO
/9.D1 716/G3600 -E1
LIFT PUMP RLY 333/C3351
9 FUEL PUMP
-S_SRC17 7212/0052 -C_RC08 -C_RC08 7212/0052
6 7 1 2
TO RC GND
1.50 mm² 3021A 1.50 mm² 8009 1/2 M 2/2 2.00 mm² 6000NGROUND TO
/16.C5
0.50 mm² 3021B 8 100.50 mm² 8022

FROM ENG ECU
FUEL PUMP FROM
/9.E1
-RB05
TO WIF 7241/0003 C
TO
/9.D1 LIFT PUMP RLY
0.75 mm² 3021C
0.75 mm² 3020

/1.A6
TO

TO BRAKE LIGHT RELAY
TO
/15.D5
TO PARK / FOOT BRAKE
TO
/15.D1
TO
/13.D1 TO SEAT SWITCH
Direction Inhibit Ecu
TO IGNITION 2 / HEATER
BLOWER RELAYS
6.00 mm² 3000 TO
/11.D1 B
TO ENG ECU
TO
/9.E1
-R12
STARTER RELAY 716/G3600
716/09800 START INTERLOCK RLY
9
6 7
TO START SOL
3.00 mm² 800 3.00 mm² 800 3.00 mm² 842 START SOL TO
/1.D3
FROM COL. SW NEUTRAL
TO ENG ECU 8 10 GROUND TO RC GND
1.00 mm² 8006 START RELAY GND 0.75 mm² 810A 0.75 mm² 6140
TO
/9.E1 /13.F6 FROM TO
/16.D1
DIE ECU 0.75 mm² 810B -RB03
/13.D2 TO
7241/0003
START INTERLOCK RLY
7241/0005 A
400/M1730-6
5 6 7 8
33 - 19 9813/8950-2 33 - 19
33 - 20 9813/8950-2 33 - 20
Page 33-22 Figure 610. Fusebox C Circuit

(400/M1730 Sheet 3 of 16) Page 33-23
1 2 3 4 5 6 7 8
F
F
4.00 mm² 134C TO FUSE FB7

TO
/2.B2
1.00 mm² 106F 1.00 mm² 106F

N/14 N/14
TO
/12.E6 TO RADIO IGN POWER
-C_RC44 -C_C01
1.00 mm² 106C IGN RLY O/P TO
/7.E1 TO INSTRUMENT PANEL
E -FB-C-43 1.00 mm² 106E IGN RLY O/P

-R1 FUSEBOX C
TO
/14.D2 TO LIVELINK IGN E
716/G3600 7241/0001
IGN RELAY 3 0.75 mm² 106D IGN RLY O/P TO
/7.A1 TO CAMERA TRANSFER POWER BOX
4
FROM PRI FUSE PF4 -FC1
4.00 mm² 0100C 1 2 4.00 mm² 134 4.00 mm² 134A 1 2 1.00 mm² 106 0.75 mm² 106A IGN RLY O/P
/1.D7 FROM
7.5A TO
/7.D1 TO PARK BRAKE BUZZER
-S_SRC29 -S_SRC15 1.00 mm² 106B IGN RLY O/P
GROUND S_SCR25
TO
/7.F1 TO SERVICE RESET SW
0.75 mm² 133D 3 5 0.75 mm² 602JC
/16.D1
TO
-FC2 -C_RC03 -C_OP24
3 4 1.50 mm² 804 9/62 9/62 1.50 mm² 804 IGN RLY O/P TO HAZARD SWITCH
15A TO
/4.C2
-RB02
7241/0003
-FC3 -S_SRC08 -C_RC03 -C_OP24 TO LH COLOUMN SWITCH-FNR
5 6 1.00 mm² 107 1.00 mm² 107F 10/62 10/62 1.00 mm² 1707F
7.5A
TO
/13.F2
-D_RC1
-FC4 7514/0005
7 7.5A 8 1.50 mm² 1002 1.00 mm² 107FA 1 2 1.00 mm² 107A TO TRANS DUMP RELAY
TO
/13.A2
7214/0024
-FC5 -C_RC03 -C_OP24 -C_RC33
9 10 IGN RLY O/P TO ROADLIGHT SWITCH -C001 IGN RLY O/P
1.50 mm² 1703 8/62 8/62 1.50 mm² 1703 1.00 mm² 107B 1.00 mm² 107B
15A
TO
/4.E2 LOW BEAM 1/4 1/4
FROM
/7.B1
D
-FC6
D
11 7.5A 12 1.00 mm² 1726 TO GREEN BEACON RELAY
TO
/13.C1 SEAT BELT / DI ECU
-FC7 TO AMBER BEACON

FROM IGNITION 1.50 mm² 010 13 7.5A 14 1.00 mm² 1706
/1.C7 FROM TO
/5.C1 TO RH COL SW - HORN
1.00 mm² 1002A TO
/13.F1
-FC8 -R11
15 3A 16 1.00 mm² 133 716/G3600
HORN RELAY
9
-FC9
FROM ROADLIGHT SWITCH ILL 1.50 mm² 828 17 5A 18 1.00 mm² 830 ILL TO SIDE/WORK LIGHTS 1.50 mm² 1002B 6 7 1.50 mm² 8035 HORN TO HORN
/4.F4 FROM TO
/6.B1 R/H SIDE TO
/6.D3
-S_SRC18
1.00 mm² 820A 8 10 1.00 mm² 6001D GROUND TO RC GND
-FC10 /13.F7 FROM TO
/16.C1
19 5A 20 1.00 mm² 829 TO SIDE/WORK LIGHTS FROM LH COL SW - HORN
TO
/6.D1 L/H SIDE
-RB01
7241/0003
C
C
TO ENG ECU - IGN SENSE
0.75 mm² 133C TO
/9.F1
-C_RC44 -C_C01
1.00 mm² 133 0.75 mm² 133B A/14 A/14 0.75 mm² 133B IGN TO HEATER/IGN RELAY 2
TO
/11.E1
-S_SRC28
TO IGN RELAY
0.75 mm² 133D 0.75 mm² 133A TO
/2.E2
B
B
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 21 9813/8950-2 33 - 21
Page Page
33-22 33-23
Figure 610. 1(Part 1 of 2) 2 3 4
4.00 mm² 134C TO FUSE FB7

TO
/2.B2
E -FB-C-43
-R1 FUSEBOX C
716/G3600 7241/0001
IGN RELAY 3
4
FROM PRI FUSE PF4 -FC1
4.00 mm² 0100C 1 2 4.00 mm² 134 4.00 mm² 134A 1 2 1.00 mm² 106
/1.D7 FROM
7.5A
-S_SRC29
3 5 GROUND S_SCR25
0.75 mm² 133D 0.75 mm² 602JC -FC2 -C_RC03 -C_OP24
TO
/16.D1
3 15A 4 1.50 mm² 804 9/62 9/62
-RB02
7241/0003
-FC3
5 6 1.00 mm² 107
7.5A
-FC4
7 7.5A 8 1.50 mm² 1002
-FC5 -C_RC03 -C_OP24

9 10 1.50 mm² 1703 8/62 8/62 1.50 mm² 1703 IGN RLY O/P TO ROADLIGHT SWITCH
15A
TO
/4.E2 LOW BEAM
D
-FC6
11 7.5A 12 1.00 mm² 1726 TO GREEN BEACON RELAY
TO
/13.C1 SEAT BELT / DI ECU
-FC7 TO AMBER BEACON

FROM IGNITION 1.50 mm² 010 13 7.5A 14 1.00 mm² 1706
/1.C7 FROM TO
/5.C1
-FC8
15 3A 16 1.00 mm² 133
-FC9
Page 33-23
FROM ROADLIGHT SWITCH ILL 1.50 mm² 828 17 5A 18 1.00 mm² 830 ILL TO SIDE/WORK LIGHTS
/4.F4 FROM TO
/6.B1 R/H SIDE
-FC10
19 5A 20 1.00 mm² 829 TO SIDE/WORK LIGHTS
TO
/6.D1 L/H SIDE
0.75 mm² 133D
1 2 3 4
33 - 22 9813/8950-2 33 - 22
Page Page
33-22 33-23
Figure 610. (Part

5 2 of 2) 6 7 8
1.00 mm² 106F 1.00 mm² 106F

N/14 N/14
TO
/12.E6 TO RADIO IGN POWER
-C_RC44 -C_C01
1.00 mm² 106C IGN RLY O/P TO
/7.E1 TO INSTRUMENT PANEL
1.00 mm² 106E IGN RLY O/P TO

/14.D2 TO LIVELINK IGN E
0.75 mm² 106D IGN RLY O/P TO
/7.A1 TO CAMERA TRANSFER POWER BOX
0.75 mm² 106A IGN RLY O/P TO

/7.D1 TO PARK BRAKE BUZZER
-S_SRC15 1.00 mm² 106B IGN RLY O/P TO
/7.F1 TO SERVICE RESET SW
1.50 mm² 804 IGN RLY O/P TO HAZARD SWITCH

TO
/4.C2
-S_SRC08 -C_RC03 -C_OP24 TO LH COLOUMN SWITCH-FNR

1.00 mm² 107F 10/62 10/62 1.00 mm² 1707F TO
/13.F2
-D_RC1
7514/0005
1.00 mm² 107FA 1 2 1.00 mm² 107A TO TRANS DUMP RELAY
TO
/13.A2
7214/0024
TO ROADLIGHT SWITCH -C_RC33 -C001 IGN RLY O/P
1.00 mm² 107B 1.00 mm² 107B
LOW BEAM 1/4 1/4
FROM
/7.B1
D
TO GREEN BEACON RELAY
SEAT BELT / DI ECU
TO RH COL SW - HORN
1.00 mm² 1002A TO
/13.F1
-R11
716/G3600
HORN RELAY
9
Page 33-22
TO SIDE/WORK LIGHTS 1.50 mm² 1002B 6 7 1.50 mm² 8035 HORN TO HORN
TO
/6.D3
-S_SRC18
1.00 mm² 820A 8 10 1.00 mm² 6001D GROUND TO RC GND
/13.F7 FROM TO
/16.C1
TO SIDE/WORK LIGHTS FROM LH COL SW - HORN
-RB01
7241/0003
C
TO ENG ECU - IGN SENSE
0.75 mm² 133C TO
/9.F1
-C_RC44 -C_C01
1.00 mm² 133 0.75 mm² 133B A/14 A/14 0.75 mm² 133B IGN TO HEATER/IGN RELAY 2
TO
/11.E1
-S_SRC28
TO IGN RELAY
0.75 mm² 133A TO
/2.E2
400/M1730-6
5 6 7 8
33 - 23 9813/8950-2 33 - 23
33 - 24 9813/8950-2 33 - 24
Page 33-26 Figure 611. Right Side Column Switch

Circuit (400/M1730 Sheet 4 of 16) Page 33-27
1 2 3 4 5 6 7 8
F -SW02
701/60004 F
ROADLIGHT SWITCH
0.50 mm² 829G 8/10 8 7 7/10 0.50 mm² 6005E GROUND TO OP GND
TO
/16.E1
FROM FUSE FA9 -C_RC03 -C_OP24 -C_OP06

1.50 mm² 306 2/62 2/62 1.50 mm² 306 2/10 2
/2.D5 FROM
-C_OP24 -C_RC03
3 3/10 1.50 mm² 828 20/62 20/62 1.50 mm² 828 ILL TO FUSEBOX C
TO
/3.C1 SIDE LIGHTS
FROM FUSE FC5 5
/3.D4 IGN RLY O/P
FROM 1.50 mm² 1703 5/10
6 6/10
E
E
R/H COLUMN SWITCH
-C_OP08
1.50 mm² 8701 5/14 5
-C_OP24 -C_RC03 TO DIP BEAM
7 7/14 1.50 mm² 832 60/62 60/62 1.50 mm² 832 SUPPLY TO
/6.F1
FROM FUSE FA3 -C_RC03 -C_OP24
1.50 mm² 312 62/62 62/62 4/14 4
/2.F5 -C_OP24 -C_RC03
TO MAIN BEAM
FROM
312 1.50 mm²

SUPPLY 6 6/14 1.50 mm² 836 1.50 mm² 836A 59/62 59/62 1.50 mm² 836A MAIN BEAM TO
/6.F1
-S001
400/G8164 high beam 1.00 mm² 836B MAIN BEAM TO INSTRUMENT PANEL
TO
/7.E2
D
D
-SW04
701/60005
-C_OP07 704/50082
HAZARD SWITCH
FROM FUSE FC10 -C_RC03 -C_OP24 7219/0014 -D4 7232/0017
1.00 mm² 829D 6/62 6/62 1.00 mm² 829D 0.50 mm² 829E 8/10 8
/6.C1 FROM
-C_OP15
-S007 0.50 mm² 805B 1 2 0.50 mm² 806 INDI TO INSTRUMENT PANEL
TO
/7.E1
console side lights 10 10/10 0.50 mm² 6005D GROUND TO OP GND
TO
/16.E1
FROM FUSE FC2 IGN RLY O/P
1.50 mm² 804 1/10 1
/3.E7 FROM
2 2/10 1.50 mm² 8027 1.00 mm² 8029B RH INDI TO RH REAR INDICATOR
FROM FUSE FA1 -C_RC03 -C_OP24 TO
/6.A1
1.50 mm² 3008 3/62 3/62 1.50 mm² 3008 3/10 3
/2.F5 FROM
-D1 704/50082 -C_OP24 -C_RC03

5 17 1 2 -S002 RH INDI
1.00 mm² 8031D 5/10 17/10 1.00 mm² 8028 1.00 mm² 8028 1.00 mm² 805D 1.00 mm² 805AA 32/62 32/62 1.00 mm² 8029A 1.00 mm² 8029C
C /6.E3
TO
18 18/10 1.50 mm² 8026B -S_SRC03

-C_OP14-A 7232/0017 TO RH FRONT INDICATOR C
-R14 400/G8164 RH SPLICE
716/C6032
FLASHER -C_OP08
5 7219/0005 2 2/14 1.00 mm² 8031C
-C_RC03 -C_OP24
8 2 1.50 mm² 8026 21/62 21/62 1.50 mm² 8026 1.00 mm² 8026A 1/14 1
3
-C_RC03 -C_OP24 -S004 3/14 1.00 mm² 805C
TO RC GNDGROUND 6 4 hazards
1.50 mm² 6001F 1.50 mm² 0827 22/62 22/62 DIR
/16.C1 TO
3 9 R/H COLUMN SWITCH

1 7
-RB06
7241/0005
B
B
704/50082
7232/0017
-D3 -C_OP14-B
-S_SRC01 -C_RC03 -C_OP24
TO LH FRONT INDICATOR LH INDI 1 2 INDI
1.00 mm² 8031A 1.00 mm² 8031 31/62 31/62 1.00 mm² 8031 0.50 mm² 8031A 0.50 mm² 806A
/6.F5 TO TO
/7.E2
-S005 TO INSTRUMENT PANEL
TO LH REAR INDICATOR LH INDI LH SPLICE
1.00 mm² 8031B
/6.C4 TO
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 25 9813/8950-2 33 - 25
Page Page
33-26 33-27
Figure 611. 1(Part 1 of 2) 2 3 4
F -SW02
701/60004
ROADLIGHT SWITCH
0.50 mm² 829G 8/10 8 7 7/10 0.50 mm² 6005E GROUND TO OP GND
TO
/16.E1
FROM FUSE FA9 -C_RC03 -C_OP24 -C_OP06

1.50 mm² 306 2/62 2/62 1.50 mm² 306 2/10 2
/2.D5 FROM
-C_OP24 -C_RC03
3 3/10 1.50 mm² 828 20/62 20/62 1.50 mm² 828 ILL TO FUSEBOX C
TO
/3.C1 SIDE LIGHTS
FROM FUSE FC5 5
/3.D4 IGN RLY O/P
FROM 1.50 mm² 1703 5/10
6 6/10
FROM FUSE FA3 -C_RC03

1.50 mm² 312 62/62
/2.F5 FROM
SUPPLY
-SW04
701/60005
-C_OP07
HAZARD SWITCH
FROM FUSE FC10 -C_RC03 -C_OP24 7219/0014
1.00 mm² 829D 6/62 6/62 1.00 mm² 829D 0.50 mm² 829E 8/10 8
/6.C1
Page 33-27
FROM
-S007
console side lights 10 10/10 0.50 mm² 6005D GROUND TO OP GND
TO
/16.E1
1.50 mm² 804 1/10 1
/3.E7 FROM
2 2/10 1.50 mm² 8027

FROM FUSE FA1 -C_RC03 -C_OP24
1.50 mm² 3008 3/62 3/62 1.50 mm² 3008 3/10 3
/2.F5 FROM
1.00 mm² 8031D 5/10 5 17 17/10 1.00 mm² 8028

C 18 18/10 1.50 mm² 8026B
-R14
716/C6032
FLASHER
5
-C_RC03 -C_OP24
8 2 1.50 mm² 8026 21/62 21/62 1.50 mm² 8026 1.00 mm² 8026A
-C_RC03 -C_OP24 -S004

TO RC GNDGROUND 6 4 hazards
1.50 mm² 6001F 1.50 mm² 0827 22/62 22/62
/16.C1 TO
3 9
1 7
-RB06
7241/0005
-S_SRC01 -C_RC03 -C_OP24

TO LH FRONT INDICATOR LH INDI
1.00 mm² 8031A 1.00 mm² 8031 31/62 31/62 1.00 mm² 8031
/6.F5 TO
-S005
TO LH REAR INDICATOR LH INDI LH SPLICE
1.00 mm² 8031B
/6.C4 TO
1 2 3 4
33 - 26 9813/8950-2 33 - 26
Page Page
33-26 33-27
Figure 611. (Part

5 2 of 2) 6 7 8
TO FUSEBOX C
/3.C1 SIDE LIGHTS
E
R/H COLUMN SWITCH
-C_OP08
1.50 mm² 8701 5/14 5
-C_OP24 -C_RC03 TO DIP BEAM
7 7/14 1.50 mm² 832 60/62 60/62 1.50 mm² 832 SUPPLY TO
/6.F1
-C_RC03 -C_OP24
62/62 62/62 4/14 4
-C_OP24 -C_RC03
312 1.50 mm²
6 MAIN BEAM TO MAIN BEAM
6/14 1.50 mm² 836 1.50 mm² 836A 59/62 59/62 1.50 mm² 836A TO
/6.F1
-S001
400/G8164 high beam 1.00 mm² 836B MAIN BEAM TO INSTRUMENT PANEL
TO
/7.E2
704/50082
-D4 7232/0017
-C_OP15
Page 33-26
0.50 mm² 805B 1 2 0.50 mm² 806 INDI TO INSTRUMENT PANEL

TO
/7.E1
1.00 mm² 8029B RH INDI TO RH REAR INDICATOR

TO
/6.A1
-D1 704/50082 -C_OP24 -C_RC03

1 2 -S002 RH INDI
1.00 mm² 8028 1.00 mm² 805D 1.00 mm² 805AA 32/62 32/62 1.00 mm² 8029A 1.00 mm² 8029C
/6.E3
TO
-C_OP14-A 7232/0017 -S_SRC03 TO RH FRONT INDICATOR

400/G8164 RH SPLICE C
-C_OP08
7219/0005 2 2/14 1.00 mm² 8031C
1/14 1
3 3/14 1.00 mm² 805C
DIR
R/H COLUMN SWITCH
B
704/50082
7232/0017
-D3 -C_OP14-B
0.50 mm² 8031A 1 2 0.50 mm² 806A INDI TO
/7.E2
-S005 TO INSTRUMENT PANEL
LH SPLICE
400/M1730-6
5 6 7 8
33 - 27 9813/8950-2 33 - 27
33 - 28 9813/8950-2 33 - 28
Page 33-30 Figure 612. Beacon and Work Light

1 2 3 4 5 6 7 8
F
F
OPTIONAL
7216/0017 7216/0018
-C041 -C_RC40
4/6 4/6 0.50 mm² 6010A GROUND TO RC GND FRONT LH WORK LAMP
TO
/16.B5 7212/0052
-C_C13
0.75 mm² 8001A 1/2 2/2 0.75 mm² 6010U TO CAB GND
TO
/16.E5
-SW03
E 701/60004
-C_RC41
WORK LAMP SWITCH 1.00 mm² 8001C
7213/0030 E
FROM RH LIGHT SPLICE ILL 8 7 A/3 -S006
0.50 mm² 830G 0.50 mm² 8500C 8/10 7/10 0.50 mm² 6010A
/6.B3 FROM
3/6 3/6 FRONT RH WORK LAMP

7216/0018 -C_RC40 -C041 7216/0017 7212/0052
7219/0013 -C_C14
0.75 mm² 8001C 1/2 2/2 0.75 mm² 6010V TO CAB GND
-C005 TO
/16.E5
FROM FUSE FA4 1.00 mm² 1800 2/10 2
/2.E5 FROM
-C041 -C_RC40 -C_RC44 -C_C01

3 3/10 1.00 mm² 8001 1.00 mm² 8001 1.00 mm² 8001A B/14 B/14 1.00 mm² 8001
5/6 5/6
-S_SRC30
FROM FUSE FA5 1.00 mm² 1801 5/10 5
/2.E5 FROM
-C041 -C_RC40
6 6/10 1.00 mm² 8002 1.00 mm² 8002 1.00 mm² 8002A 1.00 mm² 8002 REAR LH WORK LAMP
6/6 6/6 C/14 C/14 7212/0052
-S_SRC31 -C_RC44 -C_C01 -C_C15
0.75 mm² 8002A 1/2 2/2 0.75 mm² 6010W TO CAB GND
TO
/16.E5
1.00 mm² 8002C -S007

B/3
D
REAR RH WORK LAMP D
7212/0052
-C_C16
0.75 mm² 8002C 1/2 2/2 0.75 mm² 6010X TO CAB GND
TO
/16.E5
C 7214/0024
0.75 mm² 1706C

-C_RC42
1/4
C
AMBER BEACON
7201/0827 7201/0438
-C_RC44 -C_C01 -C_C24-X1 -C_C24-X2
FROM FUSE FC7 1.00 mm² 1706 0.75 mm² 1706A D/14 D/14 0.75 mm² 1706 1/1 1/1 0.75 mm² 6010S TO CAB GND
/3.D4 FROM TO
/16.E5
-S_SRC32
GREEN BEACON
7201/0827 7201/0438
FROM GREEN BEACON RELAY -S_SRC33 -C_RC44 -C_C01 -C_C23-X1 -C_C23-X2
0.75 mm² 8025 0.75 mm² 8025A E/14 E/14 0.75 mm² 8025 1/1 1/1 0.75 mm² 6010T TO CAB GND
/13.C3 FROM TO
/16.E5
B
B
-C_RC42
0.75 mm² 8025C 2/4
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 29 9813/8950-2 33 - 29
Page Page
33-30 33-31
Figure 612. 1(Part 1 of 2) 2 3 4
OPTIONAL
7216/0017 7216/0018
-C041 -C_RC40
4/6 4/6 0.50 mm² 6010A GROUND TO RC GND
TO
/16.B5
-SW03
E 701/60004
-C_RC41
7213/0030
WORK LAMP SWITCH 1.00 mm² 8001C
FROM RH LIGHT SPLICE ILL 8 7 A/3
0.50 mm² 830G 0.50 mm² 8500C 8/10 7/10 0.50 mm² 6010A
/6.B3 FROM
3/6 3/6
7216/0018 -C_RC40 -C041 7216/0017
7219/0013
-C005
FROM FUSE FA4 1.00 mm² 1800 2/10 2
/2.E5 FROM
-C041 -C_RC40 -C_RC44 -C_C01

3 3/10 1.00 mm² 8001 1.00 mm² 8001 1.00 mm² 8001A B/14 B/14 1.00 mm² 8001
5/6 5/6
-S_SRC30
FROM FUSE FA5 1.00 mm² 1801 5/10 5
/2.E5 FROM
-C041 -C_RC40
6 6/10 1.00 mm² 8002 1.00 mm² 8002 1.00 mm² 8002A 1.00 mm² 8002
6/6 6/6 C/14 C/14
-S_SRC31 -C_RC44 -C_C01
1.00 mm² 8002C

B/3
D
Page 33-31
C 7214/0024
-C_RC42
0.75 mm² 1706C 1/4
AMBER BEACON
7201/0827 7201/0438
-C_RC44 -C_C01 -C_C24-X1 -C_C24-X2
FROM FUSE FC7 1.00 mm² 1706 0.75 mm² 1706A D/14 D/14 0.75 mm² 1706 1/1 1/1
/3.D4 FROM
-S_SRC32
GREEN BEACON
7201/0827 7201/0438
FROM GREEN BEACON RELAY -S_SRC33 -C_RC44 -C_C01 -C_C23-X1 -C_C23-X2
0.75 mm² 8025 0.75 mm² 8025A E/14 E/14 0.75 mm² 8025 1/1 1/1
/13.C3 FROM
-C_RC42
0.75 mm² 8025C 2/4
1 2 3 4
33 - 30 9813/8950-2 33 - 30
Page Page
33-30 33-31
Figure 612. (Part

5 2 of 2) 6 7 8
FRONT LH WORK LAMP

7212/0052
-C_C13
0.75 mm² 8001A 1/2 2/2 0.75 mm² 6010U TO CAB GND
TO
/16.E5
E
-S006
FRONT RH WORK LAMP
7212/0052
-C_C14
0.75 mm² 8001C 1/2 2/2 0.75 mm² 6010V TO CAB GND
TO
/16.E5
8001
8002 REAR LH WORK LAMP

7212/0052
-C_C15
0.75 mm² 8002A 1/2 2/2 0.75 mm² 6010W TO CAB GND
TO
/16.E5
-S007
REAR RH WORK LAMP D

7212/0052
-C_C16
0.75 mm² 8002C 1/2 2/2 0.75 mm² 6010X TO CAB GND
TO
/16.E5
Page 33-30
AMBER BEACON
7201/0438
-C_C24-X2
1/1 0.75 mm² 6010S TO CAB GND
TO
/16.E5
GREEN BEACON
7201/0438
-C_C23-X2
1/1 0.75 mm² 6010T TO CAB GND
TO
/16.E5
400/M1730-6
5 6 7 8
33 - 31 9813/8950-2 33 - 31
33 - 32 9813/8950-2 33 - 32
Page 33-34 Figure 613. Road Light Circuit

(400/M1730 Sheet 6 of 16) Page 33-35
1 2 3 4 5 6 7 8
-L6
700/50119
LH HEADLIGHT
F MAIN
FROM RH COLUMN SWITCH MAIN BEAM
-C_RC35 -C_FC06
-S002 3
F
1.50 mm² 836A 2/12 2/12 1.50 mm² 836A 1.00 mm² 836AA 3/6
/4.E7 FROM
7216/0018 DIP
-C_RC35 -C_FC06 -S001 -C_FC01
FROM RH COLUMN SWITCH SUPPLY 1.50 mm² 832 1/12 1/12 1.50 mm² 832 1.00 mm² 832A 2/6 2
/4.E7 FROM
6 6/6 2.00 mm² 6004B

SIDE
-C_RC35 -C_FC06
1.00 mm² 829A 3/12 3/12 1.00 mm² 829A 4/6 4
-C_RC35 -C_FC06 IND

FROM LH DIR SWITCH LH INDI 1.00 mm² 8031A 4/12 4/12 1.00 mm² 8031A 5/6 5
/4.B2 FROM
-L7
700/50121
RH HEADLIGHT
MAIN
E 1.00 mm² 836AB 3/6 3
E
7216/0018
DIP
-C_FC02
1.00 mm² 832B 2/6 2
6 6/6 2.00 mm² 6004C
SIDE
-C_RC35 -C_FC06
1.00 mm² 830D 8/12 8/12 1.00 mm² 830D 4/6 4
-C_RC35 -C_FC06 IND

FROM RH DIR SWITCH RH INDI 1.00 mm² 8029C 5/12 5/12 1.00 mm² 8029C 5/6 5
/4.C7 FROM
TO RC GND GROUND -C_RC35 -C_FC06 -S003

6004 2.00 mm² 6004 2.00 mm² 6004B 2.00 mm²
/16.B1 TO
7/12 7/12
6004C 2.00 mm²
D
-C_FC03 6004D 0.75 mm² FROM
FROM PROXIMITY SENSOR
/7.C4
D
-C_RC35 -C_FC06 7212/0008
FROM HORN RELAY HORN 1.50 mm² 8035 6/12 6/12 1.00 mm² 8035 1/2 1 2 2/2 1.00 mm² 6004A
TO SERVICE RESET SWITCH /3.C7 FROM
-L8
/7.F1 0.50 mm² 829F 700/41600
-A3
TO
LH TAIL LIGHTS
335/B4669 7214/0025
Horn -C_RC11 Tail
FROM FUSE FC10 1.00 mm² 829 -S_SRC02 1.00 mm² 829B 4/4 4
/3.C4 FROM
Stop
1.00 mm² 816A 1/4 1 3 3/4 1.50 mm² 6001H GROUND TO RC GND
TO HAZARD / LIGHT SW
TO
/16.C1
1.00 mm² 829D
/4.C1 TO
FROM LH DIR SWITCH LH INDI 1.00 mm² 8031B 2/4 2

/4.B2 FROM
-C_RC42
4/4 1.00 mm² 829G Indicator
C
C
-L10
LH NO. PLATE LIGHT
334/D4912
-C_C21
-C_RC44 -C_C01 7212/0052
0.75 mm² 829C K/14 K/14 0.75 mm² 8019C 1/2 2/2 0.75 mm² 6010L TO CAB GND
TO
/16.F5
1 2
-L9
RH NO. PLATE LIGHT
334/D4912
-C_C22
-C_RC44 -C_C01 7212/0052 -C_C22
0.75 mm² 830C J/14 J/14 0.75 mm² 8501C 1/2 2/2 0.75 mm² 6010Q TO CAB GND
TO
/16.F5
1 2
1.00 mm² 830H ILL TO SPEEEDOMETER

TO
/7.B1
B
B
ILL 700/41600
0.50 mm² 830G TO
/5.E1 TO WORKLIGHT SWITCH
RH Tail LIGHT
ILL
0.75 mm² 830F TO
/12.E1 TO RADIO/AC/WW Tail -L9
FROM FUSE FC9 ILL 1.00 mm² 830 1.00 mm² 830B 4/4 4
/3.C4 FROM
-S_SRC22 -C_RC25 Stop

FROM BRAKE LIGHTS RELAY 1 3 GROUND TO RC GND
1.00 mm² 816 1.00 mm² 816B 1/4 3/4 1.50 mm² 6001G
/15.D7 FROM TO
/16.C1
-S_SRC09
FROM RH DIR SWITCH RH INDI 1.00 mm² 8029B 2/4 2
/4.C7 FROM
7214/0025
Indicator
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 33 9813/8950-2 33 - 33
Page Page
33-34 33-35
Figure 613. 1(Part 1 of 2) 2 3 4
F
-C_RC35 -C_FC06
FROM RH COLUMN SWITCH MAIN BEAM -S002
1.50 mm² 836A 2/12 2/12 1.50 mm² 836A 1.00 mm² 836AA
/4.E7 FROM
-C_RC35 -C_FC06 -S001

FROM RH COLUMN SWITCH SUPPLY 1.50 mm² 832 1/12 1/12 1.50 mm² 832
/4.E7 FROM
-C_RC35 -C_FC06
1.00 mm² 829A 3/12 3/12 1.00 mm² 829A
FROM LH DIR SWITCH

/4.B2
E 1.00 mm² 836AB
-C_RC35 -C_FC06
1.00 mm² 830D 8/12 8/12 1.00 mm² 830D
-C_RC35 -C_FC06
FROM RH DIR SWITCH RH INDI 1.00 mm² 8029C 5/12 5/12 1.00 mm² 8029C
/4.C7 FROM
TO RC GND GROUND 6004

/16.B1 TO
D
-C_FC03
-C_RC35 -C_FC06 7212/0008
FROM HORN RELAY HORN 1.50 mm² 8035 6/12 6/12 1.00 mm² 8035 1/2
TO SERVICE RESET SWITCH /3.C7 FROM
0.50 mm² 829F

/7.F1 TO
FROM FUSE FC10 1.00 mm² 829 -S_SRC02 1.00 mm² 829B
/3.C4 FROM
Page 33-35
TO HAZARD / LIGHT SW
1.00 mm² 829D
/4.C1 TO
FROM LH DIR SWITCH LH INDI

/4.B2 FROM
-C_RC42
4/4 1.00 mm² 829G
-C_RC44 -C_C01
0.75 mm² 829C K/14 K/14 0.75 mm² 8019C
-C_RC44 -C_C01
0.75 mm² 830C J/14 J/14 0.75 mm² 8501C
1.00 mm² 830H
B
ILL
0.50 mm² 830G TO
/5.E1 TO WORKLIGHT SWITCH
RH Tail LIGHT
ILL
0.75 mm² 830F TO
/12.E1 TO RADIO/AC/WW
FROM FUSE FC9 ILL 1.00 mm² 830 1.00 mm² 830B 4/4
/3.C4 FROM
-S_SRC22 -C_RC25
FROM BRAKE LIGHTS RELAY
1.00 mm² 816 1.00 mm² 816B 1/4
/15.D7 FROM
-S_SRC09
FROM RH DIR SWITCH RH INDI 1.00 mm² 8029B 2/4
/4.C7 FROM
7214/0025
Indicator
1 2 3 4
33 - 34 9813/8950-2 33 - 34
Page Page
33-34 33-35
Figure 613. (Part

5 2 of 2) 6 7 8
-L6
700/50119
LH HEADLIGHT
MAIN
3
F
3/6
7216/0018 DIP
-C_FC01
1.00 mm² 832A 2/6 2
6 6/6 2.00 mm² 6004B
SIDE
4/6 4
-C_RC35 -C_FC06 IND

FROM LH DIR SWITCH LH INDI 1.00 mm² 8031A 4/12 4/12 1.00 mm² 8031A 5/6 5
/4.B2 FROM
-L7
700/50121
RH HEADLIGHT
MAIN
3/6 3
E
7216/0018
DIP
-C_FC02
1.00 mm² 832B 2/6 2
6 6/6 2.00 mm² 6004C
SIDE
4/6 4
IND
5/6 5
GROUND -C_RC35 -C_FC06 -S003

6004 2.00 mm² 6004 2.00 mm² 6004B 2.00 mm²
7/12 7/12
6004C 2.00 mm²
-C_FC03 6004D 0.75 mm² FROM

FROM PROXIMITY SENSOR
/7.C4
D
7212/0008
1/2 1 2 2/2 1.00 mm² 6004A -L8
700/41600
-A3 LH TAIL LIGHTS
335/B4669 7214/0025
Horn -C_RC11 Tail
4/4 4
Stop
1.00 mm² 816A 1/4 1 3 3/4 1.50 mm² 6001H GROUND TO RC GND
/16.C1
Page 33-34
TO
1.00 mm² 8031B 2/4 2
Indicator
C
-L10
LH NO. PLATE LIGHT
334/D4912
-C_C21
7212/0052
1/2 2/2 0.75 mm² 6010L TO CAB GND
TO
/16.F5
1 2
-L9
RH NO. PLATE LIGHT
334/D4912
-C_C22
7212/0052 -C_C22
1/2 2/2 0.75 mm² 6010Q TO CAB GND
TO
/16.F5
1 2
ILL TO SPEEEDOMETER
TO
/7.B1
B
700/41600
RH Tail LIGHT
Tail -L9
4/4 4
-C_RC25 Stop
1/4 1 3 3/4 1.50 mm² 6001G GROUND TO RC GND
TO
/16.C1
2/4 2
7214/0025
Indicator
400/M1730-6
5 6 7 8
33 - 35 9813/8950-2 33 - 35
33 - 36 9813/8950-2 33 - 36
Page 33-38 Figure 614. Instrument Panel

1 2 3 4 5 6 7 8
service reset
701/E0008
-C_RC15
F FROM FUSE FA10 LIGHT SPLICE 8 7 GROUND TO RC GND
/6.D1 FROM 0.50 mm² 829F 8/10 7/10 0.50 mm² 6001N TO
/16.D1 F
/3.E7 FROM 1.00 mm² 106B 2/10 2
-DIS2
3 3/10 1.00 mm² 4700 400/D9268
-C_RC03 -C_OP24 7219/0075
40/62 40/62
5
6
X1 CONNECTOR
FROM LH COLUMN SWITCH 0.75 mm² 810D 1/8
/13.F7 FROM
X1-1 NEUTRAL INDICATOR (B+)
1.00 mm² 4700 2/8
-S010hazard instrument X1-2 SERVICE HOURMETER RESET (B+)
INDI
FROM LH INDICATOR /4.B7 FROM 0.50 mm² 806A 0.50 mm² 806C 3/8 X1-3 TURN SIGNAL (B+)
INDI 0.50 mm² 806 4/8 GROUND TO OP GND
FROM RH INDICATOR /4.C7 FROM
B- X1-4 1.00 mm² 6005F TO
/16.E1
ALT D+
0.75 mm² 4023 5/8
FROM ALT D+ /1.E4 X1-5 ALTERNATOR (D+)
E
FROM
MAIN BEAM 6/8

FROM RH COLUMN SWITCH /4.D6 1.00 mm² 836B X1-6 HIGH BEAM (B+)
E
FROM
#2660 0.50 mm² 4003 7/8 TRANS OIL PRESSURE

FROM PARK BRAKE /15.E7 FROM
X1-7 PARK BRAKE (B+) -C_OP24 -C_RC03 -C_RC10
IGN RLY O/P 1 2 GROUND TO RC GND
1.00 mm² 106C 14/62 14/62 1.00 mm² 1709 8/8 28/62 28/62 1.00 mm² 4019 1/2 2/2
FROM FUSE FC1 /3.E7 X1-8 B+ /16.C5
FROM TO
6000J 1.00 mm²

-C_RC03 -C_OP24 7212/0052
X2 CONNECTOR
4300/0007
-C_RC30 -C_RC03 -C_OP24 X2-5 NC TRANS OIL PRESSURE (B-) X2-2 2/12 1.00 mm² 4019 -C_OP24 -C_RC03 -C_RC17 TEMPERATURE SWITCH
TO BATT -VE GROUND
2/2 2 1 1/2 1 2 2/2 GROUND TO RC GND
1.00 mm² 6006 1.00 mm² 4016 27/62 27/62 1.00 mm² 4016 6/12 3/12 1.00 mm² 4020 29/62 29/62 1.00 mm² 4020 1/2 1.00 mm² 6000L
/16.D5 TO
F E
X2-6 FUEL LEVEL TRANS OIL TEMP (B-) X2-3 TO
/16.C5
X2-8 NC BLOCKED AIR FILTER (B-) X2-4 4/12 7212/0052
4022 0.75 mm²
Sender
X2-9 NC
X2-10 NC
0.75 mm² 4022B AIR FILTER TO LIVELINK
X2-11 NC /14.C2
X2-7 CAN LO
TO
X2-1 CAN HI
6014 0.75 mm² X2-12 FET OUTPUT AIR FILTER VACUUM
12/12
-C_RC23
BUZZER -C_OP24 -C_RC03 7212/0013
1.00 mm² 4022A 26/62 26/62 0.75 mm² 4022A 1/2 1 2 2/2 0.75 mm² 6000K GROUND TO RC GND
TO
/16.C5
704/10000 -S009 VACUUM SW (AIR FILTER)
FROM FUSE FC1 5BUZZER 7241/0005 air filter
IGN RLY O/P106A 0.75 mm² 2 8 -RB09
/3.E7 FROM IGN
D -C_RC03 -C_OP24
4
BUZ
6
GND 6014A 0.75 mm²
-S_SRC19 6014 0.75 mm² 30/62 30/62 D
9 3
-R15 7 1
716/G3600
SEATBELT BUZZER RELAY
9
TO RC GND GROUND 6 7
0.75 mm² 601W 0.75 mm² 6014C
/16.B1 TO
DIE ECU BUZZ 0.75 mm² 8110 8 10 0.75 mm² 601V GROUND TO RC GND
/13.C2 TO TO
/16.B1
-RB10 -SW8
7241/0003 701/80608
SEAT BELT BUZZER RELAY
PROXIMITY SWITCH
7213/0005
+V
1 -C_FC04
1/3 0.75 mm² 8125B
-C_FC06
9/12
-C_RC35
9/12 0.75 mm² 8125 FROM F-R DIODE Skip Warning Buzzer
FROM
/13.E3 717/20264
C
PROXIMITY
+VE
C
-VE
SENSOR
7201/0827 7204/0408
4 3/3 0.75 mm² 5101 10/12 10/12 0.75 mm² 5101
-C_RC03
17/62
-C_OP24
17/62 0.75 mm² 5101
-C_OP22
1/1 1 2 -C_OP23
1/1 0.75 mm² 6005G GROUND TO OP GND
OUTPUT
TO
/16.F1
3 2/3 0.75 mm² 6004D TO GND SPLICE S003
TO
/6.D6
0V
7213/0031 -SPEED SENSOR

-C003 716/30123
IGN RLY O/P -S001 A/3
1.00 mm² 107B 0.75 mm² 107C 0.75 mm² 6000TC
/3.D7 TO GROUND
A DIAGNOSTIC
SPEEDOMETER
7238/0004
-C002 SPEED I/P 6/8 6/8 0.75 mm² 5100A
0.75 mm² 107D 4/8 4/8 +12V R1
C/3
SPEED I/P 8/8 8/8 0.75 mm² 5100 0.75 mm² 5100 0.75 mm² 107C
SENSOR
C
R2 ELEMENT
B B/3
RL
GND 3/8 3/8 0.75 mm² 6000TA
B 7214/0024 7201/0403
-C_RC33 -C001 -C004 -C001 -C_RC33 B
FROM FUSE FC9 LIGHT SPLICE ILL -S003 1/1 2/4 2/4 GROUND
3/4 3/4
/6.B5 FROM 1.00 mm² 830H 1.00 mm² 8500E 0.75 mm² 8500EA
BULB 1 POS BULB 1 NEG -C005 0.75 mm² 6000TA 1.00 mm² 6000T 1.00 mm² 6000T TO
/16.C5 TO CAB GND
1/1 0.75 mm² 6000TE -S002
-C006
0.75 mm² 8500EC 1/1 BULB 2 POS BULB 2 NEG -C007
1/1 0.75 mm² 6000TF
0.75 mm² 6000TE
0.75 mm² 6000TF

CAMERA TRANSFER POWER BOX
-C_OP11
IGN RLY O/P
0.75 mm² 106D 5/62 5/62 0.75 mm² 1004 1/6 1/6 2/6 2/6 GROUND TO OP GND
/3.E7 FROM
IGN GND 1.00 mm² 6005A TO
/16.E1
0.75 mm² 811C 3/6 3/6 REV

/13.E5
A
FROM
400/M1730-6
1 2 3 4 5 6 7 8
33 - 37 9813/8950-2 33 - 37
Page Page
33-38 33-39
Figure 614. 1(Part 1 of 2) 2 3 4

service reset
701/E0008
-C_RC15
F FROM FUSE FA10 LIGHT SPLICE 0.50 mm² 829F 8/10 8 7 7/10 0.50 mm² 6001N GROUND TO RC GND
/6.D1 FROM TO
/16.D1
/3.E7 FROM 1.00 mm² 106B 2/10 2
-DIS2
3 3/10 1.00 mm² 4700 400/D9268
-C_RC03 -C_OP24 7219/0075
40/62 40/62
5
6
X1 CONNECTOR
FROM LH COLUMN SWITCH 0.75 mm² 810D 1/8
/13.F7 FROM
X1-1 NEUTRAL INDICATOR (B+)
1.00 mm² 4700 2/8
-S010hazard instrument X1-2 SERVICE HOURMETER RESET (B+)
INDI
FROM LH INDICATOR /4.B7 FROM 0.50 mm² 806A 0.50 mm² 806C 3/8 X1-3 TURN SIGNAL (B+)
INDI 0.50 mm² 806 4/8
FROM RH INDICATOR /4.C7 FROM
B- X1-4
ALT D+
0.75 mm² 4023 5/8
FROM ALT D+ /1.E4 X1-5 ALTERNATOR (D+)
E
FROM
MAIN BEAM 6/8

