Service Manual: Foreword

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

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

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

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

VARIABLE REACH TRUCK) Contents
506-23, 509-23, 512-26
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
EN - 9813/9400 - ISSUE 1 - 11/2017
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
Copyright 2017 © JCB SERVICE

78 - After Sales
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9813/9400-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
506-23, 509-23, 512-26 506-23, 509-23, 512-26
EN 9813/9400 EN 9813/9400
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
506-23, 509-23, 512-26 506-23, 509-23, 512-26
EN 9813/9400 EN 9813/9400
9813/9400-1
Notes:
9813/9400-1
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-15
01-06-06 Using the Manual ........................................................................................................... 01-16
01-09 Description
01-09-00 General ........................................................................................................................... 01-19
01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-33
9813/9400-1
2017-10-26
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9813/9400-1
2017-10-26
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 9813/9400-1 01 - 1
Notes:
01 - 2 9813/9400-1 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

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

warning messages, 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 9813/9400-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual and on the machine, there are safety

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

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

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

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

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

important safety messages in this manual and on the
machine. When you see this symbol, be alert, your
safety is involved, carefully read the message that
follows, and inform other operators.
Figure 1. The safety alert system
01 - 4 9813/9400-1 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. If you are a new operator, get yourself drop and injure you if the hydraulic system fails
trained in the skills of using a machine before trying or if the control is operated (even with the engine
to work with it. If you don't, you will not do your job stopped).
well, and you will be a danger to yourself and others. Make sure that no-one goes near the machine while
In some markets and for work on certain jobsites you you install or remove the mechanical device.
may be required to have been trained and assessed
in accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements - it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9813/9400-1 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9813/9400-1 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300°C
(571.6°F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (571.6°F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.
01 - 7 9813/9400-1 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety Worksites

Worksites can be hazardous. Examine the site
Introduction before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
Training and hidden debris, logs, ironwork etc. Any of these
Make sure that you have had adequate training and could cause you to lose control of your machine.
that you are confident in your ability to operate the Check for utilities such as electric cables (overhead
machine safely before you use it. Practice using the and underground), gas and water pipes etc. Mark
machine and its attachments until you are completely the positions of the underground cables and pipes.
familiar with the controls and what they do. With Make sure that you have enough clearance beneath
a careful, well trained and experienced operator, overhead cables and structures.
your machine is a safe and efficient machine. With Communications
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others, Bad communications can cause accidents. Keep
at risk by using the machine irresponsibly. Before you people around you informed of what you will be
start to work, tell your colleagues what you will be doing. If you will be working with other people,
doing and where you will be working. On a busy site, make sure any hand signals that may be used are
use a signalman. understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Before doing any job not covered in this manual, find
out the correct procedure. Your local JCB distributor Parking
will be glad to advise you. An incorrectly parked machine can move without an
Fuel operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Banks and Trenches
leak is suspected. Do not smoke while refuelling or Banked material and trenches can collapse. Do not
working on the fuel system. Do not refuel with the work or drive too close to banks and trenches where
engine running. Completely wipe off any spilt fuel there is danger of collapse.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. Safety Barriers
Machine Condition Unguarded machines in public places can be
dangerous. In public places, or where your visibility
A defective machine can injure you or others. Do not is reduced, place barriers around the work area to
operate a machine which is defective or has missing keep people away.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Sparks
Machine Limits Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Operating the machine beyond its design limits can machine in closed areas where there is flammable
damage the machine, it can also be dangerous. material, vapour or dust.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Hazardous Atmospheres
unapproved modifications or additional equipment. This machine is designed for use in normal out
Engine/Steering Failure door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
If the engine or steering fails, stop the machine as Do not use the machine in a potentially explosive
quickly as possible. Do not operate the machine until atmosphere, i.e. combustible vapours, gas or dust,
the fault has been corrected. without first consulting your JCB dealer.
Exhaust Gases Regulations
Machine exhaust gases can harm and possibly kill Obey all laws, worksite and local regulations which
you or bystanders if they are inhaled. Do not operate affect you and your machine.
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
01 - 8 9813/9400-1 01 - 8
01 - Machine
03 - Safety
18 - Operating Safety
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine.
the machine or its attachments too close to electrical When using the machine, keep your hands and feet
power cables. clear of moving parts. Keep your hands and feet
You are strongly advised to make sure that the safety within the operator compartment while the vehicle is
arrangements on site comply with the local laws in motion.
and regulations concerning work near electric power Controls
lines.
You or others can be killed or seriously injured
Before you start using the machine, check with your if you operate the control levers from outside the
electricity supplier if there are any buried power machine. Operate the control levers only when you
cables on the site. are correctly seated.
There is a minimum clearance required for working Passengers
beneath overhead power cables. You must obtain
details from your local electricity supplier. Passengers in or on the machine can cause
accidents. Do not carry passengers.
Working Platform
Fires
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured. If your machine is equipped with a fire extinguisher,
Never use the machine as a working platform make sure it is checked regularly. Keep it in the
unless with approved man-basket or man-crate (if correct machine location until you need to use it.
applicable). Do not use water to put out a machine fire, you could
Machine Safety spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
Stop work at once if a fault develops. Abnormal extinguishers. Contact your nearest fire department
sounds and smells can be signs of trouble. Examine as quickly as possible.
and repair before resuming work.
Roll Over Protection
Hot Components
If the machine starts to roll over, you can be crushed
Touching hot surfaces can burn skin. The engine and if you try to leave the cab. If the machine starts to roll
machine components will be hot after the unit has over, do not try and jump from the cab. Stay in the
been running. Allow the engine and components to cab, with your seat belt fastened.
cool before servicing the unit.
Confined Areas
Travelling at High Speeds
Pay extra attention to proximity hazards when
Travelling at high speeds can cause accidents. operating in confined areas. Proximity hazards
Always travel at a safe speed to suit working include buildings, traffic and bystanders.
conditions.
Safe Working Loads
Hillsides
Overloading the machine can damage it and make it
Operating the machine on hillsides can be unstable. Study the specifications in the Operator's
dangerous if the correct precautions are not taken. Manual before using the machine.
Ground conditions can be changed by rain, snow, ice
etc. Check the site carefully. When applicable, keep Lightning
all attachments low to the ground. If you are inside the machine during a lightning storm
Visibility stay in the machine until the storm has passed. If
you are outside of the machine during a lightning
Accidents can be caused by working in poor visibility. storm stay away from the machine until the storm
Use your lights to improve visibility. Keep the road has passed. Do not attempt to mount or enter the
lights, windows and mirrors clean. machine.
Do not operate the machine if you cannot see clearly. If the machine is struck by lightning do not use the
Modification of the machine's configuration by the machine until it has been checked for damage and
user (e.g. the fitting of large and non-approved malfunction by trained personnel.
attachments) may result in a restriction of the
machine visibility.
01 - 9 9813/9400-1 01 - 9
01 - Machine
03 - Safety
21 - Worksite Safety
21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on
the site. Ban smoking, make sure that all naked
lights are extinguished and switch off any engines
which may be running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.
01 - 10 9813/9400-1 01 - 10
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 11 9813/9400-1 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12
Health and Safety .......................................... 01-13
(For: 506-23 [T4F])
You can complete most of the maintenance
procedures with the lift arm lowered. Unless a
maintenance procedure instructs you differently, you
must lower the lift arm.
Lift Arm Lowered