FROM RH COLUMN SWITCH /4.D6 FROM 1.00 mm² 836B X1-6 HIGH BEAM (B+)
#2660 0.50 mm² 4003 7/8
FROM PARK BRAKE /15.E7 FROM
X1-7 PARK BRAKE (B+)
IGN RLY O/P
1.00 mm² 106C 14/62 14/62 1.00 mm² 1709 8/8
FROM FUSE FC1 /3.E7 X1-8 B+
FROM
-C_RC03 -C_OP24
X2 CONNECTOR
4300/0007
-C_RC30 -C_RC03 -C_OP24 X2-5 NC TRANS OIL PRESSURE (B-) X2-2 2/12
TO BATT -VE GROUND
2/2 2 1 1/2
1.00 mm² 6006 1.00 mm² 4016 27/62 27/62 1.00 mm² 4016 6/12 3/12
/16.D5 TO
F E
X2-6 FUEL LEVEL TRANS OIL TEMP (B-) X2-3
X2-8 NC BLOCKED AIR FILTER (B-) X2-4 4/12
Sender
X2-9 NC
X2-10 NC
X2-11 NC
X2-7 CAN LO
X2-1 CAN HI
6014 0.75 mm² X2-12 FET OUTPUT
12/12
BUZZER
704/10000
FROM FUSE FC1 5BUZZER 7241/0005
IGN RLY O/P106A 0.75 mm² 2 8 -RB09
/3.E7 FROM IGN
D -C_RC03 -C_OP24
4
BUZ
6
GND 6014A 0.75 mm²
-S_SRC19 6014 0.75 mm² 30/62 30/62
9 3
-R15 7 1
716/G3600
SEATBELT BUZZER RELAY
9
TO RC GND GROUND 6 7
0.75 mm² 601W 0.75 mm² 6014C
/16.B1 TO
Page 33-39
DIE ECU BUZZ 0.75 mm² 8110 8 10 0.75 mm² 601V GROUND TO RC GND
/13.C2 TO TO
/16.B1
-RB10 -SW8
7241/0003 701/80608
PROXIMITY SWITCH
7213/0005
+V
1 -C_FC04
1/3 0.75 mm² 8125B
-C_FC06
9/12
-C_RC35
9/12 0.75 mm² 8125
C
PROXIMITY
SENSOR
4 3/3 0.75 mm² 5101 10/12 10/12 0.75 mm² 5101

-C_RC03
OUTPUT
3 2/3 0.75 mm² 6004D TO GND SPLICE S003
TO
/6.D6
0V
IGN RLY O/P -S001

1.00 mm² 107B 0.75 mm² 107C
/3.D7 TO
SPEEDOMETER
7238/0004
-C002 SPEED I/P 6/8 6/8 0.75 mm²
0.75 mm² 107D 4/8 4/8 +12V
8/8 8/8 0.75 mm²
SPEED I/P
3/8 3/8 0.75 mm²

GND
B 7214/0024 7201/0403
-C_RC33 -C001 -C004
FROM FUSE FC9 LIGHT SPLICE ILL -S003 1/1
3/4 3/4
/6.B5 FROM 1.00 mm² 830H 1.00 mm² 8500E 0.75 mm² 8500EA
BULB 1 POS BULB 1 NEG -C005
1/1 0.75 mm²
-C006
0.75 mm² 8500EC 1/1 BULB 2 POS BULB 2 NEG -C007
1/1 0.75 mm²
CAMERA TRANSFER POWER BOX

-C_OP11
IGN RLY O/P
0.75 mm² 106D 5/62 5/62 0.75 mm² 1004 1/6 1/6 IGN GND 2/6 2/6
/3.E7 FROM
0.75 mm² 811C 3/6 3/6 REV

/13.E5
A
FROM
1 2 3 4
33 - 38 9813/8950-2 33 - 38
Page Page
33-38 33-39
Figure 614. (Part

5 2 of 2) 6 7 8
4/8 1.00 mm² 6005F GROUND TO OP GND

TO
/16.E1
TRANS OIL PRESSURE

E
-C_OP24 -C_RC03 -C_RC10
28/62 28/62 1.00 mm² 4019 1/2 1 2 2/2 GROUND TO RC GND
6000J 1.00 mm²
TO
/16.C5
7212/0052
2/12 1.00 mm² 4019 -C_OP24 -C_RC03 -C_RC17 TEMPERATURE SWITCH

3/12 1.00 mm² 4020 29/62 29/62 1.00 mm² 4020 1/2 1 2 2/2 1.00 mm² 6000L GROUND TO RC GND
TO
/16.C5
4/12 7212/0052
4022 0.75 mm²
0.75 mm² 4022B AIR FILTER TO LIVELINK

TO
/14.C2
AIR FILTER VACUUM
-C_RC23
-C_OP24 -C_RC03 7212/0013
1.00 mm² 4022A 26/62 26/62 0.75 mm² 4022A 1/2 1 2 2/2 0.75 mm² 6000K GROUND TO RC GND
TO
/16.C5
-S009 VACUUM SW (AIR FILTER)
air filter
D
Page 33-38
8125 FROM F-R DIODE Skip Warning Buzzer

FROM
/13.E3 717/20264
+VE
C
-VE
7201/0827 7204/0408
-C_RC03 -C_OP24 -C_OP22 -C_OP23
5101 17/62 17/62 0.75 mm² 5101 1/1 1 2 1/1 0.75 mm² 6005G GROUND TO OP GND
TO
/16.F1
7213/0031 -SPEED SENSOR

-C003 716/30123
A/3
0.75 mm² 6000TC GROUND
A DIAGNOSTIC
0.75 mm² 5100A
R1
C/3
0.75 mm² 5100 0.75 mm² 5100 SENSOR 0.75 mm² 107C
C
R2 ELEMENT
B B/3
RL
0.75 mm² 6000TA
-C001 -C_RC33 B
0.75 mm² 6000TA 1.00 mm² 6000T 2/4 2/4 1.00 mm² 6000T GROUND TO
/16.C5 TO CAB GND
0.75 mm² 6000TE -S002
0.75 mm² 6000TF

0.75 mm² 6000TE
0.75 mm² 6000TF
1.00 mm² 6005A GROUND TO OP GND

TO
/16.E1
400/M1730-6
5 6 7 8
33 - 39 9813/8950-2 33 - 39
33 - 40 9813/8950-2 33 - 40
Page 33-42 Figure 615. Engine Dressed

1 2 3 4 5 6 7 8
CYLINDER#1(GOLD) ENGINE ECU (BLACK)

-C19_T4i -C1_T4i
F ACCELEROMETER 1 (TIN)
7212/0094
-TW1:TW1
7219/0075
-C2_T4i F
HSD 1/2 1/2 1.00 mm² 5001 TP01 49/62 49/62 7212/0090
EGR 56+KW (SILVER)
2/2 2/2 50/62 50/62 20/62 20/62 1/2 1/2 SIG(-VE)
-C_RC06 -C18_T4i -C8_T4i -B163
LSD 1.00 mm² 5002 TP01 1.00 mm² MC03
FROM FUSE FB1 7219/0086 7219/0087 18/62 18/62 1.00 mm² MC03 2/2 2/2 SIG(+VE)
7214/0062
PWR HOLD SUPPLY1.00 mm² 3013 A/14 A/14 1.00 mm² 3013 1/4 1/4
-B152
/2.D5 FROM
VBAT
GROUND 1.00 mm² 6000B B/14 B/14 1.00 mm² 6000B 2/4 2/4
/16.D5 TO
GND CYLINDER#2(GOLD) -MC5:SH1 #2358
0.50 mm² CANL1/4 3/4 3/4 CANL -C20_T4i 0.50 mm² MC03 SCN
TO RC GND
0.50 mm² CANH1/4 4/4 4/4 CANH 7212/0094
-TW2:TW1 ACCELEROMETER 2 (TIN)
HSD 1/2 1/2 1.00 mm² 5003 TP02 33/62 33/62 35/62 35/62 0.75 mm² MC03 SCN
-S4
-B174
LSD 2/2 2/2 1.00 mm² 5004 TP02 34/62 34/62
-MC1:SH1 GROUND -B164
16/62 16/62 1.00 mm² MC04 1/2 1/2 SIG(-VE)
-RES1_T4i
7213/0015 14/62 14/62 1.00 mm² MC04 2/2 2/2 SIG(+VE)
0.75 mm² 5501 A/3
-B153
C B A
CYLINDER#3(GOLD)
0.75 mm² 5502 B/3 -CAN1
727/00002 -C21_T4i -MC6:SH1 #2358
7212/0094 0.50 mm² MC03 SCN
HSD 1/2 1/2 -TW3:TW1 37/62 37/62

0.50 mm² CAN SCN0/5
1.00 mm² 5005 TP03
LSD 2/2 2/2 1.00 mm² 5006 TP03 38/62 38/62

-B165
E
VGT ACTUATOR 56+KW(TIN) E
-C16_T4i
7216/0041 CYLINDER#4(GOLD)
-S7
0.50 mm² CANL3 C/14 C/14 0.50 mm² CANL1/1 0.50 mm² CANL1/5 5/6 5/6 CANL -C22_T4i
D/14 D/14 6/6 6/6 7212/0094
0.50 mm² CANH3 0.50 mm² CANH1/1 0.50 mm² CANH1/5 CANH
-S6 HSD 1/2 1/2 1.00 mm² 5007 TP04 -TW4:TW1 45/62 45/62
IMV (GOLD)
LSD 2/2 2/2 1.00 mm² 5008 TP04 46/62 46/62 -C23_T4i
-MC2:SH1 GROUND -MC3:SH1 GROUND -B166 7212/0098
TO RC GND
GROUND 0.50 mm² 6001E -S8
0.50 mm² 6001E 0.50 mm² 6001E 0.50 mm² CAN SCN1/5 36/62 36/62 0.75 mm² 8004 1/2 1/2 HI
/16.C1 TO
K/14 K/14
40/62 40/62 0.75 mm² 8005 2/2 2/2 LO
CAM POS SENSOR (GOLD) -B154
-C7_T4i
PWR HOLD SUPPLY
FROM FUSE FB2 /2.D5 E/14 E/14 1/6 1/6 7213/0051
1.00 mm²
FROM 3014 1.00 mm² 3014 BATT+
1.00 mm² 6000D F/14 F/14 1.00 mm² 6000D 4/6 4/6 GND SIGNAL 1/3 1/3 1.00 mm² 5009 19/62 19/62
TO RC GND/16.D5 TO
-B175
GROUND
GND 2/3 2/3
-S2 HP FUEL VALVE HPV (TIN)
-B167 VREF 3/3 3/3 1.00 mm² 5027A 1.00 mm² 5027 7/62 7/62 -C17_T4i
7212/0100
52/62 52/62 1.00 mm² 8006 1/2 1/2 HI
1.00 mm² 7003A

D 56/62 56/62 1.00 mm² 8007 2/2 2/2 LO -B155
0.75 mm² 5027B

INTERCOOL OUT TEMP (TIN)
D
-C10_T4i
7212/0092
NTC 1/2 1/2 1.00 mm² 5010 10/62 10/62
GND 2/2 2/2 1.00 mm² 7003B 0.75 mm² 7003 13/62 13/62 ECU EARTH
-B168 HP RAIL PRESS (SILVER)
-S1
1.00 mm² CAN SCN 58/62 58/62 CAN 0V BATT -C14_T4i
7213/0052
-CANLS5
CANL3 0.50 mm² CAN1L 0.50 mm² 50/62 8/62 8/62 1.00 mm² 5022 1/3 1/3 SIG
-CANHS5 9/62 9/62 1.00 mm² 7006 2/3 2/3 GND
CANH3 0.50 mm² CAN1H 0.50 mm² 45/62 29/62 29/62 1.00 mm² 5031 3/3 3/3 +5V
-B156
EXH MAN PRESS P3 (GOLD)
7213/0031 -C9_T4i
-C_RC29 7213/0049
727/00002
A/3 CANH2 0.50 mm² 1/3 1/3 0.75 mm² 5029 31/62 31/62
A
-CAN3
B/3 CANL2 0.50 mm² 2/3 2/3 0.75 mm² 7002B 39/62 39/62
CB
3/3 3/3 0.75 mm² 5014 32/62 32/62

C -B169
-C11_T4i OIL PRESS SWITCH (TIN) C
TMAP (TIN) -C4_T4i 7211/0013
7214/0063 22/62 22/62 0.75 mm² 4403 1/1 1/1
-B157
NTC 1/4 1/4 0.75 mm² 5015 15/62 15/62
GND 2/4 2/4 0.75 mm² 7001 5/62 5/62

SIGNAL 3/4 3/4 0.75 mm² 5016 28/62 28/62
VCC 4/4 4/4

-B170
INTAKE THROTTLE VALVE -C24_T4i COOLANT TEMP (GOLD)

7216/0047
-C6_T4i
1/6 1/6 0.75 mm² 8000 57/62 57/62
MOTOR+ 7212/0093
6/62 6/62 1.00 mm² 4409 1/2 1/2 NTC
MOTOR- 2/6 2/6 0.75 mm² 8001 60/62 60/62 1.00 mm² 7000A 2/2 2/2
GND -B158
SIGNAL 3/6 3/6 0.75 mm² 5011 23/62 23/62
4/6 4/6
GND
B
6/6
VREF 5/6 5/6 0.75 mm² 5028 11/62 11/62
FUEL TEMP SENSOR
B
-B171 -C15_T4i
7212/0097
44/62 44/62 0.75 mm² 5023 1/2 1/2 NTC
43/62 43/62 1.00 mm² 7000 0.75 mm² 7000B 2/2 2/2 GND
EXH TEMP SENSOR(Ni) -C13_T4i
-S5 -B159
7212/0113
HI 1/2 1/2 0.75 mm² 5018 51/62 51/62
LO 2/2 2/2 0.75 mm² 7007 55/62 55/62

-B172
OIL TEMP SENSOR
-C12_T4i
CRANK SPEED SENSOR (Ni) 7212/0095
-C5_T4i
30/62 30/62 1.00 mm² 5024 1/2 1/2 NTC
7213/0034
+5V 1/3 1/3 0.75 mm² 5030 21/62 21/62 1.00 mm² 7000C 2/2 2/2 GND
-B160
SIGNAL 2/3 2/3 0.75 mm² 5019 1/62 1/62
A -B173
GND 3/3 3/3 0.75 mm² 7005 2/62 2/62
-B162
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 41 9813/8950-2 33 - 41
Page Page
33-42 33-43
Figure 615. 1(Part 1 of 2) 2 3 4
CYLINDER#1(GOLD)
F -C19_T4i
7212/0094
HSD 1/2 1/2 1.00 mm² 5001 TP01

EGR 56+KW (SILVER)
2/2 2/2
-C_RC06 -C18_T4i -C8_T4i -B163
LSD 1.00 mm² 5002 TP01
FROM FUSE FB1 7219/0086 7219/0087

7214/0062
PWR HOLD SUPPLY1.00 mm² 3013 A/14 A/14 1.00 mm² 3013 1/4 1/4
/2.D5 FROM
VBAT
GROUND 1.00 mm² 6000B B/14 B/14 1.00 mm² 6000B 2/4 2/4
/16.D5 TO
GND CYLINDER#2(GOLD)
0.50 mm² CANL1/4 3/4 3/4 CANL -C20_T4i
TO RC GND
0.50 mm² CANH1/4 4/4 4/4 CANH 7212/0094
HSD 1/2 1/2 1.00 mm² 5003 TP02
-B174
LSD 2/2 2/2 1.00 mm² 5004 TP02
-MC1:SH1 GROUND -B164
-RES1_T4i
7213/0015
0.75 mm² 5501 A/3
C B A
CYLINDER#3(GOLD)
0.75 mm² 5502 B/3 -CAN1
727/00002 -C21_T4i
7212/0094
HSD 1/2 1/2
0.50 mm² CAN SCN0/5

1.00 mm² 5005 TP03
LSD 2/2 2/2 1.00 mm² 5006 TP03

-B165
E
VGT ACTUATOR 56+KW(TIN)
-C16_T4i
7216/0041 CYLINDER#4(GOLD)
-S7
0.50 mm² CANL3 C/14 C/14 0.50 mm² CANL1/1 0.50 mm² CANL1/5 5/6 5/6 CANL -C22_T4i
D/14 D/14 6/6 6/6 7212/0094
0.50 mm² CANH3 0.50 mm² CANH1/1 0.50 mm² CANH1/5 CANH
-S6 HSD 1/2 1/2 1.00 mm² 5007 TP04
LSD 2/2 2/2 1.00 mm² 5008 TP04

-MC2:SH1 GROUND -MC3:SH1 GROUND -B166
TO RC GND
GROUND 0.50 mm² 6001E -S8
0.50 mm² 6001E 0.50 mm² 6001E 0.50 mm² CAN SCN1/5
/16.C1 TO
K/14 K/14
CAM POS SENSOR (GOLD)
-C7_T4i
PWR HOLD SUPPLY
FROM FUSE FB2 /2.D5 E/14 E/14 1/6 1/6 7213/0051
1.00 mm²
FROM 3014 1.00 mm² 3014 BATT+
1.00 mm² 6000D F/14 F/14 1.00 mm² 6000D 4/6 4/6 GND SIGNAL 1/3 1/3 1.00 mm² 5009
TO RC GND/16.D5 TO
-B175
GROUND
GND 2/3 2/3
-B167 VREF 3/3 3/3 1.00 mm² 5027A
1.00 mm² 7003A

D INTERCOOL OUT TEMP (TIN)
-C10_T4i
7212/0092
NTC 1/2 1/2
GND 2/2 2/2 1.00 mm² 7003B

-B168 -S1
1.00 mm² CAN SCN
-CANLS5
CANL3 0.50 mm² CAN1L 0.50 mm²
Page 33-43
-CANHS5
CANH3 0.50 mm² CAN1H 0.50 mm²
EXH MAN PRESS P3 (GOLD)

7213/0031 -C9_T4i
-C_RC29 7213/0049
727/00002
A/3 CANH2 0.50 mm² 1/3 1/3

A
-CAN3
B/3 CANL2 0.50 mm² 2/3 2/3

CB
3/3 3/3
C -B169
TMAP (TIN) -C4_T4i

7214/0063
NTC 1/4 1/4
GND 2/4 2/4

SIGNAL 3/4 3/4
VCC 4/4 4/4

-B170
INTAKE THROTTLE VALVE -C24_T4i

7216/0047
1/6 1/6
MOTOR+
MOTOR- 2/6 2/6
SIGNAL 3/6 3/6
4/6 4/6
GND
B
6/6 5/6 5/6
VREF
-B171
EXH TEMP SENSOR(Ni) -C13_T4i

7212/0113
HI 1/2 1/2 0.75 mm²
LO 2/2 2/2 0.75 mm²

-B172
CRANK SPEED SENSOR (Ni)

-C5_T4i
7213/0034
+5V 1/3 1/3 0.75 mm²
SIGNAL 2/3 2/3 0.75 mm²
A -B173
GND 3/3 3/3 0.75 mm²
1 2 3 4
33 - 42 9813/8950-2 33 - 42
Page Page
33-42 33-43
Figure 615. (Part

5 2 of 2) 6 7 8
ENGINE ECU (BLACK)

-C1_T4i
ACCELEROMETER 1 (TIN)
-TW1:TW1
7219/0075
-C2_T4i F
1.00 mm² 5001 TP01 49/62 49/62 7212/0090
1.00 mm² 5002 TP01 50/62 50/62 20/62 20/62 1.00 mm² MC03 1/2 1/2 SIG(-VE)
18/62 18/62 1.00 mm² MC03 2/2 2/2 SIG(+VE)
-B152
-MC5:SH1 #2358
0.50 mm² MC03 SCN
-TW2:TW1 ACCELEROMETER 2 (TIN)

1.00 mm² 5003 TP02 33/62 33/62 35/62 35/62 0.75 mm² MC03 SCN
-S4
1.00 mm² 5004 TP02 34/62 34/62
16/62 16/62 1.00 mm² MC04 1/2 1/2 SIG(-VE)
14/62 14/62 1.00 mm² MC04 2/2 2/2 SIG(+VE)
-B153
-MC6:SH1 #2358
0.50 mm² MC03 SCN
1.00 mm² 5005 TP03 -TW3:TW1 37/62 37/62
1.00 mm² 5006 TP03 38/62 38/62
1.00 mm² 5007 TP04 -TW4:TW1 45/62 45/62

IMV (GOLD)
1.00 mm² 5008 TP04 46/62 46/62 -C23_T4i
7212/0098
36/62 36/62 0.75 mm² 8004 1/2 1/2 HI

40/62 40/62 0.75 mm² 8005 2/2 2/2 LO
-B154
19/62 19/62
-S2 HP FUEL VALVE HPV (TIN)

1.00 mm² 5027 7/62 7/62 -C17_T4i
7212/0100
52/62 52/62 1.00 mm² 8006 1/2 1/2 HI
1.00 mm² 7003A
56/62 56/62 1.00 mm² 8007 2/2 2/2 LO -B155

0.75 mm² 5027B
1.00 mm² 5010 10/62 10/62

0.75 mm² 7003 13/62 13/62 ECU EARTH
HP RAIL PRESS (SILVER)
-S1
58/62 58/62 CAN 0V BATT -C14_T4i
7213/0052
50/62 8/62 8/62 1.00 mm² 5022 1/3 1/3 SIG
Page 33-42
9/62 9/62 1.00 mm² 7006 2/3 2/3 GND

45/62 29/62 29/62 1.00 mm² 5031 3/3 3/3 +5V
-B156
0.75 mm² 5029 31/62 31/62

0.75 mm² 7002B 39/62 39/62
0.75 mm² 5014 32/62 32/62
-C11_T4i OIL PRESS SWITCH (TIN) C

7211/0013
22/62 22/62 0.75 mm² 4403 1/1 1/1
-B157
0.75 mm² 5015 15/62 15/62
0.75 mm² 7001 5/62 5/62
0.75 mm² 5016 28/62 28/62
COOLANT TEMP (GOLD)

-C6_T4i
0.75 mm² 8000 57/62 57/62 7212/0093
6/62 6/62 1.00 mm² 4409 1/2 1/2 NTC
0.75 mm² 8001 60/62 60/62 1.00 mm² 7000A 2/2 2/2
GND -B158
0.75 mm² 5011 23/62 23/62
0.75 mm² 5028 11/62 11/62

FUEL TEMP SENSOR
B
-C15_T4i
7212/0097
44/62 44/62 0.75 mm² 5023 1/2 1/2 NTC
43/62 43/62 1.00 mm² 7000 0.75 mm² 7000B 2/2 2/2 GND
-S5 -B159
0.75 mm² 5018 51/62 51/62
0.75 mm² 7007 55/62 55/62
OIL TEMP SENSOR

-C12_T4i
7212/0095
30/62 30/62 1.00 mm² 5024 1/2 1/2 NTC
0.75 mm² 5030 21/62 21/62 1.00 mm² 7000C 2/2 2/2 GND
-B160
0.75 mm² 5019 1/62 1/62
0.75 mm² 7005 2/62 2/62
-B162
A
400/M1730-6
5 6 7 8
33 - 43 9813/8950-2 33 - 43
33 - 44 9813/8950-2 33 - 44
Page 33-46 Figure 616. Engine ECU Circuit

(400/M1730 Sheet 9 of 16) Page 33-47
1 2 3 4 5 6 7 8
F
ENGINE ECU
F
ENGINE
DIESEL MAX
-C_RC37
FROM FUSE FC8 7219/0076 CAN
0.75 mm² 133C 44/62 44/62 IGN SENSE
/3.C7 FROM
FROM START INTERLOCK RLY

0.75 mm² 8020 39/62 39/62 START SW
/2.B5 FROM
FROM START RELAY

START RELAY GND 1.00 mm² 8006 28/62 28/62
/2.A5 FROM
START RELAY
E
E
TO FUEL PUMP RELAY
/2.C7 TO
0.50 mm² 8022 40/62 40/62 FUEL PUMP
FUEL PUMP
TMAF
WATER IN FUEL INLET AIR TEMP 18/62 18/62 0.75 mm² 4028 2/6 2/4 VOUT TEMP
B/3
-C_RC20
FROM FUSE FB5 7213/0031 B/3 0.75 mm² 4000 55/62 55/62 WIF
/2.C5 FROM 1.00 mm² 3019 A/3 A/3 -B29 TMAP FEED 52/62 52/62 0.75 mm² 4027 3/6 3/4 SUPPLY
C/3 C/3 1.00 mm² 6000F GROUND TO RC GND -B27

TO
/16.C5
GND 38/62 38/62 0.75 mm² 4026 4/6 4/4 GND

FROM POWER HOLD RELAY POWER HOLD-ECU O/P 1.00 mm² 8007 2/62 2/62 POWER HOLD
/2.D2 FROM
D FROM FUSE FB3

/2.C5 FROM ECU FEEDS 1.00 mm² 3015A 57/62 57/62 FEED #1 TMAF FREQ 22/62 22/62 0.75 mm² 4025 5/6 5/4 VOUT MAF D
-S_SRC35
1.00 mm² 3015C 60/62 60/62 FEED #2
1.00 mm² 3015D 53/62 53/62 FEED #3

FOOT THROTTLE
7216/0059
-C_RC31
1.00 mm² 3015E 49/62 49/62 FEED #4 TRACK 1 FEED 21/62 21/62 0.75 mm² 4009 C/6 C/6
TRACK 1 SIGNAL 17/62 17/62 0.75 mm² 4010 A/6 A/6
FROM GRID HEATER RELAY #2581 48/62 48/62 GRID HEATER

0.75 mm² 6010 TRACK 1 RETURN 14/62 14/62 0.75 mm² 4011 B/6 B/6
C /1.A4 FROM
15/62 15/62 0.75 mm² 4012 D/6 D/6

C
TRACK 2 FEED
TRACK 2 SIGNAL 29/62 29/62 0.75 mm² 4013 E/6 E/6
TRACK 2 RETURN 19/62 19/62 0.75 mm² 4014 F/6 F/6 -B26
B -S_SRC27
GND 58/62 58/62 2.00 mm² 6000RA 4.00 mm² 6000R GROUND TO RC GND B
TO
/16.A3
GND 59/62 59/62 2.00 mm² 6000RB
GND 61/62 61/62 2.00 mm² 6000RC
GND 62/62 62/62 2.00 mm² 6000RD
/10.E1
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 45 9813/8950-2 33 - 45
Page Page
33-46 33-47
Figure 616. 1(Part 1 of 2) 2 3 4
ENGINE ECU
F
ENGINE
DIESEL MAX
-C_RC37
FROM FUSE FC8 7219/0076 CAN
0.75 mm² 133C 44/62 44/62 IGN SENSE
/3.C7 FROM
FROM START INTERLOCK RLY

0.75 mm² 8020 39/62 39/62 START SW
/2.B5 FROM
FROM START RELAY

START RELAY GND 1.00 mm² 8006 28/62 28/62
/2.A5 FROM
START RELAY
E
TO FUEL PUMP RELAY
/2.C7 TO
0.50 mm² 8022 40/62 40/62 FUEL PUMP
FUEL PUMP
WATER IN FUEL INLET AIR TEMP
B/3
-C_RC20
FROM FUSE FB5 7213/0031 B/3 0.75 mm² 4000 55/62 55/62 WIF
/2.C5 FROM 1.00 mm² 3019 A/3 A/3 -B29 TMAP FEED
C/3 C/3 1.00 mm² 6000F GROUND TO RC GND

TO
/16.C5
FROM POWER HOLD RELAY POWER HOLD-ECU O/P 1.00 mm² 8007 2/62 2/62 POWER HOLD
/2.D2 FROM
D FROM FUSE FB3

/2.C5 FROM ECU FEEDS 1.00 mm² 3015A 57/62 57/62 FEED #1 TMAF FREQ
-S_SRC35
1.00 mm² 3015C 60/62 60/62 FEED #2
1.00 mm² 3015D 53/62 53/62 FEED #3
Page 33-47
1.00 mm² 3015E 49/62 49/62 FEED #4 TRACK 1 FEED
TRACK 1 SIGNAL
FROM GRID HEATER RELAY #2581 48/62 48/62 GRID HEATER

0.75 mm² 6010 TRACK 1 RETURN
C /1.A4 FROM
TRACK 2 FEED
TRACK 2 SIGNAL
TRACK 2 RETURN
/10.E1
1 2 3 4
33 - 46 9813/8950-2 33 - 46
Page Page
33-46 33-47
Figure 616. (Part

5 2 of 2) 6 7 8
F
ENGINE ECU
DIESEL MAX
TMAF
INLET AIR TEMP 18/62 18/62 0.75 mm² 4028 2/6 2/4 VOUT TEMP
TMAP FEED 52/62 52/62 0.75 mm² 4027 3/6 3/4 SUPPLY
-B27
GND 38/62 38/62 0.75 mm² 4026 4/6 4/4 GND
TMAF FREQ 22/62 22/62 0.75 mm² 4025 5/6 5/4 VOUT MAF D
Page 33-46
FOOT THROTTLE
7216/0059
-C_RC31
TRACK 1 FEED 21/62 21/62 0.75 mm² 4009 C/6 C/6
TRACK 1 SIGNAL 17/62 17/62 0.75 mm² 4010 A/6 A/6
TRACK 1 RETURN 14/62 14/62 0.75 mm² 4011 B/6 B/6
15/62 15/62 0.75 mm² 4012 D/6 D/6

C
TRACK 2 FEED
TRACK 2 SIGNAL 29/62 29/62 0.75 mm² 4013 E/6 E/6
TRACK 2 RETURN 19/62 19/62 0.75 mm² 4014 F/6 F/6 -B26
-S_SRC27
GND 58/62 58/62 2.00 mm² 6000RA 4.00 mm² 6000R GROUND TO RC GND B
TO
/16.A3
GND 59/62 59/62 2.00 mm² 6000RB
GND 61/62 61/62 2.00 mm² 6000RC
GND 62/62 62/62 2.00 mm² 6000RD
400/M1730-6
5 6 7 8
33 - 47 9813/8950-2 33 - 47
33 - 48 9813/8950-2 33 - 48
Page 33-50 Figure 617. CANbus Circuit

(400/M1730 Sheet 10 of 16) Page 33-51
1 2 3 4 5 6 7 8
0.50 mm² CANSHD4 1/1 CUTEND

CUT END -C_RCCUTEND3
0.50 mm² CANLS4 TO DRIVE INHIBIT ECU

F /13.B3
TO
ENGINE ECU F
0.50 mm² CANHS4 TO DRIVE INHIBIT ECU
TO
/13.B3
-MC9:SH1 DIAGNOSTIC
7219/0076
-MC10:SH1 -MC8:SH1 -CANHS3
GROUND
27/62-C_RC37 -MC3:SH1 -CANHS1 FROM FUSE FA7
27/62 0.50 mm² CANHS1 0.50 mm² CANHS3 0.50 mm² CANHS5 0.50 mm² CANHS6 C/9 C/9 B/9 B/9 1.00 mm² 300A
CAN A H FROM
/2.E5
-CANHS2
23/62 -CANLS1 -CANLS3
CAN A L 23/62 0.50 mm² CANLS1 0.50 mm² CANLS3 0.50 mm² CANLS5 0.50 mm² CANLS6 D/9 D/9 TO RC GND
GROUND
-CANLS2 A/9 A/9 1.00 mm² 6001C
/16.C1
CUT END GROUND -CANSHD1 GROUND GROUND -CANSHD3 -MC4:SH1 GROUND
TO
CUTEND 1/1 0.50 mm² CANS1 0.50 mm² CANSHD3 0.50 mm² CANSHD5 0.50 mm² CANSHD6 E/9 E/9
-CANSHD2
-C_RCCUTEND1
0.50 mm² CANSHD7

0.50 mm² CANHS7
0.50 mm² CANLS7

CANSHD2
0.50 mm² 6001J GROUND TO RC GND

-MC2:SH1
TO
/16.C1
GROUND
-C_RCCUTEND2
0.50 mm² CANHS2

0.50 mm² CANLS2
1/1 0.50 mm²
/9.A4 7219/0075
-C_RC03 -C_OP24 -CANSHD2
E 12/62 12/62 0.50 mm² CANSHD7
-MC2:SH1
0.50 mm² CANSHD8
-TW1:TW1 TO LIVELINK
/14.B4 E
CUT END
TO
-C_RC03 -C_OP24 -CANLS2

TO LIVELINK
CUTEND
34/62 34/62 0.50 mm² CANLS7 0.50 mm² CANLS8 CAN L

7213/0031 TO
/14.B4
-CANHS2
A/3
B/3
-C_RC03 -C_OP24
35/62 35/62 0.50 mm² CANHS7 0.50 mm² CANHS8 CAN H TO LIVELINK
C B A
TO
/14.B4
-C_RC14
727/00002
0.50 mm² CANSHD4

0.50 mm² CANHS4
0.50 mm² CANLS4

-CAN1
-MC3:SH1
-C_OPCUTEND1
INSTRUMENT PANEL
CUT END
-CANSHD1 NO CONNECTOR1/1
0.50 mm² CANSHD1
LEAD CUT
-MC4:SH1
D 0.50 mm² CANLS1 7/12 7/12 CAN L
-CANLS1 D
0.50 mm² CANHS1 1/12 1/12 CAN H
-CANHS1
CANH S6
CANS D6
CANL S6
0.50 mm²
0.50 mm²
0.50 mm²
C
C
-C_OPCUTEND3
CUT END
0.50 mm² CANS D6 1/1 CUTEND
-MC6:SH1
-C_OP12
727/00002
7213/0031
-CAN2
BC
0.50 mm² CANL S6
B/3
0.50 mm² CANH S6
A/3
A
B
B
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 49 9813/8950-2 33 - 49
Page Page
33-50 33-51
Figure 617. 1(Part 1 of 2) 2 3 4
0.50 mm² CANSHD4 1/1 CUTEND

CUT END -C_RCCUTEND3
0.50 mm² CANLS4 TO DRIVE INHIBIT ECU

F /13.B3
TO
ENGINE ECU
0.50 mm² CANHS4 TO DRIVE INHIBIT ECU
TO
/13.B3
7219/0076
-MC9:SH1
-MC10:SH1 -MC8:SH1 -CANHS3
GROUND
27/62-C_RC37 -MC3:SH1 -CANHS1
27/62 0.50 mm² CANHS1 0.50 mm² CANHS3 0.50 mm² CANHS5
CAN A H
-CANHS2
23/62 -CANLS1 -CANLS3
23/62 0.50 mm² CANLS1 0.50 mm² CANLS3 0.50 mm² CANLS5
CAN A L
-CANLS2
CUT END GROUND -CANSHD1 GROUND GROUND -CANSHD3
CUTEND 1/1 0.50 mm² CANS1 0.50 mm² CANSHD3 0.50 mm² CANSHD5
-CANSHD2
-C_RCCUTEND1
0.50 mm² CANSHD7

0.50 mm² CANHS7
0.50 mm² CANLS7

CANSHD2
-MC2:SH1
GROUND
-C_RCCUTEND2
0.50 mm² CANHS2

0.50 mm² CANLS2
1/1 0.50 mm²
/9.A4 7219/0075
-C_RC03 -C_OP24
E 12/62 12/62
CUT END -C_RC03 -C_OP24

CUTEND
7213/0031 34/62 34/62
A/3
B/3
-C_RC03 -C_OP24
35/62 35/62
C B A
-C_RC14
727/00002
-CAN1
Page 33-51
C
1 2 3 4
33 - 50 9813/8950-2 33 - 50
Page Page
33-50 33-51
Figure 617. (Part

5 2 of 2) 6 7 8
-C_RCCUTEND3
TO DRIVE INHIBIT ECU

TO
/13.B3
TO DRIVE INHIBIT ECU
F
TO
/13.B3
DIAGNOSTIC
FROM FUSE FA7

0.50 mm² CANHS6 C/9 C/9 B/9 B/9 1.00 mm² 300A FROM
/2.E5
0.50 mm² CANLS6 D/9 D/9 TO RC GND

GROUND
A/9 A/9 1.00 mm² 6001C
-MC4:SH1 GROUND
TO
/16.C1
0.50 mm² CANSHD6 E/9 E/9
0.50 mm² 6001J GROUND TO RC GND

TO
/16.C1
7219/0075
-C_OP24 -CANSHD2
12/62 0.50 mm² CANSHD7
-MC2:SH1
0.50 mm² CANSHD8
-TW1:TW1 TO LIVELINK
/14.B4 E
TO
-C_OP24 -CANLS2
34/62 0.50 mm² CANLS7 0.50 mm² CANLS8 CAN L TO LIVELINK
TO
/14.B4
-C_OP24 -CANHS2
35/62 0.50 mm² CANHS7 0.50 mm² CANHS8 CAN H TO LIVELINK
TO
/14.B4
0.50 mm² CANSHD4
0.50 mm² CANHS4
0.50 mm² CANLS4

-MC3:SH1
-C_OPCUTEND1
INSTRUMENT PANEL
CUT END
-CANSHD1 NO CONNECTOR1/1
0.50 mm² CANSHD1
LEAD CUT
-MC4:SH1
0.50 mm² CANLS1 7/12 7/12 CAN L
-CANLS1 D
0.50 mm² CANHS1 1/12 1/12 CAN H
-CANHS1
CANH S6
CANS D6
CANL S6
0.50 mm²
0.50 mm²
0.50 mm²
Page 33-50
-C_OPCUTEND3
CUT END
0.50 mm² CANS D6 1/1 CUTEND
-MC6:SH1
-C_OP12
727/00002
7213/0031
-CAN2
BC
0.50 mm² CANL S6

B/3
0.50 mm² CANH S6
A/3
A
400/M1730-6
5 6 7 8
33 - 51 9813/8950-2 33 - 51
33 - 52 9813/8950-2 33 - 52
Page 33-54 Figure 618. HVAC Circuit

(400/M1730 Sheet 11 of 16) Page 33-55
1 2 3 4 5 6 7 8
F
HEATER BLOWER F
HEATER MODE SWITCH 400/M9929
-R19 7214/0006
716/G3600 MIN -C_C19
HEATER BLOWER RELAY 4/5 L/5 3.00 mm² 8900 B/4 B/4 MIN TO CAB GND
4 7235/0006
-C_C20 A/4 A/4 3.00 mm² 6010N
+12V MAX GND TO
/16.F5
1 2 B/5 1/5 3/5 H/5 C/4 C/4
4.00 mm² 3000C 4.00 mm² 1860 3.00 mm² 8901 MAX
TO CAB GND MED
3 5 5/5 M/5 D/4 D/4
0.75 mm² 6010M TO
/16.F5 3.00 mm² 8902 MED
-RB C011
7241/0003
HEATER/IGN-2 RELAY
E
E
133C
0.75 mm²
FROM FUSE FC8 IGN 0.75 mm² 133B

-S004
/3.C7 FROM
133A
-R18
D
0.75 mm²
716/G3600
IGNITION RELAY 2 D
9
4.00 mm² 3000C 6 7 3.00 mm² 1805
8 10 0.75 mm² 6010A TO CAB GND

TO
/16.F5
FROM FB9 6.00 mm² 3000 3.00 mm² 3000A -RB C011
/2.B5 FROM
7241/0003
-S002 HEATER/IGN-2 RELAY
C
C
_AC BLOWER SWITCH AC UNIT

7216/0041
2/5 C/5 2.00 mm² 8903 -C_C26
2.00 mm² 8903 4/6 4/6 6/6 6/6 2.00 mm² 6010P TO CAB GND
TO
/16.F5
BINARY SWITCH AC COMPRESSOR

7212/0030
7212/0070 701/80231 -C_RC07 TO RC GND
-C_C27 1 2 1ON/OFF
2 GROUND
B 5/6 5/6 1.00 mm² 8909
A/2
B/2 1.00 mm² 8908
F/14 F/14
2.00 mm² 8908 1/2 2/2 2.00 mm² 6000U TO
/16.C5
7235/0006 -C_C01 -C_RC44 B
-C_C25 MAX 3/5 H/5 2.00 mm² 8905 1/6 1/6 MAX
3.00 mm² 1805 B/5 1/5
MIN 4/5 L/5 2.00 mm² 8906 3/6 3/6 MIN
MED 5/5 M/5 2.00 mm² 8907 2/6 2/6 MED
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 53 9813/8950-2 33 - 53
Page Page
33-54 33-55
Figure 618. 1(Part 1 of 2) 2 3 4
F
HEATER MODE SWITC
-R19
716/G3600
HEATER BLOWER RELAY
4 7235/0006
-C_C20 +12V
4.00 mm² 3000C 1 2 4.00 mm² 1860 B/5 1/5
TO CAB GND
3 5 0.75 mm² 6010M TO
/16.F5
-RB C011
7241/0003
HEATER/IGN-2 RELAY
E
133C
0.75 mm²
FROM FUSE FC8 IGN 0.75 mm² 133B

-S004
/3.C7 FROM
133A
-R18
D
0.75 mm²
716/G3600
IGNITION RELAY 2
9
4.00 mm² 3000C 6 7
8 10 0.75 mm² 6010A TO CAB GND

TO
/16.F5
FROM FB9 6.00 mm² 3000 3.00 mm² 3000A -RB C011
/2.B5 FROM
7241/0003
-S002 HEATER/IGN-2 RELAY
Page 33-55
C
_AC BLOWER SWITCH AC UNIT

7216/0041
2/5 C/5 2.00 mm² 8903 -C_C26
2.00 mm² 8903 4/6 4/6
B
7235/0006
-C_C25 MAX 3/5 H/5 2.00 mm² 8905 1/6 1/6 MAX
3.00 mm² 1805 B/5 1/5
MIN 4/5 L/5 2.00 mm² 8906 3/6 3/6 MIN
MED 5/5 M/5 2.00 mm² 8907 2/6 2/6 MED
1 2 3 4
33 - 54 9813/8950-2 33 - 54
Page Page
33-54 33-55
Figure 618. (Part

5 2 of 2) 6 7 8
HEATER BLOWER F
HEATER MODE SWITCH 400/M9929
7214/0006
MIN -C_C19
4/5 L/5 3.00 mm² 8900 B/4 B/4 MIN TO CAB GND
7235/0006
-C_C20 A/4 A/4 3.00 mm² 6010N
+12V MAX GND TO
/16.F5
B/5 1/5 3/5 H/5 3.00 mm² 8901 C/4 C/4 MAX
MED
5/5 M/5 3.00 mm² 8902 D/4 D/4 MED
3.00 mm² 1805
TO CAB GND
/16.F5
Page 33-54
AC UNIT
6/6 6/6 2.00 mm² 6010P TO CAB GND

TO
/16.F5
BINARY SWITCH AC COMPRESSOR

7212/0030
7212/0070 701/80231 -C_RC07 TO RC GND
-C_C27 1 2 1ON/OFF
2 GROUND
5/6 5/6 1.00 mm² 8909 B/2 1.00 mm² 8908 2.00 mm² 8908 1/2 2/2 2.00 mm² 6000U
A/2 F/14 F/14
TO
/16.C5
-C_C01 -C_RC44 B
MAX
MIN
MED
400/M1730-6
5 6 7 8
33 - 55 9813/8950-2 33 - 55
33 - 56 9813/8950-2 33 - 56
Page 33-58 Figure 619. Speakers Circuit

(400/M1730 Sheet 12 of 16) Page 33-59
1 2 3 4 5 6 7 8
F
F
-L1
700/20500
INTERIOR LIGHT
7201/0304 7201/0304
-C_C07 1 ON 2 -C_C08
0.75 mm² 302B 1/1 1/1 0.75 mm² 6010C TO
/16.F5 TO CAB GND
3
DOOR
FROM FUSE FA8 1.00 mm² 302 0.75 mm² 302A

/2.E5 FROM
-S003 -A4
717/K4986
RADIO
E
7238/0003 E
-C_C03 A2 MUTE
SPEED
SIGNAL A1
0.75 mm² 302A 4/8 A4 BATT +
A3 REAR SPEAKER RH
-S005
N/C
FROM FUSE FC9 LIGHT SPLICE ILL 0.75 mm² 830F 0.75 mm² 830F 0.75 mm² 830FA 6/8 717/20020
/6.B3
AUTO
FROM
H/14 H/14 A6 ILLUM ANTENNA A5

FROM FUSE FC1
-C_RC44 -C_C01 /16.F5 TO 6010G 1.00 mm² 8/8 A8 GND IGN A7 7/8 1.00 mm² 106F FROM
/3.E7
TO CAB GND 7231/0008 -C_C17 -C_C18 7231/0011
2/8 B2 RR(-) RR(+)
B1 1/8 0.75 mm² 4503 1/1 + - 1/1
B4 RF(-) RF(+)
B3 7238/0002
REAR SPEAKER LH
B6 LF(-) LF(+)
B5 -C_C04 -C_C05 -C_C06
4504
8/8 B8 B7 7/8 0.75 mm² 4501 1/1 1/1
LR(-) LR(+)
+ - 7231/0011
0.75 mm²
7231/0008
0.50 mm² 830C
0.50 mm² 830E
717/20020
D 0.75 mm² 4502

D
FRONT WIPER MOTOR

7214/0070 400/M0055
-C_C12
FROM FUSE FA2 1.00 mm² 1804C 4/4 4
/2.F5 FROM
FRONT WIPER WASHER SWITCH

701/E0003 3
3/4
-
1.00 mm² 8557
C 7219/0013
w
-C_C11 C
8/10 8 7 7/10 0.75 mm² 6010H TO CAB GND
TO
/16.F5
+
1 1/10 1.00 mm² 8556 1.00 mm² 8556 2/4 2 15H
1.00 mm² 8557 2/10 2 1/4 1

3 FROM FUSE FA2
3/10 1.00 mm² 1804A 0.47F
FROM
/2.F5
WASHER PUMP TO CAB GND
2.00 mm² 6010K
7232/0028 331/44573
TO
/16.F5
5
-S009 -C_RC13
6 6/10 1/2 1 2 2/2 GROUND TO RC GND
0.50 mm² 8558 0.50 mm² 8558A
G/14 G/14
0.50 mm² 8558A M 0.50 mm² 6000S TO
/16.C5
-C_C01 -C_RC44
REAR WIPER MOTOR

7214/0070 400/M0055
FROM FUSE FA2 -C_C29 4
1.00 mm² 1804F 4/4
/2.F5 FROM
REAR WIPER WASHER SWITCH

701/E0003 1.00 mm² 8559 3/4 3
-
7219/0013
B
w
-C_C28
0.50 mm² 830E 8/10 8 7 7/10 0.50 mm² 6010F TO CAB GND B
TO
/16.F5
+
1 1/10 1.00 mm² 8560 1.00 mm² 8560 2/4 2 15H
1.00 mm² 8559 2/10 2 1.00 mm² 6010E 1/4 1

3 FROM FUSE FA2
3/10 1.00 mm² 1804E 0.47F
FROM
/2.F5
5 TO CAB GND
TO
/16.F5
6 6/10 0.50 mm² 8558C
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 57 9813/8950-2 33 - 57
Page Page
33-58 33-59
Figure 619. 1(Part 1 of 2) 2 3 4
7201/0304
-C_C07
0.75 mm² 302B
FROM FUSE FA8 1.00 mm² 302 0.75 mm² 302A

/2.E5 FROM
-S003
E
7238/0003
-C_C03
0.75 mm² 302A
FROM FUSE FC9 LIGHT SPLICE ILL -S005
0.75 mm² 830F 0.75 mm² 830F 0.75 mm² 830FA
/6.B3 FROM
H/14 H/14
-C_RC44 -C_C01 /16.F5 TO 6010G 1.00 mm²
TO CAB GND
0.50 mm² 830C

0.50 mm² 830E
Page 33-59
FRONT WIPER WASHER SWITCH
701/E0003
C 7219/0013
-C_C11
8/10 8 7 7/10 0.75 mm² 6010H
1 1/10 1.00 mm² 8556
1.00 mm² 8557 2/10 2
3 3/10 1.00 mm² 1804A
5
6 -S009
6/10 0.50 mm² 8558 0.50 mm² 8558A
G/14 G/14
-C_C01
REAR WIPER WASHER SWITCH

701/E0003
7219/0013
B -C_C28
8 7 TO CAB GND
0.50 mm² 830E 8/10 7/10 0.50 mm² 6010F TO
/16.F5
1 1/10 1.00 mm² 8560
1.00 mm² 8559 2/10 2
3 FROM FUSE FA2
3/10 1.00 mm² 1804E FROM
/2.F5
5
6 6/10 0.50 mm² 8558C
1 2 3 4
33 - 58 9813/8950-2 33 - 58
Page Page
33-58 33-59
Figure 619. (Part

5 2 of 2) 6 7 8
F
-L1
700/20500
INTERIOR LIGHT
7201/0304 7201/0304
-C_C07 1 ON 2 -C_C08
1/1 1/1 0.75 mm² 6010C TO
/16.F5 TO CAB GND
3
DOOR
-A4
717/K4986
RADIO
7238/0003 E
-C_C03 A2 MUTE
SPEED
SIGNAL A1
4/8 A4 BATT + N/C A3 REAR SPEAKER RH
6/8 AUTO 717/20020
A6 ILLUM ANTENNA A5
1.00 mm² 8/8 7/8 1.00 mm² 106F FROM FUSE FC1
A8 GND IGN A7 FROM
/3.E7
7231/0008 -C_C17 -C_C18 7231/0011
2/8 B2 RR(-) RR(+)
B1 1/8 0.75 mm² 4503 1/1 + - 1/1
B4 RF(-) RF(+)
B3 7238/0002
REAR SPEAKER LH
B6 LF(-) LF(+)
B5 -C_C04 -C_C05 -C_C06
4504
8/8 B8 B7 7/8 0.75 mm² 4501 1/1 1/1
LR(-) LR(+)
+ - 7231/0011
0.75 mm²
7231/0008
717/20020
0.75 mm² 4502

D
Page 33-58
FRONT WIPER MOTOR

7214/0070 400/M0055
-C_C12
FROM FUSE FA2 1.00 mm² 1804C 4/4 4
/2.F5 FROM
3
3/4
-
1.00 mm² 8557

w
TO CAB GND C
TO
/16.F5
+
1.00 mm² 8556 2/4 2 15H
1/4 1
FROM FUSE FA2 0.47F
FROM
/2.F5
WASHER PUMP TO CAB GND
2.00 mm² 6010K
7232/0028 331/44573
TO
/16.F5
-C_RC13
1/2 1 2 2/2 GROUND TO RC GND
G/14 G/14
0.50 mm² 8558A M 0.50 mm² 6000S TO
/16.C5
-C_C01 -C_RC44
REAR WIPER MOTOR

7214/0070 400/M0055
FROM FUSE FA2 -C_C29 4
1.00 mm² 1804F 4/4
/2.F5 FROM
1.00 mm² 8559 3/4 3

-
w
TO CAB GND B
TO
/16.F5
+
1.00 mm² 8560 2/4 2 15H
1.00 mm² 6010E 1/4 1

FROM FUSE FA2 0.47F
FROM
/2.F5
TO CAB GND
TO
/16.F5
400/M1730-6
5 6 7 8
33 - 59 9813/8950-2 33 - 59
33 - 60 9813/8950-2 33 - 60
Page 33-62 Figure 620. F n R Circuit

(400/M1730 Sheet 13 of 16) Page 33-63
1 2 3 4 5 6 7 8
400/G8164
R/H COLUMN SWITCH
FROM FUSE FC4 -C_RC03 -C_OP24 7219/0005 -C_OP08 -C_OP08 7219/0005 -C_OP24 -C_RC03 -S_SRC36
1.00 mm² 1002A 4/62 4/62 1.00 mm² 1002A 8/14 9 8 9/14 1.00 mm² 820 13/62 13/62 1.00 mm² 820 1.00 mm² 820A TO HORN RELAY
F /3.D7 /3.C5
FROM TO
F
-SW05 1.00 mm² 812 1.00 mm² 812B
0.75 mm² 820C -S_SRC25
-C_OP24 -C_RC03
1.00 mm² 812A 15/62 15/62 0.75 mm² 812A TO FWD DIODE
TO
/13.E1
3 3/6 1.00 mm² 811A -C_OP24 -C_RC03
0.75 mm² 810A 23/62 23/62 0.75 mm² 810A TO
/2.A6
4 4/6 1.00 mm² 810 TO START INTERLOCK RLY
7216/0001 -S003 704/50132
-C_OP09 Neutral -D2 TO INSTRUMENT PANEL
FROM FUSE FC3 1.00 mm² 1707F 1/6 1 0.75 mm² 810C 1
/3.D7 FROM
2 /7.E2
TO
2 2/6 1.00 mm² 812A 0.75 mm² 810D

3
-C_RC03 -C_OP24
400/G8163 TO DIECU:15 0.75 mm² 810EE 52/62 52/62 0.50 mm² 810DD -C_OP18
LH COLUMN SWITCH /13.C3 TO
7233/0015
-C_OP24 -C_RC03 -S_SRC26
-S011 1.00 mm² 811 16/62 16/62 1.00 mm² 811 1.00 mm² 811A
-D2
704/50132 TO PROXIMITY SWITCH TO REV DIODE
FR DIODE 0.75 mm² 8125 TO
/7.C5 0.75 mm² 811B TO
/13.E1
FROM FWD 0.75 mm² 812A 1 0.75 mm² 811C TO CAMERA POWER BOX
/13.F6 /7.A2
E
FROM TO
2 0.50 mm² 8125A

FROM REV
/13.E6 FROM 0.75 mm² 811B 3
E
-C_RC38 0.75 mm² 812B
7233/0015
FR DIODE
-CM04-10
728/G5771
Drive Inhibit Ecu
20 WAY MOLEX MX150 KEY B
-C_RC45 GROUND TO REAR CHASSIS GND

1.00 mm² 3008C 1/20 2/20 0.75 mm² 6014Z
1 VBATT GND POWER 2 TO
/16.C1
-D7
704/50132 5/20 5 INPUT4
D RB03-8 0.75 mm² 810B 1
/2.A6
D
FROM
2 0.75 mm² 1808 6/20

3 6 INPUT 3
S_SRC07 0.75 mm² 4003D -DH2 7233/0015
/15.E4 FROM
7/20 7 INPUT 2
1.00 mm² 3008D 1/2 1 2 2/2 0.75 mm² 8121
SEAT BELT -C_RC24 0.75 mm² 1807 8/20 8 INPUT 1
1.00 mm² 3008B 0.75 mm² 3008A 2 1 0.75 mm² 8123 -D6
/2.B5 FROM
2/2 1/2 704/50132 9 CS1_IN

-S_SRC34 PERSON PRESENT
FROM FUSE FB8
1
2 10 CS1_OUT
0.50 mm² 8125A 3

11 OUTPUT 9
-R13 -DH1
716/G3600 7233/0015
GREEN BEACON RELAY 12 OUTPUT 10
9
FROM FUSE FC6 6 7 TO GREEN BEACON
1.00 mm² 1726 0.75 mm² 8025
/3.D4 FROM TO
/5.B1 13 OUTPUT 7
8 10 0.75 mm² 6001B GROUND TO RC GND

C /16.D1 14 OUTPUT 8
TO
-RB02 FROM NEUTRAL DIODE D2 0.75 mm² 810EE 15/20

C
7241/0003 /13.E4 FROM
15 OUTPUT 5
REVERSE ALARM
717/07700
16 OUTPUT 6
RB10-8 BUZZ 0.75 mm² 8110 17/20

/7.C1 FROM
17 OUTPUT 3
0.75 mm² 8066 0.75 mm² 8066 18/20 18 OUTPUT 4 7212/0001

2 2/2 GROUND TO RC GND
704/50082 1.00 mm² 8013C 1/2 1 1.00 mm² 6001Y
-D8
TO
/16.D1
0.75 mm² 8027B 0.75 mm² 8070 19/20 19 OUTPUT 1 -C_RC39
2 1 7232/0017 REVERSE ALARM
-DH3 0.75 mm² 820C 20/20 20 OUTPUT 2
3 CAN1_LO
4 CAN1_HI
-R6
4/20
3/20
FROM ENG ECU

B /10.F4 FROM 0.50 mm² CANHS4 716/G3600
REVERSE RLY
-C_RC27 B
FROM ENG ECU 0.50 mm² CANLS4 4
7212/0052
REVERSE SOL
/10.F4 FROM
TO RC GND
1.00 mm² 8011A 1 2 1.00 mm² 8013 1.00 mm² 8013A 1/2 1 ON/OFF
2 2/2 GROUND
1.00 mm² 6000E TO
/16.C5
-S_SRC20
CLUTCH PEDAL SWITCH 7213/0031
3 5 GROUND TO RC GND
-C_RC05 1.00 mm² 811A 1.00 mm² 6001P
-R5
TO
/16.B1
PARK 0.75 mm² 8027C 0.75 mm² 8027 B/3 B/3 A/3 A/3
/15.E7 -SW09 716/G3600
0.75 mm² 1707B
FROM
-S_SRC14 TRANS DUMP RLY -RB04

FROM PARK BRAKE DIODE 4 -S_SRC05 7241/0003
1.00 mm² 8011
FROM FUSE FC3 1 2 -R7
1.00 mm² 107A 1.00 mm² 1707A 716/G3600
/3.D7 FROM
-S_SRC04 FORWARD RLY

-C_RC26
0.75 mm² 8027A 3 5 0.75 mm² 6001R GROUND TO RC GND 9
7212/0052
FORWARD SOL
TO
/16.B1
1.00 mm² 8011B 6 7 1.00 mm² 8028 1/2 1 ON/OFF
2 2/2 1.00 mm² 6000CGROUND TO RC GND
TO
/16.D5
-RB05
7241/0003 8 10 GROUND TO RC GND
1.00 mm² 812B 1.00 mm² 6001Q TO
/16.B1
A -RB04
7241/0003 A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 61 9813/8950-2 33 - 61
Page Page
33-62 33-63
Figure 620. 1(Part 1 of 2) 2 3 4

400/G8164
R/H COLUMN SWITCH
FROM FUSE FC4 -C_RC03 -C_OP24 7219/0005 -C_OP08 -C_OP08 7219/0005 -C_OP24 -C_RC03
1.00 mm² 1002A 4/62 4/62 1.00 mm² 1002A 8/14 9 8 9/14 1.00 mm² 820 13/62 13/62 1.00 mm² 820
F /3.D7 FROM
-SW05
0.75 mm² 820C -C_OP24
1.00 mm² 812A 15/62
3 3/6 1.00 mm² 811A
4 4/6 1.00 mm² 810

7216/0001
-C_OP09
FROM FUSE FC3 1.00 mm² 1707F 1/6 1
/3.D7 FROM
2 2/6 1.00 mm² 812A
400/G8163 TO DIECU:15 -C_RC03

0.75 mm² 810EE 52/62
LH COLUMN SWITCH /13.C3 TO
-C_OP24
-S011 1.00 mm² 811 16/62
-D2
704/50132 TO PROXIMITY SWITCH
FR DIODE 0.75 mm² 8125 TO
/7.C5
FROM FWD 0.75 mm² 812A 1 0.75 mm² 811C
/13.F6
E
FROM
2 0.50 mm² 8125A

FROM REV 0.75 mm² 811B 3
/13.E6 FROM
-C_RC38 0.75 mm² 812B

7233/0015
FR DIODE
-CM04-10
728/G5771
Drive Inhibit Ecu
20 WAY MOLEX MX150 KEY B
-C_RC45
1.00 mm² 3008C 1/20 1 VBATT GND POWER 2 2/20
-D7
704/50132 5/20 5 INPUT4
D RB03-8 0.75 mm² 810B 1
/2.A6 FROM
2 0.75 mm² 1808 6/20

3 6 INPUT 3
S_SRC07 0.75 mm² 4003D -DH2 7233/0015
/15.E4 FROM
7/20 7 INPUT 2
1.00 mm² 3008D 1/2 1 2 2/2 0.75 mm² 8121
SEAT BELT -C_RC24 0.75 mm² 1807 8/20 8 INPUT 1
1.00 mm² 3008B 0.75 mm² 3008A 2 1 0.75 mm² 8123 -D6
/2.B5 FROM
2/2 1/2 704/50132 9 CS1_IN

-S_SRC34 PERSON PRESENT
FROM FUSE FB8
1
Page 33-63
2 10 CS1_OUT
0.50 mm² 8125A 3

11 OUTPUT 9
-R13 -DH1
716/G3600 7233/0015
GREEN BEACON RELAY 12 OUTPUT 10
9
FROM FUSE FC6 6 7 TO GREEN BEACON
1.00 mm² 1726 0.75 mm² 8025
/3.D4 FROM TO
/5.B1 13 OUTPUT 7
8 10 0.75 mm² 6001B GROUND TO RC GND

C /16.D1 14 OUTPUT 8
TO
-RB02 FROM NEUTRAL DIODE D2 0.75 mm² 810EE 15/20

7241/0003 /13.E4 FROM
15 OUTPUT 5
16 OUTPUT 6
RB10-8 BUZZ 0.75 mm² 8110 17/20

/7.C1 FROM
17 OUTPUT 3
0.75 mm² 8066 0.75 mm² 8066 18/20 18 OUTPUT 4

704/50082
-D8
0.75 mm² 8027B 0.75 mm² 8070 19/20 19 OUTPUT 1
2 1 7232/0017
-DH3 0.75 mm² 820C 20/20 20 OUTPUT 2
3 CAN1_LO
4 CAN1_HI
4/20
3/20
FROM ENG ECU

B /10.F4 FROM 0.50 mm² CANHS4
FROM ENG ECU 0.50 mm² CANLS4

/10.F4 FROM
CLUTCH PEDAL SWITCH 7213/0031

-C_RC05 -R5
PARK 0.75 mm² 8027C 0.75 mm² 8027 B/3 B/3 A/3 A/3
/15.E7 -SW09 716/G3600
0.75 mm² 1707B
FROM
-S_SRC14 TRANS DUMP RLY

FROM PARK BRAKE DIODE 4 -S_SRC05
1.00 mm² 8011
FROM FUSE FC3 1.00 mm² 107A 1.00 mm² 1707A 1 2
/3.D7 FROM
-S_SRC04
0.75 mm² 8027A 3 5 0.75 mm² 6001R GROUND TO RC GND
TO
/16.B1
-RB05
7241/0003
1 2 3 4
33 - 62 9813/8950-2 33 - 62
Page Page
33-62 33-63
Figure 620. (Part

5 2 of 2) 6 7 8
-S_SRC36 TO HORN RELAY

1.00 mm² 820A TO
/3.C5
F
1.00 mm² 812 1.00 mm² 812B
-S_SRC25
-C_OP24 -C_RC03
1.00 mm² 812A 15/62 15/62 0.75 mm² 812A TO FWD DIODE
TO
/13.E1
-C_OP24 -C_RC03
0.75 mm² 810A 23/62 23/62 0.75 mm² 810A TO
/2.A6
704/50132 TO START INTERLOCK RLY
-S003
Neutral -D2 TO INSTRUMENT PANEL
0.75 mm² 810C 1
2 /7.E2
TO
0.75 mm² 810D

3
-C_RC03 -C_OP24
810EE 52/62 52/62 0.50 mm² 810DD -C_OP18
7233/0015
-C_OP24 -C_RC03 -S_SRC26
16/62 16/62 1.00 mm² 811 1.00 mm² 811A
0.75 mm² 811B TO REV DIODE

TO
/13.E1
TO CAMERA POWER BOX
TO
/7.A2
E
2/20 0.75 mm² 6014Z GROUND TO REAR CHASSIS GND

2 TO
/16.C1
D
Page 33-62
C
REVERSE ALARM
717/07700
7212/0001
1 2 2/2 GROUND TO RC GND
1.00 mm² 8013C 1/2 1.00 mm² 6001Y TO
/16.D1
-C_RC39
REVERSE ALARM
-R6
716/G3600
REVERSE RLY
-C_RC27 B
4
7212/0052
REVERSE SOL
1 2 1 ON/OFF
2 2/2 GROUND TO RC GND
1.00 mm² 8011A 1.00 mm² 8013 1.00 mm² 8013A 1/2 1.00 mm² 6000E TO
/16.C5
-S_SRC20
1.00 mm² 811A 3 5 1.00 mm² 6001P GROUND TO RC GND
TO
/16.B1
-RB04
7241/0003
-R7
716/G3600
FORWARD RLY
-C_RC26
9
7212/0052
FORWARD SOL
1.00 mm² 8011B 6 7 1.00 mm² 8028 1/2 1 ON/OFF
2 2/2 1.00 mm² 6000CGROUND TO RC GND
TO
/16.D5
1.00 mm² 812B 8 10 1.00 mm² 6001Q GROUND TO RC GND

TO
/16.B1
-RB04
7241/0003 A
400/M1730-6
5 6 7 8
33 - 63 9813/8950-2 33 - 63
33 - 64 9813/8950-2 33 - 64
Page 33-66 Figure 621. LiveLink Circuit

(400/M1730 Sheet 14 of 16) Page 33-67
1 2 3 4 5 6 7 8
F
F
DUMP LINK LEAD
-C_DL1 -C_DL2
7213/0030 7213/0031
-S_DL1
A/3 1.00 mm² 1707 0.75 mm² 1707B A/3
TO W/H TO CLUTCH PEDAL

B/3 1.00 mm² 8027A
-S_DL2 0.75 mm² 8027 B/3
E -C_DL3
0.75 mm² 1707A
7212/0001
1/2
E
TO LEVER SW
0.75 mm² 8027B 2/2
D
D
-ECU1
334/G8518
LIVELINK III
7219/0284
-C_RC03 -C_OP24 -C_OP13
FROM FUSE FA7 1.00 mm² 300B 38/62 38/62 1.00 mm² 3038 M4/48 M4
/2.E5 FROM
V_BATT
-C_RC03 -C_OP24
FROM FUSE FA1 IGN RLY O/P 1.00 mm² 106E 36/62 36/62 1.00 mm² 1702B M2/48 M2
/3.E7 FROM
V_IGN
E2
ENG_RUN
ANTI-TAMPER LINKJ1
ANTI-TAMPER LINK
H1 K1
CH_1_INPUT
G1
CH_2_INPUT
FROM BLOCKED AIR FILTER DISPLAY AIR FILTER 4022B 0.75 mm² F1/48 F1
C /7.D7 CH_3_INPUT
FROM
-S006 -C_OP24 -C_RC03

C1 M3 M3/48 0.75 mm² 6015B 617 livelink 6015 1.00 mm² 37/62 37/62 6015 1.00 mm² FROM FUSE FA10 C
CH_4_INPUT BATTERY NEG FROM
/2.D5
L3 L3/48 0.75 mm² 6015A
BATTERY NEG
L2 L2/48 1.00 mm² 6005J GROUND TO OP GND

CHASSIS GND TO
/16.F1
CAN_SHD
CAN_H
CAN_L
C3
D4
E4
C3/48
D4/48
E4/48
-C_OP13
-C_OP13
-C_OP13
CANSHD8
0.50 mm² CANHS8
CANLS8
CAN H 7219/0284
7219/0284
7219/0284
0.50 mm²
0.50 mm²
B
B
CAN L
FROM
FROM
FROM
/10.E7
/10.E7
/10.E7
FROM ENG ECU
FROM ENG ECU
FROM ENG ECU
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 65 9813/8950-2 33 - 65
Page Page
33-66 33-67
Figure 621. 1(Part 1 of 2) 2 3 4
DUMP LINK LEAD
-C_DL1
7213/0030
-S_DL1
A/3 1.00 mm² 1707 0.75 mm² 1707B
TO W/H
B/3 1.00 mm² 8027A
-S_DL2 0.75 mm² 8027
E 7212/0001
0.75 mm² 1707A
0.75 mm² 8027B
D
-ECU1
334/G8518
LIVELINK III
7219/0284
-C_RC03 -C_OP24 -C_OP13
FROM FUSE FA7 1.00 mm² 300B 38/62 38/62 1.00 mm² 3038 M4/48 M4
/2.E5 FROM
V_BATT
-C_RC03 -C_OP24
FROM FUSE FA1 IGN RLY O/P 1.00 mm² 106E 36/62 36/62 1.00 mm² 1702B M2/48 M2
/3.E7 FROM
V_IGN
Page 33-67
E2
ENG_RUN
ANTI-TAMPER LINKJ1
ANTI-TAMPER LINK
H1 K1
CH_1_INPUT
G1
CH_2_INPUT
FROM BLOCKED AIR FILTER DISPLAY AIR FILTER 4022B 0.75 mm² F1/48 F1
C /7.D7 CH_3_INPUT
FROM
C1 M3
CH_4_INPUT BATTERY NEG
L3
BATTERY NEG
L2
CHASSIS GND
CAN_SHD
CAN_H
CAN_L
C3
D4
E4
C3/48
D4/48
E4/48
-C_OP13
-C_OP13
-C_OP13
CANSHD8
0.50 mm² CANHS8
CANLS8
CAN H 7219/0284
7219/0284
7219/0284
0.50 mm²
0.50 mm²
B
CAN L
FROM
FROM
FROM
/10.E7
/10.E7
/10.E7
FROM ENG ECU
FROM ENG ECU
FROM ENG ECU
1 2 3 4
33 - 66 9813/8950-2 33 - 66
Page Page
33-66 33-67
Figure 621. (Part

5 2 of 2) 6 7 8
-C_DL2
7213/0031
A/3
TO CLUTCH PEDAL
B/3
7212/0001 -C_DL3 E
1/2
TO LEVER SW
2/2
D
334/G8518
LIVELINK III
Page 33-66
ANTI-TAMPER LINKJ1
ANTI-TAMPER LINK
K1
-S006 -C_OP24 -C_RC03

M3 M3/48 0.75 mm² 6015B 617 livelink 6015 1.00 mm² 37/62 37/62 6015 1.00 mm² FROM FUSE FA10 C
BATTERY NEG FROM
/2.D5
L3 L3/48 0.75 mm² 6015A
BATTERY NEG
L2 L2/48 1.00 mm² 6005J GROUND TO OP GND

CHASSIS GND TO
/16.F1
400/M1730-6
5 6 7 8
33 - 67 9813/8950-2 33 - 67
33 - 68 9813/8950-2 33 - 68
Page 33-70 Figure 622. Handbrake Circuit

(400/M1730 Sheet 15 of 16) Page 33-71
1 2 3 4 5 6 7 8
F
F
0.75 mm² 4003D DIE ECU

TO
/13.D2
-SW5
332/C9990
Park brake
E -C_RC09
2
-C_RC09 -C_RC03 -C_OP24
0.75 mm² 1708AA 3/3 3 1 1/3 0.75 mm² 4003A 0.50 mm² 4003 24/62 24/62 0.50 mm² 4003 #2660 TO INSTRUMENT CLUSTER E
TO
/7.E1
-S_SRC07
-D1
704/50082
PARK DIODE
0.75 mm² 4003C 1 2 0.75 mm² 8027C PARK TO TRANS DUMP SPLICE
TO
/13.B1
-C_RC36
7232/0017
PARK BRAKE DIODE
-R10
716/G3600
BRAKE LIGHT RELAY
FROM FUSE FB7 1.00 mm² 1708A 4
/2.B5 FROM
-S_SRC13
BRAKE PRESSURE SWITCH FROM FUSE FB8 1.00 mm² 1708C 1 2 1.00 mm² 816 TO STOP LIGHTS
-D3 /2.C5 /6.B1
-C_RC16
FROM TO
704/50082
0.75 mm² 1708AB 1 2 0.75 mm² 3035 A/3 2 1 C/3 0.75 mm² 8017 0.75 mm² 8017 3 5 0.75 mm² 6001L GROUND TO GND SPLICE S011
TO
/16.C1
-C_RC32
D 7232/0017 -RB01
DIODE D1 7241/0003 D
B/3
0.75 mm² 6141 GROUND TO GND SPLICE -S_SRC23

TO
/16.D1
C
C
B
B
A
A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 69 9813/8950-2 33 - 69
Page Page
33-70 33-71
Figure 622. 1(Part 1 of 2) 2 3 4
0.75 mm² 4003D DIE ECU

TO
/13.D2
-SW5
332/C9990
Park brake
E -C_RC09
2
-C_RC09
0.75 mm² 1708AA 3/3 3 1 1/3 0.75 mm² 4003A 0.50 mm² 4003
-S_SRC07
704/50082
PARK DIODE
0.75 mm² 4003C 1
-C_RC36
7232/0017
PARK BRAKE DIODE
FROM FUSE FB7 1.00 mm² 1708A

/2.B5 FROM
-S_SRC13
BRAKE PRESSURE SWITCH
-D3
704/50082 -C_RC16
0.75 mm² 1708AB 1 2 0.75 mm² 3035 A/3 2 1 C/3 0.75 mm² 8017
-C_RC32
D 7232/0017
DIODE D1
B/3
0.75 mm² 6141
Page 33-71
C
1 2 3 4
33 - 70 9813/8950-2 33 - 70
Page Page
33-70 33-71
Figure 622. (Part

5 2 of 2) 6 7 8
DIE ECU
TO
/13.D2
-C_RC03 -C_OP24 E
4003 24/62 24/62 0.50 mm² 4003 #2660 TO INSTRUMENT CLUSTER
TO
/7.E1
-D1
704/50082
PARK DIODE
1 2 0.75 mm² 8027C PARK TO TRANS DUMP SPLICE
TO
/13.B1
-C_RC36
7232/0017
PARK BRAKE DIODE
-R10
716/G3600
BRAKE LIGHT RELAY
4
FROM FUSE FB8 1.00 mm² 1708C 1 2 1.00 mm² 816 TO STOP LIGHTS
/2.C5 FROM TO
/6.B1
8017 0.75 mm² 8017 3 5 0.75 mm² 6001L GROUND TO GND SPLICE S011
TO
/16.C1
-RB01
7241/0003 D
6141 GROUND TO GND SPLICE -S_SRC23

TO
/16.D1
Page 33-70
400/M1730-6
5 6 7 8
33 - 71 9813/8950-2 33 - 71
33 - 72 9813/8950-2 33 - 72
Page 33-74 Figure 623. Earthing Circuit

(400/M1730 Sheet 16 of 16) Page 33-75
1 2 3 4 5 6 7 8
0.75 mm² 6010A

-S001 8.00 mm² 6010
FROM IGNITION RELAY 2 /11.D4 FROM
0.75 mm² 6010C

F FROM INTERIOR LIGHT /12.F6 FROM
FROM REAR WIPER MOTOR /12.B7 FROM 1.00 mm² 6010E

F
0.50 mm² 6010F
FROM REAR WIPE WASH SWITCH /12.B4
FROM
1.00 mm² 6010G

FROM RADIO /12.E4 FROM
0.75 mm² 6010H

FROM FRONT WIPE WASH SWITCH /12.C5 FROM
2.00 mm² 6010K

FROM WIPER MOTOR /12.C7 FROM
0.75 mm² 6010M

FROM LIVELINK GROUND
FROM BLOWER RELAY /11.F4 FROM
1.00 mm² 6005J 3.00 mm² 6010N 7207/1510

/14.C6 FROM
FROM HEATER BLOWER /11.F7

FROM
2.00 mm² 6010P -T_C01

FROM AC UNIT /11.B5
FROM
FROM SKIP WARNING BUZZER GROUND 0.75 mm² 6005G 0.75 mm² 6010Q M10
/7.C7 FROM
FROM RH NO PLATE /6.B7 FROM
0.75 mm² 6010L

FROM HAZARD SWITCH GROUND
FROM LH NO PLATE /6.C7 FROM
0.50 mm² 6005D 0.75 mm² 6010S

/4.C4 FROM
FROM AMBER BEACON /5.C6 FROM
0.75 mm² 6010T

FROM GREEN BEACON /5.B6 FROM
FROM ROADLIGHT SWITCH GROUND 0.50 mm² 6005E 0.75 mm² 6010U
/4.F4 FROM
FROM FRONT LH WORK LAMP /5.E7 FROM
gnd FROM FRONT RH WORK LAMP /5.E7 0.75 mm² 6010V

FROM INSTRUMENT PANEL
FROM
GROUND 1.00 mm² 6005F

-S008 4.00 mm² 6005 0.75 mm² 6010W REAR CHASSIS (MID LH)
/7.E7 FROM
FROM REAR LH WORK LAMP /5.D7 FROM
0.75 mm² 6010X

FROM REAR RH WORK LAMP/5.D7
E
FROM
E
-T_C02
FROM ACC SOCKET GROUND 1.50 mm² 6005H 7207/1513
/2.E7 FROM
M10
1.00 mm² 6010Y
6003
FROM CAMERA TRANSFER POWER BOX GROUND 1.00 mm² 6005A ANTENA EARTH
/7.A7 FROM
2.00 mm²
-T_OP01
7207/1502
M10
CAB EARTH
-C_OP24
61/62
FROM START INTERLOCK RLY GROUND 0.75 mm² 6140 OP EARTH

/2.A7 FROM
FROM BRAKE PRESS SW GROUND

61/62
0.75 mm² 6141

/15.D5 FROM
-C_RC03
FROM REVERSE ALARM

D /13.C8
GROUND 1.00 mm² 6001Y
D
FROM
FROM SERVICE HOUR RESET SWITCH GROUND 0.50 mm² 6001N FROM FUEL SENDER GROUND 1.00 mm² 6006
/7.F3 FROM
/7.E1 FROM
FROM IGN RELAY GROUND

FROM EGR GROUND
0.75 mm² 6001M 1.00 mm² 6000B
/2.E2 FROM
/8.F1 FROM
6003
RB02-5 GROUND FROM FORWARD SOLENOID GROUND

0.75 mm² 602JC 1.00 mm² 6000C
IGN 3 /3.E2 FROM
/13.A7 FROM
2.00 mm²
FROM GREEN BEACON RELAY GROUND FROM VGT GROUND

0.75 mm² 6001B 1.00 mm² 6000D
/13.C3 FROM
/8.D2 FROM
FROM J1939 CONN GROUND FROM REVERSE SOLENOID GROUND

1.00 mm² 6001C 1.00 mm² 6000E
/10.F7 FROM
/13.B7 FROM
FROM HORN RELAY GROUND 1.00 mm² 6001D FROM WIF GROUND 1.00 mm² 6000F
/3.C7 FROM
/9.D3 FROM
-S_SRC06
FROM SCREEN VGT/EGR GROUND 0.50 mm² 6001E 6.00 mm² 6000H GROUND 1.00 mm² 6000T
/8.E1 FROM
FROM SPEEDOMETER /7.B7 FROM
-S_SRC23
FROM FLASHER RELAY GROUND 1.50 mm² 6001F FROM TRANS OIL PRESS SW GROUND 1.00 mm² 6000J
/4.C1 FROM
/7.E7 FROM
C FROM RH TAIL LIGHTS GROUND 1.50 mm² 6001G FROM AIR FILTER GROUND 0.75 mm² 6000K
/6.B7 /7.D8 C
FROM FROM
FROM LH TAIL LIGHTS GROUND 1.50 mm² 6001H FROM TRANS OIL TEMP SW. GROUND 1.00 mm² 6000L
/6.D7 FROM
/7.E7 FROM
FROM FUEL PUMP

FROM CAN SHIELD SPLICE GROUND 0.50 mm² 6001J
GROUND 2.00 mm² 6000N
/10.E7 FROM
/2.C7 FROM
FROM DI ECU GROUND 0.75 mm² 6014Z FROM AC COMPRESSOR GROUND 2.00 mm² 6000U
/13.D6 FROM
/11.B8 FROM
FROM BRAKE LIGHT RELAY GROUND 0.75 mm² 6001L GROUND 0.50 mm² 6000S
/15.D7 FROM
FROM WASHER PUMP /12.C7 FROM
FROM FORWARD RELAY GROUND 1.00 mm² 6001Q FROM WORKLIGHT SWITCH GROUND 0.50 mm² 6010A
/13.A7 FROM
/5.E4 FROM
FROM TRANS DUMP RLY GROUND 0.75 mm² 6001R

/13.A3 FROM
-C_RC42
3/4 2.00 mm² 6000P
FROM REVERSE RELAY GROUND 1.00 mm² 6001P
/13.B7 FROM
-C_RC41
7207/1510
FROM PARK BUZZER RELAY GROUND 0.75 mm² 601V C/3 2.00 mm² 6000G
/7.C2 FROM
B FROM PARK BUZZER RELAY

/7.D1 FROM
GROUND 0.75 mm² 601W B
FRONT ROAD LIGHTS GROUND 2.00 mm² 6004
FROM RC44-7 /6.D4 FROM
-T_RC01
M10
M10 -T_RC02 7207/1510 8.00 mm² 6000
FROM ENGINE ECU GROUND 4.00 mm² 6000R -T_RC03 M10

/9.B7 FROM
7207/1502
A REAR CHASSIS (FRONT RH)

A
400/M1730-6
1 2 3 4 5 6 7 8
33 - 73 9813/8950-2 33 - 73
Page Page
33-74 33-75
Figure 623. 1(Part 1 of 2) 2 3 4
FROM IGNITION RELAY 2 /11.D4 FROM
F FROM INTERIOR LIGHT /12.F6 FROM
FROM REAR WIPER MOTOR /12.B7 FROM
FROM REAR WIPE WASH SWITCH /12.B4

FROM
FROM RADIO /12.E4 FROM
FROM FRONT WIPE WASH SWITCH /12.C5 FROM
FROM WIPER MOTOR /12.C7 FROM
FROM LIVELINK GROUND

FROM BLOWER RELAY /11.F4 FROM
1.00 mm² 6005J

/14.C6 FROM
FROM HEATER BLOWER /11.F7

FROM
FROM AC UNIT /11.B5

FROM
FROM SKIP WARNING BUZZER GROUND 0.75 mm² 6005G

/7.C7 FROM
FROM HAZARD SWITCH GROUND

0.50 mm² 6005D

/4.C4 FROM
FROM ROADLIGHT SWITCH GROUND 0.50 mm² 6005E

/4.F4 FROM
FROM FRONT LH WORK LAMP /5.E7 FROM
gnd FROM FRONT RH WORK LAMP /5.E7

FROM INSTRUMENT PANEL
FROM
GROUND 1.00 mm² 6005F

-S008 4.00 mm² 6005
/7.E7 FROM
FROM REAR LH WORK LAMP /5.D7 FROM
FROM REAR RH WORK LAMP/5.D7

E
FROM
FROM ACC SOCKET GROUND 1.50 mm² 6005H

/2.E7 FROM
6003
FROM CAMERA TRANSFER POWER BOX GROUND 1.00 mm² 6005A
/7.A7 FROM
2.00 mm²
-T_OP01
7207/1502
M10
-C_OP24
61/62
FROM START INTERLOCK RLY GROUND 0.75 mm² 6140 OP EARTH
/2.A7 FROM
FROM BRAKE PRESS SW GROUND
61/62
0.75 mm² 6141
/15.D5 FROM
-C_RC03
FROM REVERSE ALARM
D /13.C8 FROM
GROUND 1.00 mm² 6001Y
FROM SERVICE HOUR RESET SWITCH GROUND 0.50 mm² 6001N FROM FUEL SENDER
/7.F3 FROM
/7.E1
FROM IGN RELAY GROUND
FROM EGR
0.75 mm² 6001M
/2.E2 FROM
/8.F1
6003
RB02-5 GROUND FROM FORWARD SOLENOID

0.75 mm² 602JC
IGN 3 /3.E2 FROM
/13.A7
2.00 mm²
FROM GREEN BEACON RELAY GROUND FROM VGT

0.75 mm² 6001B
/13.C3 FROM
/8.D2
FROM REVERSE SOLENOID
Page 33-75
FROM J1939 CONN GROUND 1.00 mm² 6001C
/10.F7 FROM
/13.B7
FROM HORN RELAY GROUND 1.00 mm² 6001D FROM WIF
/3.C7 FROM
/9.D3
FROM SCREEN VGT/EGR GROUND 0.50 mm² 6001E 6.00 mm² 6000H
/8.E1 FROM
FROM SPEEDOMETER /7.B7

-S_SRC23
FROM FLASHER RELAY GROUND 1.50 mm² 6001F FROM TRANS OIL PRESS SW
/4.C1 FROM
/7.E7
C FROM RH TAIL LIGHTS GROUND 1.50 mm² 6001G FROM AIR FILTER
/6.B7 FROM
/7.D8
FROM LH TAIL LIGHTS GROUND 1.50 mm² 6001H FROM TRANS OIL TEMP SW.
/6.D7 FROM
/7.E7
FROM FUEL PUMP
FROM CAN SHIELD SPLICE GROUND 0.50 mm² 6001J
/10.E7 FROM
/2.C7
FROM DI ECU GROUND 0.75 mm² 6014Z FROM AC COMPRESSOR
/13.D6 FROM
/11.B8
FROM BRAKE LIGHT RELAY GROUND 0.75 mm² 6001L
/15.D7 FROM
FROM WASHER PUMP /12.C7
FROM FORWARD RELAY GROUND 1.00 mm² 6001Q FROM WORKLIGHT SWITCH
/13.A7 FROM
/5.E4
FROM TRANS DUMP RLY GROUND 0.75 mm² 6001R
/13.A3 FROM
FROM REVERSE RELAY GROUND 1.00 mm² 6001P

/13.B7 FROM
7207/1510
FROM PARK BUZZER RELAY GROUND 0.75 mm² 601V

/7.C2 FROM
B FROM PARK BUZZER RELAY GROUND 0.75 mm² 601W

/7.D1 FROM
FRONT ROAD LIGHTS GROUND 2.00 mm² 6004

FROM RC44-7 /6.D4 FROM
-T_RC01
M10
M10 -T_RC02
FROM ENGINE ECU GROUND 4.00 mm² 6000R -T_RC03 M10

/9.B7 FROM
7207/1502
A REAR CHASSIS (FRONT RH)
1 2 3 4
33 - 74 9813/8950-2 33 - 74
Page Page
33-74 33-75
Figure 623. (Part

5 2 of 2) 6 7 8
0.75 mm² 6010A

-S001 8.00 mm² 6010
/11.D4 FROM
0.75 mm² 6010C

FROM INTERIOR LIGHT /12.F6 FROM
/12.B7 FROM 1.00 mm² 6010E

F
0.50 mm² 6010F
/12.B4 FROM
1.00 mm² 6010G

/12.E4 FROM
0.75 mm² 6010H

/12.C5 FROM
2.00 mm² 6010K

/12.C7 FROM
0.75 mm² 6010M

/11.F4 FROM
3.00 mm² 6010N 7207/1510

/11.F7 FROM
/11.B5 FROM 2.00 mm² 6010P -T_C01

0.75 mm² 6010Q M10
0.75 mm² 6010L

0.75 mm² 6010S

0.75 mm² 6010T

0.75 mm² 6010U

ROM FRONT LH WORK LAMP /5.E7 FROM
0.75 mm² 6010V

ROM FRONT RH WORK LAMP /5.E7 FROM
FROM REAR LH WORK LAMP /5.D7 FROM 0.75 mm² 6010W REAR CHASSIS (MID LH)
0.75 mm² 6010X
FROM REAR RH WORK LAMP/5.D7 FROM
E
-T_C02
7207/1513
M10
1.00 mm² 6010Y
ANTENA EARTH
CAB EARTH
D
FROM FUEL SENDER GROUND 1.00 mm² 6006
/7.E1 FROM
FROM EGR GROUND 1.00 mm² 6000B

/8.F1 FROM
FROM FORWARD SOLENOID GROUND 1.00 mm² 6000C

/13.A7 FROM
FROM VGT GROUND 1.00 mm² 6000D

/8.D2 FROM
FROM REVERSE SOLENOID

Page 33-74
GROUND
1.00 mm² 6000E
/13.B7 FROM
FROM WIF GROUND 1.00 mm² 6000F

/9.D3 FROM
-S_SRC06
GROUND 1.00 mm² 6000T
FROM SPEEDOMETER /7.B7 FROM
FROM TRANS OIL PRESS SW GROUND 1.00 mm² 6000J

/7.E7 FROM
FROM AIR FILTER GROUND 0.75 mm² 6000K

/7.D8 C
FROM
FROM TRANS OIL TEMP SW. GROUND 1.00 mm² 6000L

/7.E7 FROM
FROM FUEL PUMP GROUND 2.00 mm² 6000N

/2.C7 FROM
FROM AC COMPRESSOR GROUND 2.00 mm² 6000U

/11.B8 FROM
GROUND 0.50 mm² 6000S

FROM WASHER PUMP /12.C7 FROM
FROM WORKLIGHT SWITCH GROUND 0.50 mm² 6010A

/5.E4 FROM
-C_RC42
3/4 2.00 mm² 6000P
-C_RC41
C/3 2.00 mm² 6000G
M10 -T_RC02 7207/1510 8.00 mm² 6000
M10
REAR CHASSIS (FRONT RH)

A
400/M1730-6
5 6 7 8
33 - 75 9813/8950-2 33 - 75
90 - Earth Point
90 - Earth Point
Introduction
The ground or earth refers to the reference point in an

electrical circuit from which voltages are measured,
a common return path for electrical current, or a
direct physical connection to earth. Electrical circuits
may be connected to ground or earth to prevent
user contact with dangerous voltage if the electrical
insulation fails.
Earth points can be useful when tracing electrical

faults typically when several electrical devices are
malfunctioning.
33 - 76 9813/8950-2 33 - 76
03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ........................................................................................................................... 33-79