1. Park the machine on level, solid ground.
2. Make the machine safe.
Refer to: PIL 01-03.
3. Retract and lower the lift arm.
4. Put the attachment flat on the ground.
5. Release the hydraulic pressure.
6. Stop the engine and remove the ignition key. If
the keyless ignition option is installed stop the
engine and wait the specified time.
Duration: 15s
7. Disconnect the battery to prevent accidental
operation of the engine.
8. Make sure there are no loose articles in the
enclosure.
9. If necessary, put blocks against the two ends of
the wheels before you get below the machine.
Figure 2.
A Lift arm lowered
Lift Arm Raised

1. Install the maintenance strut.
01 - 12 9813/9400-1 01 - 12
01 - Machine
03 - Safety
27 - Maintenance Positions
Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery 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 - 13 9813/9400-1 01 - 13
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-15

01-06-06 Using the Manual ........................................................................................................... 01-16
01 - 14 9813/9400-1 01 - 14
01 - Machine
03 - Model and Serial Number
03 - Model and Serial Number
Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
506-23 2902000
509-23 2902000
512-26 2902000
01 - 15 9813/9400-1 01 - 15
01 - Machine
06 - Using the Manual
06 - Using the Manual
Introduction
Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification
Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included information is contained within another PIL reference
under a set of standard headings such as a cross reference is provided.
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System 30-00-50 Schematic Circuit
Electrical System 33-03-03 Battery - Isolator Switch
33-09-00 Power Distribution (including fuses
and relays)
33-00-50 Schematic Circuit
Electronic Diagnostic 33-57 Electronic Diagnostic (including
Servicemaster)
Machine Variants • Use the applicable Servicemaster diagnostics

tools. Refer to PIL 33-57-03.
Where information is different depending on machine
variant, the applicable information sets are included Torque Tightening
within the same PIL reference. Headings are
included to identify which information is for which When you replace components, always tighten the
variant. Make sure you use the correct information. applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
Diagnostics procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified,
Information in this manual can help you diagnose use the standard torque tightening values. Refer
machine faults. to Fasteners and Fixings, Screws, Bolts, Nuts,
Technical Data (PIL 72-00). For the torque setting to
Before attempting to diagnose possible faults check be effective, do the following before you install the
the following. fixings.
• Ensure that the operator understands the • Make sure that all the applicable component
machine controls, functions and use. Refer to assemblies are correct.
the applicable Operator Manual. • Make sure that the applicable fixings are to the
• Check that the maintenance record complies correct specification. If necessary discard the
with the applicable schedule for the operating original fixings and replace them with new ones.
environment. Refer to PIL 78-24. The relevant procedures indicate when this is
• Check that the fluids in use comply with the necessary.
standards specified. Refer to PIL 75-00. • Make sure that the applicable fixings and
• Ensure that the machine electronic set-up is threaded holes are free from contamination.
applicable. Use the applicable Servicemaster This includes dirt, debris, old sealants and
vehicle set-up tool. Refer to PIL 33-57-03. compounds, fluids and lubricants.
01 - 16 9813/9400-1 01 - 16
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-00 General ........................................................................................................................... 01-19

01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01 - 17 9813/9400-1 01 - 17
Notes:
01 - 18 9813/9400-1 01 - 18
01 - Machine
09 - Description
00 - General
00 - General Introduction
Introduction .................................................... 01-19 The JCB Loadall is a self propelled, seated operator,
Operation ....................................................... 01-20 wheeled machine for operation on unimproved
natural terrain and disturbed terrain.
A main structural support is designed to carry an

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

loads by extending/retracting, raising/lowering the
boom.
01 - 19 9813/9400-1 01 - 19
01 - Machine
09 - Description
00 - General
Operation
The machine is intended to be used in normal

conditions for the applications described in this
manual. If the machine is used for other applications
or in dangerous environments, for example in
a flammable atmosphere or in areas with dust
containing asbestos, special safety regulations must
be obeyed and the machine must be equipped for
use in these environments.
01 - 20 9813/9400-1 01 - 20
01 - Machine
09 - Description
03 - Log Moving/Object Handling
03 - Log Moving/Object Handling
Introduction
Do not use the machine to move or handle logs

unless sufficient log protection is installed. You could
cause serious injury to yourself and damage to the
machine. For more information, contact your JCB
dealer.
01 - 21 9813/9400-1 01 - 21
01 - Machine
09 - Description
06 - Optional Equipment and Attachments
06 - Optional Equipment and

Attachments
Introduction
A wide range of optional attachments are available

to increase the versatility of your machine. Only the
JCB approved attachments are recommended for
use with your machine. Contact your JCB dealer for
the full list of approved attachments available.
01 - 22 9813/9400-1 01 - 22
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Component Identification
Figure 3.
A D
E F
C
B
A Lift arm B Carriage

C Battery D ROPS (Roll-Over Protective Structure)/FOPS
(Falling Object Protective Structure) cab
E Hydraulic tow hitch (Agricultural machines only) F Mechanical tow hitch
01 - 23 9813/9400-1 01 - 23
01 - Machine
09 - Description
15 - Service Point Locations
Engine Compartment
Figure 4.
A B
H
C
G E
F
A Air filter B Transmission oil dipstick

C Water separator D Radiator
E Engine oil filter F Drive belt guard
G Engine oil dipstick H Engine oil filler cap
J Coolant expansion tank
01 - 24 9813/9400-1 01 - 24
01 - Machine
09 - Description
Battery Isolator
Figure 5.
A
A
A Battery isolator
01 - 25 9813/9400-1 01 - 25
01 - Machine
09 - Description
Hydraulic Oil Level Indicator

Machines with External Sight Gauge
Figure 6.
A Hydraulic oil level indicator
Figure 7.
A B
C
A Label - hydraulic oil filling point B Hydraulic oil level indicator

C Hydraulic tank filler cap
01 - 26 9813/9400-1 01 - 26
01 - Machine
09 - Description
Machines without External Sight Gauge

Figure 8.
A
A Hydraulic oil level indicator
Figure 9.
C
A
A Hydraulic oil level indicator B Label - hydraulic oil filling point

C Hydraulic tank filler cap
01 - 27 9813/9400-1 01 - 27
01 - Machine
09 - Description
Axles
For: 550-80
Figure 10.
A A
A Axle fill/level plug
01 - 28 9813/9400-1 01 - 28
01 - Machine
09 - Description
For: Other Models
Figure 11. Machines with Double Acting Cylinders
A
A
A Axle fill/level plug
Filling the Tank

Figure 12.
A
B
A Diesel exhaust fluid tank cap (blue)