33-03-03 Isolator Switch ................................................................................................................ 33-88
33 - 77 9813/8950-2 33 - 77
Notes:
33 - 78 9813/8950-2 33 - 78
03 - Battery
00 - General
Introduction .................................................... 33-79 Batteries used in normal temperate climate
Health and Safety .......................................... 33-80 applications should not need topping up. However,
Fault-Finding .................................................. 33-81 in certain conditions (such as prolonged operation
Disconnect and Connect ............................... 33-81 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Check (Condition) .......................................... 33-83 frequently and topped up as necessary.
Charge ........................................................... 33-84
Remove and Install ....................................... 33-86 The electrolyte level should be checked in
accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
machine is operating at high ambient temperatures
or continuously for long periods.
Later Machines may have the new type batteries

installed which include a sight glass to check the
condition of the battery. New batteries should be
used as replacements if replacing the battery on
earlier machines.
Figure 624.
A Maintenance free battery
Maintenance
To make sure that the battery provides optimum
performance the following steps should be observed:
• Make sure that the electrical connections are

clean and tight. Smear petroleum jelly on
connectors to prevent corrosion.
• When applicable - never allow the electrolyte
level to fall below the recommended level of 6
mm above the plates. Use only distilled water
for topping up.
• Keep the battery at least three quarters
charged, otherwise the plates may become
sulphated (hardened) - this condition makes
recharging the battery very difficult.
Extra precautions must be taken when bench

charging maintenance free batteries, they are more
prone to damage by overcharging than the standard
type of battery:
• Never boost charge a maintenance free battery

(if installed).
33 - 79 9813/8950-2 33 - 79
03 - Battery
00 - General
• Never charge a battery at a voltage in excess Health and Safety

of 15.8 V.
• Never continue to charge a battery after it DANGER Batteries give off an explosive gas.
begins to gas. Do not smoke when handling or working on the
battery. Keep the battery away from sparks and
Quiescent Current Drain flames.
Battery electrolyte contains sulphuric acid. It can
If the machine has no permanently live circuits there burn you if it touches your skin or eyes. Wear
should be zero quiescent current drain, when the goggles. Handle the battery carefully to prevent
key-switch is off and all the lights are switched off. spillage. Keep metallic items (watches, rings, zips
etc) away from the battery terminals. Such items
It should be noted that some permanently live circuits could short the terminals and burn you.
will place a quiescent drain on the battery. Typically
the quiescent drain will be in the range of 10–20 Set all switches to off before disconnecting and
mA. If the quiescent drain measures 40 mA or more, connecting the battery. When disconnecting the
there is a problem with the wiring insulation or the battery, take off the earth (-) lead first.
accessories, if the fault is not rectified it will continue Re-charge the battery away from the machine,
to drain the battery. in a well ventilated area. Switch the charging
circuit off before connecting or disconnecting the
battery. When you have installed the battery in the
machine, wait 5 min before connecting it up.
When reconnecting, attach the positive (+) lead
first.
WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it
happens you can get burned.
WARNING Battery electrolyte is toxic and
corrosive. Do not breathe the gases given off
by the battery. Keep the electrolyte away from
your clothes, skin, mouth and eyes. Wear safety
glasses.
WARNING Do not top the battery up with acid.
The electrolyte could boil out and burn you.
CAUTION Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION The machine is negatively earthed.
Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first.
DANGER If you try to charge a frozen battery, or
jump start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
33 - 80 9813/8950-2 33 - 80
03 - Battery
00 - General
suitable closed receptacle and must be disposed

of in accordance with local environmental waste
regulations.
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.
Fault-Finding
The most obvious sign of a battery problem is a Disconnect and Connect
machine not being able to start. However, because
the battery is part of a larger electrical system Notice: Before you install a pair of batteries to
connected to other parts of the machine, a flat battery a machine, make sure you know the machines
may indicate another problem. voltage. Some machines require two batteries but
If something else is going wrong in the electrical have a 12 V electrical system. This means the
system, for example, a weak alternator, corrosion or batteries need to be connected in parallel.
loose connections, cold weather starting, electrical
For 24 V machines, the batteries must be
equipment being left on without the engine running,
connected in series. Incorrect voltage may result
interrogate the cause of the problem.
in serious damage to the electrical system.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition. Disconnect
2. Get access to the battery.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key.
4. Disconnect the negative battery lead first.
5. Disconnect the positive battery lead and store
away from the battery.
6. Disconnect and remove the battery leads.
33 - 81 9813/8950-2 33 - 81
03 - Battery
00 - General
Figure 625. 12V Battery Connection (Example) 2.1. Connect the positive lead then the negative
lead.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
_ +
A
C B
12 V
A Battery
B Positive lead
C Negative lead
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 626.
Figure 626.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
33 - 82 9813/8950-2 33 - 82
03 - Battery
00 - General
Check (Condition) Table 218. Fault Diagnosis

Battery Tester Read- Remedy
ings
Battery Test CHECK: 0 -12.6 Volts: Renew battery
LOAD: less than 6 Volts
This test is to determine the electrical condition of
the battery and to give an indication of the remaining CHECK: 6 -12.4 Volts: Recharge and re-test. If
useful life. LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery
Before you test the battery, make sure that the mains in yellow zone
battery is at least 75% charged (Specific Gravity of CHECK: less than 10 Indicates battery has
1.23 to 1.25 for ambient temperature up to 27°C). Volts: LOAD: less than 3 been over-discharged
Volts and unlikely to recover.
Make sure that the battery is completely Renew battery
disconnected from the vehicle. CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover
Figure 627. steady
Specific Gravity Test

The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings
should be taken using a hydrometer, when the
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one
hour (or slightly discharge the battery) to dissipate
the surface charge before testing.
Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15°C

(60°F) a 'correction factor' must be applied to the
reading obtained. Add 0.07 per 10°C (18°F) if the
A Battery voltage switch temperature is higher than 15°C (60°F) and subtract
B Check load switch the same if the temperature is lower.
Connect up the battery tester as follows: Table 219. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. Ambient Fully Half Dis- Fully Dis-
Temper- Charged charged charged
2. Set the battery voltage switch to 12V. ature de-
grees C
3. Connect the red flying lead to the battery positive (degrees
(+) terminal and the black flying lead to the F)
battery negative (-) terminal.
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
4. Set the Check/Load switch to CHECK to read the ( 80 )
battery no-load voltage which should be at least Above 27 1.240-1.260 1.170-1.190 1.090-1.110
12.4 volts. ( 80 )
5. Set the Check/Load switch to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 83 9813/8950-2 33 - 83
03 - Battery
00 - General
Charge 6.3. Discard the battery, if the voltage is more

than the specified.
Special Tools Voltage: 16 V
Battery Tester 993/85700 1 6.4. If the charging voltage of the battery is
within the above specified limits, continue
the battery charging process for the
Before Charging the Battery specified duration.
1. Discard the battery, if: Duration: 15 h
1.1. The electrolyte is excessively low. 7. Check the battery temperature regularly during
the battery charging process.
1.2. Electrolyte levels between cells vary by
more than the specified. 7.1. If the battery temperature reaches the
Dimension: 20 mm specified limit, stop the battery charging
process.
1.3. Battery case, lid or mountings are cracked
or damaged. Temperature: 60 °C ( 139.9 °F)
1.4. Terminals are damaged or loose in the 8. After the battery is charged fully, do the following:
case.
8.1. Switch off the battery charger.
Slow Charging Method 8.2. Disconnect the cables from the battery.
Make sure that you disconnect the (-)
1. Use a battery charger of constant current type. negative cable first.
Make sure that the output current and the upper
voltage limit per battery of the charger is more 8.3. Allow the battery to stand for specified
that the specified here. duration.
Current: 14 A Duration: 24 h
Voltage: 50 V 8.4. Load test the battery. Refer to (PIL 33-03).
Special Tool: Battery Tester (Qty.: 1)
2. Remove the battery from the machine. Refer to Standard Charging Method
(PIL 33-03).
Do not use the standard charging method on a
3. If a battery has been neglected and produces battery producing an open circuit voltage of 11 V or
an open circuit voltage of 11V or less, it will less.
be completely discharged and the plates will
have suffered sulphation. Initially the battery will 1. Use a battery charger of constant current type.
draw higher than normal voltage but lower than Make sure that the output current of the charger
specified current. is more that the specified.
Current: 9 A Current: 14 A
4. Connect the battery charger to the battery. Make 2. Remove the battery from the machine. Refer to
sure that the polarity of the connections is correct (PIL 33-03).
and connect the (+) positive connection first.
3. Connect the battery charger to the battery. Make
5. Switch on the battery charger. sure that the polarity of the connections is correct
6. Check the charging voltage of the battery after
the specified duration. 4. Switch on the battery charger.
Duration: 30 min 5. Set the specified charger current.
6.1. The charging current may still be lower than Current: 9 A
specified.
6. Continue the battery charging process for the
Current: 9 A specified duration. Refer to Table 221.
6.2. Discard the battery, if the voltage is lower 7. Check the battery temperature regularly during
than the specified. the battery charging process.
Voltage: 12 V
33 - 84 9813/8950-2 33 - 84
03 - Battery
00 - General
7.1. If the battery temperature reaches the 6.1. To avoid deterioration of the battery, do not
specified limit, stop the battery charging exceed the charging time specified in the
process. table.
Temperature: 60 °C ( 139.9 °F) 7. Check the battery temperature frequently during
8. After the battery is charged fully, do the following:
8.1. Switch off the battery charger. 7.1. Make a note that in the fast charging
method, the high charging current can
8.2. Disconnect the cables from the battery. cause a rapid rise in temperature.
Make sure that you disconnect the (-)
negative cable first. 7.2. If the battery temperature reaches the
specified limit, stop the battery charging
8.3. Load test the battery. Refer to (PIL 33-03). process.
Temperature: 60 °C ( 139.9 °F)
Table 220. Minimum Charging 8. After the battery is charged fully, do the following:
Duration (Slow Charging Method)
Open circuit voltage Charging duration 8.1. Switch off the battery charger.
Above 12.5 V 0h 8.2. Disconnect the cables from the battery.
12.4 V 3h Make sure that you disconnect the (-)
12.3 V 4h negative cable first.
12.2 V 5h 8.3. Load test the battery. Refer to (PIL 33-03).
12.1 V 6h
12 V 7h Table 221. Maximum Charging
11.9 V 8h Duration (Fast Charging Method)
11.8 V 9h Open circuit voltage Charging duration
11.7 V 10 h Above 12.5 V 0h
11.6 V 11 h 12.4 V 0.25 h
11 –11.6 V 12 h 12.3 V 0.5 h
Below 11 V Use slow charge method 12.2 V 0.75 h
12.1 V 1h
Fast Charging Method 12 V 1.25 h
11.9 V 1.5 h
The standard charging method should always be
used in preference to the fast charging method. 11.8 V 1.75 h
11.7 V 2h
Do not use the fast charging method on a battery 11.6 V 2.25 h
producing an open circuit voltage of 11 V or less. 11 –11.6 V 2.5 h
1. Use a battery charger of constant current type. Below 11 V Use slow charge method
Make sure that the output current of the charger
is more that the specified. Boost Charging Method
Current: 35 A
Important: The boost charging method is not
2. Remove the battery from the machine. Refer to recommended. The boost charging method may be
(PIL 33-03). carried out but the current must be limited to 60 A.
3. Connect the battery charger to the battery. Make 1. Remove the battery from the machine. Refer to
sure that the polarity of the connections is correct (PIL 33-03).
2. Connect the battery charger to the battery. Make
4. Switch on the battery charger. sure that the polarity of the connections is correct
5. Set the specified charger current.
3. Switch on the battery charger.
Current: 9 A
4. Set the charger current. Do not exceed the
6. Continue the battery charging process for the specified charging current.
specified duration. Refer to Table 220.
Current: 9 A
33 - 85 9813/8950-2 33 - 85
03 - Battery
00 - General
5. Continue the battery charging process for the Remove and Install
minimum duration required for the battery to start
the engine. CAUTION This component is heavy. It must only
6. Check the battery temperature frequently during method and device.
6.1. Make a note that in the boost charging Remove
method, the high charging current can
cause a rapid rise in temperature. 1. Make the machine safe.
6.2. If the battery temperature reaches the Refer to: PIL 01-03-27.
specified limit, stop the battery charging
process. 2. Isolate the battery.
Temperature: 60 °C ( 139.9 °F) Refer to: PIL 33-03-00.
7. After the battery is charged fully, do the following: 3. Remove the floor plate.
7.1. Switch off the battery charger.
7.2. Disconnect the cables from the battery. 4. Remove the terminal cover from the battery
Make sure that you disconnect the (-) positive terminal.
negative cable first. 5. Loosen the nut 1 from battery terminals.
6. Remove the leads from the battery terminals.
6.1. Disconnect the negative battery lead first.
Figure 628.
B
A
A Battery
B Terminal cover
7. Collect the washers.
8. Remove the wing nut.
9. Remove the battery retaining clamp.
33 - 86 9813/8950-2 33 - 86
03 - Battery
00 - General
Figure 629.
A Battery
C Wing nut
D Retaining clamp
10. Remove the battery from the machine.
Install
removal procedure.
2. When reconnecting, attach the positive (+) lead
first.
33 - 87 9813/8950-2 33 - 87
03 - Battery
03 - Isolator Switch
03 - Isolator Switch Introduction

Introduction .................................................... 33-88 The battery isolator switch is used to disconnect the
Remove and Install ....................................... 33-89 battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect. Refer to: PIL
33-03-00.
33 - 88 9813/8950-2 33 - 88
03 - Battery
03 - Isolator Switch
Remove and Install
Remove
2. Open the transmission compartment cover.
3. Turn the battery isolator switch anticlockwise.
4. Remove the screws from the battery isolator
switch.
5. Remove the battery isolator switch.
Figure 630.
B
A
A Battery isolator switch

B Screws
Install
step.
1.1. Turn the battery isolator switch clockwise.
33 - 89 9813/8950-2 33 - 89
09 - Power Distribution
Contents Page No.
33-09-00 General ........................................................................................................................... 33-91

33-09-03 Fuse ............................................................................................................................... 33-93
33-09-06 Relay .............................................................................................................................. 33-96
33-09-09 Primary Fusebox ............................................................................................................ 33-97
33 - 90 9813/8950-2 33 - 90
00 - General
Introduction .................................................... 33-91 The electrical circuits are protected by fuses. If a
Health and Safety .......................................... 33-92 fuse blows, find out why and rectify the fault before
installing a new one.
A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.
33 - 91 9813/8950-2 33 - 91
00 - General
Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
33 - 92 9813/8950-2 33 - 92
03 - Fuse
03 - Fuse
Introduction
Primary Fuses
Figure 631.
1 3
2 4
Table 222.
Fuse Number Description Rating
1 Lights and grid heater 30 A
2 Air condition (If installed) 60 A
3 Hazard warning light 50 A
4 Ignition 60 A
33 - 93 9813/8950-2 33 - 93
03 - Fuse
Secondary Fuses
Figure 632.
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Table 223.
Fusebox A Description Rating
A1 Hazard 15 A
A2 Wash wipe/ wiper motor 15 A
A3 Roadlight 15 A
A4 Front worklight 7.5 A
A5 Rear worklight 7.5 A
A6 Accessory socket 10 A
A7 Live link and diagnostic 7.5 A
A8 Radio/ interior light 7.5 A
A9 Roadlight 7.5 A
A10 Livelink 3A
Table 224.
Fusebox B Description Rating
B1 EGR actuator 10 A
B2 VGT 10 A
B3 Engine ECU feeds 10 A
B4 Fuel pump 10 A
B5 Water in fuel 10 A
B6 Grid heater relay 5A
B7 Seat switch 5A
B8 Brake lights 3A
33 - 94 9813/8950-2 33 - 94
03 - Fuse
Fusebox B Description Rating

B9 Ignition 2 / Pre-heater 30 A
B10 Start interlock relay 5A
Table 225.
Fusebox C Description Rating
C1 Radio/Instrument panel/ ll3 ignition/ 7.5 A
camera
C2 Hazard lights 15 A
C3 Left hand column sw/ dump relay\ 7.5 A
C4 Horn 7.5 A
C5 Roadlight 15 A
C6 Beacon 7.5 A
C7 Beacon 7.5 A
C8 Engine ECU/ heater/ ignition relay2 3A
C9 Worklight 5A
C10 Worklight 5A
33 - 95 9813/8950-2 33 - 95
06 - Relay
06 - Relay
Introduction
Figure 633.
R1 R6
R2 R7
R3 R8
R4 R9
R10
R5
Relay Base Description

Table 226.
Lift pump relay
Relay Base Description R6 Flasher (indicators)
R1 Brake light relay R7 Power hold relay
Horn relay R8 Starter relay
R2 Ignition relay 3 R9 Buzzer
Green beacon relay R10 Park buzzer relay 1
R3 Start interlock relay Main buzzer relay 2
Ignition relay
R4 Forward relay
Reverse relay
R5 Trans dump relay
33 - 96 9813/8950-2 33 - 96
09 - Primary Fusebox
09 - Primary Fusebox
Remove and Install
Remove
5. Disconnect the electrical connections from the
primary fusebox.
6. Remove the nut (x2), washer (x2) and bolt (x2).
7. Remove the primary fusebox with bracket from
the machine.
Figure 634.
A
D
E
C
B
A Primary fusebox
B Nut (x2)
C Washer (x2)
D Bolt (x2)
E Bracket
Install
removal procedure.
33 - 97 9813/8950-2 33 - 97
12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ........................................................................................................................... 33-99

33-12-04 Chassis ......................................................................................................................... 33-109
33-12-05 Rear Chassis ................................................................................................................ 33-130
33-12-12 Operator Station ........................................................................................................... 33-170
33-12-15 Front Console ............................................................................................................... 33-188
33-12-36 Work Lights .................................................................................................................. 33-200
33 - 98 9813/8950-2 33 - 98
12 - Harness
00 - General
Introduction .................................................... 33-99
Health and Safety ........................................ 33-100
Harness Drawings
Component Identification ............................. 33-101 Drawings are reproduced from production electrical
Repair .......................................................... 33-103 harness drawings. Each harness drawing includes
Check (Condition) ........................................ 33-105 tables showing wire connections and destinations
for all the connectors on the harness. To identify
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.
33 - 99 9813/8950-2 33 - 99
12 - Harness
00 - General
Health and Safety

Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
Harness Repair (Butane Heater)

WARNING In addition to the warnings
incorporated into this procedure, extreme care
should be taken when handling the gas heating
tool to ensure that the flame does not damage or
set fire to any items in the vicinity of the repair,
i.e. other wires, floor panels, floor mats, sound
proofing, paintwork, etc. This tool should not be
used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas
or similar safety parameters apply. No other heat
source should be used to attempt a sealed joint.
CAUTION When the heater is in use, the reflector
and the air coming out are extremely hot. Keep
away to avoid accidental burns. Do not touch the
reflector until it has had time to cool down after
switching off. If flame reappears at the reflector
when the heater is in use, the catalytic element is
damaged or used up. Stop work immediately and
replace the heater.
33 - 100 9813/8950-2 33 - 100

12 - Harness
00 - General
Wire and Harness Number Identification

This section details the allocation of wire numbers
and the identification of wires in the wiring harness.
Figure 635.
The illustration shows a typical connector and wires. Identifica- Description

Each wire has an individual identification number tion Num-
permanently marked on it, at regular intervals along ber
it's length. The number stamped on the wire identifies 819 The wire's unique identification num-
the following: ber. The wire functions and num-
bers allocated to them are consis-
Table 227. Wire and Harness tent through out the JCB range of
Number Identification products. Refer to Wire Numbers and
Identifica- Description Functions.
tion Num- 9/371 If applicable - The part number of
ber the harness that the wire originates
# The # indicates the start of the identi- from. If the harness part number is
fication number. It is always printed to 719/37100, the number printed on the
the left of the identification number. harness wires will be 9/371 (71 and
B If applicable - The colour of the fly- 00 are common numbers and there-
ing lead that the harness wire should fore deleted).
mate with. For instance, if wire 819
from harness 719/37100 mated with Wire Numbers and Functions
a flying lead coloured black (colour
code B) then the number printed on
the wire would be B-819 9/371. Table 228. Wires 000-199, 1000-1999 (These
numbers are reserved for ignition feeds,
heater start circuits and start circuits)
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds (feeds via
and 1000 -1999 ignition relays are also classed
as ignition feeds). Power sup-
plies output by a control module.
33 - 101 9813/8950-2 33 - 101

12 - Harness
00 - General
Table 229. Wires 200-399, 2000-3999 (These Table 233. Wires In Splices
numbers are reserved for battery feeds)
Wire Number Description Various The main input wire is allocated
Wires 200-299 Unfused battery feeds. Pow- with a wire number and a suit-
and 2000-2999 er supplies output by a control able description, i.e. Wire 640
module. earth splice to earth. The addi-
Wires 300-399 Fused battery feeds. Power sup- tional wires in the splice are al-
and 3000-3999 plies output by a control module. located the same wire number
and a postfix, i.e. 640A, 640B,
etc.
Table 230. Wires 400-599, 4000-5999
Figure 637.
Wires 400-599 These numbers are reserved for
and 1000-5999 instruments, sensors and vari-
able input/output signal wires
used in electronic systems. CAN
wires also use numbers in this
series.
Table 231. Wires 600-799, 6000-7999

Wires 600-799 These numbers are used for
and 6000-7999 earth wires. When the number
is printed on to a wire it is pre-
fixed by the Earth symbol. This
symbol is printed onto the wire,
it may however be omitted from General Points
harness drawings. Where a load 1. Wires continue to have the same number even
is switched negative, the wire after passing through a connector block to
number from the load to the another harness.
switch shall be different to that
of the wire from the switch to the 2. The descriptions are applicable to JCB
earth. specification wiring harnesses. The machine
may be installed with some wiring that does
not conform to the JCB specifications, typically
Figure 636. when it is part of equipment supplied by other
manufacturers.
600
Table 232. Wires 800-999, 8000-9999
Wires 800-999 These numbers are reserved
and 8000-9999 for switched supplies to electri-
cal loads, i.e. to lights, etc. Pow-
er supplies output by a control
module.
33 - 102 9813/8950-2 33 - 102

12 - Harness
00 - General
Repair 2. Using the correct sized splice, attach the new

section of wire required or auxiliary flying
Special Tools lead to the existing harness and secure using
Description Part No. Qty. the crimp tool. Note that each of the splices
Wiring Crimp Tool 892/00349 1 detailed is colour-coded to make size and range
readily visible. They are secured using the
Butane Heater 892/00350 1 corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
Consumables This tool also incorporates a ratchet closing
Description Part No. Size mechanism which will not release until the splice
Wiring Splice 892/00351 - is fully closed to the correct compression size.
(0.5-1.5mm Red,
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
contains 50 off)
Wiring Splice 892/00352 - Consumable: Wiring Splice (1.5-2.5mm Blue,
(1.5-2.5mm Blue, contains 50 off)
contains 50 off) Consumable: Wiring Splice (3-6mm Yellow,
Wiring Splice (3-6mm 892/00353 - contains 50 off)
Yellow, contains 50 off)
3. With the Butane heater assembly, seal the
Instances occur where it is necessary to incorporate connection.
auxiliary electrical components into existing electrical Special Tool: Butane Heater (Qty.: 1)
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires 3.1. Remove the cap from the end of the
within a harness. This will also apply to other disposable gas cartridge.
machines in addition to those of manufacture.
Figure 639.
To make sure that either the inclusion of an auxiliary
electrical component or a repair within a harness is
completed to an acceptable standard it is strongly A
recommended that the following tools, equipment
and procedures are always used. Note that JCB
harnesses have an Ingress Protection rating of 67
(I.P.67). B
The sheath covering of the recommended splice is A Cap

heat shrunk onto the original wire insulation. This B Gas cartridge
results in a seal and corresponding joint to IP 67
specifications. 3.2. Before assembling the gas cartridge to the
reflector element, turn the red ring to the left,
Procedure (in the direction of the minus sign marked
on the ring).
1. Cut the wire and remove the protective insulation
for a suitable distance dependent upon the size Figure 640.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 638.
A
C Reflector element
D Red ring
3.3. Position the tube hanging down from inside
the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas
A Distance for splice (check size)
33 - 103 9813/8950-2 33 - 103

12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 643.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 641.
D Red ring
3.6. Hold the heater vertically and, using a
match or cigarette lighter, light the gas as
shown. Hold the heater vertically for 1 to 2
minutes until the catalytic reaction occurs.
This is indicated when the blue flame fades
3.4. Turn the small ring so that the air holes are and the ceramic element glows red. Then
completely closed. turn the small ring until the air holes at
are completely open. The tool is ready
Figure 642. for use. Note: The fact that the sound of
liquid cannot be heard when the cartridge is
shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
Figure 644.
E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the E Small ring
gas. Important: Before turning the heater F Air holes
on, make sure that the cartridge is not hotter
than the reflector element. This may occur 3.7. The heater can be used in two modes:
if the cartridge is held in the hand for a long
time. The temperature difference between 3.8. Side wings down, reflector head completely
the cartridge and the reflector element may open. In this mode the infra-red heat waves
cause long yellow flames to appear on are dominant (recommended for the light
ignition. coloured plastic splices).
33 - 104 9813/8950-2 33 - 104

12 - Harness
00 - General
Figure 645. Check (Condition)
This section describes how to use electrical

measuring devices that are used in electrical fault
finding.
Use of Multimeters
In order to obtain the maximum benefit from the
fault finding information contained in the Electrical
Section, it is important that the technician fully
understands the approach to fault finding and the
use of the recommended test equipment, in this case
a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer analogue multimeter. The approach
is based on a fault finding check list. In tracing
G Side wings the fault from the symptoms displayed you will be
directed to make measurements using a multimeter.
3.9. Side wings up, reflector head opening These instructions are intended to cover the use of
reduced. In this mode the heating is done the recommended meters.
only by the hot gas (use for dark coloured
plastic splices). 1. Make sure that the test leads are plugged into
the correct sockets. The black test lead should
Figure 646.
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that
the test probes have a good clean contact with
bare metal, free from grease, dirt, and corrosion
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
D Red ring there is no 12V range, set the selector to the next
G Side wings range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.
33 - 105 9813/8950-2 33 - 105

12 - Harness
00 - General
Figure 647. Fluke 85 Multimeter Figure 648. AVO 2003 Multimeter
1.2. On the AV0 meter, move the right slider

switch to position A, and the left hand slider 1.3. On an analogue meter, turn the dial to the
switch to the appropriate range. appropriate DC Volts range.
Figure 649. Typical Analogue Multimeter
2. Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
33 - 106 9813/8950-2 33 - 106

12 - Harness
00 - General
Measuring Resistance Measuring Frequency

1. Make sure that there is no power to the part of The AVO meter and the analogue meter are not
the circuit you are about to measure. capable of measuring frequency, therefore a digital
multimeter must be used.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the 1. Insert the black plug into the COM socket on
other end. It does not matter which way round the the meter and attach the probe to the nearest
two probes are placed. suitable earth point on the chassis, for example,
the battery negative terminal.
3. Select the correct range on the multimeter.
2. Insert the red probe into socket J.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the 3. Turn the selector switch to position A and
right hand side of the display window is on. depress G repeatedly until F is highlighted on the
If the F sign is on instead, press the blue top row of the display.
button G to change the reading to Ω. Touch
the meter lead probes together and press 4. Press button H once.
the REL3 key on the meter to eliminate the
lead resistance from the meter reading. 5. Touch or connect the red probe to the frequency
source to be measured. Press and hold the
3.2. On the AV0 meter, move the right hand button if an average reading is required.
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω) Testing a Diode or a Diode Wire
range.
3.3. On an analogue meter, move the dial to the A diode wire is a diode with male connector installed
appropriate Ohms (Ω) range. on one end and a female connector installed on the
other end. The diode is sealed in heatshrink sleeving.
Measuring Continuity To test a Diode or a Diode Wire.
1. Make sure that there is no power to the part of 1. On the digital multimeter:
the circuit you are checking for continuity.
1.1. Turn the switch to position D.
2. Connect one probe to one end of the component 1.2. Press the HOLD button and check that the
or wire to be checked and the other probe to the H sign appears at the top right hand side of
other end. It does not matter which way round the the display window.
two probes are placed.
1.3. Connect the black probe to the end of the
3. Select the correct range on the multimeter. diode with a band or to the male connector
of the diode wire. Connect the red probe
3.1. On the digital multimeter, turn the switch to the other end of the diode or diode wire.
to position C and check that the beeper If the beeper does not sound the diode or
symbol appears at the left hand side of diode wire is faulty.
the display window. If the F sign is on
instead, press the button labelled F. If there 1.4. Connect the red probe to the end of the
is continuity in the circuit, the beeper will diode marked with a band, or to the male
sound. If there is no continuity (open circuit), connector of the diode wire, the black probe
the beeper will not sound. should be connected to the other end of the
diode or diode wire. If the beeper sounds or
3.2. On the AV0 meter, move the right hand the meter does not read O.L., the diode or
slider switch to position B, and the left diode wire is faulty.
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between 1.5. Press the HOLD button and check that the
two points the buzzer will sound. H sign disappears from the right hand side
of the display window.
3.3. On an analogue meter, turn the dial to
the lowest Ohms (Ω) range. If there is 2. On the AV0 meter:
continuity (i.e. very low resistance) between
two points the needle will move across fully 2.1. Move the right hand slider to position A, and
(or almost fully) to the right hand side of the the left hand slider switch to position C.
scale. 2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
33 - 107 9813/8950-2 33 - 107

12 - Harness
00 - General
diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
2.3. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
diode or diode wire. If the Avo meter does
not read 1 the diode is faulty.
3. On an analogue meter:
3.1. Select the Ohms 1000s (1k) range, connect
the black probe to the end of the diode
marked with a band, or to the male
connector of the diode wire, the red probe
diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
diode is faulty.
3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
the diode wire, the black probe should
be connected to the other end of the
diode or diode wire. The meter should read
300-400Ω, if it reads less than this the diode
is faulty.
33 - 108 9813/8950-2 33 - 108

12 - Harness
04 - Chassis
04 - Chassis
Diagram
For: 6T-1 Front Tip .................. Page 33-109

For: 6T-1 Swivel Tip ................ Page 33-118
For: 7T-1 Front Tip [Hi-Viz] ...... Page 33-126

Figure 650. Front Chassis Harness - 336/E5778 (Sheet 1 of 2).......................................... Page 33-111
33 - 109 9813/8950-2 33 - 109

Notes:
33 - 110 9813/8950-2 33 - 110

12 - Harness
04 - Chassis
Page 33-112 Figure 650. Front Chassis

Harness - 336/E5778 (Sheet 1 of 2) Page 33-113
1 6
2 5
3 4
-C_FC01#3
7216/0018
LH FRONT HEADLIGHT
-C_FC01
2 1
-C_FC04#1
7213/0005 2 1
TO PROXIMITY SENSOR
7243/0150
20 mm
-P79
-C_FC03#3
7212/0008
NC12 HORN
-C_FC04
-C_FC03
1100 mm
70 mm
240 mm
7000/3206
-P81
-S003
7000/3206
50 mm
-P13
NC08
7000/3206
30 mm
-P11
NC12 20 mm -C_FC02
-C_FC06 100 mm 1800 mm 250 mm 50 mm 50 mm 160 mm 1800 mm
NC12
7000/3206 7000/3206 7000/3206
-P80
-ID6 -S002 -S001 -P12 -P14
-P78
NC12 NC12 NC12
ID Label 7243/0150
6 5 4 3 2 1
1 6
7 8 9 10 11 12 2 5
3 4
-C_FC02#3
-C_FC06#3 7216/0018
7219/0016 RH FRONT HEADLIGHT
TO CHASSIS HARNESS
336/E5778-3
33 - 111 9813/8950-2 33 - 111

12 - Harness
04 - Chassis
Page Page
33-112 33-113
Figure 650. (Part 1 of 2)
1 6
2 5
3 4
-C_FC01#3
7216/0018
LH FRONT HEADLIGHT
-C_FC01
2 1
-C_FC04#1
7213/0005
TO PROXIMITY SENSOR
7243/0150
20 mm
-P79
NC12
-C_FC04
1100 mm
70 mm
7000/3206
-P81
-S003
50 mm
7000/3206
-P11
30 mm NC12
-C_FC06 100 mm 1800 mm 250 mm 50 mm 50 mm
Page 33-113
7000/3206 7000/3206
-P80
-ID6 -S002 -S001 -P12
NC12 NC12
ID Label
6 5 4 3 2 1
7 8 9 10 11 12
-C_FC06#3
7219/0016
TO CHASSIS HARNESS
33 - 112 9813/8950-2 33 - 112

12 - Harness
04 - Chassis
Page Page
33-112 33-113
2 1
-C_FC03#3
7212/0008
HORN
-C_FC03
240 mm
7000/3206
-P13
NC08
20 mm -C_FC02
160 mm 1800 mm
NC12
Page 33-112
7000/3206 7000/3206
-P12 -P14
NC12 NC12 -P78
7243/0150
1 6
2 5
3 4
-C_FC02#3
7216/0018
RH FRONT HEADLIGHT
336/E5778-3
33 - 113 9813/8950-2 33 - 113

12 - Harness
04 - Chassis
33 - 114 9813/8950-2 33 - 114

12 - Harness
04 - Chassis

-S001
-C_FC01 LH FRONT HEADLIGHT ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal S 832A 1.00 mm² YE -C_FC01:2 -W1_FC
1 7210/0030 S 832B 1.00 mm² YE -C_FC02:2 -W1_FC
2 832A 1.00 mm² YE -S001:S -W1_FC S 832 1.50 mm² YE -C_FC06:1 -W1_FC
3 836AA 1.00 mm² YE -S002:S -W1_FC
4 829A 1.00 mm² YE -C_FC06:3 -W1_FC 7000/3104 In Line Ultrasonic Splice
5 8031A 1.00 mm² YE -C_FC06:4 -W1_FC
6 6004B 2.00 mm² YE -S003:S -W1_FC 7000/3212 ; 45
7216/0018 6 Way DT06 Socket Housing

Additional Components
7216/0016;1 # 6 Way DT06 Wedge -S002
ID Tag Size Colour Destination Cable Cavity Seal
S 836AA 1.00 mm² YE -C_FC01:3 -W1_FC
RH FRONT HEADLIGHT S 836AB 1.00 mm² YE -C_FC02:3 -W1_FC
-C_FC02
ID Tag Size Colour Destination Cable Cavity Seal S 836A 1.50 mm² YE -C_FC06:2 -W1_FC
1 7210/0030
7000/3104 In Line Ultrasonic Splice
2 832B 1.00 mm² YE -S001:S -W1_FC
3 836AB 1.00 mm² YE -S002:S -W1_FC
7000/3212 ; 45
4 830D 1.00 mm² YE -C_FC06:8 -W1_FC
5 8029C 1.00 mm² YE -C_FC06:5 -W1_FC
6 6004C 2.00 mm² YE -S003:S -W1_FC -S003
7216/0018 6 Way DT06 Socket Housing S 6004B 2.00 mm² YE -C_FC01:6 -W1_FC
Additional Components S 6004 2.00 mm² YE -C_FC06:7 -W1_FC
7216/0016;1 # 6 Way DT06 Wedge S 6004A 1.00 mm² YE -C_FC03:2 -W1_FC
S 6004C 2.00 mm² YE -C_FC02:6 -W1_FC
S 6004D 0.75 mm² YE -C_FC04:2 -W1_FC
-C_FC03 HORN
1 8035 1.00 mm² YE -C_FC06:6 -W1_FC
7000/3212;45 # Adhesive Lined Heatshrink
2 6004A 1.00 mm² YE -S003:S -W1_FC
7212/0008 2 Way Econo 070 Socket Housing

7212/0009;1 # 2 Way Econo 070 Socket Retainer
-C_FC04 TO PROXIMITY SENSOR

1 5101 0.75 mm² YE -C_FC06:10 -W1_FC
2 6004D 0.75 mm² YE -S003:S -W1_FC
3 8125B 0.75 mm² YE -C_FC06:9 -W1_FC
7213/0005 3 Way HW090 Socket Housing

7213/0007;1 # 3 Way HW090 Socket Retainer
-C_FC06 TO CHASSIS HARNESS

1 832 1.50 mm² YE -S001:S -W1_FC
2 836A 1.50 mm² YE -S002:S -W1_FC
3 829A 1.00 mm² YE -C_FC01:4 -W1_FC
4 8031A 1.00 mm² YE -C_FC01:5 -W1_FC
5 8029C 1.00 mm² YE -C_FC02:5 -W1_FC
6 8035 1.00 mm² YE -C_FC03:1 -W1_FC
7 6004 2.00 mm² YE -S003:S -W1_FC
8 830D 1.00 mm² YE -C_FC02:4 -W1_FC
9 8125B 0.75 mm² YE -C_FC04:3 -W1_FC
10 5101 0.75 mm² YE -C_FC04:1 -W1_FC
11 7210/0030
12 7210/0030

7219/0012;1 # 12 Way DT06 Wedge
336/E5778-3
33 - 115 9813/8950-2 33 - 115

12 - Harness
04 - Chassis
Page Page
33-116 33-117
-C_FC01 LH FRONT HEADLIGHT

1 7210/0030
2 832A 1.00 mm² YE -S001:S -W1_FC
3 836AA 1.00 mm² YE -S002:S -W1_FC
4 829A 1.00 mm² YE -C_FC06:3 -W1_FC
5 8031A 1.00 mm² YE -C_FC06:4 -W1_FC
6 6004B 2.00 mm² YE -S003:S -W1_FC

7216/0016;1 # 6 Way DT06 Wedge
-C_FC02 RH FRONT HEADLIGHT

1 7210/0030
2 832B 1.00 mm² YE -S001:S -W1_FC
3 836AB 1.00 mm² YE -S002:S -W1_FC
4 830D 1.00 mm² YE -C_FC06:8 -W1_FC
5 8029C 1.00 mm² YE -C_FC06:5 -W1_FC
6 6004C 2.00 mm² YE -S003:S -W1_FC

7216/0016;1 # 6 Way DT06 Wedge
-C_FC03 HORN
1 8035 1.00 mm² YE -C_FC06:6 -W1_FC
2 6004A 1.00 mm² YE -S003:S -W1_FC
Page 33-117
-C_FC04 TO PROXIMITY SENSOR

1 5101 0.75 mm² YE -C_FC06:10 -W1_FC
2 6004D 0.75 mm² YE -S003:S -W1_FC
3 8125B 0.75 mm² YE -C_FC06:9 -W1_FC


1 832 1.50 mm² YE -S001:S -W1_FC
2 836A 1.50 mm² YE -S002:S -W1_FC
3 829A 1.00 mm² YE -C_FC01:4 -W1_FC
4 8031A 1.00 mm² YE -C_FC01:5 -W1_FC
5 8029C 1.00 mm² YE -C_FC02:5 -W1_FC
6 8035 1.00 mm² YE -C_FC03:1 -W1_FC
7 6004 2.00 mm² YE -S003:S -W1_FC
8 830D 1.00 mm² YE -C_FC02:4 -W1_FC
9 8125B 0.75 mm² YE -C_FC04:3 -W1_FC
10 5101 0.75 mm² YE -C_FC04:1 -W1_FC
11 7210/0030
12 7210/0030

7219/0012;1 # 12 Way DT06 Wedge
33 - 116 9813/8950-2 33 - 116

12 - Harness
04 - Chassis
Page Page
33-116 33-117

-S001
S 832A 1.00 mm² YE -C_FC01:2 -W1_FC
S 832B 1.00 mm² YE -C_FC02:2 -W1_FC
S 832 1.50 mm² YE -C_FC06:1 -W1_FC
7000/3212 ; 45
-S002
S 836AA 1.00 mm² YE -C_FC01:3 -W1_FC
S 836AB 1.00 mm² YE -C_FC02:3 -W1_FC
S 836A 1.50 mm² YE -C_FC06:2 -W1_FC

7000/3212 ; 45
-S003
S 6004B 2.00 mm² YE -C_FC01:6 -W1_FC
S 6004 2.00 mm² YE -C_FC06:7 -W1_FC
S 6004A 1.00 mm² YE -C_FC03:2 -W1_FC
S 6004C 2.00 mm² YE -C_FC02:6 -W1_FC
S 6004D 0.75 mm² YE -C_FC04:2 -W1_FC

Page 33-116
336/E5778-3
33 - 117 9813/8950-2 33 - 117

12 - Harness
04 - Chassis

33 - 118 9813/8950-2 33 - 118

12 - Harness
04 - Chassis

-C_FC01
20 mm
400 mm
NC12
1 6
2 5
3 4
7000/3206
-P6 -P9
-C_FC01#1
NC12
7243/0150
7216/0018
LH FRONT HEADLIGHT
270 mm
-S002
50 mm
-S001
50 mm
30 mm
100 mm 780 mm 1500 mm 60 mm
6 5 4 3 2 1 -C_FC06
7 8 9 10 11 12
7000/3206 7000/3206
-P89 -P2 -S003
NC12 NC12
-C_FC06#1 ID Label
-ID1
7219/0016
TO CHASSIS HARNESS
-C_FC01 LH FRONT HEADLIGHT -S001

ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 7210/0030 S 832A 1.00 mm² YE -C_FC01:2 -W1_FC
370 mm
2 832A 1.00 mm² YE -S001:S -W1_FC S 832B 1.00 mm² YE -C_FC02:2 -W1_FC
3 836AA 1.00 mm² YE -S002:S -W1_FC S 832 1.50 mm² YE -C_FC06:1 -W1_FC
4 829A 1.00 mm² YE -C_FC06:3 -W1_FC
7000/3206
5 8031A 1.00 mm² YE -C_FC06:4 -W1_FC 7000/3104 In Line Ultrasonic Splice -P4
NC12
6 6004B 2.00 mm² YE -S003:S -W1_FC Additional Components
7000/3212 ; 45
2225 mm
ID Tag Size Colour Destination Cable Cavity Seal -C_FC03
7216/0016;1 # 6 Way DT06 Wedge
1 832 1.50 mm² YE -S001:S -W1_FC -S002 210 mm 2 1
2 836A 1.50 mm² YE -S002:S -W1_FC ID Tag Size Colour Destination Cable Cavity Seal
3 829A 1.00 mm² YE -C_FC01:4 -W1_FC S 836AA 1.00 mm² YE -C_FC01:3 -W1_FC
7000/3206 -C_FC03#1
4 8031A 1.00 mm² YE -C_FC01:5 -W1_FC -C_FC02 RH FRONT HEADLIGHT S 836AB 1.00 mm² YE -C_FC02:3 -W1_FC -P3 7212/0008
5 8029C 1.00 mm² YE -C_FC02:5 -W1_FC 7000/3206 ID Tag Size Colour Destination Cable Cavity Seal S 836A 1.50 mm² YE -C_FC06:2 -W1_FC NC08 HORN
-P88
6 8035 1.00 mm² YE -C_FC03:1 -W1_FC NC08 1 7210/0030
7 6004 2.00 mm² YE -S003:S -W1_FC 2 832B 1.00 mm² YE -S001:S -W1_FC 7000/3104 In Line Ultrasonic Splice
8 830D 1.00 mm² YE -C_FC02:4 -W1_FC 3 836AB 1.00 mm² YE -S002:S -W1_FC Additional Components
9 8125B 0.75 mm² YE -C_FC04:3 -W1_FC 4 830D 1.00 mm² YE -C_FC06:8 -W1_FC 7000/3212 ; 45
10 5101 0.75 mm² YE -C_FC04:1 -W1_FC 5 8029C 1.00 mm² YE -C_FC06:5 -W1_FC
11 7210/0030 6 6004C 2.00 mm² YE -S003:S -W1_FC
12 7210/0030
7219/0016 12 Way DT06 Socket Housing Additional Components
Additional Components 7216/0016;1 # 6 Way DT06 Wedge -S003
7219/0012;1 # 12 Way DT06 Wedge ID Tag Size Colour Destination Cable Cavity Seal
S 6004B 2.00 mm² YE -C_FC01:6 -W1_FC
S 6004 2.00 mm² YE -C_FC06:7 -W1_FC
-C_FC03 HORN S 6004A 1.00 mm² YE -C_FC03:2 -W1_FC
ID Tag Size Colour Destination Cable Cavity Seal S 6004C 2.00 mm² YE -C_FC02:6 -W1_FC
700 mm
-C_FC04 1 8035 1.00 mm² YE -C_FC06:6 -W1_FC S 6004D 0.75 mm² YE -C_FC04:2 -W1_FC
2 6004A 1.00 mm² YE -S003:S -W1_FC
7212/0008 2 Way Econo 070 Socket Housing Additional Components
Additional Components 7000/3212;45 # Adhesive Lined Heatshrink
2 1
3
-C_FC04#3
7213/0005
TO PROXIMITY SENSOR -C_FC04 TO PROXIMITY SENSOR
1 5101 0.75 mm² YE -C_FC06:10 -W1_FC
2 6004D 0.75 mm² YE -S003:S -W1_FC
3 8125B 0.75 mm² YE -C_FC06:9 -W1_FC