B Diesel fuel tank cap (green - USA only, black -
all other territories)
01 - 29 9813/9400-1 01 - 29
01 - Machine
09 - Description
Figure 13.
A Diesel exhaust fluid tank cap (blue) B Diesel fuel tank cap (green - USA only, black -
all other territories)
01 - 30 9813/9400-1 01 - 30
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-33
01 - 31 9813/9400-1 01 - 31
Notes:
01 - 32 9813/9400-1 01 - 32
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-33 or other chemicals, you must adhere to
Preparation .................................................... 01-34 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 - 33 9813/9400-1 01 - 33
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 - 34 9813/9400-1 01 - 34
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-33 Fork
03-33-00 General ............................................................................................................................. 03-7
03-33-03 Carriage .......................................................................................................................... 03-10
03-82 Jib
03-82-00 General ........................................................................................................................... 03-13
03-82-06 Shackle ........................................................................................................................... 03-15
03-84 Hook
03-84-06 Snatch Block .................................................................................................................. 03-19
9813/9400-1
2017-08-14
Notes:
9813/9400-1
2017-08-14
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/9400-1 03 - 1
Notes:
03 - 2 9813/9400-1 03 - 2
00 - Attachments
00 - General
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.
Some attachments are supplied complete with

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

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

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

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

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

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

until the machine hydraulic oil has reached its normal
working temperature.
03 - 3 9813/9400-1 03 - 3
00 - Attachments
00 - General
Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty.
Attachments
If you have an attachment which is not covered in the
Operator's Manual do not install it, use it or remove
it until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.
03 - 4 9813/9400-1 03 - 4
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-7

03-33-03 Carriage .......................................................................................................................... 03-10
03 - 5 9813/9400-1 03 - 5
Notes:
03 - 6 9813/9400-1 03 - 6
33 - Fork
00 - General
Introduction ...................................................... 03-7 Forks can be installed on many different types of
Health and Safety ........................................... 03-8 agricultural or construction machines. Forks can be
Adjust .............................................................. 03-8 directly mounted on to a lift arm or carriage or
mounted to a lift arm via a quickhitch assembly.
There are a vast amount and size of forks used for
numerous applications.
Forks can be used to lift, raise and carry heavy things

and stack them where required.
03 - 7 9813/9400-1 03 - 7
33 - Fork
00 - General
Health and Safety Adjust

DANGER Using the forks alone as a working WARNING Loads can fall off incorrectly spaced
platform is hazardous; you can fall off and be forks. Always space the forks correctly for the
killed or injured. Never use the forks as a working load. Make sure the forks are completely under
platform. the load before lifting.
WARNING Loads can fall off incorrectly spaced CAUTION To prevent unintentional detachment
forks. Always space the forks correctly for the of forks during travel or transportation, the forks
load. Make sure the forks are completely under must not overlap the lower removal notch or be
the load before lifting. secured in the central two positions on top of the
carriage.
WARNING If the fork/locking pin is not fully
engaged, the fork could become unintentionally CAUTION The forks are heavy. Make sure
disengeged. suitable lifting equipment is used to support and
transport them.
WARNING Do not try to correct the alignment
of the fork tips by bending the forks or adding WARNING If the fork/locking pin is not fully
shims. Never repair damaged forks by heating or engaged, the fork could become unintentionally
welding. Forks are made of special steel using disengeged.
special procedures. Always replace the damaged
forks.
Repositioning the Forks
WARNING Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation Industrial Carriage Fork Adjustment
capacity.
WARNING The forks project in front of the 1. Make the machine safe. Apply the park brake (if
machine. Make sure there is enough clearance installed).
for the forks when making turns.
2. Lower the forks as required to enable the use of
CAUTION A load lifted on one fork can slip off. suitable lifting equipment to move the forks.
Never lift a load with one fork.
3. Stop the engine. Remove the ignition key.
CAUTION Never unload the forks by stopping the
machine suddenly. Follow the procedures in the 4. Release the locking pins and slide the forks to the
Operator Manual for unloading. desired position using suitable lifting equipment.
CAUTION The forks are heavy. Make sure Your machine will have either 'twist and pull'
suitable lifting equipment is used to support and or 'pull' type fork locking pins. Forks must not
transport them. overlap the lower removal notch or be secured in
the central two positions on top of the carriage,
CAUTION Do not exceed the total rated load see shaded 'no fork' zone.
capacity of the forks being used. Forks can break
resulting in a loss of load and possible injury.
CAUTION Loads stacked on uneven ground can
topple. Never stack loads on uneven ground.
03 - 8 9813/9400-1 03 - 8
33 - Fork
00 - General
Figure 14.
A Locking pins
B Lower removal notch
C 'No fork' zone
5. Re-engage the locking pins. Make sure the pins
and forks are correctly located.
6. Remove the lifting equipment.
03 - 9 9813/9400-1 03 - 9
33 - Fork
03 - Carriage
03 - Carriage
Remove and Install
For: 506-23 [T4F], 509-23 [T4F] Figure 15.

................................................... Page 03-10
For: 512-26 [T4F] ...................... Page 03-10 B C
(For: 506-23 [T4F], 509-23 [T4F])
Two stage booms (P1)

Remove
2. Position the lift arm so that the fork carriage can D A
be safely supported when it is disconnected from
the lift arm assembly.
3. Discharge the hydraulic pressure.
4. Support the fork carriage.
5. Remove the bolt and tipping lever pivot pin. A Fork carriage
B Bolt
6. Remove the lock nut and bolt from the pivot pin C Tipping lever pivot
trunnion. D Pivot pin
7. Remove the pivot pin from its location. Install

8. Remove the fork carriage. 1. The installation procedure is the opposite of the
removal procedure.
(For: 512-26 [T4F])
Two stage booms (P2)

Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Position the lift arm so that the fork carriage can
be safely supported when it is disconnected from
the lift arm assembly.
3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
4. Support the fork carriage.
5. Remove the securing bolt and remove the pivot
pin 1 from the tipping link.
03 - 10 9813/9400-1 03 - 10
33 - Fork
03 - Carriage
6. Remove the securing bolt and remove the pivot 7. Remove the fork carriage.
pin 2.
Figure 16.
D
E
A
A Fork carriage B Pivot pin 1

C Tipping link D Bolt
E Pivot pin 2
Install
1. The installation procedure is the opposite of the
removal procedure.
03 - 11 9813/9400-1 03 - 11
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-13

03-82-06 Shackle ........................................................................................................................... 03-15
03 - 12 9813/9400-1 03 - 12
82 - Jib
00 - General
Introduction .................................................... 03-13
Safety
Read and understand all the warning messages.
Follow all the safety instructions given in this
Operator Manual. Do not install/operate an
attachment until you are sure that you can operate it.
Use the attachment only if it carries up to date test

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

attachment, check the appropriate load chart in
the cab and understand the lift capacities.
• Make sure the machine is in a level position.
If necessary, reposition the machine using
chassis levelling control or stabilisers (if fitted).
• Use the lifting shackle which is suitable for the
job, in good condition and proof tested where
necessary.
• Always sling the load safely and in accordance
with any local regulations.
• Make sure that the hook safety catch is closed
correctly to prevent the sling(s) from slipping off
the hook.
• Always lift the load carefully, to avoid snatching
the sling(s).
• Keep yourself and other people clear of a
suspended load, especially from beneath the
load.
• Always remember that the effective length of
the boom is increased when an attachment is
installed. Before manoeuvring the machine with
an attachment make sure you have sufficient
clearance.
• You must be careful while carrying a suspended
load. Keep the load as low to the ground
as possible. If necessary, use guide ropes to
prevent the load from swinging.
• Always travel in 1st gear at walking speed when
carrying a suspended load. Wherever possible,
travel on firm, level ground. Avoid rough or
excessively uneven ground.
• Do not carry suspended loads on public roads.
• Always be aware of the affects of wind velocity
on the load being handled.
03 - 13 9813/9400-1 03 - 13
82 - Jib
00 - General
Health and Safety

WARNING This attachment has a maximum safe
working load. Do not exceed the safe working
load. Do not exceed the machine stability limits
shown on the load chart(s) in the cab.
WARNING Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
WARNING The attachment is heavy. Take care
when lifting and handling it. Use suitable lifting
equipment. Make sure the lifting equipment is in
good condition. Make sure the lifting equipment
complies with all pertinent regulations. Wear
gloves and safety shoes.
WARNING Refer to the load chart in the cab for
permissible loading for each position of the jib
extension.
03 - 14 9813/9400-1 03 - 14
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 18.

reach and height. This attachment is supplied with
test certificates for its fabrication, its hook and its D
shackle. The safe working load is stamped on a plate
mounted on the attachment.
Figure 17.
A F
G
A Roof truss jib
B Hook B
Installing/Removing
A
The attachment is heavy. Take care when lifting
and handling it. Use suitable lifting equipment. Make
sure the lifting equipment is in good condition. Make C
sure the lifting equipment complies with all relevant
regulations. Wear gloves and safety shoes. A Skid
B Lynch pin
The installation will be easier if the attachment is C Pin
rested on wooden blocks. D Jib- fully extended
E Jib- extended position 1
Store the attachment carefully to prevent damage F Jib- extended position 2
and corrosion. G Jib- fully retracted
Extending the Jib 1. Remove the load and lower the jib to the ground.
2. Make sure the skid is supporting the weight of
The jib may be extended to one of four positions:
the jib.
3. Remove the lynch pin, then pin.
4. Move the jib extension to the required position;
fully extended or fully retracted.
5. Insert the pin and secure with lynch pin.
Changing the Jib Angle

The angle of the jib may be set in one of two
positions.
03 - 15 9813/9400-1 03 - 15
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 19.
A B
D F
C E
C
A Placing position B Travel position

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

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

2. Make sure the skid is supporting the weight of
the jib.
3. Remove the lynch pin, then pin.
4. Use the tilt control in the cab to rotate the carriage
until the holes align in the required position.
Stops will prevent excessive movement of the jib.
5. Insert the bar and secure with lynch pin.
03 - 16 9813/9400-1 03 - 16
84 - Hook
84 - Hook
Contents Page No.
03-84-06 Snatch Block .................................................................................................................. 03-19
03 - 17 9813/9400-1 03 - 17
Notes:
03 - 18 9813/9400-1 03 - 18
84 - Hook
06 - Snatch Block
06 - Snatch Block Introduction

Introduction .................................................... 03-19 The fork mounted hook allows the machine to carry
Remove and Install ....................................... 03-20 slung loads with safety. It incorporates a swivel hook
with a spring loaded safety catch. This attachment is
supplied with test certificates for its fabrication and
its hook. Its safe working load is stamped on a plate
mounted on the attachment.
03 - 19 9813/9400-1 03 - 19
84 - Hook
06 - Snatch Block
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 20.
C A
A Mounting sockets
B Lynch pin
C Locking bar
Remove
2. Lower the attachment so that it just clears the
ground.
3. Apply the park brake and stop the engine.
4. Remove the attachment.
4.1. Remove the lynch pin and locking bar.
4.2. Carefully slide the attachment off the forks.
4.3. Install the locking bar and secure with lynch
pin.
4.4. Store the attachment carefully to prevent
damage and corrosion.
Install
1. Space the forks, equally on either side of the
machine centreline, so that the mounting sockets
can be slid onto them.
2. Tighten the fork clamping screws to prevent
movement.
3. Install the attachment.
3.1. Remove the lynch pin and locking bar.
3.2. Slide attachment over the forks so that the
rear of the attachment butts against the
heels of the forks.
3.3. Install the locking bar and secure with lynch
pin.
03 - 20 9813/9400-1 03 - 20
Contents Page No.
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-7
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-11
06-06-03 Battery Compartment ..................................................................................................... 06-12
06-06-06 Engine Compartment ..................................................................................................... 06-13
06-06-10 Transmission Compartment ........................................................................................... 06-16
06-06-12 Front Cover .................................................................................................................... 06-18
06-06-14 Rear Cover ..................................................................................................................... 06-20
06-06-30 Undershield .................................................................................................................... 06-21
06-06-33 Lift Arm ........................................................................................................................... 06-22
06-06-39 Cab/Canopy ................................................................................................................... 06-23
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-27
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-43
06-12-24 Shim ............................................................................................................................... 06-44
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-51
06-42 Stabiliser
06-42-00 General ........................................................................................................................... 06-55
06-49 Step
06-49-00 General ........................................................................................................................... 06-59
06-54 Fender
06-54-00 General ........................................................................................................................... 06-61
06-57 Counterweight
06-57-00 General ........................................................................................................................... 06-65
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-67
06-63-03 Machine .......................................................................................................................... 06-68
06-63-06 Engine ............................................................................................................................ 06-70
06-63-09 Axle ................................................................................................................................ 06-72
06-63-12 Gearbox .......................................................................................................................... 06-73
06-63-15 Operator Protective Structure ........................................................................................ 06-74
06-66 Tools
06-66-00 General ........................................................................................................................... 06-77
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-79
06-69-03 Lift Arm ........................................................................................................................... 06-80
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-83
9813/9400-1
2017-10-20
06-89 Window Guard
06-89-00 General ........................................................................................................................... 06-85
9813/9400-1
2017-10-20
Acronyms Glossary
FOPS Falling Object Protective Structure

OECD Organization for Economic
Cooperation and Development
PIN Product Identification Number
9813/9400-1
2017-10-20
Notes:
9813/9400-1
2017-10-20
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9813/9400-1 06 - 1
Notes:
06 - 2 9813/9400-1 06 - 2
00 - General
00 - General Clean
Clean ............................................................... 06-3 Keep all intakes and grilles clear from snow, ice and
Check (Condition) ............................................ 06-4 debris.
Debris can collect under the boom. Remove all

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

clean transmission or hydraulic oil if necessary.
06 - 3 9813/9400-1 06 - 3
00 - General
Check (Condition)
1. Make sure that all of the guards and protective
devices are in position, secured by their locking
devices and free from damage.
2. Inspect all of the steelwork for damage. Include
the following:
2.1. Examine all of the lifting point welds.
2.2. Examine all of the pivot point welds.
2.3. Examine the condition of all the pivot pins.
2.4. Check that the pivot pins are correctly
in position and secured by their locking
devices.
3. Check the steps and handrails are undamaged
and correctly attached.
4. Check for broken, cracked or crazed window
glass and mirrors. Replace the damaged items.
4.1. The right hand side cab glass is installed
for the operators protection. If the cab glass
becomes damaged, the machine should not
be operated until it has been replaced.
5. Check that the lamp lenses are undamaged.
6. Check that all of the attachment teeth are
undamaged and correctly attached.
7. Check that all of the safety and instructional
labels are undamaged and in position. Install new
labels where necessary.
8. Note any damaged paintwork for future repair.
9. Inspect the machine for broken or loose
fasteners.
06 - 4 9813/9400-1 06 - 4
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 5 9813/9400-1 06 - 5
Notes:
06 - 6 9813/9400-1 06 - 6
03 - Chassis
00 - General
Introduction ...................................................... 06-7 The chassis is the underpart of the vehicle or
Health and Safety ........................................... 06-8 machine, consisting of the frame on which the body
or cab is mounted.
06 - 7 9813/9400-1 06 - 7
03 - Chassis
00 - General
Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
06 - 8 9813/9400-1 06 - 8
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-11