20 mm -C_FC02
600 mm
NC12
1 6
2 5
3 4
7000/3206
-P5 -P10 -C_FC02#1
NC12
7243/0150 7216/0018
RH FRONT HEADLIGHT
336-E4506-4
33 - 119 9813/8950-2 33 - 119

12 - Harness
04 - Chassis
Page Page
33-120 33-121
30 mm
100 mm 780 mm 1500 mm
6 5 4 3 2 1 -C_FC06
7 8 9 10 11 12
7000/3206
-P89
NC12
-C_FC06#1 ID Label
-ID1
7219/0016
TO CHASSIS HARNESS
-C_FC01 LH FRONT HEADLIGHT

1 7210/0030
2 832A 1.00 mm² YE -S001:S -W1_FC
3 836AA 1.00 mm² YE -S002:S -W1_FC
4 829A 1.00 mm² YE -C_FC06:3 -W1_FC
5 8031A 1.00 mm² YE -C_FC06:4 -W1_FC
6 6004B 2.00 mm² YE -S003:S -W1_FC

2225 mm
7216/0016;1 # 6 Way DT06 Wedge
1 832 1.50 mm² YE -S001:S -W1_FC
2 836A 1.50 mm² YE -S002:S -W1_FC
3 829A 1.00 mm² YE -C_FC01:4 -W1_FC
4 8031A 1.00 mm² YE -C_FC01:5 -W1_FC -C_FC02 RH FRONT HEADLIGHT
5 8029C 1.00 mm² YE -C_FC02:5 -W1_FC 7000/3206 ID Tag Size Colour Destination Cable Cavity Seal
-P88
6 8035 1.00 mm² YE -C_FC03:1 -W1_FC NC08 1 7210/0030
7 6004 2.00 mm² YE -S003:S -W1_FC 2 832B 1.00 mm² YE -S001:S -W1_FC
8 830D 1.00 mm² YE -C_FC02:4 -W1_FC 3 836AB 1.00 mm² YE -S002:S -W1_FC
Page 33-121
9 8125B 0.75 mm² YE -C_FC04:3 -W1_FC 4 830D 1.00 mm² YE -C_FC06:8 -W1_FC
10 5101 0.75 mm² YE -C_FC04:1 -W1_FC 5 8029C 1.00 mm² YE -C_FC06:5 -W1_FC
11 7210/0030 6 6004C 2.00 mm² YE -S003:S -W1_FC
12 7210/0030
Additional Components 7216/0016;1 # 6 Way DT06 Wedge
7219/0012;1 # 12 Way DT06 Wedge
-C_FC03 HORN
-C_FC04 1 8035 1.00 mm² YE -C_FC06:6 -W1_FC
2 6004A 1.00 mm² YE -S003:S -W1_FC

2 1
3
-C_FC04#3
7213/0005
TO PROXIMITY SENSOR -C_FC04 TO PROXIMITY SENSOR
1 5101 0.75 mm² YE -C_FC06:10 -W1_FC
2 6004D 0.75 mm² YE -S003:S -W1_FC
3 8125B 0.75 mm² YE -C_FC06:9 -W1_FC

33 - 120 9813/8950-2 33 - 120

12 - Harness
04 - Chassis
Page Page
33-120 33-121
Figure 652. (Part 2 of 2) 20 mm

-C_FC01
400 mm
NC12
1 6
2 5
3 4
7000/3206
-P6 -P9
-C_FC01#1
NC12
7243/0150
7216/0018
LH FRONT HEADLIGHT
270 mm
-S002
50 mm
-S001
50 mm
60 mm
7000/3206
-P2 -S003
NC12
-S001
Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
7210/0030 S 832A 1.00 mm² YE -C_FC01:2 -W1_FC
-S001:S -W1_FC S 832B 1.00 mm² YE -C_FC02:2 -W1_FC 370 mm
-S002:S -W1_FC S 832 1.50 mm² YE -C_FC06:1 -W1_FC
-C_FC06:3 -W1_FC
7000/3206
-C_FC06:4 -W1_FC 7000/3104 In Line Ultrasonic Splice -P4
NC12
-S003:S -W1_FC Additional Components
7000/3212 ; 45
-C_FC03
-S002 210 mm 2 1
S 836AA 1.00 mm² YE -C_FC01:3 -W1_FC
7000/3206 -C_FC03#1
S 836AB 1.00 mm² YE -C_FC02:3 -W1_FC -P3 7212/0008
NC08
Destination Cable Cavity Seal S 836A 1.50 mm² YE -C_FC06:2 -W1_FC HORN
7210/0030
-S001:S -W1_FC 7000/3104 In Line Ultrasonic Splice
-S002:S -W1_FC Additional Components
Page 33-120
-C_FC06:8 -W1_FC 7000/3212 ; 45

-C_FC06:5 -W1_FC
-S003:S -W1_FC
-S003
S 6004B 2.00 mm² YE -C_FC01:6 -W1_FC
S 6004 2.00 mm² YE -C_FC06:7 -W1_FC
S 6004A 1.00 mm² YE -C_FC03:2 -W1_FC
Destination Cable Cavity Seal S 6004C 2.00 mm² YE -C_FC02:6 -W1_FC
700 mm
-C_FC06:6 -W1_FC S 6004D 0.75 mm² YE -C_FC04:2 -W1_FC

-S003:S -W1_FC
PROXIMITY SENSOR
Destination Cable Cavity Seal
-C_FC06:10 -W1_FC
-S003:S -W1_FC
-C_FC06:9 -W1_FC
20 mm -C_FC02
600 mm
NC12
1 6
2 5
3 4
7000/3206
-P5 -P10 -C_FC02#1
NC12
7243/0150 7216/0018
RH FRONT HEADLIGHT
336-E4506-4
33 - 121 9813/8950-2 33 - 121

12 - Harness
04 - Chassis

33 - 122 9813/8950-2 33 - 122

12 - Harness
04 - Chassis

20 mm -C_FC01
700 mm
NC12
1 6
2 5
3 4
7000/3206
-P72 -P68 -C_FC01#2
NC12 7216/0018
7243/0150
460 mm
LH FRONT HEADLIGHT
-S002
50 mm
-S001
50 mm
-C_FC06
30 mm 100 mm 1750 mm 550 mm 60 mm
6 5 4 3 2 1
7 8 9 10 11 12
7000/3206 7000/3206
-C_FC06#2 -P76
NC12
-P91 -S003
NC12
7219/0016
TO CHASSIS HARNESS -ID5
ID Label

1 7210/0030 S 832A 1.00 mm² YE -C_FC01:2 -W1_FC
7000/3206
70 mm
NC12
-P73
4 829A 1.00 mm² YE -C_FC06:3 -W1_FC
70 mm
7000/3212 ; 45 7000/3206
-P90
7216/0018 6 Way DT06 Socket Housing NC08
-C_FC03
7216/0016;1 # 6 Way DT06 Wedge
240 mm 2 1
-S002
ID Tag Size Colour Destination Cable Cavity Seal 7000/3206
-C_FC03#2
S 836AA 1.00 mm² YE -C_FC01:3 -W1_FC -P74 7212/0008
-C_FC02 RH FRONT HEADLIGHT NC08 HORN
S 836AB 1.00 mm² YE -C_FC02:3 -W1_FC
S 836A 1.50 mm² YE -C_FC06:2 -W1_FC
1 7210/0030
2 832B 1.00 mm² YE -S001:S -W1_FC 7000/3104 In Line Ultrasonic Splice
3 836AB 1.00 mm² YE -S002:S -W1_FC Additional Components
4 830D 1.00 mm² YE -C_FC06:8 -W1_FC
7000/3212 ; 45
5 8029C 1.00 mm² YE -C_FC06:5 -W1_FC
6 6004C 2.00 mm² YE -S003:S -W1_FC

Additional Components -S003
1000 mm
7000/3206
7216/0016;1 # 6 Way DT06 Wedge
NC12
-P75
S 6004B 2.00 mm² YE -C_FC01:6 -W1_FC
S 6004 2.00 mm² YE -C_FC06:7 -W1_FC
S 6004A 1.00 mm² YE -C_FC03:2 -W1_FC
S 6004C 2.00 mm² YE -C_FC02:6 -W1_FC 2 1
S 6004D 0.75 mm² YE -C_FC04:2 -W1_FC

-C_FC03 HORN 3
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice -C_FC04#4
1 8035 1.00 mm² YE -C_FC06:6 -W1_FC Additional Components 7213/0005
2 6004A 1.00 mm² YE -S003:S -W1_FC TO PROXIMITY SENSOR
-C_FC02
-C_FC06 TO CHASSIS HARNESS 20 mm
7212/0009;1 # 2 Way Econo 070 Socket Retainer ID Tag Size Colour Destination Cable Cavity Seal 900 mm 1
2
6
5
NC12
1 832 1.50 mm² YE -S001:S -W1_FC 3 4
TO PROXIMITY SENSOR 2 836A 1.50 mm² YE -S002:S -W1_FC -C_FC02#2

-C_FC04 7216/0018
ID Tag Size Colour Destination Cable Cavity Seal 3 829A 1.00 mm² YE -C_FC01:4 -W1_FC -P69
RH FRONT HEADLIGHT
1 5101 0.75 mm² YE -C_FC06:10 -W1_FC 4 8031A 1.00 mm² YE -C_FC01:5 -W1_FC 7243/0150
2 6004D 0.75 mm² YE -S003:S -W1_FC 5 8029C 1.00 mm² YE -C_FC02:5 -W1_FC
3 8125B 0.75 mm² YE -C_FC06:9 -W1_FC 6 8035 1.00 mm² YE -C_FC03:1 -W1_FC
7 6004 2.00 mm² YE -S003:S -W1_FC
7213/0005 3 Way HW090 Socket Housing 8 830D 1.00 mm² YE -C_FC02:4 -W1_FC
Additional Components 9 8125B 0.75 mm² YE -C_FC04:3 -W1_FC
7213/0007;1 # 3 Way HW090 Socket Retainer 10 5101 0.75 mm² YE -C_FC04:1 -W1_FC
11 7210/0030
12 7210/0030

Additional Components 400/E3656-4
7219/0012;1 # 12 Way DT06 Wedge
33 - 123 9813/8950-2 33 - 123

12 - Harness
04 - Chassis
Page Page
33-124 33-125
-C_FC06
30 mm 100 mm 1750 mm
6 5 4 3 2 1
7 8 9 10 11 12
7000/3206
-C_FC06#2 -P76
NC12
7219/0016
TO CHASSIS HARNESS -ID5
ID Label

1 7210/0030 S 832A 1.00 mm² YE -C_FC01:2 -W1_FC
4 829A 1.00 mm² YE -C_FC06:3 -W1_FC
70 mm
7000/3212 ; 45 7000/3206
-P90
7216/0018 6 Way DT06 Socket Housing NC08
7216/0016;1 # 6 Way DT06 Wedge
-S002
S 836AA 1.00 mm² YE -C_FC01:3 -W1_FC
-C_FC02 RH FRONT HEADLIGHT
S 836AB 1.00 mm² YE -C_FC02:3 -W1_FC
S 836A 1.50 mm² YE -C_FC06:2 -W1_FC
1 7210/0030
Page 33-125
2 832B 1.00 mm² YE -S001:S -W1_FC 7000/3104 In Line Ultrasonic Splice
3 836AB 1.00 mm² YE -S002:S -W1_FC Additional Components
4 830D 1.00 mm² YE -C_FC06:8 -W1_FC
7000/3212 ; 45
5 8029C 1.00 mm² YE -C_FC06:5 -W1_FC
6 6004C 2.00 mm² YE -S003:S -W1_FC

7216/0016;1 # 6 Way DT06 Wedge
S 6004B 2.00 mm² YE -C_FC01:6 -W1_FC
S 6004 2.00 mm² YE -C_FC06:7 -W1_FC
S 6004A 1.00 mm² YE -C_FC03:2 -W1_FC
S 6004C 2.00 mm² YE -C_FC02:6 -W1_FC 2 1
S 6004D 0.75 mm² YE -C_FC04:2 -W1_FC

-C_FC03 HORN 3
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice -C_FC04#4
1 8035 1.00 mm² YE -C_FC06:6 -W1_FC Additional Components 7213/0005
2 6004A 1.00 mm² YE -S003:S -W1_FC TO PROXIMITY SENSOR
7212/0009;1 # 2 Way Econo 070 Socket Retainer ID Tag Size Colour Destination Cable Cavity Seal
1 832 1.50 mm² YE -S001:S -W1_FC
TO PROXIMITY SENSOR 2 836A 1.50 mm² YE -S002:S -W1_FC
-C_FC04
ID Tag Size Colour Destination Cable Cavity Seal 3 829A 1.00 mm² YE -C_FC01:4 -W1_FC
1 5101 0.75 mm² YE -C_FC06:10 -W1_FC 4 8031A 1.00 mm² YE -C_FC01:5 -W1_FC
2 6004D 0.75 mm² YE -S003:S -W1_FC 5 8029C 1.00 mm² YE -C_FC02:5 -W1_FC
3 8125B 0.75 mm² YE -C_FC06:9 -W1_FC 6 8035 1.00 mm² YE -C_FC03:1 -W1_FC
7 6004 2.00 mm² YE -S003:S -W1_FC
7213/0005 3 Way HW090 Socket Housing 8 830D 1.00 mm² YE -C_FC02:4 -W1_FC
Additional Components 9 8125B 0.75 mm² YE -C_FC04:3 -W1_FC
7213/0007;1 # 3 Way HW090 Socket Retainer 10 5101 0.75 mm² YE -C_FC04:1 -W1_FC
11 7210/0030
12 7210/0030

7219/0012;1 # 12 Way DT06 Wedge
33 - 124 9813/8950-2 33 - 124

12 - Harness
04 - Chassis
Page Page
33-124 33-125
Figure 653. (Part 2 of 2) 20 mm -C_FC01

700 mm
NC12
1 6
2 5
3 4
7000/3206
-P72 -P68 -C_FC01#2
NC12 7216/0018
7243/0150
460 mm
LH FRONT HEADLIGHT
-S002
50 mm
-S001
50 mm
550 mm 60 mm
7000/3206
-P91 -S003
NC12
7000/3206
70 mm
NC12
-P73
7000/3206
-P90
NC08
-C_FC03
240 mm 2 1
-C_FC03#2
7000/3206
-P74 7212/0008
NC08 HORN
Page 33-124
1000 mm
-C_FC04
7000/3206
NC12
-P75
TO PROXIMITY SENSOR
-C_FC02
20 mm
900 mm 1
2
6
5
NC12
3 4
-C_FC02#2
7216/0018
-P69
RH FRONT HEADLIGHT
7243/0150
400/E3656-4
33 - 125 9813/8950-2 33 - 125

12 - Harness
04 - Chassis

Figure 654. Front Chassis Harness 400/M3159 (Sheet 1 of 1)............................................Page 33-127
33 - 126 9813/8950-2 33 - 126

12 - Harness
04 - Chassis

Harness 400/M3159 (Sheet 1 of 1) Page 33-129
2 1
-C004#2
7213/0005
TO PROXIMITY SENSOR
1 6
2 5
3 4
-C004
-C001#4
7216/0018
LH FRONT HEADLIGHT
-C001
20 mm
7243/0150
-P1
NC12
80 mm
1200 mm
7000/3206
-P83
NC08
7000/3206
-P85
NC12
-IC03 20 mm
7243/0150
30 mm 100 mm 1450 mm 1950 mm 50 mm 50 mm 50 mm 100 mm 1900 mm

-P87
6 5 4 3 2 1
1 6
NC12
-C002 2
3
5
4
7 8 9 10 11 12
7000/3206 7000/3206 7000/3206 7000/3206
-P82 -P84 -P7 -P86
NC12 -S003 -S001 NC16 -S002 NC12 NC12
-C002#4
-IC03#4 ID Label 7216/0018
7219/0016 -ID7 RH FRONT HEADLIGHT
TO CHASSIS HARNESS
200 mm
-C001 LH FRONT HEADLIGHT 7000/3206
-P8
-IC03 TO CHASSIS HARNESS
ID Tag Size Colour Destination Cable Cavity Seal -S001 NC08
1 7210/0030 ID Tag Size Colour Destination Cable Cavity Seal 1 8003 2.00 mm² YE -S001:S -W1
2 8003A 2.00 mm² YE -S001:S -W1 S 8003A 2.00 mm² YE -C001:2 -W1 2 8010A 2.00 mm² YE -S002:S -W1
3 8010AA 2.00 mm² YE -S002:S -W1 S 8003B 2.00 mm² YE -C002:2 -W1 3 8019A 1.00 mm² YE -C001:4 -W1
4 8019A 1.00 mm² YE -IC03:3 -W1 S 8003 2.00 mm² YE -IC03:1 -W1 4 8031A 1.00 mm² YE -C001:5 -W1
5 8031A 1.00 mm² YE -IC03:4 -W1 5 8029C 1.00 mm² YE -C002:5 -W1
6 6004B 2.00 mm² YE -S003:S -W1 6 8035 1.00 mm² YE -C003:1 -W1
7 6004 2.00 mm² YE -S003:S -W1
7216/0018 6 Way DT06 Socket Housing 7000/3212 ; 45 8 8501D 1.00 mm² YE -C002:4 -W1
Additional Components -S002 9 8125B 0.75 mm² YE -C004:3 -W1
7216/0016;1 # 6 Way DT06 Wedge ID Tag Size Colour Destination Cable Cavity Seal 10 5101 0.75 mm² YE -C004:1 -W1
S 8010AA 2.00 mm² YE -C001:3 -W1 11 7210/0030
RH FRONT HEADLIGHT S 8010AB 2.00 mm² YE -C002:3 -W1 12 7210/0030
-C002 -C003
ID Tag Size Colour Destination Cable Cavity Seal S 8010A 2.00 mm² YE -IC03:2 -W1
1 7210/0030
7000/3104 In Line Ultrasonic Splice Additional Components
2 8003B 2.00 mm² YE -S001:S -W1 2 1
Additional Components 7219/0012;1 # 12 Way DT06 Wedge
3 8010AB 2.00 mm² YE -S002:S -W1
7000/3212 ; 45 -C003#4
4 8501D 1.00 mm² YE -IC03:8 -W1 7212/0008
HORN
5 8029C 1.00 mm² YE -IC03:5 -W1
-S003
6 6004C 2.00 mm² YE -S003:S -W1 ID Tag Size Colour Destination Cable Cavity Seal
-C004 TO PROXIMITY SENSOR
S 6004B 2.00 mm² YE -C001:6 -W1 ID Tag Size Colour Destination Cable Cavity Seal
S 6004 2.00 mm² YE -IC03:7 -W1 1 5101 0.75 mm² YE -IC03:10 -W1
S 6004A 1.00 mm² YE -C003:2 -W1 2 6004D 0.75 mm² YE -S003:S -W1
7216/0016;1 # 6 Way DT06 Wedge
S 6004C 2.00 mm² YE -C002:6 -W1 3 8125B 0.75 mm² YE -IC03:9 -W1
S 6004D 0.75 mm² YE -C004:2 -W1
-C003 HORN 7213/0005 3 Way HW090 Socket Housing
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice Additional Components
1 8035 1.00 mm² YE -IC03:6 -W1 Additional Components
2 6004A 1.00 mm² YE -S003:S -W1 7000/3212;45 # Adhesive Lined Heatshrink

33 - 127 9813/8950-2 33 - 127

12 - Harness
04 - Chassis
Page Page
33-128 33-129
Figure 654. (Part 1 of 2) 2 1
-C004#2
7213/0005
TO PROXIMITY SENSOR
1 6
2 5
3 4
-C004
-C001#4
7216/0018
LH FRONT HEADLIGHT
-C001
20 mm
7243/0150
-P1
NC12
80 mm
1200 mm
7000/3206
-P83
NC08
7000/3206
-P85
NC12
-IC03
6 5 4 3 2 1
30 mm 100 mm 1450 mm 1950 mm 50 mm 50 mm 50 mm
7 8 9 10 11 12
7000/3206 7000/3206
-P82 -P84
NC12 -S003 -S001 NC16 -S002
-IC03#4 ID Label
7219/0016 -ID7
TO CHASSIS HARNESS
-C001 LH FRONT HEADLIGHT

ID Tag Size Colour Destination Cable Cavity Seal -S001
1 7210/0030 ID Tag Size Colour Destination Cable
2 8003A 2.00 mm² YE -S001:S -W1 S 8003A 2.00 mm² YE -C001:2 -W1
3 8010AA 2.00 mm² YE -S002:S -W1 S 8003B 2.00 mm² YE -C002:2 -W1
4 8019A 1.00 mm² YE -IC03:3 -W1 S 8003 2.00 mm² YE -IC03:1 -W1
5 8031A 1.00 mm² YE -IC03:4 -W1
6 6004B 2.00 mm² YE -S003:S -W1
Page 33-129
7216/0018 6 Way DT06 Socket Housing 7000/3212 ; 45
7216/0016;1 # 6 Way DT06 Wedge ID Tag Size Colour Destination Cable
S 8010AA 2.00 mm² YE -C001:3 -W1
RH FRONT HEADLIGHT S 8010AB 2.00 mm² YE -C002:3 -W1
-C002
ID Tag Size Colour Destination Cable Cavity Seal S 8010A 2.00 mm² YE -IC03:2 -W1
1 7210/0030
2 8003B 2.00 mm² YE -S001:S -W1
3 8010AB 2.00 mm² YE -S002:S -W1
7000/3212 ; 45
4 8501D 1.00 mm² YE -IC03:8 -W1
5 8029C 1.00 mm² YE -IC03:5 -W1
-S003
6 6004C 2.00 mm² YE -S003:S -W1 ID Tag Size Colour Destination Cable
S 6004B 2.00 mm² YE -C001:6 -W1
S 6004 2.00 mm² YE -IC03:7 -W1
S 6004A 1.00 mm² YE -C003:2 -W1
7216/0016;1 # 6 Way DT06 Wedge
S 6004C 2.00 mm² YE -C002:6 -W1
S 6004D 0.75 mm² YE -C004:2 -W1
-C003 HORN
ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice
1 8035 1.00 mm² YE -IC03:6 -W1 Additional Components
2 6004A 1.00 mm² YE -S003:S -W1 7000/3212;45 # Adhesive Lined Heatshrink

33 - 128 9813/8950-2 33 - 128

12 - Harness
04 - Chassis
Page Page
33-128 33-129
LH FRONT HEADLIGHT
-P1
7000/3206
-P85
NC12
20 mm
7243/0150
50 mm 100 mm 1900 mm
-P87
1 6
NC12
-C002 2
3
5
4
7000/3206 7000/3206
-P7 -P86
-S002 NC12 NC12
-C002#4
7216/0018
RH FRONT HEADLIGHT
200 mm
7000/3206
-P8
-IC03 TO CHASSIS HARNESS
NC08
Destination Cable Cavity Seal 1 8003 2.00 mm² YE -S001:S -W1
-C001:2 -W1 2 8010A 2.00 mm² YE -S002:S -W1
-C002:2 -W1 3 8019A 1.00 mm² YE -C001:4 -W1
-IC03:1 -W1 4 8031A 1.00 mm² YE -C001:5 -W1
5 8029C 1.00 mm² YE -C002:5 -W1
6 8035 1.00 mm² YE -C003:1 -W1
Page 33-128
7 6004 2.00 mm² YE -S003:S -W1

8 8501D 1.00 mm² YE -C002:4 -W1
9 8125B 0.75 mm² YE -C004:3 -W1
Destination Cable Cavity Seal 10 5101 0.75 mm² YE -C004:1 -W1
-C001:3 -W1 11 7210/0030
-C002:3 -W1 12 7210/0030
-IC03:2 -W1 -C003
2 1
7219/0012;1 # 12 Way DT06 Wedge
-C003#4
7212/0008
HORN
Destination Cable Cavity Seal TO PROXIMITY SENSOR

-C004
-C001:6 -W1 ID Tag Size Colour Destination Cable Cavity Seal
-IC03:7 -W1 1 5101 0.75 mm² YE -IC03:10 -W1
-C003:2 -W1 2 6004D 0.75 mm² YE -S003:S -W1
-C002:6 -W1 3 8125B 0.75 mm² YE -IC03:9 -W1
-C004:2 -W1
33 - 129 9813/8950-2 33 - 129

12 - Harness
05 - Rear Chassis
05 - Rear Chassis
Diagram

Front Tip [Hi-Viz], Cab ............. Page 33-130
(For: 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 Front Tip [Hi-Viz], Cab)
Figure 655. Rear Chassis Harness - 400/M1627 (Sheet 1 of 5).......................................... Page 33-131
33 - 130 9813/8950-2 33 - 130

12 - Harness
05 - Rear Chassis
Page 33-132 Figure 655. Rear Chassis Harness

- 400/M1627 (Sheet 1 of 5) Page 33-133
-C_RC41
25 mm -C_RC34
B A
50 mm
7000/3206 1 2
-P247
C
mm -C_RC14 -CAN1
-C_RC41#1
7213/0030 50 7000/3206
-P84 7212/0044 727/00002
NC08 -C_RC34#1
25 mm -C_RC20
TO WORKLAMPHARNESS GRID HEATER A B -C_RC08 20 mm 20 mm
50 mm 50 mm
10
120 OHM
0m
CAN TERM
B
NC08
NC08
C A
7000/3206
m
-P207 -C_RC14#1 2 1
7213/0031
25 mm
7000/3206 7000/3206
C
mm
-C_RC08#1
50 mm
FIX WITH C014 AFTER TEST. DGN TR 1 -P21 -P20 -P17
-P16 NC08 NC08
7212/0052 7243/0137 7210/0066 -C_RC20#1
20
FUELPUMP 7213/0031
-C_RC29 W. I. F.
20
-CAN3
727/00002
-C_RC31
mm
300 mm 200 mm 70 mm 30 mm 170 mm 30 mm 70 mm 50 mm 30 mm 80 mm 50 mm A B
120 OHM
F E D CB A
CAN TERM
-C_RC31#1 7000/3206 75 7000/3206 7000/3206
7000/3206
7000/3206
C
7216/0059 -P71
NC08 mm -P72
NC32
-S_SRC06 -P192 -CANLS5 -CANHS5 -P85
-P208
-C_RC29#1
FOOT THROTTLE
mm FIX WITH C029 AFTER TEST.
7000/3206 NC32
170 mm
-P73 7213/0031
40
-C_RCC
NC12 ENGINE TR
UTEND1
-FB-C-43#1
-C_RC16 7241/0001
FUSEBOX C 7000/3206
200 mm
UTEND21/1
-P19
-C_RC32 -D3
CUTEND
330 mm
CUTEND
-C_RCC
NC12
A B 30 mm -C_RC01
7207/1513 1 7.5A-FC1 2
1/1
1 2 LIVELINK GND 3 4
NO CONNECTOR
15A-FC2
NO CONNECTOR
70 mm
7000/3206 -C_RC32#1 5 6
CUT
LEAD
C 7.5A-FC3
40 mm
-P70
7232/0017
LEAD
NC08 7 8
-FB-C-43
7.5A-FC4
TAPE BACKT O
CUT
-C_RC16#1 DIODE D1
MAIN BRANCH. 9 15A-FC5 10
7213/0031
11 7.5A-FC6 12
20 mm
M10
13 14
-C_RC10
7.5A-FC7
125 mm 240 mm
180 mm
100 mm
15 3A-FC8 16
M10 17 5A-FC9 18
NC08
-T_RC02
mm
7207/1510 50 2 1
19 5A-FC10 20
TO CHASSIS EARTH 7000/3202 mm 7000/3206 7000/3206
30
-P67 -P109 -C_RC10#1
-P74 -C_RC25
-P113 7243/0121
20 mm
NC28
NC32 -P75
NC08 7212/0052 -FB-B-42#1
1 2 7243/0137
TRANS OILPRESS SW 7000/3203
7241/0001
100 mm 40 mm 30 mm 30 mm 50 mm 50 mm 80 mm 20 mm 230 mm 30 mm 270 mm 700 mm
175 mm
100 mm
FUSEBOX B
-P250
NC28
1 4
NC12
-T_RC03 M10
7207/1502 -C_RC02#1 1 10A-FB1 2 2 3
ECU EARTH 7000/3206 7000/3206 7000/3206 7000/3206
332/E9928 7000/3206
mm
ECU FEEDS -P94 -P194 -P195
7000/3202
TO OPERATOR HARNESS
3 10A-FB2 4 -P87 -CANLS1 -CANHS1 -S_SRC35 -CANSHD1 -P22 -C_RC25#1
mm
NC16
50 mm
-P68 NC32
NC12 7243/0157
220 mm
5 6 7214/0025
50
150 mm
10A-FB3
-C_RC02
210
-FB-B-42
-P4
1 3
RH REAR LIGHTS
-P25/320
7 10A-FB4 8
-P90
125 mm
7000/3206
30 mm
7000
-P82 9 10A-FB5 10 7000/3206 7000/3206
NC25
150 mm
NC12 11 12 -P95
-T_RC01 M10 5A-FB6
NC08
7207/1510 13 5A-FB7 14
TO CHASSIS EARTH 15 16
70 mm
7000/3202 3A-FB8
-P69
-C_RC05#1
3203
17 18 -S_SRC27
10 mm
7000/3206 7000/ 30A-FB9
-P252
60 mm 200 mm 140 mm
-P66 7213/0031 A
mm
B 19 5A-FB10 20
75 mm
NC32 7000/3206
mm 170
CLUTCH PEDALSWITCH -P196
-FB-A-41#1
-S_SRC22
C -C_RC27 20 mm 20 mm -C_RC26
10 120 7241/0001
100 mm 90 mm mm FUSEBOX A
5
C0
NC08
NC08
_R
1 15A-FA1 2
10 mm
2 1 2 1 2 1
30 mm
-C
7000/3206 -P25
7000 3 15A-FA2
4
7000/3206 3
-C_RC27#1 -P80 -C_RC26#1
D
-P81 /3203
-C_RC24#1
E
5 15A-FA3
6
C
7212/0052 -P76 NC08 NC08 -P77

7212/0052
F A B
7243/0137 7243/0137
J
REVERSE SOLENOID FORWARD SOLENOID 7 7.5A-FA4

8
G
-FB-A-41
H
375 mm
SEATBE LTSWITCH
-C_RC35 9 10
7.5A-FA5
30 mm 240 mm -C_RC12#1 11 10A-FA6

12
500 mm
7219/0098 7000/3206
1 2 3 4 5 6
DIAGNOSTIC
13 7.5A-FA7 14 -C_RC24 -P98
15 7.5A-FA8 16 NC08
-C_RC12
200 mm
40 mm
12 11 10 9 8 7
7000/3206 17 7.5A-FA9 18
25 mm
-C_RC07
NC0 72 06
-P65
0 mm
-C_RC35#1
250 mm
7000/3206
5
-P10/32
NC12
19 3A-FA10 20
7219/0015 -P62
8
C1
700
/3206 NC12
TO FRONTCHASSIS HARNESS 7000/3206
25
-C_RC40
7000
-P115 -P79 _R
-S_SRC03 -S_SRC18
30 mm 25 mm NC08 -C 2 1
40 mm
10 9
mm
1
7243/0137
2
6
5
7000/3206 3 6 -C_RC07#1
-P49
-P64
20 mm
3 4
NC32 2 5 7212/0030
30 AC COMPRESSOR CLUTCH
7000/3203
1 4
-C_RC40#1
-S_SRC01
-P255
7216/0018 8 7
170 mm
TO WORK LAMPSW HARNESS
0 mm
-C_RC15#1 NC08
40 mm
7219/0013
30 mm 80 mm 50 mm 50 mm 100 mm 15 03 SERVICE HOUR RESETSWITCH

-D1 -C_RC36 40 mm -C_RC03
0/3256
40 mm
700 -P2
NC08 7241/0003
-RB01
20 mm
105 mm 110 mm 145 mm 100 mm 10 mm
1 2
7000/3206
-C_RC36#1 -S_SRC14 7000/3206
7243/0137
-P171
7232/0017 NC32 -S_SRC07 -P63
1000 mm
-P78
PARK BRAKE DIODE ID Label NC25 -C_RC37
03
TAPE BACKT O
0/32
-ID1
7000/3203
40 mm
2
-P18
MAIN BRANCH.
mm
-P254
7241/0003
700
NC08
-RB02
-RB03#1
90 mm
-RB01#1
20 mm
-RB02#1 -RB04#1 -RB05#1
7241/0003 7241/0003
200 mm
7241/0003 7241/0003
P
7241/0003
60
E N
BRAKE LIGHT/HORN RLY IGN RLY/GR BEACON RLY STRTINTERLOCK/IGN R LY FWD/REV RELAY TRANS DUMP/LIFTPUM PR LY
F D
M
7243/0137
8 8 8 8 8
mm
A C
03
G
B L
7 6 7 6 7 6 7 6 7 6
-P96
9 9 9 9
100 9 H K
0/323
J
700
-P18 40 mm 10 10 10 10 10
-C_RC06#1
-RB03
5 5 5 5 5 7000/3206
-S_SRC30 mm 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4
7219/0086 -P50
-C_RC17 130 ENGINE HARNESS NC08
7241/0003 3 3 3 3 3
-C_RC06
40 mm
7000/3206 -P200 -C_RC37#1
-P48 203 7241/0003 -C_RC39
30 mm
-RB04
7000/3 7000/3203 7219/0076
2 1 100 mm -P202
ENGINE ECU
4 12 62
-C_RC17#1 -C_RC30
7212/0052 70 mm
TRANS OIL TEMPSW
-S_SRC05 2 1
7000/3203
1 9 13 17 25 29 37 41 45 49 53 57 60
-P181
40 mm 7241/0003
-RB05
-P184
2 1
-S_SRC31 7514/0005
7000/3203
210 mm -C_RC04 -C_RC39#1
-D_RC1
170 mm 30 mm -C_RC30#1
7212/0001
50 mm
7212/0052
7000/3203 REVERSE ALARM
-DH2 -D7
-DH1 -D6
-P249
FUELSENDER
-C_RC03#1
DESCRIBED IN STD00141
TAPET O HARNESS AS
TO OPERATOR HARNESS 2 1
7000/3206 -C_RC28
40 mm -P170 -C_RC04#1
350 mm
100 mm
-DH2#1 7212/0052
-RB06
-DH1#1 NC08
7233/0015 7233/0015 -S_SRC29 SEATSWITCH
80 mm
-C_RC33 3 2 1 3 2 1 X
6 5 4 3 2 X
1
-VE
+VE
190 mm
120 mm 30 mm -RB06#1 -RB07#1 -RB09#1
-RB10#1
7241/0003 7000/3206 -C_RC28#1
40 mm
-RB08#1
7241/0005
FLASHER RERLAY
7241/0005
PWR HOLD RLY
7241/0005
STARTER RELAY
7241/0005
WARNING BUZZER
SEATBE LTBUZZER REL AY
-P32 7216/0060
1 4 8 NC08 TMAF
15 mm
15 mm
15 mm
-RB07
mm
7 6 7000/3206
mm
7 4 1 7 4 1 7 4 1 7 4 1
6 3
9
2 3
-P17/320
-P110
10 NC32
50 mm
7000/3206 mm
70
8 5 2 8 5 2 8 5 2 8 5 2
7000
7000/3206
50
-P8
80 mm
-C_RC33#1 100 5 -P36

7214/0025
03
40 mm 9 6 3 9 6 3 9 6 3 9 6 3
1 2 4 NC16
-RB08
TO SPEEDOMETER HARNESS mm
3
15 mm
0/3277
130 -S_SRC25 30 mm 910 mm 910 mm 210 mm 130 mm
-CANHS3 15 700 -P1
15 mm mm -P1783203
7000/
40 mm
50 mm 50 mm
-RB09
170 mm 7000/3206 7000/3206 7000/3206
-S_SRC19 -P37 -P35 -P34
NC08
-C_RC09 NC12
30 mm 410 mm 30 mm 150 mm
NC16
-P179
-CANLS3 210 mm 40 mm
7000/3203
30 mm
-RB10
3 2 1
-C_RC23
30
30 7000/3203 -P180
70 mm 60 mm 60 mm 70 mm
7241/0003
-S_SRC13
mm
-C_RC09#1
280 mm
7000/3206
7000/3203
0 mm
-P175
-S_SRC04 -P248 CUTEND
60 mm
7213/0034 NO CONNECTOR
15 mm
LEAD CUT 1/1
PARK BRAKE
-D8 -DH3 -S_SRC15 -C_RCCUTEND3
15 mm 50 mm 50 mm 50 mm 50 mm -C_RC45 10 1
A B 18
AGREYB
1 2
-C_
RC
30 mm
20 GREY'B' 11
BLUE
RC
GREY -C_ 7000/3206
700 -P25 -C_RC19#1 -C_RC18#1 -P33 -C_RC23#1
19
1 2
-S_SRC24 0/32 7
TAPE BACKT O 7232/0008 7232/0009 NC08 7212/0013
-DH3#2 03 -C_RC45#1
7000/3211
MAIN BRANCH. PRIMARYFUSE-2 PRIMARYFUSE-1 AIR FILTER

-CANSHD3 7000/3203 332/E3213
-P266
7232/0017 -P258 -CANLS2 -CANSHD2 -CANHS2 Drive Inhibit ECU

DIECU DUMPDIODE
-S_SRC21
10 mm
30 mm 30 mm 30 mm 30 mm 30 mm 30 mm 30 mm 30 mm 100 mm 70 mm 50 mm 40 mm 30 mm 30 mm 30 mm 60 mm 30 mm -C_RC38 -D2 m -C_RC42

80 mm 0m 50 mm
20
120
4 1
3 2 1
-P269 3 2
7000/3211
-S_SRC10 -S_SRC23 -S_SRC20 -S_SRC34 7000/3211
-S_SRC28 -S_SRC32 -S_SRC33 -C_RC38#1
-S_SRC36 -S_SRC17 -S_SRC08 7000/3211
-S_SRC26 -S_SRC09 -S_SRC16
mm
-P271 -P270 06
-S_SRC02 7233/0015 0/32
-C_RC11 -C_RC42#1
20 mm
2
-P1
7000-P11
FR DIODE 700 7214/0024
400 mm
/320
ROP'S HARNESS
mm
6
6
200
4 1
120 mm
NC12
/320
3 2 35 7000 -P1
200 mm P
80 mm
E
-C_RC44
N
mm
M D
150 mm
7000/3206 7000/3206
F
-P174 -P15 7000/3206 C A
-C_RC11#1 -P7 -P10 PLEASE PROVIDE L

B G
NC12
7214/0025 7243/0157 M5 SIDE VIEW
50 mm
K H
-C_RC22
J
7000/3206
LH REAR LIGHTS -P13
100 mm
7207/1213
7000/3206 STARTER SOL
100 mm
-C_RC44#1
mm
-P204
20 7219/0187
mm
50
BLACK -C_RC13
300 mm 70 mm 250 mm
-C_RC43 CABIN HARNESS
1
50 mm 400 mm 180 mm 215 mm 135 mm 215 mm 275 mm 275 mm 105 mm 600 mm -P197
7000/3206
M5 -C_RC21
7207/1211
2 -C_RC43#1
ALTERNATOR D+ 7000/3206
7211/0005
7000/3206 -P205 7000/3206 -P9
-C_RC13#1 -P173 7000/3206 7000/3206 -P203 TO CABIN HARENESS
-P18
7232/0028
WASHER PUMP
400/M1627-5
33 - 131 9813/8950-2 33 - 131

12 - Harness
05 - Rear Chassis
Page Page
33-132 33-133

-C_RC41
25 mm -C_RC34
B A
50 mm
7000/3206
mm
1 2
C -P247
-C_RC41#1
7213/0030 50 7000/3206
-P84
NC08
7212/0044
-C_RC34#1
TO WORKLAMPHARNESS GRID HEATER
10
0m
m
50 mm
-C_RC31
300 mm 200 mm 70 mm 30 mm 170 mm 30 mm 70 mm 50 mm 30 mm 80 mm
F E D CB A
-C_RC31#1 7000/3206 75 7000/3206 7000/3206

7000/3206
7216/0059 -P71
mm -P72 -S_SRC06 -P192 -CANLS5 -CANHS5
mm
NC08 NC32 -P85
FOOT THROTTLE 7000/3206 NC32
40
-P73
NC12
-FB-C-43#1
-C_RC16 7241/0001
FUSEBOX C
200 mm -C_RC32 -D3
330 mm
A B 30 mm -C_RC01
7207/1513 1 7.5A-FC1 2
1 2 LIVELINK GND 3 15A-FC2 4
C 7000/3206 -C_RC32#1 5 7.5A-FC3 6
40 mm
-P70
NC08 7232/0017 7 7.5A-FC4 8
-FB-C-43
-C_RC16#1 TAPE BACKT O DIODE D1
MAIN BRANCH. 9 15A-FC5 10
7213/0031
11 7.5A-FC6 12
20 mm
M10
13 14
-C_RC10
7.5A-FC7
125 mm 240 mm
100 mm
15 3A-FC8 16
M10 17 5A-FC9 18
NC08
-T_RC02
mm
7207/1510 50 2 1
19 5A-FC10 20
TO CHASSIS EARTH 7000/3202 mm 7000/3206 7000/3206
30
-P67 -P109 -P74 -C_RC10#1
NC32 -P75
NC08 7212/0052 -FB-B-42#1
7243/0137 7241/0001
1 2 TRANS OILPRESS SW 7000/3203
175 mm
100 mm
FUSEBOX B
-P250
-T_RC03 M10
7207/1502 -C_RC02#1 1 10A-FB1 2
ECU EARTH 332/E9928
mm
7000/3202
m 3 4
10A-FB2
TO OPERATOR HARNESS
m
50 mm
-P68
50
220 mm
5 10A-FB3 6
-C_RC02
210
-FB-B-42
25 03
7 10A-FB4 8
-P /32
m
1
125 mm
7000/3206
30 m
00
-P82 9 10A-FB5 10
70
150 mm
NC12 11 12
-T_RC01 M10 5A-FB6
7207/1510 13 5A-FB7 14
TO CHASSIS EARTH 7000/3202 15 3A-FB8 16
203
-P69 0/3
-C_RC05#1 700 52 17 18
10 mm
30A-FB9
7000/3206 -P2
60 mm 200 mm 140 mm
mm
-P66 7213/0031 A B 19 5A-FB10 20
170
NC32
CLUTCH PEDALSWITCH
m
-FB-A-41#1
120
m
C -C_RC27 20 mm 20 mm -C_RC26 7241/0001
10
-S_SRC22
100 mm 90 mm mm FUSEBOX A
05
NC08
NC08
C
_R
1 15A-FA1 2
10 mm
2 1 2 1
30 m
-C
70 -P253
15A-FA2
7000/3206 7000/3206 3 4
00
-C_RC27#1 -P80 -C_RC26#1
m
D
-P81
E
/32
5 15A-FA3
6
C
-P76 NC08 -P77 03

7212/0052 NC08 7212/0052
F A B
7243/0137 7243/0137
J
REVERSE SOLENOID FORWARD SOLENOID 7 7.5A-FA4

8
G
-FB-A-41
H
-C_RC35 9 10
7.5A-FA5
30 mm 240 mm -C_RC12#1
7219/0098
11 10A-FA6
12
1 2 3 4 5 6 13 7.5A-FA7 14
DIAGNOSTIC
15 7.5A-FA8 16
-C_RC12
200 mm
mm
40 mm
12 11 10 9 8 7
7000/3206 17 7.5A-FA9 18
08 2 6
-P65
m
NC 17 20
-C_RC35#1
25
250 mm
7000/3206
15
19 20
-P /3
3A-FA10
0m
7219/0015 NC12 -P62
00
06
NC12 C
70
/32
_R
TO FRONTCHASSIS HARNESS 00
70 -P115 7000/3206
25
-C_RC40 -S_SRC03 -P79