06-06-03 Battery Compartment ..................................................................................................... 06-12
06-06-06 Engine Compartment ..................................................................................................... 06-13
06-06-10 Transmission Compartment ........................................................................................... 06-16
06-06-12 Front Cover .................................................................................................................... 06-18
06-06-14 Rear Cover ..................................................................................................................... 06-20
06-06-30 Undershield .................................................................................................................... 06-21
06-06-33 Lift Arm ........................................................................................................................... 06-22
06-06-39 Cab/Canopy ................................................................................................................... 06-23
06 - 9 9813/9400-1 06 - 9
Notes:
06 - 10 9813/9400-1 06 - 10
00 - General
00 - General
Introduction
When moved to their maintenance position, the

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

of the access panels are correctly in their closed or
installed positions.
06 - 11 9813/9400-1 06 - 11
03 - Battery Compartment
03 - Battery Compartment
Remove and Install
Single Step Installation Close
Open 1. Close the battery compartment cover.
1. Make the machine safe. Refer to (PIL 01-03). 2. Make sure the battery compartment cover is
closed correctly.
2. Use the key to unlock the battery compartment
cover. 3. Use the key to lock the battery compartment
cover.
3. Open the battery compartment cover.
Twin Step Installation
Figure 21.
Open
2. Remove the bolts (and washers).
3. Lift the battery compartment cover to a small
distance and allow the cover to pivot forward.
A Battery compartment cover
Figure 22.
A
A Bolts B Battery compartment cover
Close 3. Tighten the bolts to the correct torque value.
1. Position the battery compartment cover.

2. Install the bolts.
06 - 12 9813/9400-1 06 - 12
06 - Engine Compartment
Remove and Install
CAUTION The exhaust pipe becomes extremely 4. Support the cover using suitable overhead lifting
hot when the engine is running and will remain so equipment.
for some time after the engine is stopped. If you
touch the hot pipe you could be severely burned. 5. Remove the gas strut mount securing nut and
remove the strut from the support bracket.
A typical engine cover removal and installation 6. Remove the hinge bolts.
procedure is given below. Your machine may differ
from that shown. 7. Take the top engine cover away from the
machine with the lifting equipment.
Remove 8. Remove the exhaust outlet pipe. Refer to fuel
1. Make the machine safe. Refer to (PIL 01-03). system- Exhaust. Refer to (PIL 18-24).
2. Follow the general safety precautions. Refer to 9. Support the engine pod base.
(PIL 01-03). 10. Remove the bolts and washers and lower the
3. Open the engine compartment cover. Refer to engine pod complete along with the guards to the
(PIL 06-06) ground.
06 - 13 9813/9400-1 06 - 13
Figure 23.
A
D
C
G
F
A Engine pod cover B Hinge bolts

C Support bracket D Strut mount securing nut
E Engine pod base F Bolts
G Washers
06 - 14 9813/9400-1 06 - 14
Install
removal procedure. Additionally do the following
steps.
1.1. Tighten the bolts to the specified torque
value.
1.2. Tighten the strut mount securing nut to the
specified torque value.
Table 3. Torque Values

Item Description Nm
B Hinge bolts 18
D Strut mount securing nut 18
06 - 15 9813/9400-1 06 - 15
10 - Transmission Compartment
10 - Transmission Compartment Component Identification

Component Identification ............................... 06-16
Remove and Install ....................................... 06-17
(For: HM560 Variable Transmission)
Figure 24. Access cover- Dual
Tech Variable Transmission
A Chassis (components removed for clarity)

B Access cover- Gearbox valve block
C Access cover- Gearbox hydrostatic pump
priming pipe
06 - 16 9813/9400-1 06 - 16
10 - Transmission Compartment
Remove and Install

Refer to Body and Framework, Access
Cover, Transmission Compartment, Component
Identification, (PIL 06-06-10).
Remove
2. Raise the lift arm and install the maintenance
strut. Refer to (PIL 06-69).
3. Turn the battery isolator switch to the off position.
Refer to (PIL 33-03-03).
4. Remove the bolts that secure the access plates.
5. Remove the access plates.
Install
step.
2. Tighten the bolts to the correct torque value.
Refer to (PIL-72-00).
06 - 17 9813/9400-1 06 - 17
12 - Front Cover
12 - Front Cover Figure 25.
Remove and Install
Remove
2. Isolate the battery and remove the isolator key.
3. Open the top cover to gain access to the cover
securing bolts.
4. Remove the bolts (x3) located outside the cab
beneath the front window.
5. Remove the bolts (x3) located inside the cab.
6. Disconnect any pipes or electrical connectors.
A
7. Lift and remove the cover.
B
A Cab
B Front cover assembly
06 - 18 9813/9400-1 06 - 18
12 - Front Cover
Figure 26.
C C
C
B
D D
B Front cover assembly
C Bolt locations- from outside cab
D Bolt locations- from inside cab (floor pan not
shown)
Install
steps.
2. Tighten the fasteners to the correct torque value.
3. Make sure the washer fluid level is correct and
that the window wash/wipe system operates
correctly.
06 - 19 9813/9400-1 06 - 19
14 - Rear Cover
14 - Rear Cover
Remove and Install
Open the rear cover for access to the filler cap and
sight glass.
Open
2. Use the key to unlock the rear cover.
3. Open the rear cover.
Figure 27.
B
A Key
B Rear cover
Close
1. Position the rear cover.
2. Use the key to lock the rear cover.
06 - 20 9813/9400-1 06 - 20
30 - Undershield
30 - Undershield
(For: 506-23 [T4F], 509-23 [T4F])
Figure 28. Belly Guards- R28 Tyres

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

C Front panel- 28" tyre D Centre guard
E Rubber cover F Pop rivet and washer
G Edge seal
06 - 21 9813/9400-1 06 - 21
33 - Lift Arm
33 - Lift Arm 2. Tighten all fastenings to the correct torque. Refer

to (PIL 72).
Remove and Install (For: 506-23 [T4F], 509-23 [T4F])

For: 512-26 [T4F] ...................... Page 06-22
For: 506-23 [T4F], 509-23 [T4F]
Remove- Lift Arm Nose Cover
................................................... Page 06-22
(For: 512-26 [T4F]) 2. Fully lower the lift arm.

3. Remove the securing bolts.
Remove
4. Remove the cover from the inner lift arm nose.
Figure 30.
2. Fully lower the lift arm.
3. Remove the securing bolts.
4. Remove the cover from the inner lift arm nose.
Figure 29. 1
2 1 1
2
1
1
1
1 Securing bolts
2 Cover
Install
1 removal procedure.
1 Securing bolts
2 Cover
Install
step.
06 - 22 9813/9400-1 06 - 22
39 - Cab/Canopy
39 - Cab/Canopy
Remove and Install
Remove Install
1. Make the machine safe. Refer to (PIL 01-03). 1. The installation procedure is the opposite of the
2. Isolate the battery and remove the isolator key. step.
1.1. Tighten the floor cover bolts to the correct
3. Lift and remove the floor mat. torque value.
4. Remove the floor cover bolts (X6).
Cab Rear Cover
5. Remove the cover.
Remove
Figure 31. Access Plate- Cab Floor
2. Isolate the battery and remove the isolator key.
A 3. Remove the rear cover bolts (X5).
4. Remove the cover.
B
A Cab
B Access plate- cab floor
06 - 23 9813/9400-1 06 - 23
39 - Cab/Canopy
Figure 32. Cab Rear Cover

A
C
A Cab B Rear cover

C Bolts (X5) D Rubber flap
06 - 24 9813/9400-1 06 - 24
39 - Cab/Canopy
Install
steps.
1.1. Make sure that the rubber flap is located
in the recess on the fuel tank during
installation.Refer to Figure 32.
1.2. Tighten the bolts to the correct toque value.
06 - 25 9813/9400-1 06 - 25
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-27

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-43
06-12-24 Shim ............................................................................................................................... 06-44
06 - 26 9813/9400-1 06 - 26
12 - Lift Arm
00 - General
Introduction .................................................... 06-27
Hydraulic Ram Operated Lift Arms
Technical Data ............................................... 06-30 The lift arms on these machines are extended and
Calibrate ........................................................ 06-31 retracted by hydraulic rams. No chain system is
Lubricate ........................................................ 06-32 used. There are differences in the configuration
and location of components depending on machine
model. Refer to Table 4.
Disassemble and Assemble .......................... 06-39
Refer to body and framework, lift arm, general,
component identification (PIL 06-12-00).
All lift arm sections are identified in a similar way

irrespective of the number of sections or method of
operation.
Table 4.
Machine Lift Arm
506-23 2 Section, 2 stage
06 - 27 9813/9400-1 06 - 27
12 - Lift Arm
00 - General
Figure 33.
E
A
E
A B
A B C
A B D
C
A Outer lift arm section
B Intermediate lift arm section (identified as
intermediate section 1 on H and J)
C Intermediate lift arm section 2
D Intermediate lift arm section 3
E Inner lift arm section
F 2 Stage, 2 section lift arm
G 3 Stage, 3 section lift arm
H 4 Stage, 4 section lift arm
J 5 Stage, 5 section lift arm
All intermediate and inner lift arm sections slide

against adjustable / replaceable wear pads installed
in the lift arm sections. Refer to body and framework,
lift arm, general, (PIL 06-12-00) and body and
framework, lift arm, shims and wear pads, (PIL
06-12-24 and 06-12-30).
06 - 28 9813/9400-1 06 - 28
12 - Lift Arm
00 - General
Health and Safety

Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
DANGER! Before removing the boom from the
machine, make sure that the counterweight is
adequately supported as in certain ground conditions
the machine could tip backwards. Never travel or
transport the machine with the boom removed.
CAUTION! Make sure you know the weight of the
load before trying to lift it. Raise the load only a
few centimetres at first, to check that the machine is
stable. Lower the load straight away if the machine
begins to feel unstable. Do not exceed the loading
limits shown on the Load Charts.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
WARNING! The limits shown on the load charts are
for a stationary, level machine. Do not raise or extend
the lift arm while the machine is moving. Retract the
lift arm fully and lower it as far as possible before you
travel with a load.
WARNING! Under no circumstances should
personnel be lifted into the air without using an
approved and properly secured platform. Failure to
follow this warning could result in death or serious
injury.
WARNING! Do not work under raised lift arms unless
they are adequately supported by stands and/or
slings.
WARNING! You could be killed or injured if the boom
drops while you are working under it. Install the
boom maintenance strut as instructed before doing
any maintenance work with the boom raised. Keep
people away from the machine while you install or
remove the boom maintenance strut.
WARNING! Make sure the machine cannot tip
over when this component (or components) is (are)
removed during this operation.
06 - 29 9813/9400-1 06 - 29
12 - Lift Arm
00 - General
Technical Data
Wear pad Clearance- 2 Stage (2 section) Figure 34. 2 Stage (2 section) Lift Arm
Lift Arm
Make sure that the wear pads are installed correctly
to prevent fouling. Refer to body and framework-
wear pads. Refer to (PIL 06-30).
A
Refer to Table 5.
Table 5. Maximum Gap

Dimension mm
A
Lift arm front 3mm (1.5mm)
(1)
Lift arm rear 1.5mm

B
Lift arm front 3mm (1.5mm)
(1)
Lift arm rear 1.5mm

(1) 550-80 machines only
06 - 30 9813/9400-1 06 - 30
12 - Lift Arm
00 - General
Calibrate 8. Make sure that the difference in shim thickness of

shim 1 and shim 2 does not exceed the specified
value.
When the boom is assembled, do a check of
Length/Dimension/Distance: 3.2mm
the carriage alignment to make sure that the
measurement is accurate. 9. Make sure that the maximum wear pad clearance
does not exceed the specified value.
Length/Dimension/Distance: 3mm
2. Make sure that the tyre pressures are correct.
Figure 37.
3. Make sure that the machine is parked on flat level
ground.
B
4. Check the inclinometer to make sure that the
chassis is level.
Figure 35.
A
A Inclinometer
5. Measure the left and right side carriage height
from the ground to the top of the carriage and C F
D E
note the dimensions.
B Maximum wear pad clearance
Figure 36. C Lower wear pad 1
D Lower wear pad 2
E Shim 1
F Shim 2
X Y
X Left side dimension

Y Right side dimension
6. If there is a difference between left and right side
dimension, the front lower wear pads 1 and wear
pads 2 can be shimmed.
7. Add or remove the shim 1 and shim 2 as
necessary to align the carriage. Refer to adjust
(PIL 06-12-30).
06 - 31 9813/9400-1 06 - 31
12 - Lift Arm
00 - General
Lubricate
For: 512-26 [T4F] ...................... Page 06-32

For: 506-23 [T4F], 509-23 [T4F]
................................................... Page 06-33
(For: 512-26 [T4F])

Consumables
Description Part No. Size
Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
Figure 38.
B C
1. Make the machine safe, refer to (PIL 01-03). Consumable: Special HP Grease
2. Apply grease to the points shown.
06 - 32 9813/9400-1 06 - 32
12 - Lift Arm
00 - General
(For: 506-23 [T4F], 509-23 [T4F])
Figure 39.
B F
A
C
E
G H
J K
M N
P Q