-S_SRC18
30 mm 25 mm NC08 -C
40 mm
10 9
mm
1 6
2
7000/3206
5 3 6
-P64
30
3 4
NC32 2 5
7000/3203
1 4
-C_RC40#1
-S_SRC01
-P255
7216/0018 8 7
170 mm
mm
TO WORK LAMPSW HARNESS
-C_RC15#1
40 mm
0
15
7219/0013
3 SERVICE HOUR RESETSWITCH
-D1 -C_RC36 30 mm 80 mm 40 mm 50 mm 50 mm 100 mm 20
/3 6
00 25
-C_RC03
40 mm
70 -P
NC08 7241/0003
-RB01
20 mm
105 mm 110 mm 145 mm 100 mm 10 mm
1 2
7000/3206
-C_RC36#1 -S_SRC14 7000/3206
7243/0137
-P171
7232/0017 NC32 -S_SRC07 -P63
-P78
PARK BRAKE DIODE ID Label NC25
2 3
18 20
TAPE BACKT O
-ID1
7000/3203
-P /3
MAIN BRANCH. 40 mm
00
-P254
7241/0003
-RB02
70
m
-RB03#1
90 mm
-RB01#1 -RB05#1
-RB02#1 -RB04#1
7241/0003 7241/0003
200 mm
7241/0003 7241/0003 7241/0003
60
m 8 8 8 8 8
0m
3
20 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6
10 /3
40 mm
00 3 10 10 10 10 10
70 18
-P
-RB03
5 5 5 5 5
-S_SRC30 mm 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4
-C_RC17 130 7241/0003 3 3 3 3 3
40 mm
7000/3206 -P200
-P48 203 7241/0003
30 mm
0/3
-RB04
700 02 7000/3203
2 1 100 mm -P2
4 12 62
-C_RC17#1
7212/0052 70 mm
TRANS OIL TEMPSW
-S_SRC05
7000/3203
1 9 13 17 25 29 37 41 45 49 53 57 60
-P181
40 mm 7241/0003
-RB05
-P184
7000/
-S_SRC31 7514/0005
-D_RC1
3203
210 mm
50 mm
7000/3203
-DH2 -D7
-DH1 -D6
-P249
-C_RC03#1
TAPET O HARNESS AS
TO OPERATOR HARNESS
-DH2#1
40 mm
-RB06
-DH1#1
7233/0015 7233/0015 -S_SRC29
80 mm
-C_RC33 3 2 1 3 2 1
-VE
+VE
120 mm 30 mm -RB06#1 -RB07#1 -RB09#1
-RB10#1
7241/0003
40 mm
-RB08#1
7241/0005 7241/0005 7241/0005 7241/0005 SEATBE LTBUZZER REL AY
FLASHER RERLAY PWR HOLD RLY STARTER RELAY WARNING BUZZER
1 4 8
15 mm
15 mm
15 mm
-RB07
mm
7 4 1 7 4 1 7 4 1 7 4 1 7 6
17 03
9
2 3
m
-P /32
10
6
50 mm
0m
7000/3206
70
8 5 2 8 5 2 8 5 2 8 5 2
00
-P8
80 mm
10
70
5
-C_RC33#1
7214/0025 3 40 mm 9 6 3 9 6 3 9 6 3 9 6 3
1 2 4
-RB08
TO SPEEDOMETER HARNESS 20
/3 7 mm
3
130 -S_SRC25
15 m
00 17
-CANHS3 m 15 70 -P
15 mm mm 78
-P10/3203
700
40 mm
50 mm 50 mm
-RB09
170 mm
-C_RC09
-CANLS3 30 mm 410 mm 30 mm 150 mm -P179
3203
210 mm 40 mm
7000/
30 mm
-RB10
3 2 1
30 7000/3203 -P180
70 mm 60 mm 60 mm 70 mm
7241/0003
-C_RC09#1 7000/3206 -S_SRC13 7000/3203
0m
-P175
-S_SRC04 -P248 CUTEND
60 mm
7213/0034
m
NO CONNECTOR
15 m m
LEAD CUT 1/1
PARK BRAKE
-D8 -DH3 -S_SRC15 -C_RCCUTEND3
15 mm 50 mm 50 mm 50 mm 50 mm -C_RC45 10 1
30 mm
20 GREY'B' 11
70 -P GREY
1 2 00 25
-S_SRC24 /3 7
-DH3#2 20 -C_RC45#1
7000/3211
3
-CANSHD3 7000/3203 332/E3213
-P266
7232/0017 -P258 -CANLS2 -CANSHD2 -CANHS2 Drive Inhibit ECU
DIECU DUMPDIODE
-S_SRC21
10 mm
30 mm 30 mm 30 mm 30 mm 30 mm 30 mm 30 mm 30 mm 100 mm 70 mm 50 mm 40 mm 30 mm 30 mm 30 mm 60 mm
80 mm
-P269
7000/3211
-S_SRC10 -S_SRC23 -S_SRC20 -S_SRC34 7000/3211
-S_SRC28 -S_SRC32 -S_SRC33
-P271 -S_SRC36 -S_SRC17 -S_SRC08 7000/3211
-S_SRC26 -S_SRC09 -S_SRC02 -S_SRC16 -P270
-C_RC11
20 mm
400 mm
4 1
NC12
3 2 35
80 mm
-C_RC11#1 -P7
7000/3206
-P174
7000/3206
-P15 150 mm mm
NC12
7214/0025 7243/0157 M5
LH REAR LIGHTS
100 mm
7000/3206
mm
-P204
20
mm
50
-C_RC13
BLACK
50 mm 400 mm 180 mm 215 mm 135 mm 215 mm 275 mm 275 mm 105 mm 300 mm 600 mm
1
2
7000/3206 -P205 7000/3206
-C_RC13#1 -P173 7000/3206 7000/3206 -P203
-P18
7232/0028
WASHER PUMP
Page 33-133
33 - 132 9813/8950-2 33 - 132

12 - Harness
05 - Rear Chassis
Page Page
33-132 33-133

-C_RC14 -CAN1
7212/0044 727/00002
-C_RC34#1
25 mm -C_RC20
TER A B -C_RC08 20 mm 20 mm
120 OHM
CAN TERM
50 mm 50 mm
B
NC08
NC08
C A
7000/3206
-P207 -C_RC14#1 2 1
7213/0031
25 mm
7000/3206 7000/3206
C
m
FIX WITH C014 AFTER TEST. DGN TR 1 -C_RC08#1 -P21 -P20 -P17
-P16
m
NC08 NC08
7212/0052 7243/0137 7210/0066 -C_RC20#1
20
FUELPUMP 7213/0031
-C_RC29 W. I. F.
20
-CAN3
727/00002
m
50 mm 30 mm 80 mm 50 mm
m
A B
120 OHM
CAN TERM
C
7000/3206
7000/3206
-CANHS5 -P85
-P208
-C_RC29#1
NC32 FIX WITH C029 AFTER TEST.
170 mm
7213/0031
-C_R
ENGINE TR
TEND1
CCU
7000/3206
-P19
CCU
ND
TEND21/1
CUTE
NC12
CTORCUTE
-C_R
ND
1/1
NO CONNE
70 mm
CUT
LEAD
NO CONNE
LEAD
CUT
CTOR
180 mm
mm
30
-C_RC25
-P113 7243/0121
20 mm
NC28
100 mm 40 mm 30 mm 30 mm 50 mm 50 mm 80 mm 20 mm 230 mm 30 mm 270 mm 700 mm

NC28
1 4
NC12
2 3
7000/3206 7000/3206 7000/3206 7000/3206
7000/3206
mm
ECU FEEDS -P94 -P194 -P195

-P87
NC32
-CANLS1 -CANHS1 -S_SRC35 -CANSHD1 NC16 -P22 -C_RC25#1
NC12 7243/0157 7214/0025
150 mm
210
-P4
25 03
RH REAR LIGHTS
-P /32
m
1
-P90
30 m
00
7000/3206 7000/3206
70
NC25 -P95
NC08
70 mm
203
0/3
700 52
-S_SRC27
-P2
mm
75 mm
170
7000/3206
-P196
120
mm
2 1
70 -P253
00 30 m
/32
03 m -C_RC24#1
375 mm
SEATBE LTSWITCH
500 mm
7000/3206
-C_RC24 -P98
NC08
-C_RC07
15
C
_R
-C 2 1
mm
7243/0137
-C_RC07#1
-P49
20 mm
7212/0030
30 AC COMPRESSOR CLUTCH
m
0m
NC08
15 20
/3 6
3
00 25
70 -P
1000 mm
-C_RC37
2 3
18 20
-P /3
m
00
NC08
70
m
-RB01#1 -RB03#1
20 mm
-RB02#1 -RB04#1 -RB05#1
7241/0003 7241/0003 7241/0003 7241/0003 7241/0003 P
60
E N
F D
m
M
7243/0137
8 8 8 8 8
0m
A C
3 G
B L
20 7 6 7 6 7 6 7 6
-P96
9 7 6 9 9 9 9
10 /3
H K
J
00 3 10 10 10 10 10
70 18
-P -C_RC06#1
5 5 5 5 5 7000/3206
7219/0086 -P50
mm 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4
ENGINE HARNESS
130 3 3 3 3 3
NC08
-P200 -C_RC06 -C_RC37#1

0/3
700 02
203
7000/3203 7219/0076 -C_RC39
-P2
ENGINE ECU
-C_RC30
70 mm
2 1
2 1
210 mm -C_RC04 -C_RC39#1
170 mm 30 mm -C_RC30#1
7212/0052
7212/0001
REVERSE ALARM
FUELSENDER
2 1
7000/3206
-C_RC04#1
-C_RC28
-P170
350 mm
100 mm
NC08 7212/0052
SEATSWITCH
X
6 5 4 3 2 X
1
190 mm
-RB06#1 -RB07#1 -RB08#1 -RB09#1

-RB10#1
7241/0003 7000/3206 -C_RC28#1
7241/0005
FLASHER RERLAY
7241/0005
PWR HOLD RLY
7241/0005
STARTER RELAY
7241/0005
WARNING BUZZER
SEATBE LTBUZZER REL AY
-P32 7216/0060
8 NC08 TMAF
mm
7 6 7000/3206
mm
7 4 1 7 4 1 7 4 1 7 4 1
17 03
9
-P110
mm
-P /32
10
6
NC32
70
8 5 2 8 5 2 8 5 2 8 5 2
00
7000/3206
0
50
10
70
5 -P36
9 6 3 9 6 3 9 6 3 9 6 3 NC16
1 2 4
3
20 3
mm
/3 7
00 17
70 -P 130 -S_SRC25 30 mm 910 mm 910 mm 210 mm 130 mm
78
-P10/3203
700
170 mm 7000/3206 7000/3206 7000/3206

-S_SRC19 -P37 -P35 -P34
NC08
NC16 NC12
-P179
3203
7000/
-C_RC23
30
280 mm
mm
60 mm
50 mm -C_RC45 1 2
A B
10 1
18
AGREYB
-C
GREY'B'
_R
20
BLUE
_R
11
GREY 7000/3206
-C
-C_RC19#1
C19
-C_RC18#1 -P33 -C_RC23#1

TAPE BACKT O 7232/0008 7232/0009 NC08 7212/0013
-C_RC45#1 PRIMARYFUSE-2
332/E3213 MAIN BRANCH. PRIMARYFUSE-1 AIR FILTER
Drive Inhibit ECU
30 mm 30 mm 30 mm 60 mm 30 mm -C_RC38 -D2 -C_RC42

50 mm
0mm
120
4 1
20
3 2 1
3 2
7000/3211
-S_SRC28 -S_SRC32 -S_SRC33 -C_RC38#1
mm
-P270
6
12 20
7233/0015
-P /3
-C_RC42#1
00
70 -P
FR DIODE
70
7214/0024
00 11
/32
ROP'S HARNESS
mm
06
06
200
120 mm
/32
200 mm
00 1
35 70 -P P
E
-C_RC44
N
mm
M D
150 mm
F
7000/3206 C A
-P10 PLEASE PROVIDE L

B G
M5 SIDE VIEW K
50 mm
H
-C_RC22
J
7000/3206
7207/1213 -P13
7000/3206 STARTER SOL

100 mm
-C_RC44#1
mm
-P204
20 7219/0187
m m
50
300 mm 70 mm 250 mm
-C_RC43 CABIN HARNESS
600 mm -P197
7000/3206
M5 -C_RC21
7207/1211
ALTERNATOR D+ 7000/3206 -C_RC43#1
-P9 7211/0005
-P205 7000/3206
7000/3206 -P203 TO CABIN HARENESS
400/M1627-5
Page 33-132
33 - 133 9813/8950-2 33 - 133

12 - Harness
05 - Rear Chassis
33 - 134 9813/8950-2 33 - 134

12 - Harness
05 - Rear Chassis

- 400/M1627 (Sheet 2 of 5) Page 33-137
-C_RC01 LIVELINK GND -C_RC05 CLUTCH PEDAL SWITCH
1 6011 1.00 mm² YE -FB-A-41:19 -W1_RC A 1707B 0.75 mm² YE -S_SRC04:S -W1_RC -C_RC14 DGN TR 1 -C_RC23 AIR FILTER
B 8027 0.75 mm² YE -S_SRC14:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
7207/1513 Ring Terminal M10 0.5-1.0 C 7210/0030 A CANHS2 0.50 mm² YE -CANHS1:S -MC5 1 4022A 0.75 mm² YE -C_RC03:26 -W1_RC
Additional Components B CANLS2 0.50 mm² GN -CANLS1:S -MC5 2 6000K 0.75 mm² YE -S_SRC06:S -W1_RC
7000/3212;45 # Adhesive Lined Heatshrink 7213/0031 3 Way DT06 Socket Housing C 7210/0030
Additional Components 7212/0013 2 Way Junior Power Timer Housing
-C_RC02 TO OPERATOR HARNESS 7213/0016;1 # 3 Way DT06 Wedge 7213/0031 3 Way DT06 Socket Housing Additional Components
ID Tag Size Colour Destination Cable Cavity Seal Additional Components
1 3003 6.00 mm² YE -C_RC19:B -W1_RC -C_RC06 ENGINE HARNESS 7213/0043;1 # 3 Way DT06 Wedge CAN J1939 -C_RC24 SEAT BELT SWITCH
2 0101 3.00 mm² YE -FB-B-42:19 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
A 3013 1.00 mm² YE -FB-B-42:2 -W1_RC -C_RC15 SERVICE HOUR RESET SWITCH 1 3008D 1.00 mm² YE -S_SRC34:S -W1_RC
332/E9928 2 Way DL305 Male Hsg B 6000B 1.00 mm² YE -S_SRC06:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal 2 8121 0.75 mm² YE -C_RC45:7 -W1_RC
Additional Components C CANL3 0.50 mm² GN -CANLS5:S -MC1 1
D CANH3 0.50 mm² YE -CANHS5:S -MC1 2 106B 1.00 mm² YE -S_SRC15:S -W1_RC 7212/0052 2 Way DT06 Socket Housing
-C_RC03 TO OPERATOR HARNESS Additional Components
E 3014 1.00 mm² YE -FB-B-42:4 -W1_RC 3 4700 1.00 mm² YE -C_RC03:40 -W1_RC
F 6000D 1.00 mm² YE -S_SRC06:S -W1_RC 4 7212/0031;1 # 2 Way DT06 Wedge
1 4023 0.75 mm² YE -C_RC21:1 -W1_RC
G 7210/0030 5 -C_RC25 RH REAR LIGHTS
2 306 1.50 mm² YE -FB-A-41:18 -W1_RC
H 7210/0030 6 ID Tag Size Colour Destination Cable Cavity Seal
3 3008 1.50 mm² YE -FB-A-41:2 -W1_RC
J 7210/0030 7 6001N 0.50 mm² YE -S_SRC23:S -W1_RC 1 816B 1.00 mm² YE -S_SRC09:S -W1_RC
4 1002A 1.00 mm² YE -S_SRC18:S -W1_RC
K 6001E 0.50 mm² YE -S_SRC23:S -W1_RC 8 829F 0.50 mm² YE -S_SRC02:S -W1_RC 2 8029B 1.00 mm² YE -S_SRC03:S -W1_RC
5 106D 0.75 mm² YE -S_SRC15:S -W1_RC
L 7210/0030 9 3 6001G 1.50 mm² YE -S_SRC23:S -W1_RC
6 829D 1.00 mm² YE -S_SRC02:S -W1_RC
M 7210/0030 10 4 830B 1.00 mm² YE -S_SRC22:S -W1_RC
7 4003B 0.75 mm² YE -S_SRC07:S -W1_RC
N 7210/0030
8 1703 1.50 mm² YE -FB-C-43:10 -W1_RC 7219/0013 10 Way 6.3 Fastin Switch Hsg 7214/0025 4 Way DT06 Socket Housing
P 7210/0030
9 804 1.50 mm² YE -FB-C-43:4 -W1_RC Additional Components Additional Components
10 107F 1.00 mm² YE -S_SRC08:S -W1_RC 7219/0086 14 Way HDP Free Socket Housing (Plug) Size 18
-C_RC16 BRAKE PRESSURE SWITCH 7214/0016;1 # 4 Way DT06 Wedge
11 7210/0082 Additional Components ID Tag Size Colour Destination Cable Cavity Seal
12 CANSHD7 0.50 mm² ?01? -CANSHD3:S -MC7 -C_RC26 FORWARD SOLENOID
A 3035 0.75 mm² YE -C_RC32:2 -W1_RC
13 820 1.00 mm² YE -S_SRC36:S -W1_RC -C_RC07 AC COMPRESSOR CLUTCH ID Tag Size Colour Destination Cable Cavity Seal
B 6141 0.75 mm² YE -S_SRC23:S -W1_RC
14 106C 1.00 mm² YE -S_SRC15:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal 1 8028 1.00 mm² YE -RB04:7 -W1_RC
C 8017 0.75 mm² YE -RB01:3 -W1_RC
15 812 1.00 mm² YE -S_SRC25:S -W1_RC 1 8908 2.00 mm² YE -C_RC44:F -W1_RC 2 6000C 1.00 mm² YE -S_SRC06:S -W1_RC
16 811 1.00 mm² YE -S_SRC26:S -W1_RC 2 6000U 2.00 mm² YE -S_SRC06:S -W1_RC 7213/0031 3 Way DT06 Socket Housing
17 5101 0.75 mm² YE -C_RC35:10 -W1_RC 7212/0052 2 Way DT06 Socket Housing
18 7210/0082 7212/0030 2 WAY DT06 SKT HSG BLACK ENDCAP N-SEAL Additional Components
7213/0016;1 # 3 Way DT06 Wedge
19 7210/0082 Additional Components 7212/0085;1 # 2 WAY YELLOW DT06 WEDGE
20 828 1.50 mm² YE -FB-C-43:17 -W1_RC 7212/0031;1 # 2 Way DT06 Wedge -C_RC17 TRANS OIL TEMP SW
-C_RC27 REVERSE SOLENOID
21 8026 1.50 mm² YE -RB06:2 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
22 0827 1.50 mm² YE -RB06:4 -W1_RC -C_RC08 FUEL PUMP 1 4020 1.00 mm² YE -C_RC03:29 -W1_RC
1 8013A 1.00 mm² YE -S_SRC20:S -W1_RC
23 810A 0.75 mm² YE -RB03:8 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal 2 6000L 1.00 mm² YE -S_SRC06:S -W1_RC
2 6000E 1.00 mm² YE -S_SRC06:S -W1_RC
24 4003 0.50 mm² YE -S_SRC07:S -W1_RC 1 8009 1.50 mm² YE -RB05:7 -W1_RC
25 7210/0082 2 6000N 2.00 mm² YE -S_SRC06:S -W1_RC 7212/0052 2 Way DT06 Socket Housing
26 4022A 0.75 mm² YE -C_RC23:1 -W1_RC Additional Components
27 4016 1.00 mm² YE -C_RC30:1 -W1_RC 7212/0052 2 Way DT06 Socket Housing 7212/0031;1 # 2 Way DT06 Wedge
7212/0031
Additional Components PRIMARY FUSE-1
28 4019 1.00 mm² YE -C_RC10:1 -W1_RC -C_RC18
29 4020 1.00 mm² YE -C_RC17:1 -W1_RC 7212/0031;1 # 2 Way DT06 Wedge ID Tag Size Colour Destination Cable Cavity Seal -C_RC28 TMAF
30 6014 0.75 mm² YE -S_SRC19:S -W1_RC A 200 4.00 mm² YE -FB-B-42:17 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
-C_RC09 PARK BRAKE
31 8031 1.00 mm² YE -S_SRC01:S -W1_RC B 200B 6.00 mm² YE -S_SRC24:S -W1_RC x
32 8029A 1.00 mm² YE -S_SRC03:S -W1_RC 2 4028 0.75 mm² YE -C_RC37:18 -W1_RC
1 4003A 0.75 mm² YE -S_SRC07:S -W1_RC 7232/0009 2 Way Fem Hsg Pri Fuse Grey
33 7210/0082 3 4027 0.75 mm² YE -C_RC37:52 -W1_RC
2 7210/0052 Additional Components
34 CANLS7 0.50 mm² GN -CANLS3:S -MC7 4 4026 0.75 mm² YE -C_RC37:38 -W1_RC
3 1708AA 0.75 mm² YE -S_SRC13:S -W1_RC
35 CANHS7 0.50 mm² YE -CANHS3:S -MC7 5 4025 0.75 mm² YE -C_RC37:22 -W1_RC
-C_RC19 PRIMARY FUSE-2
36 106E 1.00 mm² YE -S_SRC15:S -W1_RC 7213/0034 3 Way DTM06 Socket Housing x
37 6015 1.00 mm² YE -FB-A-41:20 -W1_RC Additional Components A 3002 4.00 mm² YE -S_SRC16:S -W1_RC 7216/0060 6 WAY GET064 FEM HSG KEY B WITH CPA (POS 1&6 BLOCKED)
38 300B 1.00 mm² YE -S_SRC10:S -W1_RC
7213/0035 B 3003 6.00 mm² YE -C_RC02:1 -W1_RC
39 010 1.50 mm² YE -FB-C-43:13 -W1_RC Additional Components
B 0100C 4.00 mm² YE -RB02:1 -W1_RC
40 4700 1.00 mm² YE -C_RC15:3 -W1_RC -C_RC10 TRANS OIL PRESS SW
-C_RC29 ENGINE TR
41 7210/0082 ID Tag Size Colour Destination Cable Cavity Seal 7232/0008 2 Way Fem Hsg Pri Fuse Blue ID Tag Size Colour Destination Cable Cavity Seal
42 7210/0082 1 4019 1.00 mm² YE -C_RC03:28 -W1_RC Additional Components A CANH2 0.50 mm² YE -CANHS5:S -MC6
43 7210/0082 2 6000J 1.00 mm² YE -S_SRC06:S -W1_RC
B CANL2 0.50 mm² GN -CANLS5:S -MC6
44 7210/0082 -C_RC20 W. I. F.
7212/0052 2 Way DT06 Socket Housing C 7210/0030
45 7210/0082 ID Tag Size Colour Destination Cable Cavity Seal
46 7210/0082 Additional Components A 3019 1.00 mm² YE -FB-B-42:10 -W1_RC 7213/0031 3 Way DT06 Socket Housing
47 7210/0082 7212/0031;1 # 2 Way DT06 Wedge B 4000 0.75 mm² YE -C_RC37:55 -W1_RC Additional Components
48 7210/0082 C 6000F 1.00 mm² YE -S_SRC06:S -W1_RC
-C_RC11 LH REAR LIGHTS 7213/0043;1 # 3 Way DT06 Wedge CAN J1939
49 7210/0082
ID Tag Size Colour Destination Cable Cavity Seal 7213/0031 3 Way DT06 Socket Housing -C_RC30 FUEL SENDER
50 7210/0082
1 816A 1.00 mm² YE -S_SRC09:S -W1_RC Additional Components ID Tag Size Colour Destination Cable Cavity Seal
51 7210/0082
2 8031B 1.00 mm² YE -S_SRC01:S -W1_RC 1 4016 1.00 mm² YE -C_RC03:27 -W1_RC
52 810EE 0.75 mm² YE -C_RC45:15 -W1_RC 7213/0016
3 6001H 1.50 mm² YE -S_SRC23:S -W1_RC 2 6006 1.00 mm² YE -S_SRC06:S -W1_RC
53 7210/0082 -C_RC21 ALTERNATOR D+
4 829B 1.00 mm² YE -S_SRC02:S -W1_RC
54 7210/0082 ID Tag Size Colour Destination Cable Cavity Seal 7212/0052 2 Way DT06 Socket Housing
55 7210/0082 7214/0025 4 Way DT06 Socket Housing 1 4023 0.75 mm² YE -C_RC03:1 -W1_RC Additional Components
56 7210/0082 Additional Components 7212/0031;1 # 2 Way DT06 Wedge
57 3808 1.50 mm² YE -FB-A-41:12 -W1_RC 7207/1211 Ring Terminal M5 0.5-1.0
7214/0016;1 # 4 Way DT06 Wedge
Additional Components -C_RC31 FOOT THROTTLE
58 7204/0110
59 836A 1.50 mm² YE -C_RC35:2 -W1_RC -C_RC12 DIAGNOSTIC 7000/3212 ; 45
A 4010 0.75 mm² YE -C_RC37:17 -W1_RC
60 832 1.50 mm² YE -C_RC35:1 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal -C_RC22 STARTER SOL
B 4011 0.75 mm² YE -C_RC37:14 -W1_RC
61 6003 2.00 mm² YE -S_SRC23:S -W1_RC A 6001C 1.00 mm² YE -S_SRC23:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
C 4009 0.75 mm² YE -C_RC37:21 -W1_RC
62 312 1.50 mm² YE -FB-A-41:6 -W1_RC B 300A 1.00 mm² YE -S_SRC10:S -W1_RC 1 842 3.00 mm² YE -RB03:7 -W1_RC
D 4012 0.75 mm² YE -C_RC37:15 -W1_RC
C CANHS6 0.50 mm² YE -CANHS3:S -MC4
7219/0219 62 Way MCP 1.5K Tab Hsg Blk Key A 7207/1213 Ring Terminal M5 4.0-6.0 E 4013 0.75 mm² YE -C_RC37:29 -W1_RC
D CANLS6 0.50 mm² GN -CANLS3:S -MC4
Additional Components Additional Components F 4014 0.75 mm² YE -C_RC37:19 -W1_RC
E CANSHD6 0.50 mm² ?01? -CANSHD3:S -MC4
7219/0077;1 # 62 Way MCP1.5K Cover Black F 7210/0030 7000/3212 ; 45
7216/0059 6 WAY METRIPACK 150.2 FEM PULL TO SEAT HSG
7243/0351;1 # MC P Secondary Lock for 62 Way G 7210/0030 Additional Components
H 7210/0030
-C_RC04 SEAT SWITCH J 7210/0030
1 8123 0.75 mm² YE -DH1:1 -W1_RC 7219/0098 9 Way Male J1939 Housing Jam Nut Type
2 3008A 0.75 mm² YE -S_SRC34:S -W1_RC Additional Components
7210/0116;1 # Jam Nut Plastic M35
7212/0052 2 Way DT06 Socket Housing 7210/0117;1 # ATC10 Dust Cover with Lanyard (Amphenol)
Additional Components WASHER PUMP
-C_RC13
1 8558A 0.50 mm² YE -C_RC44:G -W1_RC
2 6000S 0.50 mm² YE -S_SRC06:S -W1_RC
7232/0028 2 Way Pos Lock Housing T Type 400/M1627-4

33 - 135 9813/8950-2 33 - 135

12 - Harness
05 - Rear Chassis
Page Page
33-136 33-137
Figure
-C_RC01656. (Part 1 of
LIVELINK 2)
GND -C_RC05 CLUTCH PEDAL SWITCH
1 6011 1.00 mm² YE -FB-A-41:19 -W1_RC A 1707B 0.75 mm² YE -S_SRC04:S -W1_RC
B 8027 0.75 mm² YE -S_SRC14:S -W1_RC
7207/1513 Ring Terminal M10 0.5-1.0 C 7210/0030
7000/3212;45 # Adhesive Lined Heatshrink 7213/0031 3 Way DT06 Socket Housing
-C_RC02 TO OPERATOR HARNESS 7213/0016;1 # 3 Way DT06 Wedge
1 3003 6.00 mm² YE -C_RC19:B -W1_RC -C_RC06 ENGINE HARNESS
2 0101 3.00 mm² YE -FB-B-42:19 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
A 3013 1.00 mm² YE -FB-B-42:2 -W1_RC
332/E9928 2 Way DL305 Male Hsg B 6000B 1.00 mm² YE -S_SRC06:S -W1_RC
Additional Components C CANL3 0.50 mm² GN -CANLS5:S -MC1
D CANH3 0.50 mm² YE -CANHS5:S -MC1
-C_RC03 TO OPERATOR HARNESS
E 3014 1.00 mm² YE -FB-B-42:4 -W1_RC
F 6000D 1.00 mm² YE -S_SRC06:S -W1_RC
1 4023 0.75 mm² YE -C_RC21:1 -W1_RC
G 7210/0030
2 306 1.50 mm² YE -FB-A-41:18 -W1_RC
H 7210/0030
3 3008 1.50 mm² YE -FB-A-41:2 -W1_RC
J 7210/0030
4 1002A 1.00 mm² YE -S_SRC18:S -W1_RC
K 6001E 0.50 mm² YE -S_SRC23:S -W1_RC
5 106D 0.75 mm² YE -S_SRC15:S -W1_RC
L 7210/0030
6 829D 1.00 mm² YE -S_SRC02:S -W1_RC
M 7210/0030
7 4003B 0.75 mm² YE -S_SRC07:S -W1_RC
N 7210/0030
8 1703 1.50 mm² YE -FB-C-43:10 -W1_RC
P 7210/0030
9 804 1.50 mm² YE -FB-C-43:4 -W1_RC
10 107F 1.00 mm² YE -S_SRC08:S -W1_RC 7219/0086 14 Way HDP Free Socket Housing (Plug) Size 18
12 CANSHD7 0.50 mm² ?01? -CANSHD3:S -MC7
13 820 1.00 mm² YE -S_SRC36:S -W1_RC -C_RC07 AC COMPRESSOR CLUTCH
14 106C 1.00 mm² YE -S_SRC15:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
15 812 1.00 mm² YE -S_SRC25:S -W1_RC 1 8908 2.00 mm² YE -C_RC44:F -W1_RC
16 811 1.00 mm² YE -S_SRC26:S -W1_RC 2 6000U 2.00 mm² YE -S_SRC06:S -W1_RC
17 5101 0.75 mm² YE -C_RC35:10 -W1_RC
18 7210/0082 7212/0030 2 WAY DT06 SKT HSG BLACK ENDCAP N-SEAL
20 828 1.50 mm² YE -FB-C-43:17 -W1_RC 7212/0031;1 # 2 Way DT06 Wedge
21 8026 1.50 mm² YE -RB06:2 -W1_RC
22 0827 1.50 mm² YE -RB06:4 -W1_RC -C_RC08 FUEL PUMP
23 810A 0.75 mm² YE -RB03:8 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
25 7210/0082 2 6000N 2.00 mm² YE -S_SRC06:S -W1_RC
26 4022A 0.75 mm² YE -C_RC23:1 -W1_RC
27 4016 1.00 mm² YE -C_RC30:1 -W1_RC 7212/0052 2 Way DT06 Socket Housing
28 4019 1.00 mm² YE -C_RC10:1 -W1_RC Additional Components
29 4020 1.00 mm² YE -C_RC17:1 -W1_RC 7212/0031;1 # 2 Way DT06 Wedge
30 6014 0.75 mm² YE -S_SRC19:S -W1_RC
-C_RC09 PARK BRAKE
31 8031 1.00 mm² YE -S_SRC01:S -W1_RC
32 8029A 1.00 mm² YE -S_SRC03:S -W1_RC
1 4003A 0.75 mm² YE -S_SRC07:S -W1_RC
Page 33-137
33 7210/0082
2 7210/0052
34 CANLS7 0.50 mm² GN -CANLS3:S -MC7
3 1708AA 0.75 mm² YE -S_SRC13:S -W1_RC
35 CANHS7 0.50 mm² YE -CANHS3:S -MC7
36 106E 1.00 mm² YE -S_SRC15:S -W1_RC 7213/0034 3 Way DTM06 Socket Housing
37 6015 1.00 mm² YE -FB-A-41:20 -W1_RC Additional Components
38 300B 1.00 mm² YE -S_SRC10:S -W1_RC
7213/0035
39 010 1.50 mm² YE -FB-C-43:13 -W1_RC
40 4700 1.00 mm² YE -C_RC15:3 -W1_RC -C_RC10 TRANS OIL PRESS SW
41 7210/0082 ID Tag Size Colour Destination Cable Cavity Seal
42 7210/0082 1 4019 1.00 mm² YE -C_RC03:28 -W1_RC
43 7210/0082 2 6000J 1.00 mm² YE -S_SRC06:S -W1_RC
44 7210/0082
45 7210/0082 7212/0052 2 Way DT06 Socket Housing
47 7210/0082 7212/0031;1 # 2 Way DT06 Wedge
48 7210/0082
-C_RC11 LH REAR LIGHTS
49 7210/0082
50 7210/0082
1 816A 1.00 mm² YE -S_SRC09:S -W1_RC
51 7210/0082
2 8031B 1.00 mm² YE -S_SRC01:S -W1_RC
52 810EE 0.75 mm² YE -C_RC45:15 -W1_RC
3 6001H 1.50 mm² YE -S_SRC23:S -W1_RC
53 7210/0082
4 829B 1.00 mm² YE -S_SRC02:S -W1_RC
54 7210/0082
55 7210/0082 7214/0025 4 Way DT06 Socket Housing
57 3808 1.50 mm² YE -FB-A-41:12 -W1_RC
7214/0016;1 # 4 Way DT06 Wedge
58 7204/0110
59 836A 1.50 mm² YE -C_RC35:2 -W1_RC -C_RC12 DIAGNOSTIC
60 832 1.50 mm² YE -C_RC35:1 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
61 6003 2.00 mm² YE -S_SRC23:S -W1_RC A 6001C 1.00 mm² YE -S_SRC23:S -W1_RC
62 312 1.50 mm² YE -FB-A-41:6 -W1_RC B 300A 1.00 mm² YE -S_SRC10:S -W1_RC
C CANHS6 0.50 mm² YE -CANHS3:S -MC4
7219/0219 62 Way MCP 1.5K Tab Hsg Blk Key A D CANLS6 0.50 mm² GN -CANLS3:S -MC4
Additional Components E CANSHD6 0.50 mm² ?01? -CANSHD3:S -MC4
7219/0077;1 # 62 Way MCP1.5K Cover Black F 7210/0030
7243/0351;1 # MC P Secondary Lock for 62 Way G 7210/0030
H 7210/0030
-C_RC04 SEAT SWITCH J 7210/0030
1 8123 0.75 mm² YE -DH1:1 -W1_RC 7219/0098 9 Way Male J1939 Housing Jam Nut Type
7210/0116;1 # Jam Nut Plastic M35
7212/0052 2 Way DT06 Socket Housing 7210/0117;1 # ATC10 Dust Cover with Lanyard (Amphenol)
Additional Components WASHER PUMP
-C_RC13
1 8558A 0.50 mm² YE -C_RC44:G -W1_RC
2 6000S 0.50 mm² YE -S_SRC06:S -W1_RC
7232/0028 2 Way Pos Lock Housing T Type

33 - 136 9813/8950-2 33 - 136

12 - Harness
05 - Rear Chassis
Page Page
33-136 33-137

-C_RC14 DGN TR 1 -C_RC23 AIR FILTER
A CANHS2 0.50 mm² YE -CANHS1:S -MC5 1 4022A 0.75 mm² YE -C_RC03:26 -W1_RC
B CANLS2 0.50 mm² GN -CANLS1:S -MC5 2 6000K 0.75 mm² YE -S_SRC06:S -W1_RC
C 7210/0030
7212/0013 2 Way Junior Power Timer Housing
7213/0043;1 # 3 Way DT06 Wedge CAN J1939 -C_RC24 SEAT BELT SWITCH
-C_RC15 SERVICE HOUR RESET SWITCH 1 3008D 1.00 mm² YE -S_SRC34:S -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal 2 8121 0.75 mm² YE -C_RC45:7 -W1_RC
1
2 106B 1.00 mm² YE -S_SRC15:S -W1_RC 7212/0052 2 Way DT06 Socket Housing
4 7212/0031;1 # 2 Way DT06 Wedge
5 -C_RC25 RH REAR LIGHTS
6 ID Tag Size Colour Destination Cable Cavity Seal
7 6001N 0.50 mm² YE -S_SRC23:S -W1_RC 1 816B 1.00 mm² YE -S_SRC09:S -W1_RC
8 829F 0.50 mm² YE -S_SRC02:S -W1_RC 2 8029B 1.00 mm² YE -S_SRC03:S -W1_RC
9 3 6001G 1.50 mm² YE -S_SRC23:S -W1_RC
10 4 830B 1.00 mm² YE -S_SRC22:S -W1_RC
7219/0013 10 Way 6.3 Fastin Switch Hsg 7214/0025 4 Way DT06 Socket Housing
Additional Components Additional Components
-C_RC16 BRAKE PRESSURE SWITCH 7214/0016;1 # 4 Way DT06 Wedge
-C_RC26 FORWARD SOLENOID
A 3035 0.75 mm² YE -C_RC32:2 -W1_RC
B 6141 0.75 mm² YE -S_SRC23:S -W1_RC
1 8028 1.00 mm² YE -RB04:7 -W1_RC
C 8017 0.75 mm² YE -RB01:3 -W1_RC
2 6000C 1.00 mm² YE -S_SRC06:S -W1_RC
7213/0016;1 # 3 Way DT06 Wedge
7212/0085;1 # 2 WAY YELLOW DT06 WEDGE
-C_RC17 TRANS OIL TEMP SW
-C_RC27 REVERSE SOLENOID
1 4020 1.00 mm² YE -C_RC03:29 -W1_RC
1 8013A 1.00 mm² YE -S_SRC20:S -W1_RC
2 6000L 1.00 mm² YE -S_SRC06:S -W1_RC
2 6000E 1.00 mm² YE -S_SRC06:S -W1_RC
7212/0031;1 # 2 Way DT06 Wedge
7212/0031
ID Tag Size Colour Destination Cable Cavity Seal -C_RC28 TMAF
A 200 4.00 mm² YE -FB-B-42:17 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
B 200B 6.00 mm² YE -S_SRC24:S -W1_RC x
2 4028 0.75 mm² YE -C_RC37:18 -W1_RC
Page 33-136
7232/0009 2 Way Fem Hsg Pri Fuse Grey 3 4027 0.75 mm² YE -C_RC37:52 -W1_RC
Additional Components 4 4026 0.75 mm² YE -C_RC37:38 -W1_RC
5 4025 0.75 mm² YE -C_RC37:22 -W1_RC
x
A 3002 4.00 mm² YE -S_SRC16:S -W1_RC 7216/0060 6 WAY GET064 FEM HSG KEY B WITH CPA (POS 1&6 BLOCKED)
B 3003 6.00 mm² YE -C_RC02:1 -W1_RC Additional Components
B 0100C 4.00 mm² YE -RB02:1 -W1_RC
-C_RC29 ENGINE TR
7232/0008 2 Way Fem Hsg Pri Fuse Blue ID Tag Size Colour Destination Cable Cavity Seal
Additional Components A CANH2 0.50 mm² YE -CANHS5:S -MC6
B CANL2 0.50 mm² GN -CANLS5:S -MC6
-C_RC20 W. I. F.
C 7210/0030
A 3019 1.00 mm² YE -FB-B-42:10 -W1_RC 7213/0031 3 Way DT06 Socket Housing
B 4000 0.75 mm² YE -C_RC37:55 -W1_RC Additional Components
C 6000F 1.00 mm² YE -S_SRC06:S -W1_RC
7213/0043;1 # 3 Way DT06 Wedge CAN J1939
7213/0031 3 Way DT06 Socket Housing -C_RC30 FUEL SENDER
Additional Components ID Tag Size Colour Destination Cable Cavity Seal
1 4016 1.00 mm² YE -C_RC03:27 -W1_RC
7213/0016
2 6006 1.00 mm² YE -S_SRC06:S -W1_RC
-C_RC21 ALTERNATOR D+
ID Tag Size Colour Destination Cable Cavity Seal 7212/0052 2 Way DT06 Socket Housing
7212/0031;1 # 2 Way DT06 Wedge
7207/1211 Ring Terminal M5 0.5-1.0
Additional Components -C_RC31 FOOT THROTTLE
7000/3212 ; 45
A 4010 0.75 mm² YE -C_RC37:17 -W1_RC
-C_RC22 STARTER SOL
B 4011 0.75 mm² YE -C_RC37:14 -W1_RC
C 4009 0.75 mm² YE -C_RC37:21 -W1_RC
1 842 3.00 mm² YE -RB03:7 -W1_RC
D 4012 0.75 mm² YE -C_RC37:15 -W1_RC
7207/1213 Ring Terminal M5 4.0-6.0 E 4013 0.75 mm² YE -C_RC37:29 -W1_RC
Additional Components F 4014 0.75 mm² YE -C_RC37:19 -W1_RC
7000/3212 ; 45
7216/0059 6 WAY METRIPACK 150.2 FEM PULL TO SEAT HSG
400/M1627-4
33 - 137 9813/8950-2 33 - 137