2. Apply grease to all the points and linkages.
06 - 33 9813/9400-1 06 - 33
12 - Lift Arm
00 - General
Remove and Install
For: 512-26 [T4F] ...................... Page 06-34 7. Support the displacement rams and disconnect
For: 506-23 [T4F], 509-23 [T4F] the ram head end from the lift arm pivots.
................................................... Page 06-36
7.1. Remove the nuts 2, bolts 2 and the washers
2 (if installed).
(For: 512-26 [T4F])
7.2. Use the slide hammer kit to remove the
Special Tools pivot pin 2. Refer to (PIL 06-30).
Description Part No. Qty.
Special Tool: Slide Hammer Kit (Qty.: 1)
Slide Hammer Kit 993/68100 1
7.3. Lower the displacement ram onto the
Consumables packing material to prevent damage to the
Description Part No. Size piston rod.
Special HP Grease 4003/2017 0.4kg 7.4. Do the step 7.1 to step 7.3 again for the
4003/2006 12.5kg other displacement ram.
4003/2005 50kg 8. Put labels on the hydraulic hoses on each side of
the lift arm to help installation.
Support the lift arm correctly at all times to prevent
personal injury and damage to the machine and 9. Disconnect the hydraulic hoses from the metal
equipment. pipes on each side of the lift arm.
Remove 10. Plug all the open ports and hoses to prevent
contamination.
11. Working on the underside of the lift arm,
2. Remove the lift arm attachments, including forks disconnect the lift arm electrical harness
and fork bar. connectors from the chassis harness.
3. Lower the lift arm onto a suitable support in the 12. Put labels on the hydraulic connections to help
semi raised position to get access to the lift ram installation.
rod end and the displacement rams head end.
13. Disconnect the extension ram hoses.
4. Support the lift arm from above with lifting
shackles of suitable capacity attached to the 14. Plug all the open ports and hoses to prevent
forward and rear lifting points. contamination.
5. Discharge the hydraulic pressure. Refer to (PIL 15. Make sure that the lift arm is fully supported.
30-00). 16. Remove the nut 3, bolt 3 and washers 3 (if
6. Support the lift ram and disconnect the ram rod installed).
end from the lift arm pivot. 17. Use the slide hammer kit to remove the pivot pin
6.1. Remove the nut 1, bolt 1 and washers 1 (if 3. Refer to (PIL 06-30).
installed). Special Tool: Slide Hammer Kit (Qty.: 1)
6.2. Use the slide hammer kit to remove the 18. Carefully lift the lift arm clear of the machine,
pivot pin 1. Refer to (PIL 06-30). checking for any remaining connections.
06 - 34 9813/9400-1 06 - 34
12 - Lift Arm
00 - General
Figure 40.
B
B
C
C
D
D
E K
K
J
J
FF
K
K
H
H KK
G
G
L
L
K
K KK
A Lift arm B Bolt 1

C Pivot pin 1 D Lift ram
E Bolt 2 F Pivot pin 2
G Nut 2 H Displacement ram
J Bolt 3 K Hydraulic hoses
L Pivot pin 3
06 - 35 9813/9400-1 06 - 35
12 - Lift Arm
00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe.
Refer to: PIL 01.
steps.
2. Fully lower the lift arm. Open the rear access
1.1. Check the hydraulic oil level and fill if cover and disconnect the displacement ram
necessary. Refer to (PIL 30-00). (if installed) by removing bolts 1, nuts 1 and
1.2. Apply grease on all the pivot pins. Refer to washers 1.
(PIL 75-06).
3. Use the slide hammer kit to remove the pivot pin.
Consumable: Special HP Grease Refer to (PIL 06-30).
(For: 506-23 [T4F], 509-23 [T4F])
Special Tools 4. Operate the carriage crowd control to retract the
displacement ram.
Slide Hammer Kit 993/68100 1 Special Tool: Slide Hammer Kit (Qty.: 1)
5. Lower the lift arm onto a suitable support in the
The complete lift arm assembly has a mass of
semi-raised position to gain access to the lift ram
approximately the specified value. 3,000kg
rod end and the displacement rams head end.
The lift ram has a mass of approximately the 6. Support the lift arm ready for removal with
specified value. 250kg suitable lifting equipment. Use lifting shackles of
suitable capacity fitted to the forward and rear
Support the ram with a suitable lifting equipment.
lifting points.
06 - 36 9813/9400-1 06 - 36
12 - Lift Arm
00 - General
Figure 41.
A Bolts 1, nuts 1 and washers 1 B Pivot pin 1

C Bolts 2, nuts 2 and washers 2 D Pivot pin 2
F Extension ram hose G Extension ram hose
H Pivot pin 3 J Bolt 3
06 - 37 9813/9400-1 06 - 37
12 - Lift Arm
00 - General
7. Support the lift ram and disconnect the lift ram (if Install
installed) rod end by removing bolt 2, nut 2 and
washers 2. 1. The installation procedure is the opposite of the
8. Use the slide hammer kit to remove the pivot pin. steps.
1.1. Check the hydraulic oil level and refill if
9. Lower the ram onto suitable packing material to necessary.
protect the piston rod. Refer to: PIL 01-03.
10. Discharge the hydraulic pressure. 1.2. Grease all pivot pins.
Refer to: PIL 30-00. Refer to: PIL 75-06.
11. Put a label on the extension ram hoses to help 1.3. For the main pivot pins types 2 and 3,
installation. identify the position and quantity of all
washers and spacers for the machine
12. Make sure the lift arm is fully supported. Note model. Align the locking plate and install
there will be one of three types of main pivot pin spacer and large washer 1, washers 2 and
for the lift arm. bolt 1.
12.1. Type 1- Remove the bolt 3 and withdraw 1.4. For main pivot pins types 2 and 3, tighten
the pivot pin 3. Refer to Figure 41. the bolt to the specified torque value.
12.2. Types 2 and 3- Remove the items 1 to 6, Torque: 476N·m

noting the quantity and arrangement of the
spacers. Refer to Figure 42.
Figure 42. Types 2 and 3
(506-23 and 509-23 Machines)
5
1
6
2
3
4
5
1
6
5
2
3
4
1 Pivot pin
2 Spacer
3 Large washer 1
4 Bolt 1
5 Washers 2
6 Nut
13. Carefully lift the lift arm clear of the machine,
checking for any remaining connections. Lower
the lift arm onto suitable packing material.
06 - 38 9813/9400-1 06 - 38
12 - Lift Arm
00 - General
Disassemble and Assemble
(For: 506-23 [T4F], 509-23 [T4F]) 7.4. Pull out the hoses through the guide
channels from the rear in the direction of the
Unless the lift arm fabrications are damaged there arrow X.
is normally no requirement to separate the lift arm 7.5. Then pull out the hoses through the
sections. The lift arm sections can be separated with apertures under the lift arm in the direction
the lift arm assembly removed or installed to the of the arrow Y.
machine as required.
7.6. Plug all the open ports and hoses to prevent
CAUTION! You can be injured if you use incorrect or contamination.
faulty lifting equipment. You must identify the weight
7.7. Put label on the auxiliary service hoses at
of the item to be lifted then choose lifting equipment
the steel pipes on the underside of the lift
that is strong enough and suitable for the job. Make
arm and at the front of the lift arm to help
sure that lifting equipment is in good condition and
installation.
complies with all local regulations.
WARNING! Hydraulic fluid at system pressure can 7.8. Disconnect and remove the hoses.
injure you. Before connecting or removing any 7.9. Pull out the hoses in the same way as the
hydraulic hose, residual hydraulic pressure trapped tilt ram hoses. Refer to 7.4 and 7.5.
in the service hose line must be vented. Make
sure the hose service line has been vented before 7.10. Plug all the open ports and hoses to
connecting or removing hoses. Make sure the engine prevent contamination.
cannot be started while the hoses are open. 8. Remove the inner lift arm.
WARNING! Never position yourself or any part
of your body under a raised machine which is 8.1. Remove the front wear pads from the outer
not properly supported. If the machine moves lift arm.
unexpectedly you could become trapped and suffer 8.2. Make sure that the lift arm assembly is fully
serious injury or be killed. supported by the outer lift arm and then
remove the upper and side wear pads.
Disassemble 8.3. Lift the front of the inner lift arm clear of
the lower wear pads and then remove them.
The following procedures can be carried out without
Label all the wear pads and keep them
the need to separate the lift arm sections or remove
together with their shims.
the lift arm from the machine.
8.4. Support the front end of the inner lift arm
1. Make the machine safe. Refer to (PIL 01-03). and draw it out from the outer section.
2. Discharge the hydraulic pressure. Refer to (PIL 8.5. Before the inner section is all the way out
30-00). attach suitable lifting equipment. Make sure
the section is fully supported by the lifting
3. Remove the fork carriage. Refer to (PIL 03-33). equipment and then draw it free from the
outer section.
4. Remove the tilt ram. Refer to (PIL 30-15).
If the lift arm assembly has been removed from the
5. Remove the lift arm nose cover (if installed).
machine, make sure that it is securely supported.
Refer to (PIL 06-06).
When the inner lift arm section is removed, forces
6. Remove the extension ram. Refer to (PIL 30-15). may cause the whole assembly to move.
7. Remove the telescopic hydraulic service hoses. Assemble