12 - Harness
05 - Rear Chassis
33 - 138 9813/8950-2 33 - 138

12 - Harness
05 - Rear Chassis

- 400/M1627 (Sheet 3 of 5) Page 33-141
-C_RC32 DIODE D1 -C_RC42 ROP'S HARNESS -C_RC37 ENGINE ECU -FB-A-41 FUSEBOX A
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
1 1708AB 0.75 mm² YE -S_SRC13:S -W1_RC 1 1706C 0.75 mm² YE -S_SRC32:S -W1_RC 1 7210/0082 1 3002A 1.50 mm² YE -S_SRC16:S -W1_RC
2 3035 0.75 mm² YE -C_RC16:A -W1_RC 2 8025C 0.75 mm² YE -S_SRC33:S -W1_RC 2 8007 1.00 mm² YE -RB07:4 -W1_RC 2 3008 1.50 mm² YE -C_RC03:3 -W1_RC
3 6000P 2.00 mm² YE -S_SRC06:S -W1_RC 3 7210/0082 3 3080 4.00 mm² YE -RB03:2 -W1_RC
7232/0017 2 Way Diode Fem Hsg - plug in 4 829G 1.00 mm² YE -S_SRC02:S -W1_RC 4 7210/0082 4 1804 2.00 mm² YE -C_RC44:M -W1_RC
Additional Components 5 7210/0082 5
7214/0024 4 Way DT04 Pin Housing 6 7210/0082 6 312 1.50 mm² YE -C_RC03:62 -W1_RC
TO SPEEDOMETER HARNESS Additional Components 7 7210/0082 7
-C_RC33
ID Tag Size Colour Destination Cable Cavity Seal 7214/0014;1 # 4 Way DT04 Wedge 8 7210/0082 8 1800 1.00 mm² YE -C_RC40:1 -W1_RC
1 107B 1.00 mm² YE -S_SRC08:S -W1_RC 9 7210/0082 9
-C_RC43 TO CABIN HARENESS 10 7210/0082 10 1801 1.00 mm² YE -C_RC40:2 -W1_RC
2 6000T 1.00 mm² YE -S_SRC06:S -W1_RC
3 830H 1.00 mm² YE -S_SRC22:S -W1_RC 11 7210/0082 11 200A 3.00 mm² YE -S_SRC24:S -W1_RC
1 3000 6.00 mm² YE -FB-B-42:18 -W1_RC
4 7210/0030 12 7210/0082 12 3808 1.50 mm² YE -C_RC03:57 -W1_RC
7211/0005 1 Way Power DT Size 8 13 7210/0082 13
7214/0025 4 Way DT06 Socket Housing 14 4011 0.75 mm² YE -C_RC31:B -W1_RC 14 300 1.00 mm² YE -S_SRC10:S -W1_RC
Additional Components 15 4012 0.75 mm² YE -C_RC31:D -W1_RC 15
7214/0016;1 # 4 Way DT06 Wedge -C_RC44 CABIN HARNESS 16 7210/0082 16 302 1.00 mm² YE -C_RC44:L -W1_RC
7243/0414;2 # Cap to fit DT06-4S with fixing point ID Tag Size Colour Destination Cable Cavity Seal 17 4010 0.75 mm² YE -C_RC31:A -W1_RC 17
A 133B 0.75 mm² YE -S_SRC28:S -W1_RC 18 4028 0.75 mm² YE -C_RC28:2 -W1_RC 18 306 1.50 mm² YE -C_RC03:2 -W1_RC
-C_RC34 GRID HEATER 19 4014 0.75 mm² YE -C_RC31:F -W1_RC 19 6011 1.00 mm² YE -C_RC01:1 -W1_RC
B 8001A 1.00 mm² YE -S_SRC30:S -W1_RC
C 8002A 1.00 mm² YE -S_SRC31:S -W1_RC 20 7210/0082 20 6015 1.00 mm² YE -C_RC03:37 -W1_RC
1 3020 0.75 mm² YE -FB-B-42:12 -W1_RC
D 1706A 0.75 mm² YE -S_SRC32:S -W1_RC 21 4009 0.75 mm² YE -C_RC31:C -W1_RC
2 6010 0.75 mm² YE -C_RC37:48 -W1_RC 7241/0001 10 Way Sec Fusebox Housing
E 8025A 0.75 mm² YE -S_SRC33:S -W1_RC 22 4025 0.75 mm² YE -C_RC28:5 -W1_RC
F 8908 2.00 mm² YE -C_RC07:1 -W1_RC 23 CANLS1 0.50 mm² GN -CANLS1:S -MC3 Additional Components
7212/0044 2 Way Superseal Recept Housing
G 8558A 0.50 mm² YE -C_RC13:1 -W1_RC 24 7210/0082 7241/0002;1 # 10 Way Sec Fusebox Retainer
H 830F 0.75 mm² YE -S_SRC22:S -W1_RC 25 7210/0082
J 830C 0.75 mm² YE -S_SRC22:S -W1_RC 26 7210/0082 -FB-B-42 FUSEBOX B
-C_RC35 TO FRONT CHASSIS HARNESS 27 CANHS1 0.50 mm² YE -CANHS1:S -MC3 ID Tag Size Colour Destination Cable Cavity Seal
K 829C 0.75 mm² YE -S_SRC02:S -W1_RC
L 302 1.00 mm² YE -FB-A-41:16 -W1_RC 28 8006 1.00 mm² YE -RB08:4 -W1_RC 1 3012 4.00 mm² YE -RB07:2 -W1_RC
1 832 1.50 mm² YE -C_RC03:60 -W1_RC
M 1804 2.00 mm² YE -FB-A-41:4 -W1_RC 29 4013 0.75 mm² YE -C_RC31:E -W1_RC 2 3013 1.00 mm² YE -C_RC06:A -W1_RC
2 836A 1.50 mm² YE -C_RC03:59 -W1_RC
N 106F 1.00 mm² YE -S_SRC15:S -W1_RC 30 7210/0082 3
3 829A 1.00 mm² YE -S_SRC02:S -W1_RC
P 31 7210/0082 4 3014 1.00 mm² YE -C_RC06:E -W1_RC
4 8031A 1.00 mm² YE -S_SRC01:S -W1_RC
32 7210/0082 5
5 8029C 1.00 mm² YE -S_SRC03:S -W1_RC 7219/0187 14 WAY HDP BULKHEAD PIN HSG (RECEPTACLE)SIZE 18 LO17 33 7210/0082 6 3015B 1.00 mm² YE -S_SRC35:S -W1_RC
6 8035 1.50 mm² YE -RB01:7 -W1_RC Additional Components 34 7210/0082 7
7 6004 2.00 mm² YE -S_SRC23:S -W1_RC
7210/0119;1 # Size 18 Plastic Jam Nut 35 7210/0082 8 3021 1.50 mm² YE -S_SRC17:S -W1_RC
8 830D 1.00 mm² YE -S_SRC22:S -W1_RC 7210/0120;1 # Size 18 Lockwasher 36 7210/0082 9
9 8125 0.75 mm² YE -C_RC38:2 -W1_RC
37 7210/0082 10 3019 1.00 mm² YE -C_RC20:A -W1_RC
10 5101 0.75 mm² YE -C_RC03:17 -W1_RC
38 4026 0.75 mm² YE -C_RC28:4 -W1_RC 11
11 7210/0030
-C_RC45 Drive Inhibit ECU 39 8020 0.75 mm² YE -FB-B-42:20 -W1_RC 12 3020 0.75 mm² YE -C_RC34:1 -W1_RC
12 7210/0030
ID Tag Size Colour Destination Cable Cavity Seal 40 8022 0.50 mm² YE -RB05:10 -W1_RC 13 134C 4.00 mm² YE -S_SRC29:S -W1_RC
7219/0015 12 Way DT04 Pin Housing 1 3008C 1.00 mm² YE -S_SRC34:S -W1_RC 41 7210/0082 14 1708C 1.00 mm² YE -RB01:1 -W1_RC
Additional Components 2 6014Z 0.75 mm² YE -S_SRC23:S -W1_RC 42 7210/0082 14 1708A 1.00 mm² YE -S_SRC13:S -W1_RC
3 CANLS4 0.50 mm² GN -CANLS2:S -MC9 43 7210/0082 15 200 4.00 mm² YE -C_RC18:A -W1_RC
7219/0010;1 # 12 Way DT04 Wedge
4 CANHS4 0.50 mm² YE -CANHS2:S -MC9 44 133C 0.75 mm² YE -S_SRC28:S -W1_RC 16 3008B 1.00 mm² YE -S_SRC34:S -W1_RC
-C_RC36 PARK BRAKE DIODE 45 CAN1H 0.50 mm² YE -CANHS5:S -MC2 17
5 812B 0.75 mm² YE -S_SRC25:S -W1_RC
6 1808 0.75 mm² YE -DH2:2 -W1_RC 46 7210/0082 18 3000 6.00 mm² YE -C_RC43:1 -W1_RC
1 4003C 0.75 mm² YE -S_SRC07:S -W1_RC
7 8121 0.75 mm² YE -C_RC24:2 -W1_RC 47 7210/0082 19 0101 3.00 mm² YE -C_RC02:2 -W1_RC
2 8027C 0.75 mm² YE -S_SRC14:S -W1_RC
8 1807 0.75 mm² YE -DH1:2 -W1_RC 48 6010 0.75 mm² YE -C_RC34:2 -W1_RC 19 010A 3.00 mm² YE -RB08:8 -W1_RC
7232/0017 2 Way Diode Fem Hsg - plug in 9 7210/0205 49 3015E 1.00 mm² YE -S_SRC35:S -W1_RC 20 8020 0.75 mm² YE -C_RC37:39 -W1_RC
Additional Components 10 7210/0205 50 CAN1L 0.50 mm² GN -CANLS5:S -MC2
11 7210/0205 51 7210/0082 7241/0001 10 Way Sec Fusebox Housing
FR DIODE 52 4027 0.75 mm² YE -C_RC28:3 -W1_RC Additional Components
-C_RC38 12 7210/0205
ID Tag Size Colour Destination Cable Cavity Seal 13 7210/0205 53 3015D 1.00 mm² YE -S_SRC35:S -W1_RC 7241/0002;1 # 10 Way Sec Fusebox Retainer
1 812A 0.75 mm² YE -S_SRC25:S -W1_RC 14 7210/0205 54 7210/0082
-FB-C-43 FUSEBOX C
2 8125A 0.50 mm² YE -DH1:3 -W1_RC 15 810EE 0.75 mm² YE -C_RC03:52 -W1_RC 55 4000 0.75 mm² YE -C_RC20:B -W1_RC
2 8125 0.75 mm² YE -C_RC35:9 -W1_RC 16 7210/0205 56 7210/0082
1 134A 4.00 mm² YE -S_SRC29:S -W1_RC
3 811B 0.75 mm² YE -S_SRC26:S -W1_RC 17 8110 0.75 mm² YE -RB10:8 -W1_RC 57 3015A 1.00 mm² YE -S_SRC35:S -W1_RC
2 106 1.00 mm² YE -S_SRC15:S -W1_RC
18 8066 0.75 mm² YE -RB02:8 -W1_RC 58 6000RA 2.00 mm² YE -S_SRC27:S -W1_RC
7233/0015 3 Way Diode Housing - Orange Diode 3
19 8027B 0.75 mm² YE -S_SRC14:S -W1_RC 59 6000RB 2.00 mm² YE -S_SRC27:S -W1_RC
20 820C 0.75 mm² YE -S_SRC36:S -W1_RC 60 3015C 1.00 mm² YE -S_SRC35:S -W1_RC
-C_RC39 REVERSE ALARM 61 6000RC 2.00 mm² YE -S_SRC27:S -W1_RC
5
ID Tag Size Colour Destination Cable Cavity Seal 332/E3213 20 Way MX150 Skt hsg Grey Key B 6 107 1.00 mm² YE -S_SRC08:S -W1_RC
62 6000RD 2.00 mm² YE -S_SRC27:S -W1_RC
1 8013C 1.00 mm² YE -S_SRC20:S -W1_RC Additional Components 7
2 6001Y 1.00 mm² YE -S_SRC23:S -W1_RC 7219/0076 62 Way MCP1.5K Socket Housing Grey 8 1002 1.50 mm² YE -S_SRC18:S -W1_RC
Additional Components 9
7212/0001 2 Way HW090 Socket Housing 10 1703 1.50 mm² YE -C_RC03:8 -W1_RC
7219/0077;1 # 62 Way MCP1.5K Cover Black
7212/0003 12 1726 1.00 mm² YE -RB02:6 -W1_RC
-C_RCCUTEND1 Cutend
TO WORK LAMP SW HARNESS -D_RC1 13 010 1.50 mm² YE -C_RC03:39 -W1_RC
-C_RC40 ID Tag Size Colour Destination Cable Cavity Seal
ID Tag Size Colour Destination Cable Cavity Seal 14 1706 1.00 mm² YE -S_SRC32:S -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal 1 CANS1 0.50 mm² ?01? -CANSHD1:S -MC3
1 107FA 1.00 mm² YE -S_SRC08:S -W1_RC 15
1 1800 1.00 mm² YE -FB-A-41:8 -W1_RC
CUT END CUT END 2 107A 1.00 mm² YE -S_SRC04:S -W1_RC 16 133 1.00 mm² YE -S_SRC28:S -W1_RC
2 1801 1.00 mm² YE -FB-A-41:10 -W1_RC
3 830G 0.50 mm² YE -S_SRC22:S -W1_RC 7514/0005 BUTT DIODE ASSY 3A 1000V 18 830 1.00 mm² YE -S_SRC22:S -W1_RC
4 6010A 0.50 mm² YE -S_SRC06:S -W1_RC Additional Components 19
5 8001 1.00 mm² YE -S_SRC30:S -W1_RC -C_RCCUTEND2 Cutend 20 829 1.00 mm² YE -S_SRC02:S -W1_RC
6 8002 1.00 mm² YE -S_SRC31:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
1 CANSHD2 0.50 mm² ?01? -CANSHD1:S -MC5 7241/0001 10 Way Sec Fusebox Housing
Additional Components CUT END CUT END
7241/0002;1 # 10 Way Sec Fusebox Retainer
7216/0016;1 # 6 Way DT06 Wedge Additional Components
7243/0464;1 # CA P TO FIT DT06-6S FIXING POINT
-C_RC41 TO WORKLAMP HARNESS
-C_RCCUTEND3 Cutend
A 8001C 1.00 mm² YE -S_SRC30:S -W1_RC
B 8002C 1.00 mm² YE -S_SRC31:S -W1_RC
C 6000G 2.00 mm² YE -S_SRC06:S -W1_RC CUT END CUT END
7213/0030 3 Way DT04 Pin Housing
7213/0014;1 # 3 Way DT04 Wedge 400/M1627-4
33 - 139 9813/8950-2 33 - 139

12 - Harness
05 - Rear Chassis
Page Page
33-140 33-141
Figure 657. (Part

-C_RC32 1 of
DIODE D1 2) -C_RC42 ROP'S HARNESS -C_RC37
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal ID
1 1708AB 0.75 mm² YE -S_SRC13:S -W1_RC 1 1706C 0.75 mm² YE -S_SRC32:S -W1_RC
2 3035 0.75 mm² YE -C_RC16:A -W1_RC 2 8025C 0.75 mm² YE -S_SRC33:S -W1_RC 2
3 6000P 2.00 mm² YE -S_SRC06:S -W1_RC 3
7232/0017 2 Way Diode Fem Hsg - plug in 4 829G 1.00 mm² YE -S_SRC02:S -W1_RC 4
7214/0024 4 Way DT04 Pin Housing 6
TO SPEEDOMETER HARNESS Additional Components 7
-C_RC33
ID Tag Size Colour Destination Cable Cavity Seal 7214/0014;1 # 4 Way DT04 Wedge 8
1 107B 1.00 mm² YE -S_SRC08:S -W1_RC 9
-C_RC43 TO CABIN HARENESS 10
2 6000T 1.00 mm² YE -S_SRC06:S -W1_RC
3 830H 1.00 mm² YE -S_SRC22:S -W1_RC 11
1 3000 6.00 mm² YE -FB-B-42:18 -W1_RC
4 7210/0030 12
7211/0005 1 Way Power DT Size 8 13
7214/0025 4 Way DT06 Socket Housing 14
7214/0016;1 # 4 Way DT06 Wedge -C_RC44 CABIN HARNESS 16
7243/0414;2 # Cap to fit DT06-4S with fixing point ID Tag Size Colour Destination Cable Cavity Seal 17
A 133B 0.75 mm² YE -S_SRC28:S -W1_RC 18
-C_RC34 GRID HEATER 19
B 8001A 1.00 mm² YE -S_SRC30:S -W1_RC
C 8002A 1.00 mm² YE -S_SRC31:S -W1_RC 20
1 3020 0.75 mm² YE -FB-B-42:12 -W1_RC
D 1706A 0.75 mm² YE -S_SRC32:S -W1_RC 21
2 6010 0.75 mm² YE -C_RC37:48 -W1_RC
E 8025A 0.75 mm² YE -S_SRC33:S -W1_RC 22
7212/0044 2 Way Superseal Recept Housing F 8908 2.00 mm² YE -C_RC07:1 -W1_RC 23
Additional Components G 8558A 0.50 mm² YE -C_RC13:1 -W1_RC 24
H 830F 0.75 mm² YE -S_SRC22:S -W1_RC 25
J 830C 0.75 mm² YE -S_SRC22:S -W1_RC 26
-C_RC35 TO FRONT CHASSIS HARNESS 27
K 829C 0.75 mm² YE -S_SRC02:S -W1_RC
L 302 1.00 mm² YE -FB-A-41:16 -W1_RC 28
1 832 1.50 mm² YE -C_RC03:60 -W1_RC
M 1804 2.00 mm² YE -FB-A-41:4 -W1_RC 29
2 836A 1.50 mm² YE -C_RC03:59 -W1_RC
N 106F 1.00 mm² YE -S_SRC15:S -W1_RC 30
3 829A 1.00 mm² YE -S_SRC02:S -W1_RC
P 31
4 8031A 1.00 mm² YE -S_SRC01:S -W1_RC
32
5 8029C 1.00 mm² YE -S_SRC03:S -W1_RC 7219/0187 14 WAY HDP BULKHEAD PIN HSG (RECEPTACLE)SIZE 18 LO17 33
6 8035 1.50 mm² YE -RB01:7 -W1_RC Additional Components 34
7 6004 2.00 mm² YE -S_SRC23:S -W1_RC
7210/0119;1 # Size 18 Plastic Jam Nut 35
8 830D 1.00 mm² YE -S_SRC22:S -W1_RC 7210/0120;1 # Size 18 Lockwasher 36
9 8125 0.75 mm² YE -C_RC38:2 -W1_RC
37
10 5101 0.75 mm² YE -C_RC03:17 -W1_RC
38
11 7210/0030
-C_RC45 Drive Inhibit ECU 39
12 7210/0030
ID Tag Size Colour Destination Cable Cavity Seal 40
7219/0015 12 Way DT04 Pin Housing 1 3008C 1.00 mm² YE -S_SRC34:S -W1_RC 41
Additional Components 2 6014Z 0.75 mm² YE -S_SRC23:S -W1_RC 42
3 CANLS4 0.50 mm² GN -CANLS2:S -MC9 43
7219/0010;1 # 12 Way DT04 Wedge
4 CANHS4 0.50 mm² YE -CANHS2:S -MC9 44
-C_RC36 PARK BRAKE DIODE 45
Page 33-141
5 812B 0.75 mm² YE -S_SRC25:S -W1_RC
6 1808 0.75 mm² YE -DH2:2 -W1_RC 46
1 4003C 0.75 mm² YE -S_SRC07:S -W1_RC
7 8121 0.75 mm² YE -C_RC24:2 -W1_RC 47
2 8027C 0.75 mm² YE -S_SRC14:S -W1_RC
8 1807 0.75 mm² YE -DH1:2 -W1_RC 48
7232/0017 2 Way Diode Fem Hsg - plug in 9 7210/0205 49
Additional Components 10 7210/0205 50
11 7210/0205 51
-C_RC38 FR DIODE 12 7210/0205 52
ID Tag Size Colour Destination Cable Cavity Seal 13 7210/0205 53
1 812A 0.75 mm² YE -S_SRC25:S -W1_RC 14 7210/0205 54
2 8125A 0.50 mm² YE -DH1:3 -W1_RC 15 810EE 0.75 mm² YE -C_RC03:52 -W1_RC 55
2 8125 0.75 mm² YE -C_RC35:9 -W1_RC 16 7210/0205 56
3 811B 0.75 mm² YE -S_SRC26:S -W1_RC 17 8110 0.75 mm² YE -RB10:8 -W1_RC 57
18 8066 0.75 mm² YE -RB02:8 -W1_RC 58
7233/0015 3 Way Diode Housing - Orange Diode 19 8027B 0.75 mm² YE -S_SRC14:S -W1_RC 59
Additional Components 20 820C 0.75 mm² YE -S_SRC36:S -W1_RC 60
-C_RC39 REVERSE ALARM 61
ID Tag Size Colour Destination Cable Cavity Seal 332/E3213 20 Way MX150 Skt hsg Grey Key B 62
1 8013C 1.00 mm² YE -S_SRC20:S -W1_RC Additional Components
2 6001Y 1.00 mm² YE -S_SRC23:S -W1_RC 7219/0076
7219/0077;1 # 62 W
7212/0003
-C_RCCUTEND1 Cutend
TO WORK LAMP SW HARNESS -D_RC1
-C_RC40 ID Tag Size Colour Destination Cable Cavity Seal
ID
ID Tag Size Colour Destination Cable Cavity Seal 1 CANS1 0.50 mm² ?01? -CANSHD1:S -MC3
1 1800 1.00 mm² YE -FB-A-41:8 -W1_RC
CUT END CUT END 2
2 1801 1.00 mm² YE -FB-A-41:10 -W1_RC
3 830G 0.50 mm² YE -S_SRC22:S -W1_RC Additional Components
7514/0005
5 8001 1.00 mm² YE -S_SRC30:S -W1_RC -C_RCCUTEND2 Cutend
Additional Components CUT END CUT END
7216/0016;1 # 6 Way DT06 Wedge Additional Components
7243/0464;1 # CA P TO FIT DT06-6S FIXING POINT
-C_RC41 TO WORKLAMP HARNESS
-C_RCCUTEND3 Cutend
A 8001C 1.00 mm² YE -S_SRC30:S -W1_RC
B 8002C 1.00 mm² YE -S_SRC31:S -W1_RC
C 6000G 2.00 mm² YE -S_SRC06:S -W1_RC CUT END CUT END
7213/0030 3 Way DT04 Pin Housing
7213/0014;1 # 3 Way DT04 Wedge
33 - 140 9813/8950-2 33 - 140

12 - Harness
05 - Rear Chassis
Page Page
33-140 33-141
Figure-C_RC37
657. (Part 2 ENGINE
of 2) ECU -FB-A-41 FUSEBOX A
1 7210/0082 1 3002A 1.50 mm² YE -S_SRC16:S -W1_RC
2 8007 1.00 mm² YE -RB07:4 -W1_RC 2 3008 1.50 mm² YE -C_RC03:3 -W1_RC
3 7210/0082 3 3080 4.00 mm² YE -RB03:2 -W1_RC
4 7210/0082 4 1804 2.00 mm² YE -C_RC44:M -W1_RC
5 7210/0082 5
6 7210/0082 6 312 1.50 mm² YE -C_RC03:62 -W1_RC
7 7210/0082 7
8 7210/0082 8 1800 1.00 mm² YE -C_RC40:1 -W1_RC
9 7210/0082 9
10 7210/0082 10 1801 1.00 mm² YE -C_RC40:2 -W1_RC
11 7210/0082 11 200A 3.00 mm² YE -S_SRC24:S -W1_RC
12 7210/0082 12 3808 1.50 mm² YE -C_RC03:57 -W1_RC
13 7210/0082 13
14 4011 0.75 mm² YE -C_RC31:B -W1_RC 14 300 1.00 mm² YE -S_SRC10:S -W1_RC
15 4012 0.75 mm² YE -C_RC31:D -W1_RC 15
16 7210/0082 16 302 1.00 mm² YE -C_RC44:L -W1_RC
17 4010 0.75 mm² YE -C_RC31:A -W1_RC 17
18 4028 0.75 mm² YE -C_RC28:2 -W1_RC 18 306 1.50 mm² YE -C_RC03:2 -W1_RC
19 4014 0.75 mm² YE -C_RC31:F -W1_RC 19 6011 1.00 mm² YE -C_RC01:1 -W1_RC
20 7210/0082 20 6015 1.00 mm² YE -C_RC03:37 -W1_RC
21 4009 0.75 mm² YE -C_RC31:C -W1_RC
22 4025 0.75 mm² YE -C_RC28:5 -W1_RC 7241/0001 10 Way Sec Fusebox Housing
23 CANLS1 0.50 mm² GN -CANLS1:S -MC3 Additional Components
24 7210/0082 7241/0002;1 # 10 Way Sec Fusebox Retainer
25 7210/0082
26 7210/0082 -FB-B-42 FUSEBOX B
27 CANHS1 0.50 mm² YE -CANHS1:S -MC3 ID Tag Size Colour Destination Cable Cavity Seal
28 8006 1.00 mm² YE -RB08:4 -W1_RC 1 3012 4.00 mm² YE -RB07:2 -W1_RC
29 4013 0.75 mm² YE -C_RC31:E -W1_RC 2 3013 1.00 mm² YE -C_RC06:A -W1_RC
30 7210/0082 3
31 7210/0082 4 3014 1.00 mm² YE -C_RC06:E -W1_RC
32 7210/0082 5
33 7210/0082 6 3015B 1.00 mm² YE -S_SRC35:S -W1_RC
34 7210/0082 7
35 7210/0082 8 3021 1.50 mm² YE -S_SRC17:S -W1_RC
36 7210/0082 9
37 7210/0082 10 3019 1.00 mm² YE -C_RC20:A -W1_RC
38 4026 0.75 mm² YE -C_RC28:4 -W1_RC 11
39 8020 0.75 mm² YE -FB-B-42:20 -W1_RC 12 3020 0.75 mm² YE -C_RC34:1 -W1_RC
40 8022 0.50 mm² YE -RB05:10 -W1_RC 13 134C 4.00 mm² YE -S_SRC29:S -W1_RC
41 7210/0082 14 1708C 1.00 mm² YE -RB01:1 -W1_RC
42 7210/0082 14 1708A 1.00 mm² YE -S_SRC13:S -W1_RC
43 7210/0082 15 200 4.00 mm² YE -C_RC18:A -W1_RC
44 133C 0.75 mm² YE -S_SRC28:S -W1_RC 16 3008B 1.00 mm² YE -S_SRC34:S -W1_RC
45 CAN1H 0.50 mm² YE -CANHS5:S -MC2 17
Page 33-140
46 7210/0082 18 3000 6.00 mm² YE -C_RC43:1 -W1_RC

47 7210/0082 19 0101 3.00 mm² YE -C_RC02:2 -W1_RC
48 6010 0.75 mm² YE -C_RC34:2 -W1_RC 19 010A 3.00 mm² YE -RB08:8 -W1_RC
49 3015E 1.00 mm² YE -S_SRC35:S -W1_RC 20 8020 0.75 mm² YE -C_RC37:39 -W1_RC
50 CAN1L 0.50 mm² GN -CANLS5:S -MC2
51 7210/0082 7241/0001 10 Way Sec Fusebox Housing
53 3015D 1.00 mm² YE -S_SRC35:S -W1_RC 7241/0002;1 # 10 Way Sec Fusebox Retainer
54 7210/0082
-FB-C-43 FUSEBOX C
55 4000 0.75 mm² YE -C_RC20:B -W1_RC
56 7210/0082
1 134A 4.00 mm² YE -S_SRC29:S -W1_RC
57 3015A 1.00 mm² YE -S_SRC35:S -W1_RC
2 106 1.00 mm² YE -S_SRC15:S -W1_RC
58 6000RA 2.00 mm² YE -S_SRC27:S -W1_RC
3
59 6000RB 2.00 mm² YE -S_SRC27:S -W1_RC
4 804 1.50 mm² YE -C_RC03:9 -W1_RC
60 3015C 1.00 mm² YE -S_SRC35:S -W1_RC
5
61 6000RC 2.00 mm² YE -S_SRC27:S -W1_RC
6 107 1.00 mm² YE -S_SRC08:S -W1_RC
62 6000RD 2.00 mm² YE -S_SRC27:S -W1_RC
7
7219/0076 62 Way MCP1.5K Socket Housing Grey 8 1002 1.50 mm² YE -S_SRC18:S -W1_RC
10 1703 1.50 mm² YE -C_RC03:8 -W1_RC
7219/0077;1 # 62 Way MCP1.5K Cover Black
11
12 1726 1.00 mm² YE -RB02:6 -W1_RC
-D_RC1 13 010 1.50 mm² YE -C_RC03:39 -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal 14 1706 1.00 mm² YE -S_SRC32:S -W1_RC
1 107FA 1.00 mm² YE -S_SRC08:S -W1_RC 15
2 107A 1.00 mm² YE -S_SRC04:S -W1_RC 16 133 1.00 mm² YE -S_SRC28:S -W1_RC
17 828 1.50 mm² YE -C_RC03:20 -W1_RC
7514/0005 BUTT DIODE ASSY 3A 1000V 18 830 1.00 mm² YE -S_SRC22:S -W1_RC
20 829 1.00 mm² YE -S_SRC02:S -W1_RC
7241/0001 10 Way Sec Fusebox Housing

7241/0002;1 # 10 Way Sec Fusebox Retainer
400/M1627-4
33 - 141 9813/8950-2 33 - 141

12 - Harness
05 - Rear Chassis
33 - 142 9813/8950-2 33 - 142

12 - Harness
05 - Rear Chassis

- 400/M1627 (Sheet 4 of 5) Page 33-145
-RB01 BRAKE LIGHT/HORN RLY -RB07 PWR HOLD RLY
1 107H 1.00 mm² YE -S_SRC08:S -W1_RC 1
1 1708C 1.00 mm² YE -FB-B-42:14 -W1_RC 2 3012 4.00 mm² YE -FB-B-42:1 -W1_RC -DH2 -CANSHD1
2 816 1.00 mm² YE -S_SRC09:S -W1_RC 3 ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
3 8017 0.75 mm² YE -C_RC16:C -W1_RC 4 8007 1.00 mm² YE -C_RC37:2 -W1_RC 1 810B 0.75 mm² YE -RB03:8 -W1_RC S CANS1 0.50 mm² ?01? -C_RCCUTEND1:1 -MC3
4 5 2 1808 0.75 mm² YE -C_RC45:6 -W1_RC S CANSHD2 0.50 mm² ?01? -C_RCCUTEND2:1 -MC5
5 6001L 0.75 mm² YE -S_SRC23:S -W1_RC 6 3002BB 1.00 mm² YE -S_SRC21:S -W1_RC 3 4003D 0.75 mm² YE -S_SRC07:S -W1_RC S CANSHD3 0.50 mm² ?01? -CANSHD2:S -MC10
6 1002B 1.50 mm² YE -S_SRC18:S -W1_RC 7
7 8035 1.50 mm² YE -C_RC35:6 -W1_RC 8 3002BA 4.00 mm² YE -S_SRC21:S -W1_RC 7233/0015 3 Way Diode Housing - Orange Diode 7000/3104 In Line Ultrasonic Splice
8 820A 1.00 mm² YE -S_SRC36:S -W1_RC 9 Additional Components Additional Components
9 7000/3212;45 # Adhesive Lined Heatshrink
7241/0005 9 Way Mini Relay Base
10 6001D 1.00 mm² YE -S_SRC23:S -W1_RC -CANHS1 -CANSHD2
Additional Components ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal
7241/0003 10 Way twin micro relay base S CANHS1 0.50 mm² YE -C_RC37:27 -MC3 S CANSHD5 0.50 mm² ?01? -CANSHD3:S -MC8
Additional Components S CANHS2 0.50 mm² YE -C_RC14:A -MC5 S CANSHD3 0.50 mm² ?01? -CANSHD1:S -MC10
7241/0023;1 # 90 DEG ACTIVE BRACKET FOR RELAY HOUSING S CANHS3 0.50 mm² YE -CANHS2:S -MC10 S CANSHD4 0.50 mm² ?01? -C_RCCUTEND3:1 -MC9
-RB02 HEADLAMP/GR BEACON RLY -RB08 STARTER RELAY
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
1 0100C 4.00 mm² YE -C_RC19:B -W1_RC 1 Additional Components Additional Components
2 134 4.00 mm² YE -S_SRC29:S -W1_RC 2 800 3.00 mm² YE -RB03:6 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink 7000/3212;45 # Adhesive Lined Heatshrink
3 133D 0.75 mm² YE -S_SRC28:S -W1_RC 3 -CANHS3
4 4 8006 1.00 mm² YE -C_RC37:28 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
5 602JC 0.75 mm² YE -S_SRC23:S -W1_RC 5 S CANHS7 0.50 mm² YE -C_RC03:35 -MC7
-CANSHD3
6 1726 1.00 mm² YE -FB-C-43:12 -W1_RC 6 3021C 0.75 mm² YE -S_SRC17:S -W1_RC S CANHS5 0.50 mm² YE -CANHS2:S -MC8
S CANSHD7 0.50 mm² ?01? -C_RC03:12 -MC7
7 8025 0.75 mm² YE -S_SRC33:S -W1_RC 7 S CANHS6 0.50 mm² YE -C_RC12:C -MC4
S CANSHD5 0.50 mm² ?01? -CANSHD2:S -MC8
8 8066 0.75 mm² YE -C_RC45:18 -W1_RC 8 010A 3.00 mm² YE -FB-B-42:19 -W1_RC
7000/3104 In Line Ultrasonic Splice S CANSHD6 0.50 mm² ?01? -C_RC12:E -MC4
9 9
Additional Components S 6001J 0.50 mm² YE -S_SRC23:S -W1_RC
10 6001B 0.75 mm² YE -S_SRC23:S -W1_RC
7241/0005 9 Way Mini Relay Base 7000/3212;45 # Adhesive Lined Heatshrink
7241/0003 10 Way twin micro relay base Additional Components
Additional Components -CANHS5
ID Tag Size Colour Destination Cable Cavity Seal 7000/3212;45 # Adhesive Lined Heatshrink
-RB03 STRT INTERLOCK/IGN RLY -RB09 WARNING BUZZER S CAN1H 0.50 mm² YE -C_RC37:45 -MC2
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal S CANH2 0.50 mm² YE -C_RC29:A -MC6
-S_SRC01
1 201A 4.00 mm² YE -S_SRC24:S -W1_RC 1 S CANH3 0.50 mm² YE -C_RC06:D -MC1
S 8031B 1.00 mm² YE -C_RC11:2 -W1_RC
2 3080 4.00 mm² YE -FB-A-41:3 -W1_RC 2 106A 0.75 mm² YE -S_SRC15:S -W1_RC
7000/3104 In Line Ultrasonic Splice S 8031A 1.00 mm² YE -C_RC35:4 -W1_RC
3 133A 0.75 mm² YE -S_SRC28:S -W1_RC 3
Additional Components S 8031 1.00 mm² YE -C_RC03:31 -W1_RC
4 4
5 6001M 0.75 mm² YE -S_SRC23:S -W1_RC 5 7000/3212;45 # Adhesive Lined Heatshrink
6 800 3.00 mm² YE -RB08:2 -W1_RC 6 6014A 0.75 mm² YE -S_SRC19:S -W1_RC -CANHS2 Additional Components
7 842 3.00 mm² YE -C_RC22:1 -W1_RC 7 ID Tag Size Colour Destination Cable Cavity Seal
8 810A 0.75 mm² YE -C_RC03:23 -W1_RC 8 S CANHS5 0.50 mm² YE -CANHS3:S -MC8
8 810B 0.75 mm² YE -DH2:1 -W1_RC 9 S CANHS3 0.50 mm² YE -CANHS1:S -MC10
-S_SRC02
9 S CANHS4 0.50 mm² YE -C_RC45:4 -MC9
7241/0005 9 Way Mini Relay Base S 829A 1.00 mm² YE -C_RC35:3 -W1_RC
10 6140 0.75 mm² YE -S_SRC23:S -W1_RC
Additional Components 7000/3104 In Line Ultrasonic Splice S 829B 1.00 mm² YE -C_RC11:4 -W1_RC
7241/0003 10 Way twin micro relay base Additional Components S 829 1.00 mm² YE -FB-C-43:20 -W1_RC
Additional Components S 829C 0.75 mm² YE -C_RC44:K -W1_RC
-RB04 FWD/REV RELAY -RB10 SEAT BELT BUZZER RELAY S 829D 1.00 mm² YE -C_RC03:6 -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal S 829F 0.50 mm² YE -C_RC15:8 -W1_RC
1 8011A 1.00 mm² YE -S_SRC05:S -W1_RC 1
-CANLS1 S 829G 1.00 mm² YE -C_RC42:4 -W1_RC
2 8013 1.00 mm² YE -S_SRC20:S -W1_RC 2
S CANLS1 0.50 mm² GN -C_RC37:23 -MC3 7000/3104 In Line Ultrasonic Splice
3 811A 1.00 mm² YE -S_SRC26:S -W1_RC 3
S CANLS2 0.50 mm² GN -C_RC14:B -MC5 Additional Components
4 4
S CANLS3 0.50 mm² GN -CANLS2:S -MC10
5 6001P 1.00 mm² YE -S_SRC23:S -W1_RC 5 7000/3212;45 # Adhesive Lined Heatshrink
6 8011B 1.00 mm² YE -S_SRC05:S -W1_RC 6 601W 0.75 mm² YE -S_SRC23:S -W1_RC 7000/3104 In Line Ultrasonic Splice -S_SRC03
7 8028 1.00 mm² YE -C_RC26:1 -W1_RC 7 6014C 0.75 mm² YE -S_SRC19:S -W1_RC Additional Components ID Tag Size Colour Destination Cable Cavity Seal
8 812B 1.00 mm² YE -S_SRC25:S -W1_RC 8 8110 0.75 mm² YE -C_RC45:17 -W1_RC S 8029B 1.00 mm² YE -C_RC25:2 -W1_RC
9 9 S 8029C 1.00 mm² YE -C_RC35:5 -W1_RC
10 6001Q 1.00 mm² YE -S_SRC23:S -W1_RC 10 601V 0.75 mm² YE -S_SRC23:S -W1_RC S 8029A 1.00 mm² YE -C_RC03:32 -W1_RC
-CANLS2
7241/0003 10 Way twin micro relay base 7241/0003 10 Way twin micro relay base ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice
Additional Components Additional Components S CANLS5 0.50 mm² GN -CANLS3:S -MC8 Additional Components
7241/0023;1 # 90 DEG ACTIVE BRACKET FOR RELAY HOUSING 7000/3212 ; 45
-RB05 TRANS DUMP/LIFT PUMP RLY S CANLS4 0.50 mm² GN -C_RC45:3 -MC9
TO CHASSIS EARTH -S_SRC04
ID Tag Size Colour Destination Cable Cavity Seal -T_RC01 ID Tag Size Colour Destination Cable Cavity Seal
1 1707A 1.00 mm² YE -S_SRC04:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal 7000/3104 In Line Ultrasonic Splice
Additional Components S 1707A 1.00 mm² YE -RB05:1 -W1_RC
2 1 6000H 6.00 mm² YE -S_SRC23:S -W1_RC
S 1707B 0.75 mm² YE -C_RC05:A -W1_RC
3 8027A 0.75 mm² YE -S_SRC14:S -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
7207/1510 Ring Terminal M10 6.0-10.0 S 107A 1.00 mm² YE -D_RC1:2 -W1_RC
4 8011 1.00 mm² YE -S_SRC05:S -W1_RC
5 6001R 0.75 mm² YE -S_SRC23:S -W1_RC Additional Components -CANLS3
S CANLS7 0.50 mm² GN -C_RC03:34 -MC7 Additional Components
7 8009 1.50 mm² YE -C_RC08:1 -W1_RC
-T_RC02 TO CHASSIS EARTH S CANLS5 0.50 mm² GN -CANLS2:S -MC8 7000/3212;45 # Adhesive Lined Heatshrink
8 3021B 0.50 mm² YE -S_SRC17:S -W1_RC
9
ID Tag Size Colour Destination Cable Cavity Seal S CANLS6 0.50 mm² GN -C_RC12:D -MC4 -S_SRC05
10 8022 0.50 mm² YE -C_RC37:40 -W1_RC 7000/3104 In Line Ultrasonic Splice S 8011B 1.00 mm² YE -RB04:6 -W1_RC
7207/1510 Ring Terminal M10 6.0-10.0 Additional Components S 8011A 1.00 mm² YE -RB04:1 -W1_RC
7241/0003 10 Way twin micro relay base
Additional Components 7000/3212;45 # Adhesive Lined Heatshrink S 8011 1.00 mm² YE -RB05:4 -W1_RC
7241/0024;1 # 90 DEG PASSIVE BRACKET FOR RELAY HOUSING -CANLS5 7000/3104 In Line Ultrasonic Splice
-RB06 FLASHER RERLAY -T_RC03 ECU EARTH ID Tag Size Colour Destination Cable Cavity Seal Additional Components
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal S CAN1L 0.50 mm² GN -C_RC37:50 -MC2
1 1 6000R 4.00 mm² YE -S_SRC27:S -W1_RC S CANL2 0.50 mm² GN -C_RC29:B -MC6
2 8026 1.50 mm² YE -C_RC03:21 -W1_RC S CANL3 0.50 mm² GN -C_RC06:C -MC1
3 7207/1502 Ring Terminal M10 2.5-6.0
4 0827 1.50 mm² YE -C_RC03:22 -W1_RC Additional Components 7000/3104 In Line Ultrasonic Splice
5 7000/3212;45 # Adhesive Lined Heatshrink Additional Components
6 6001F 1.50 mm² YE -S_SRC23:S -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
7
8
-DH1
9
1 8123 0.75 mm² YE -C_RC04:1 -W1_RC
7241/0005 9 Way Mini Relay Base 2 1807 0.75 mm² YE -C_RC45:8 -W1_RC
Additional Components 3 8125A 0.50 mm² YE -C_RC38:2 -W1_RC
7241/0024;1 # 90 DEG PASSIVE BRACKET FOR RELAY HOUSING
7233/0015 3 Way Diode Housing - Orange Diode 400-M1627-4
33 - 143 9813/8950-2 33 - 143

12 - Harness
05 - Rear Chassis
Page Page
33-144 33-145
Figure
-RB01 658. (Part 1 LIGHT/HORN
BRAKE of 2) RLY -RB07 PWR HOLD RLY
1 107H 1.00 mm² YE -S_SRC08:S -W1_RC 1
1 1708C 1.00 mm² YE -FB-B-42:14 -W1_RC 2 3012 4.00 mm² YE -FB-B-42:1 -W1_RC
2 816 1.00 mm² YE -S_SRC09:S -W1_RC 3
3 8017 0.75 mm² YE -C_RC16:C -W1_RC 4 8007 1.00 mm² YE -C_RC37:2 -W1_RC
4 5
5 6001L 0.75 mm² YE -S_SRC23:S -W1_RC 6 3002BB 1.00 mm² YE -S_SRC21:S -W1_RC
6 1002B 1.50 mm² YE -S_SRC18:S -W1_RC 7
7 8035 1.50 mm² YE -C_RC35:6 -W1_RC 8 3002BA 4.00 mm² YE -S_SRC21:S -W1_RC
8 820A 1.00 mm² YE -S_SRC36:S -W1_RC 9
9
10 6001D 1.00 mm² YE -S_SRC23:S -W1_RC 7241/0005 9 Way Mini Relay Base
7241/0023;1 # 90 DEG ACTIVE BRACKET FOR RELAY HOUSING
-RB02 HEADLAMP/GR BEACON RLY -RB08 STARTER RELAY
1 0100C 4.00 mm² YE -C_RC19:B -W1_RC 1
3 133D 0.75 mm² YE -S_SRC28:S -W1_RC 3
4 4 8006 1.00 mm² YE -C_RC37:28 -W1_RC
5 602JC 0.75 mm² YE -S_SRC23:S -W1_RC 5
6 1726 1.00 mm² YE -FB-C-43:12 -W1_RC 6 3021C 0.75 mm² YE -S_SRC17:S -W1_RC
7 8025 0.75 mm² YE -S_SRC33:S -W1_RC 7
8 8066 0.75 mm² YE -C_RC45:18 -W1_RC 8 010A 3.00 mm² YE -FB-B-42:19 -W1_RC
9 9
10 6001B 0.75 mm² YE -S_SRC23:S -W1_RC
7241/0005 9 Way Mini Relay Base
7241/0003 10 Way twin micro relay base Additional Components
-RB03 STRT INTERLOCK/IGN RLY -RB09 WARNING BUZZER

1 201A 4.00 mm² YE -S_SRC24:S -W1_RC 1
2 3080 4.00 mm² YE -FB-A-41:3 -W1_RC 2 106A 0.75 mm² YE -S_SRC15:S -W1_RC
3 133A 0.75 mm² YE -S_SRC28:S -W1_RC 3
4 4
5 6001M 0.75 mm² YE -S_SRC23:S -W1_RC 5
6 800 3.00 mm² YE -RB08:2 -W1_RC 6 6014A 0.75 mm² YE -S_SRC19:S -W1_RC
7 842 3.00 mm² YE -C_RC22:1 -W1_RC 7
8 810A 0.75 mm² YE -C_RC03:23 -W1_RC 8
8 810B 0.75 mm² YE -DH2:1 -W1_RC 9
9
10 6140 0.75 mm² YE -S_SRC23:S -W1_RC 7241/0005 9 Way Mini Relay Base
FWD/REV RELAY SEAT BELT BUZZER RELAY
Page 33-145
-RB04 -RB10
1 8011A 1.00 mm² YE -S_SRC05:S -W1_RC 1
2 8013 1.00 mm² YE -S_SRC20:S -W1_RC 2
3 811A 1.00 mm² YE -S_SRC26:S -W1_RC 3
4 4
5 6001P 1.00 mm² YE -S_SRC23:S -W1_RC 5
6 8011B 1.00 mm² YE -S_SRC05:S -W1_RC 6 601W 0.75 mm² YE -S_SRC23:S -W1_RC
7 8028 1.00 mm² YE -C_RC26:1 -W1_RC 7 6014C 0.75 mm² YE -S_SRC19:S -W1_RC
8 812B 1.00 mm² YE -S_SRC25:S -W1_RC 8 8110 0.75 mm² YE -C_RC45:17 -W1_RC
9 9
10 6001Q 1.00 mm² YE -S_SRC23:S -W1_RC 10 601V 0.75 mm² YE -S_SRC23:S -W1_RC
7241/0003 10 Way twin micro relay base 7241/0003 10 Way twin micro relay base
7241/0023;1 # 90 DEG ACTIVE BRACKET FOR RELAY HOUSING
-RB05 TRANS DUMP/LIFT PUMP RLY
ID Tag Size Colour Destination Cable Cavity Seal -T_RC01 TO CHASSIS EARTH
1 1707A 1.00 mm² YE -S_SRC04:S -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
2 1 6000H 6.00 mm² YE -S_SRC23:S -W1_RC
3 8027A 0.75 mm² YE -S_SRC14:S -W1_RC
4 8011 1.00 mm² YE -S_SRC05:S -W1_RC 7207/1510 Ring Terminal M10 6.0-10.0
5 6001R 0.75 mm² YE -S_SRC23:S -W1_RC Additional Components
7 8009 1.50 mm² YE -C_RC08:1 -W1_RC
-T_RC02 TO CHASSIS EARTH
8 3021B 0.50 mm² YE -S_SRC17:S -W1_RC
9
1 6000 8.00 mm² YE -S_SRC06:S -W1_RC
10 8022 0.50 mm² YE -C_RC37:40 -W1_RC
7207/1510 Ring Terminal M10 6.0-10.0
-RB06 FLASHER RERLAY -T_RC03 ECU EARTH
1 1 6000R 4.00 mm² YE -S_SRC27:S -W1_RC
2 8026 1.50 mm² YE -C_RC03:21 -W1_RC
3 7207/1502 Ring Terminal M10 2.5-6.0
5 7000/3212;45 # Adhesive Lined Heatshrink
6 6001F 1.50 mm² YE -S_SRC23:S -W1_RC
7
8
-DH1
9
1 8123 0.75 mm² YE -C_RC04:1 -W1_RC
7241/0005 9 Way Mini Relay Base 2 1807 0.75 mm² YE -C_RC45:8 -W1_RC
Additional Components 3 8125A 0.50 mm² YE -C_RC38:2 -W1_RC
7233/0015 3 Way Diode Housing - Orange Diode
33 - 144 9813/8950-2 33 - 144

12 - Harness
05 - Rear Chassis
Page Page
33-144 33-145
-DH2 -CANSHD1
1 810B 0.75 mm² YE -RB03:8 -W1_RC S CANS1 0.50 mm² ?01? -C_RCCUTEND1:1 -MC3
2 1808 0.75 mm² YE -C_RC45:6 -W1_RC S CANSHD2 0.50 mm² ?01? -C_RCCUTEND2:1 -MC5
3 4003D 0.75 mm² YE -S_SRC07:S -W1_RC S CANSHD3 0.50 mm² ?01? -CANSHD2:S -MC10
7233/0015 3 Way Diode Housing - Orange Diode 7000/3104 In Line Ultrasonic Splice
-CANHS1 -CANSHD2
S CANHS1 0.50 mm² YE -C_RC37:27 -MC3 S CANSHD5 0.50 mm² ?01? -CANSHD3:S -MC8
S CANHS2 0.50 mm² YE -C_RC14:A -MC5 S CANSHD3 0.50 mm² ?01? -CANSHD1:S -MC10
S CANHS3 0.50 mm² YE -CANHS2:S -MC10 S CANSHD4 0.50 mm² ?01? -C_RCCUTEND3:1 -MC9
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice

7000/3212;45 # Adhesive Lined Heatshrink 7000/3212;45 # Adhesive Lined Heatshrink
-CANHS3
S CANHS7 0.50 mm² YE -C_RC03:35 -MC7
-CANSHD3
S CANHS5 0.50 mm² YE -CANHS2:S -MC8
S CANSHD7 0.50 mm² ?01? -C_RC03:12 -MC7
S CANHS6 0.50 mm² YE -C_RC12:C -MC4
S CANSHD5 0.50 mm² ?01? -CANSHD2:S -MC8
7000/3104 In Line Ultrasonic Splice S CANSHD6 0.50 mm² ?01? -C_RC12:E -MC4
Additional Components S 6001J 0.50 mm² YE -S_SRC23:S -W1_RC
-CANHS5
S CAN1H 0.50 mm² YE -C_RC37:45 -MC2
S CANH2 0.50 mm² YE -C_RC29:A -MC6
-S_SRC01
S CANH3 0.50 mm² YE -C_RC06:D -MC1
S 8031B 1.00 mm² YE -C_RC11:2 -W1_RC
7000/3104 In Line Ultrasonic Splice S 8031A 1.00 mm² YE -C_RC35:4 -W1_RC
Additional Components S 8031 1.00 mm² YE -C_RC03:31 -W1_RC
-CANHS2 Additional Components
-S_SRC02
S CANHS4 0.50 mm² YE -C_RC45:4 -MC9
S 829A 1.00 mm² YE -C_RC35:3 -W1_RC
7000/3104 In Line Ultrasonic Splice S 829B 1.00 mm² YE -C_RC11:4 -W1_RC
Additional Components S 829 1.00 mm² YE -FB-C-43:20 -W1_RC
S 829C 0.75 mm² YE -C_RC44:K -W1_RC
Page 33-144
S 829D 1.00 mm² YE -C_RC03:6 -W1_RC

S 829F 0.50 mm² YE -C_RC15:8 -W1_RC
-CANLS1 S 829G 1.00 mm² YE -C_RC42:4 -W1_RC
S CANLS1 0.50 mm² GN -C_RC37:23 -MC3 7000/3104 In Line Ultrasonic Splice
S CANLS2 0.50 mm² GN -C_RC14:B -MC5 Additional Components
7000/3104 In Line Ultrasonic Splice -S_SRC03
S 8029B 1.00 mm² YE -C_RC25:2 -W1_RC
S 8029C 1.00 mm² YE -C_RC35:5 -W1_RC
S 8029A 1.00 mm² YE -C_RC03:32 -W1_RC
-CANLS2
S CANLS5 0.50 mm² GN -CANLS3:S -MC8 Additional Components
7000/3212 ; 45
S CANLS4 0.50 mm² GN -C_RC45:3 -MC9
-S_SRC04
7000/3104 In Line Ultrasonic Splice ID Tag Size Colour Destination Cable Cavity Seal
S 1707B 0.75 mm² YE -C_RC05:A -W1_RC
S 107A 1.00 mm² YE -D_RC1:2 -W1_RC
-CANLS3
S CANLS7 0.50 mm² GN -C_RC03:34 -MC7 Additional Components
S CANLS5 0.50 mm² GN -CANLS2:S -MC8 7000/3212;45 # Adhesive Lined Heatshrink
S CANLS6 0.50 mm² GN -C_RC12:D -MC4 -S_SRC05
7000/3104 In Line Ultrasonic Splice S 8011B 1.00 mm² YE -RB04:6 -W1_RC
7000/3212;45 # Adhesive Lined Heatshrink S 8011 1.00 mm² YE -RB05:4 -W1_RC
-CANLS5 7000/3104 In Line Ultrasonic Splice

S CAN1L 0.50 mm² GN -C_RC37:50 -MC2
S CANL2 0.50 mm² GN -C_RC29:B -MC6
S CANL3 0.50 mm² GN -C_RC06:C -MC1

400-M1627-4
33 - 145 9813/8950-2 33 - 145

12 - Harness
05 - Rear Chassis
33 - 146 9813/8950-2 33 - 146

12 - Harness
05 - Rear Chassis

- 400/M1627 (Sheet 5 of 5) Page 33-149
-S_SRC06 -S_SRC15
ID Tag Size Colour Destination Cable Cavity Seal ID Tag Size Colour Destination Cable Cavity Seal -S_SRC23
S 6000E 1.00 mm² YE -C_RC27:2 -W1_RC S 106A 0.75 mm² YE -RB09:2 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 6000C 1.00 mm² YE -C_RC26:2 -W1_RC S 106 1.00 mm² YE -FB-C-43:2 -W1_RC S 6001C 1.00 mm² YE -C_RC12:A -W1_RC
-S_SRC28
S 6000D 1.00 mm² YE -C_RC06:F -W1_RC S 106B 1.00 mm² YE -C_RC15:2 -W1_RC S 6001H 1.50 mm² YE -C_RC11:3 -W1_RC
S 133B 0.75 mm² YE -C_RC44:A -W1_RC
S 6000B 1.00 mm² YE -C_RC06:B -W1_RC S 106C 1.00 mm² YE -C_RC03:14 -W1_RC S 6001G 1.50 mm² YE -C_RC25:3 -W1_RC
S 133 1.00 mm² YE -FB-C-43:16 -W1_RC
S 6000J 1.00 mm² YE -C_RC10:2 -W1_RC S 106D 0.75 mm² YE -C_RC03:5 -W1_RC S 6001F 1.50 mm² YE -RB06:6 -W1_RC
S 133A 0.75 mm² YE -RB03:3 -W1_RC
S 6000L 1.00 mm² YE -C_RC17:2 -W1_RC S 106E 1.00 mm² YE -C_RC03:36 -W1_RC S 6001D 1.00 mm² YE -RB01:10 -W1_RC
S 133C 0.75 mm² YE -C_RC37:44 -W1_RC
S 6000K 0.75 mm² YE -C_RC23:2 -W1_RC S 106F 1.00 mm² YE -C_RC44:N -W1_RC S 6001B 0.75 mm² YE -RB02:10 -W1_RC
S 133D 0.75 mm² YE -RB02:3 -W1_RC
S 6000F 1.00 mm² YE -C_RC20:C -W1_RC S 6001L 0.75 mm² YE -RB01:5 -W1_RC
S 6000N 2.00 mm² YE -C_RC08:2 -W1_RC 7000/3104 In Line Ultrasonic Splice S 6001R 0.75 mm² YE -RB05:5 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 6000U 2.00 mm² YE -C_RC07:2 -W1_RC Additional Components S 6001P 1.00 mm² YE -RB04:5 -W1_RC Additional Components
S 6000S 0.50 mm² YE -C_RC13:2 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink S 6001Q 1.00 mm² YE -RB04:10 -W1_RC
S 6010A 0.50 mm² YE -C_RC40:4 -W1_RC S 6001E 0.50 mm² YE -C_RC06:K -W1_RC
S 6000 8.00 mm² YE -T_RC02:1 -W1_RC -S_SRC16 S 601V 0.75 mm² YE -RB10:10 -W1_RC -S_SRC31
S 6006 1.00 mm² YE -C_RC30:2 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal S 601W 0.75 mm² YE -RB10:6 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 6000P 2.00 mm² YE -C_RC42:3 -W1_RC S 3002A 1.50 mm² YE -FB-A-41:1 -W1_RC S 6001Y 1.00 mm² YE -C_RC39:2 -W1_RC S 8002 1.00 mm² YE -C_RC40:6 -W1_RC
S 6000G 2.00 mm² YE -C_RC41:C -W1_RC S 3002 4.00 mm² YE -C_RC19:A -W1_RC S 6001N 0.50 mm² YE -C_RC15:7 -W1_RC S 8002C 1.00 mm² YE -C_RC41:B -W1_RC
S 6000T 1.00 mm² YE -C_RC33:2 -W1_RC S 3002B 4.00 mm² YE -S_SRC21:S -W1_RC S 6001M 0.75 mm² YE -RB03:5 -W1_RC S 8002A 1.00 mm² YE -C_RC44:C -W1_RC
S 6140 0.75 mm² YE -RB03:10 -W1_RC
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice S 602JC 0.75 mm² YE -RB02:5 -W1_RC 7000/3104 In Line Ultrasonic Splice
Additional Components Additional Components S 6004 2.00 mm² YE -C_RC35:7 -W1_RC Additional Components
7000/3212 ; 45 7000/3212;45 # Adhesive Lined Heatshrink S 6001J 0.50 mm² YE -CANSHD3:S -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
S 6014Z 0.75 mm² YE -C_RC45:2 -W1_RC
-S_SRC07
-S_SRC17 S 6000H 6.00 mm² YE -T_RC01:1 -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal S 6003 2.00 mm² YE -C_RC03:61 -W1_RC
-S_SRC32
S 4003A 0.75 mm² YE -C_RC09:1 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 3021 1.50 mm² YE -FB-B-42:8 -W1_RC S 6141 0.75 mm² YE -C_RC16:B -W1_RC
S 4003C 0.75 mm² YE -C_RC36:1 -W1_RC S 1706 1.00 mm² YE -FB-C-43:14 -W1_RC
S 3021A 1.50 mm² YE -RB05:6 -W1_RC
S 4003 0.50 mm² YE -C_RC03:24 -W1_RC 7000/3104 In Line Ultrasonic Splice S 1706C 0.75 mm² YE -C_RC42:1 -W1_RC
S 3021B 0.50 mm² YE -RB05:8 -W1_RC
S 4003B 0.75 mm² YE -C_RC03:7 -W1_RC Additional Components S 1706A 0.75 mm² YE -C_RC44:D -W1_RC
S 3021C 0.75 mm² YE -RB08:6 -W1_RC
S 4003D 0.75 mm² YE -DH2:3 -W1_RC
7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice Additional Components
Additional Components -S_SRC24 7000/3212;45 # Adhesive Lined Heatshrink
7000/3212;45 # Adhesive Lined Heatshrink ID Tag Size Colour Destination Cable Cavity Seal
S 200B 6.00 mm² YE -C_RC18:B -W1_RC
-S_SRC18 S 200A 3.00 mm² YE -FB-A-41:11 -W1_RC
-S_SRC33
-S_SRC08 ID Tag Size Colour Destination Cable Cavity Seal
S 201A 4.00 mm² YE -RB03:1 -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal S 8025 0.75 mm² YE -RB02:7 -W1_RC
S 1002A 1.00 mm² YE -C_RC03:4 -W1_RC
S 107F 1.00 mm² YE -C_RC03:10 -W1_RC 7000/3104 In Line Ultrasonic Splice S 8025A 0.75 mm² YE -C_RC44:E -W1_RC
S 1002B 1.50 mm² YE -RB01:6 -W1_RC
S 107 1.00 mm² YE -FB-C-43:6 -W1_RC Additional Components S 8025C 0.75 mm² YE -C_RC42:2 -W1_RC
S 1002 1.50 mm² YE -FB-C-43:8 -W1_RC
S 107J 0.50 mm² YE -S_SRC13:S -W1_RC
S 107H 1.00 mm² YE -RB01:1 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 107B 1.00 mm² YE -C_RC33:1 -W1_RC Additional Components
S 107FA 1.00 mm² YE -D_RC1:1 -W1_RC -S_SRC25 7000/3212;45 # Adhesive Lined Heatshrink
7000/3212;45 # Adhesive Lined Heatshrink ID Tag Size Colour Destination Cable Cavity Seal
7000/3104 In Line Ultrasonic Splice S 812 1.00 mm² YE -C_RC03:15 -W1_RC
Additional Components -S_SRC19 S 812B 1.00 mm² YE -RB04:8 -W1_RC -S_SRC34
ID Tag Size Colour Destination Cable Cavity Seal S 812A 0.75 mm² YE -C_RC38:1 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 6014 0.75 mm² YE -C_RC03:30 -W1_RC S 812B 0.75 mm² YE -C_RC45:5 -W1_RC S 3008A 0.75 mm² YE -C_RC04:2 -W1_RC
S 6014A 0.75 mm² YE -RB09:6 -W1_RC S 3008C 1.00 mm² YE -C_RC45:1 -W1_RC
-S_SRC09 S 6014C 0.75 mm² YE -RB10:7 -W1_RC 7000/3104 In Line Ultrasonic Splice S 3008D 1.00 mm² YE -C_RC24:1 -W1_RC
ID Tag Size Colour Destination Cable Cavity Seal Additional Components S 3008B 1.00 mm² YE -FB-B-42:16 -W1_RC
S 816A 1.00 mm² YE -C_RC11:1 -W1_RC 7000/3104 In Line Ultrasonic Splice 7000/3212;45 # Adhesive Lined Heatshrink
S 816 1.00 mm² YE -RB01:2 -W1_RC Additional Components 7000/3104 In Line Ultrasonic Splice
S 816B 1.00 mm² YE -C_RC25:1 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink Additional Components
-S_SRC26
-S_SRC20 S 811 1.00 mm² YE -C_RC03:16 -W1_RC
Additional Components ID Tag Size Colour Destination Cable Cavity Seal -S_SRC35 ECU FEEDS
S 811A 1.00 mm² YE -RB04:3 -W1_RC
7000/3212 ; 45 ID Tag Size Colour Destination Cable Cavity Seal
S 8013 1.00 mm² YE -RB04:2 -W1_RC S 811B 0.75 mm² YE -C_RC38:3 -W1_RC
S 3015A 1.00 mm² YE -C_RC37:57 -W1_RC
S 8013C 1.00 mm² YE -C_RC39:1 -W1_RC
7000/3104 In Line Ultrasonic Splice S 3015C 1.00 mm² YE -C_RC37:60 -W1_RC
-S_SRC10 S 8013A 1.00 mm² YE -C_RC27:1 -W1_RC
Additional Components S 3015D 1.00 mm² YE -C_RC37:53 -W1_RC
7000/3104 In Line Ultrasonic Splice S 3015E 1.00 mm² YE -C_RC37:49 -W1_RC
S 300 1.00 mm² YE -FB-A-41:14 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
Additional Components S 3015B 1.00 mm² YE -FB-B-42:6 -W1_RC
S 300B 1.00 mm² YE -C_RC03:38 -W1_RC
S 300A 1.00 mm² YE -C_RC12:B -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink -S_SRC27 7000/3104 In Line Ultrasonic Splice
S 6000RA 2.00 mm² YE -C_RC37:58 -W1_RC
Additional Components ID Tag Size Colour Destination Cable Cavity Seal 7000/3212;45 # Adhesive Lined Heatshrink
S 6000RB 2.00 mm² YE -C_RC37:59 -W1_RC
S 3002B 4.00 mm² YE -S_SRC16:S -W1_RC
7000/3212;45 # Adhesive Lined Heatshrink S 6000RC 2.00 mm² YE -C_RC37:61 -W1_RC
S 3002BB 1.00 mm² YE -RB07:6 -W1_RC
S 6000RD 2.00 mm² YE -C_RC37:62 -W1_RC
S 3002BA 4.00 mm² YE -RB07:8 -W1_RC -S_SRC36
-S_SRC13 S 6000R 4.00 mm² YE -T_RC03:1 -W1_RC
S 1708AA 0.75 mm² YE -C_RC09:3 -W1_RC Additional Components
Additional Components S 820C 0.75 mm² YE -C_RC45:20 -W1_RC
S 1708AB 0.75 mm² YE -C_RC32:1 -W1_RC
7000/3212;45 # Adhesive Lined Heatshrink S 820A 1.00 mm² YE -RB01:8 -W1_RC
S 107J 0.50 mm² YE -S_SRC08:S -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
S 1708A 1.00 mm² YE -FB-B-42:14 -W1_RC -S_SRC22 7000/3104 In Line Ultrasonic Splice
ID Tag Size Colour Destination Cable Cavity Seal -S_SRC29
7000/3104 In Line Ultrasonic Splice S 830D 1.00 mm² YE -C_RC35:8 -W1_RC
Additional Components S 134 4.00 mm² YE -RB02:2 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
S 830 1.00 mm² YE -FB-C-43:18 -W1_RC
7000/3212 ; 45 S 134A 4.00 mm² YE -FB-C-43:1 -W1_RC
S 830B 1.00 mm² YE -C_RC25:4 -W1_RC
S 134C 4.00 mm² YE -FB-B-42:13 -W1_RC
S 830C 0.75 mm² YE -C_RC44:J -W1_RC
S 830H 1.00 mm² YE -C_RC33:3 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 830F 0.75 mm² YE -C_RC44:H -W1_RC Additional Components
-S_SRC14 S 830G 0.50 mm² YE -C_RC40:3 -W1_RC
S 8027 0.75 mm² YE -C_RC05:B -W1_RC 7000/3104 In Line Ultrasonic Splice
S 8027A 0.75 mm² YE -RB05:3 -W1_RC Additional Components
S 8027C 0.75 mm² YE -C_RC36:2 -W1_RC
S 8027B 0.75 mm² YE -C_RC45:19 -W1_RC

S 8001 1.00 mm² YE -C_RC40:5 -W1_RC
S 8001C 1.00 mm² YE -C_RC41:A -W1_RC
S 8001A 1.00 mm² YE -C_RC44:B -W1_RC

7000/3212;45 # Adhesive Lined Heatshrink 400/M1627-4
33 - 147 9813/8950-2 33 - 147

12 - Harness
05 - Rear Chassis
Page Page
33-148 33-149

-S_SRC06 -S_SRC15
S 6000E 1.00 mm² YE -C_RC27:2 -W1_RC S 106A 0.75 mm² YE -RB09:2 -W1_RC
S 6000C 1.00 mm² YE -C_RC26:2 -W1_RC S 106 1.00 mm² YE -FB-C-43:2 -W1_RC
S 6000D 1.00 mm² YE -C_RC06:F -W1_RC S 106B 1.00 mm² YE -C_RC15:2 -W1_RC
S 6000B 1.00 mm² YE -C_RC06:B -W1_RC S 106C 1.00 mm² YE -C_RC03:14 -W1_RC
S 6000J 1.00 mm² YE -C_RC10:2 -W1_RC S 106D 0.75 mm² YE -C_RC03:5 -W1_RC
S 6000L 1.00 mm² YE -C_RC17:2 -W1_RC S 106E 1.00 mm² YE -C_RC03:36 -W1_RC
S 6000K 0.75 mm² YE -C_RC23:2 -W1_RC S 106F 1.00 mm² YE -C_RC44:N -W1_RC
S 6000F 1.00 mm² YE -C_RC20:C -W1_RC
S 6000N 2.00 mm² YE -C_RC08:2 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 6000U 2.00 mm² YE -C_RC07:2 -W1_RC Additional Components
S 6000S 0.50 mm² YE -C_RC13:2 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
S 6010A 0.50 mm² YE -C_RC40:4 -W1_RC
S 6000 8.00 mm² YE -T_RC02:1 -W1_RC -S_SRC16
S 6006 1.00 mm² YE -C_RC30:2 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 6000P 2.00 mm² YE -C_RC42:3 -W1_RC S 3002A 1.50 mm² YE -FB-A-41:1 -W1_RC
S 6000G 2.00 mm² YE -C_RC41:C -W1_RC S 3002 4.00 mm² YE -C_RC19:A -W1_RC
S 6000T 1.00 mm² YE -C_RC33:2 -W1_RC S 3002B 4.00 mm² YE -S_SRC21:S -W1_RC
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice

7000/3212 ; 45 7000/3212;45 # Adhesive Lined Heatshrink
-S_SRC07
-S_SRC17
S 4003A 0.75 mm² YE -C_RC09:1 -W1_RC
S 3021 1.50 mm² YE -FB-B-42:8 -W1_RC
S 4003C 0.75 mm² YE -C_RC36:1 -W1_RC
S 3021A 1.50 mm² YE -RB05:6 -W1_RC
S 4003 0.50 mm² YE -C_RC03:24 -W1_RC
S 3021B 0.50 mm² YE -RB05:8 -W1_RC
S 4003B 0.75 mm² YE -C_RC03:7 -W1_RC
S 3021C 0.75 mm² YE -RB08:6 -W1_RC
S 4003D 0.75 mm² YE -DH2:3 -W1_RC
-S_SRC18
-S_SRC08 ID Tag Size Colour Destination Cable Cavity Seal
S 1002A 1.00 mm² YE -C_RC03:4 -W1_RC
S 107F 1.00 mm² YE -C_RC03:10 -W1_RC
S 1002B 1.50 mm² YE -RB01:6 -W1_RC
S 107 1.00 mm² YE -FB-C-43:6 -W1_RC
S 1002 1.50 mm² YE -FB-C-43:8 -W1_RC
S 107J 0.50 mm² YE -S_SRC13:S -W1_RC
S 107H 1.00 mm² YE -RB01:1 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 107FA 1.00 mm² YE -D_RC1:1 -W1_RC
Additional Components -S_SRC19
S 6014 0.75 mm² YE -C_RC03:30 -W1_RC
S 6014A 0.75 mm² YE -RB09:6 -W1_RC
Page 33-149
-S_SRC09 S 6014C 0.75 mm² YE -RB10:7 -W1_RC
S 816A 1.00 mm² YE -C_RC11:1 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 816 1.00 mm² YE -RB01:2 -W1_RC Additional Components
S 816B 1.00 mm² YE -C_RC25:1 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink

-S_SRC20
7000/3212 ; 45 S 8013 1.00 mm² YE -RB04:2 -W1_RC
S 8013C 1.00 mm² YE -C_RC39:1 -W1_RC
-S_SRC10 S 8013A 1.00 mm² YE -C_RC27:1 -W1_RC
S 300 1.00 mm² YE -FB-A-41:14 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 300A 1.00 mm² YE -C_RC12:B -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink

S 3002B 4.00 mm² YE -S_SRC16:S -W1_RC
S 3002BB 1.00 mm² YE -RB07:6 -W1_RC
S 3002BA 4.00 mm² YE -RB07:8 -W1_RC
-S_SRC13
S 1708AA 0.75 mm² YE -C_RC09:3 -W1_RC Additional Components
S 1708AB 0.75 mm² YE -C_RC32:1 -W1_RC
S 107J 0.50 mm² YE -S_SRC08:S -W1_RC
S 1708A 1.00 mm² YE -FB-B-42:14 -W1_RC -S_SRC22
Additional Components S 830 1.00 mm² YE -FB-C-43:18 -W1_RC
7000/3212 ; 45 S 830B 1.00 mm² YE -C_RC25:4 -W1_RC
S 830C 0.75 mm² YE -C_RC44:J -W1_RC
S 830H 1.00 mm² YE -C_RC33:3 -W1_RC
S 830F 0.75 mm² YE -C_RC44:H -W1_RC
-S_SRC14 S 830G 0.50 mm² YE -C_RC40:3 -W1_RC
S 8027 0.75 mm² YE -C_RC05:B -W1_RC 7000/3104 In Line Ultrasonic Splice
S 8027A 0.75 mm² YE -RB05:3 -W1_RC Additional Components
S 8027C 0.75 mm² YE -C_RC36:2 -W1_RC
S 8027B 0.75 mm² YE -C_RC45:19 -W1_RC

S 8001 1.00 mm² YE -C_RC40:5 -W1_RC
S 8001C 1.00 mm² YE -C_RC41:A -W1_RC
S 8001A 1.00 mm² YE -C_RC44:B -W1_RC

33 - 148 9813/8950-2 33 - 148

12 - Harness
05 - Rear Chassis
Page Page
33-148 33-149

-S_SRC23
S 6001C 1.00 mm² YE -C_RC12:A -W1_RC
-S_SRC28
S 6001H 1.50 mm² YE -C_RC11:3 -W1_RC
S 133B 0.75 mm² YE -C_RC44:A -W1_RC
S 6001G 1.50 mm² YE -C_RC25:3 -W1_RC
S 133 1.00 mm² YE -FB-C-43:16 -W1_RC
S 6001F 1.50 mm² YE -RB06:6 -W1_RC
S 133A 0.75 mm² YE -RB03:3 -W1_RC
S 6001D 1.00 mm² YE -RB01:10 -W1_RC
S 133C 0.75 mm² YE -C_RC37:44 -W1_RC
S 6001B 0.75 mm² YE -RB02:10 -W1_RC
S 133D 0.75 mm² YE -RB02:3 -W1_RC
S 6001L 0.75 mm² YE -RB01:5 -W1_RC
S 6001R 0.75 mm² YE -RB05:5 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 6001P 1.00 mm² YE -RB04:5 -W1_RC Additional Components
S 6001Q 1.00 mm² YE -RB04:10 -W1_RC
S 6001E 0.50 mm² YE -C_RC06:K -W1_RC
S 601V 0.75 mm² YE -RB10:10 -W1_RC -S_SRC31
S 601W 0.75 mm² YE -RB10:6 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 6001Y 1.00 mm² YE -C_RC39:2 -W1_RC S 8002 1.00 mm² YE -C_RC40:6 -W1_RC
S 6001N 0.50 mm² YE -C_RC15:7 -W1_RC S 8002C 1.00 mm² YE -C_RC41:B -W1_RC
S 6001M 0.75 mm² YE -RB03:5 -W1_RC S 8002A 1.00 mm² YE -C_RC44:C -W1_RC
S 6140 0.75 mm² YE -RB03:10 -W1_RC
S 602JC 0.75 mm² YE -RB02:5 -W1_RC 7000/3104 In Line Ultrasonic Splice
S 6004 2.00 mm² YE -C_RC35:7 -W1_RC Additional Components
S 6001J 0.50 mm² YE -CANSHD3:S -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
S 6014Z 0.75 mm² YE -C_RC45:2 -W1_RC
S 6000H 6.00 mm² YE -T_RC01:1 -W1_RC
S 6003 2.00 mm² YE -C_RC03:61 -W1_RC
-S_SRC32
S 6141 0.75 mm² YE -C_RC16:B -W1_RC
S 1706 1.00 mm² YE -FB-C-43:14 -W1_RC
Additional Components S 1706A 0.75 mm² YE -C_RC44:D -W1_RC
7000/3212 ; 45
-S_SRC24 7000/3212;45 # Adhesive Lined Heatshrink
S 200B 6.00 mm² YE -C_RC18:B -W1_RC
S 200A 3.00 mm² YE -FB-A-41:11 -W1_RC
-S_SRC33
S 201A 4.00 mm² YE -RB03:1 -W1_RC
S 8025 0.75 mm² YE -RB02:7 -W1_RC
7000/3104 In Line Ultrasonic Splice S 8025A 0.75 mm² YE -C_RC44:E -W1_RC
-S_SRC25 7000/3212;45 # Adhesive Lined Heatshrink
S 812 1.00 mm² YE -C_RC03:15 -W1_RC
S 812B 1.00 mm² YE -RB04:8 -W1_RC -S_SRC34
S 812A 0.75 mm² YE -C_RC38:1 -W1_RC ID Tag Size Colour Destination Cable Cavity Seal
S 812B 0.75 mm² YE -C_RC45:5 -W1_RC S 3008A 0.75 mm² YE -C_RC04:2 -W1_RC
S 3008C 1.00 mm² YE -C_RC45:1 -W1_RC
Page 33-148

Additional Components S 3008B 1.00 mm² YE -FB-B-42:16 -W1_RC
-S_SRC26
S 811 1.00 mm² YE -C_RC03:16 -W1_RC
-S_SRC35 ECU FEEDS
S 811A 1.00 mm² YE -RB04:3 -W1_RC
S 811B 0.75 mm² YE -C_RC38:3 -W1_RC
S 3015A 1.00 mm² YE -C_RC37:57 -W1_RC
Additional Components S 3015D 1.00 mm² YE -C_RC37:53 -W1_RC
S 3015E 1.00 mm² YE -C_RC37:49 -W1_RC
S 3015B 1.00 mm² YE -FB-B-42:6 -W1_RC
-S_SRC27 7000/3104 In Line Ultrasonic Splice

S 6000RA 2.00 mm² YE -C_RC37:58 -W1_RC
S 6000RB 2.00 mm² YE -C_RC37:59 -W1_RC
S 6000RC 2.00 mm² YE -C_RC37:61 -W1_RC
S 6000RD 2.00 mm² YE -C_RC37:62 -W1_RC
S 6000R 4.00 mm² YE -T_RC03:1 -W1_RC
-S_SRC36
S 820A 1.00 mm² YE -RB01:8 -W1_RC
-S_SRC29
S 134 4.00 mm² YE -RB02:2 -W1_RC 7000/3212;45 # Adhesive Lined Heatshrink
S 134A 4.00 mm² YE -FB-C-43:1 -W1_RC
S 134C 4.00 mm² YE -FB-B-42:13 -W1_RC

400/M1627-4
33 - 149 9813/8950-2 33 - 149

12 - Harness
05 - Rear Chassis

Figure 660. Rear chassis harness - 400/M1713 (Sheet 1 of 5)........................................... Page 33-151
33 - 150 9813/8950-2 33 - 150

12 - Harness
05 - Rear Chassis
Page 33-152 Figure 660. Rear chassis harness

- 400/M1713 (Sheet 1 of 5) Page 33-153
-C_RC41 -C_RC14
-C_RC34 -CAN1
25 mm 100 mm 25 mm
NC12
727/00002
B A 700 -P26 A B
0/32 4 1 2
120 OHM
06
10 7000/3206 7000/3206 CAN TERM
C 0 mm -P84
NC08
7212/0044
-C_RC34#2
-P89 C
25 mm
-C_RC41#2 -C_RC14#2
mm
7213/0030 GRID HEATER FIX WITH C014 AFTER TEST. 7213/0031
TO WORKLAMP HARNESS DGN TR 1
50
-C_RC31
F E D CB A 400 mm 75 mm 195 mm 30 mm 50 mm 150 mm 100 mm 25 mm 25 mm 80 mm 50 mm -C_RC20
120 OHM
-C_RC08
-C_RC31#2 CAN TERM 20 mm 20 mm
7216/0059
7000/3206 7000/3206
A B
200 mm 200 mm A B
FOOT THROTTLE 7000/3206 7000/3206 7000/3206
NC08
NC08
-P85 -P88
-P71
NC08
-P72
NC32
-S_SRC06 -P83
NC32 NC32 -CANLS5 -CANHS5 NC12 727/00002
C
-FB-C-43#2 -CAN3 2 1
C
7241/0001
-C_RC29 7000/3206 7000/3206
mm
1 7.5A-FC1 2 FUSEBOX C FIX WITH C029 AFTER TEST. -C_RC29#2 -C_RC08#2 -P21 -P20 -P17 -C_RC20#2
50
7213/0031 -P16 NC08

LIVELINK GND 3 15A-FC2 4 7212/0052 NC08
7210/0066 7213/0031
40
ENGINE TR 7243/0137
7207/1513
mm
FUEL PUMP W. I. F.
mm
5 7.5A-FC3 6
-C_RC01
30 mm
30
7000/3206
7 7.5A-FC4 8 -P110
40
mm
-FB-C-43
NC32
9 15A-FC5 10
-C_RCC
11 7.5A-FC6 12
UTEND2
-C_RC16 13 7.5A-FC7 14
70 mm
15 3A-FC8 16
200 mm
M10
UTEND1
END
-C_RC32 -D3
445 mm
330 mm
18
CUT
17
-C_RCC
5A-FC9
A B
30 mm 19 20
CUT
5A-FC10
7000/3206
END
1 2 7000/3206 -P19
1/1
1/1
-P73
-C_RC32#2
NO CONNECTOR
NC12 NC12
C -FB-B-42#2
NO CONNECTOR
7000/3206 7232/0017 7241/0001
CUT
LEAD
DIODE D1
20 mm
-P70 FUSEBOX B
7000/3202
-C_RC16#2
LEAD
NC08 TAPE BACK TO
-P225
CUT
1 10A-FB1 2
-P220203
mm
7213/0031
125 mm MAIN BRANCH.
3 4
7000/3
10A-FB2
M10 5 6
285 mm
20 mm
190
10A-FB3
-T_RC02 -C_RC10 30 mm
150 mm
50 240 mm 7 8
10A-FB4
7207/1510 -C_RC25
120 mm
-FB-B-42
TO CHASSIS EARTH 7000/3202
mm 9 10A-FB5 10
20 mm
-P243 7243/0503
NC32
NC08
-P67 11 12
2 1 5A-FB6
7000/3206
-P109
NC32 -C_RC10#2
13 5A-FB7 14 100 mm 50 mm 50 mm 50 mm 50 mm 90 mm 10 mm 230 mm 30 mm 270 mm 110 mm 590 mm
175 mm
7000/3206
NC32
m
7212/0052 15 16
NC12
3A-FB8
-P74
0m
-P75 1 4
-T_RC03 M10 NC08 TRANS OIL PRESS SW 17 30A-FB9 18
7243/0137
1 2 7000/3206 7000/3206 2 3
15
7207/1502 19 5A-FB10 20 7000/3206 7000/3206 7000/3206
ECU EARTH -CANLS1 -P87 -CANHS1 -CANSHD1 -P94 -P97 -P100 -P224
30 mm
NC16
21 03
NC32 ECU FEEDS NC16 NC12
7000/3202 NC12
mm
-P20/32
-P5 -C_RC25#2
-P68 -S_SRC35
50 7243/0157 7214/0025
700
-C_RC02#2
332/E9928 -C_RC05#2 -FB-A-41#2 RH REAR LIGHTS
7213/0031
125 mm TO OPERATOR HARNESS B 7241/0001
A
130 mm 30 mm
FUSEBOX A
210 mm 10 mm
CLUTCH PEDAL SWITCH
-T_RC01 M10 -C_RC02 -P222 1 15A-FA1 2
150 mm 200 mm 160 mm
150 mm
7000/3203
mm
7207/1510 -P66 7000/3206 3 15A-FA2 4
7000/3206 C -P82 2 1
500 mm
TO CHASSIS EARTH NC12
10 5 6
5
7000/3202 NC32 15A-FA3

C0
-FB-A-41
-P69 7 8
7.5A-FA4
-C_RC24#2
_R
-C_RC12#2 9 7.5A-FA5 10 7000/3206

-C
7219/0098 11 10A-FA6 12 SEAT BELT SWITCH -P98

DIAGNOSTIC NC08
13 7.5A-FA7 14
10 9 15 7.5A-FA8 16 -C_RC24
70 mm
3 6 17 18
-C_RC26
D 7.5A-FA9
-S_SRC22 -C_RC27 20 mm 20 mm
2 5 E
C
19 3A-FA10 20
100 mm 90 mm
1 4 F A B
8 7 J
G
NC08
NC08
H
2 1 2 1 -C_RC15#2
-C_RC27#2 7000/3206 -C_RC26#2
7219/0013 -S_SRC27
7000/3206 SERVICE HOUR RESET SWITCH
7212/0052 -P80 -P81 7212/0052
REVERSE SOLENOID -P76 NC08 -P77
7243/0137
NC08 FORWARD SOLENOID 7000/3206
40 mm
375 mm
7000/3206
60 mm
7243/0137 7243/0137 -P242

-C_RC12
-P49
20 mm
70 mm
-C
-P90
NC0 9 06
NC08
-RB01
NC25
0/32
-C_RC35
30 mm 240 mm
_R
7000/3206
-P5
8
700
-P95
C1
1 2 3 4 5 6 7241/0003 NC08
5
0 mm
NC08
200 mm
12 11 10 9 8 7
7000/3206
30
70 mm
-P65
250 mm
40 mm 40 mm
7000/3206
-C_RC35#2 NC12
mm
-P62
40 mm
7000/3203
-RB02
7219/0015 NC12
-C_RC39
120
-P260
3206 7000/3206
TO FRONT CHASSIS HARNESS 7000/
-S_SRC03 -P79
700
-P26
mm
-P119 NC08
-C_RC40
-RB01#2
0/32
-RB05#2
NC12 7241/0003 -RB03#2
30 mm 120 mm
-RB02#2 -RB04#2
1
7241/0003 7241/0003 7241/0003 7241/0003 7241/0003
13
140 mm
BRAKE LIGHT/HORN RLY HEADLAMP/GR BEACON RLY STRT INTERLOCK/IGN RLY FWD/REV RELAY TRANS DUMP/LIFT PUMP RLY
03
110
8 8 8 8 8
-C_RC07
0 mm
7514/0005
1 6 7000/3206 -D_RC1 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6
2 5 -P64
NC32 10 10 10 10 10 2 1
3 4
-DH2 -D7
-S_SRC01
mm
-DH1 -D6
5 5 5 5 5
-C_RC40#2
1 2 4 1 2 4 1 2 1 2 4 1 2 4
40 mm
4
/3203
TAPE TO HARNESS AS
40 mm
-C_RC39#2
7216/0018 3 3 3 2 1
1000 mm
3
110
3
-P210
-RB03
-DH2#2 7212/0001
7000
1 3
-C_RC07#2
-P21/320
TO WORK LAMP SW HARNESS 7233/0015 -DH1#3 REVERSE ALARM
30 mm 80 mm 40 mm 50 mm 50 mm 100 mm 3 2 1
7233/0015 7212/0030
7000
-D1 -C_RC36 3 2 1 7241/0003
-C_RC03 AC COMPRESSOR CLUTCH
-S_SRC17 m
0m
1 2 NC08
-VE
+VE
20 mm
-C_RC36#2 7000/3206
12 7000/3206
150 mm
7232/0017
50 mm
40 mm
7000/3206
P
7243/0137
-P61 -P58
15 mm
15 mm
-P60
-S_SRC14 -S_SRC07
E N
30 mm
PARK BRAKE DIODE 7000/3206 NC32 -P63 F D
M
NC08
-P78
-RB04
15 mm
A C
TAPE BACK TO ID Label NC25

mm
NC32
G
B L
7000/3203
-ID1
H K
MAIN BRANCH.
70
J
-P259
3
-P21/3203 7241/0003 -C_RC06#2 NC08
20 mm
7219/0086
-S_SRC30 7000
-S_SRC10 ENGINE HARNESS
7243/0137
220 mm 220 mm
15 mm 15
-P96
-C_RC06
mm mm
70
30 mm
-S_SRC21
-RB05
15 mm -C_RC04
-C_RC17 7000/3203 40 mm 7241/0003
170 mm 30 mm -C_RC37
160 mm
-P244
-C_RC09 475 mm 30 mm 30 mm
40 mm 30 mm 60 mm 2 1
7000/3206 -C_RC04#2
3 2 1
-P232 7212/0052
2 1
4 12 62
7000/3206 -S_SRC29-S_SRC157000/3203
-P214 NC08 SEAT SWITCH -C_RC30
-S_SRC31 40 mm
-C_RC09#2 7000/3203
-C_RC17#2 -P227 -P209
7213/0034 -S_SRC04 -S_SRC13 3
75 mm
NC12
-RB06
7212/0052 /3205
50 mm
PARK BRAKE
60 mm
1 9 13 17 25 29 37 41 45 49 53 57 60 TRANS OIL TEMP SW 7000-P3 7000
-P21
mm
/3203
110
03 2 1
7000/32
-P216 40 mm
75 mm 110 mm
-RB07
-C_RC30#2
7000/3203 -RB10#2
7241/0003 7212/0052
-C_RC03#2 -P245
-RB06#2
7241/0005
-RB07#2
7241/0005
-RB08#2 -RB09#2
7219/0219
7241/0005 7241/0005
FUEL SENDER
-S_SRC05
FLASHER RERLAY PWR HOLD RLY
40 mm
STARTER RELAY WARNING BUZZER 8
120 mm
10 mm
100 mm
TO OPERATOR HARNESS 7 4 1 7 4 1 7 4 1 7 4 1 9 7 6
-C_RC37#2
310 mm
10 7000/3206
-S_SRC23
-C_RC33
-RB08
170 mm
-P57
7000
8 5 2 8 5 2 8 5 2 8 5 2 7000/3206 7219/0076
30 mm
-P26/320
5 -P230 NC08
30 mm
140 ENGINE ECU

-P219
1 4 9 6 3 9 6 3 9 6 3 9 6 3 1 2 NC16
2 3
4
7000/3203 -C_RC28
-C_RCCUTEND3
2 3 mm 40 mm 3
7000/3206 350 mm
-RB09
-P118
NC08 -C_RC33#2 -S_SRC18
700 -P217
7000/
-P2
0/3
CUT END
7214/0025 3203
18
203 X
6 5 4 3 2 X
1
30 mm
TO SPEEDOMETER HARNESS
mm
300
40 mm
-C_RC28#2
18
1/1
40 mm 50
NO CONNECTOR
6
7000/3211
7216/0060
0m
/320
LEAD CUT
-P267
TMAF
mm
-RB10
-S_SRC20 60 mm 170 mm 370 mm 210 mm 130 mm 7000-P38 8
m
NC0
7241/0003
20 mm 30 mm
7000/3206 7000/3206 30 mm
-P54 -P231 7000 -C_RC23
280 mm
NC08 /3206
NC12 -P39
-S_SRC24
100 mm
NC08
1 2
-S_SRC02
-C_RC45
50 mm 50 mm 50 mm 50 mm GREY 10 1
-C_RC23#2
18
7212/0013
20 GREY 'B' AIR FILTER
RC
11
-C_
7000/3203
-C_
-CANSHD2 -P263 -CANLS2 -CANHS2
10 mm
-C_RC45#2
RC
30 mm
332/E3213
Drive Inhibit ECU
19
7000/3206
-P91 TAPE BACK TO
-S_SRC36
300 mm
NC20 MAIN BRANCH. A B
BLUE
370 mm
-P265
7000/3206
-C_RC19#2
7232/0008
AGREYB
7000
-C_RC42
NC125
-P23/3206
30 mm 30 mm 30 mm 30 mm 50 mm 30 mm 30 mm 30 mm 30 mm 30 mm 50 mm
PRIMARY FUSE-2 -C_RC18#2
50 mm
60 mm 200 mm 30 mm 30 mm 40 mm 100 mm 30 mm
NC1 6 6
7232/0009
-C_RC38 -D2
-P23/320
PRIMARY FUSE-1 4 1
7000
2
-C_RC38#2 3 2
mm
7233/0015 7000/3206
3 2 1
7000/3211 FR DIODE -P2 -C_RC42#2

Service Manual: Foreword

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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.

This manual contains original instructions, verified by

Copyright 2018 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

SERVICE MANUAL SERVICE MANUAL

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual there are safety notices. Each notice

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system symbol (shown) also helps

Figure 1. The safety alert system symbol

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety 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: 6T-1 Front Tip, 7T-1 Front Tip [Hi-

Dumper Body Lowered

Dumper Body Raised

If you raise the dumper to get access for

The maintenance strut is only for use with a empty

movement immediately when the weight of

Dumper Body Raised

A Maintenance strut - stowage position

A Maintenance strut - installed position B Pin

Health and Safety

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-17

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-12 Main Component Locations ........................................................................................... 01-21

12 - Main Component Locations

For: 6T-1 Swivel Tip, Without Cab

(For: 6T-1 Swivel Tip, Without Cab)

A ROPS (Roll-Over Protective Structure) B Beacon

(For: 6T-1 Front Tip, 9T-1 Front Tip, Without Cab)

15 - Service Point Locations

A Fuel filter (Separator) B Engine oil filter

A Coolant expansion tank B Hydraulic oil filler neck

A Battery isolator B Relays

A Brake fluid tank cap

A Floor plate battery access cover B Battery

Contents Page No.