To ensure that the hoses do not become
damaged or tangled, they must be removed 1. The assembly procedure is the opposite of
before attempting to separate the lift arm the disassembly procedure. Additionally do the
sections. Remove the hoses as follows: following steps.
7.1. Remove the hose clamps. 1.1. Check the length of the hose pairs. The
hose lengths must be equal to within +/-
7.2. Put label on the hoses at the steel pipes
1mm for each service pair (tilt ram pair, and
on the underside of the lift arm to help
auxiliary service pair).
installation.
7.3. Disconnect and remove the hoses.
06 - 39 9813/9400-1 06 - 39
12 - Lift Arm
00 - General
1.2. Do not renew individual hoses. The hoses 1.4. To enable alignment of the rod end pivot
can stretch over time. New hoses may of the extension ram, install the hydraulic
not be the same length. Renew all four hoses so that the lift arm can be extended.
telescopic service hoses if any of the hoses
1.5. Make sure that the hose routing is correct.
are damaged.
Do not cover any hoses.
1.3. Assemble the lift arm sections so that the lift
arm is fully retracted. 2. Do the following steps for 526-56 machines only:
Figure 43.
3 3
1 1 2
1 45° coupling 2 Cable tie

3 T-pieces 4 Hose natural curvature
5 Metal pipework
2.1. The tilt ram service hoses on the 526-56 2.4. Install a cable tie to secure the two hoses
machine must be phased as shown. Refer together.
to Figure 43. Make sure that the hoses
2.5. Position the head of the cable tie to the
do not become twisted whilst tightening
outside of the hoses.
the connectors. The hoses have a natural
curvature. 2.6. Do not secure the hoses to the metal
pipework.
2.2. Make sure to orient the 45º coupling against
the curvature to allow the hoses to lie along 2.7. Tighten the hoses to the specified torque
the top of the metal pipework. Refer to value.
Figure 43.
3. Do the following steps for other machines:
2.3. Stagger the position of the T-pieces to keep
the hoses and fittings together.
06 - 40 9813/9400-1 06 - 40
12 - Lift Arm
00 - General
Figure 44.
E E
J A
B
Y
E
Y
X X D
D
C F F C
A Tilt ram C Hose clamps

D Tilt ram hoses E Auxiliary service hoses
F Guide channels G Front wear pads
H Inner lift arm J Outer lift arm
06 - 41 9813/9400-1 06 - 41
12 - Lift Arm
00 - General
X Arrow X Y Arrow Y
3.1. The tilt ram and auxiliary service hoses

pass through the guide channels in the top
of the inner lift arm. When all the hoses are
correctly connected, install the clamps at
the inside of the inner lift arm.
3.2. Check that the lift arm wear pad shimming
is correct. Refer to Body and Framework-
Lift Arm. Refer to (PIL 06-12).

Item Description Nm
1 45º Coupling 50
06 - 42 9813/9400-1 06 - 42
12 - Lift Arm
12 - Pivot Link Lever (Upper)
12 - Pivot Link Lever (Upper)
Adjust
The figure (Refer to Figure 45. ) shows the lift arm 4. If the gap is more than the specified value, add
viewed from the rear of the machine. the correct quantity of shims to get the correct
measurement. Add the shims equally at the two
1. Measure the gap 1 and the gap 2 as shown in the sides to make sure that the lift arm is at the centre
figure. Refer to Figure 45. of the pivot.
2. Add the values of gap 1 and the gap 2. Total gap Length/Dimension/Distance: 3mm
= gap 1 + gap 2.
4.1. Later shims do not have handles.
3. Make sure that the total gap is not more than the
5. When the total gap is of the correct value, if the
specified value.
shim has handles, snap the handle from the shim
Length/Dimension/Distance: 3mm at the crease.
Figure 45.
X Y
X Gap 1 Y Gap 2
Figure 46.
B
A Handled shim (earlier type)

B Crease
C Handle
06 - 43 9813/9400-1 06 - 43
12 - Lift Arm
24 - Shim
24 - Shim Technical Data

Technical Data ............................................... 06-44
Adjust ............................................................ 06-46
Number of plain washers to be installed under bolts

Table 7. Machines
Machine Table
506-23 Refer to Table 8.
Table 8. 506-23 Machines

Wear Pad Shim Thickness Number of Washers Number of Washers
(Front) (Rear)
Top 0–3mm 3 2
3.2–6mm 2 1
6.2–8mm 1 0
Side 0mm 2 2
1.6–3mm 1 2
3.2–6mm 0 1
6.2–8mm 0 0
Lower 0mm 4 N/A
1.6–3mm 3 N/A
3.2–8mm 2 N/A

(Front) (Rear)
Top 0–3mm 3 2
3.2–6mm 2 1
6.2–8mm 1 0
Side 0mm 2 2
1.6–3mm 1 2
3.2–6mm 0 1
6.2–8mm 1 0
Lower 0mm 4 N/A
1.6–3mm 3 N/A
3.2–8mm 2 N/A

(Front) (Rear)
Top 1.6–3.5mm 4 3
3.6–5.5mm 3 2
5.6–7.5mm 2 1
7.6–8mm 1 0
Side 1.6–3.5mm 4 3
3.6–5.5mm 3 2
5.6–7.5mm 2 1
Lower 0–3mm 3 N/A
06 - 44 9813/9400-1 06 - 44
12 - Lift Arm
24 - Shim

(Front) (Rear)
0.7–3mm 2 N/A
3.2–6mm 1 N/A
06 - 45 9813/9400-1 06 - 45
12 - Lift Arm
24 - Shim
Adjust Figure 48. 2 Section, 2 Stage Lift Arm
Typical shimming Procedure

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

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

the procedure for inner lift arm to the intermediate lift
arm.
Install new wear pads when the clearances are out

of specification. The clearances must be measured,
the chamfer is not a guide to the amount of wear
remaining.Refer to Figure 47. A Inner boom
B Outer boom
Make sure that the threaded insert remains a tight fit Figure 49. 3 Section 3 Stage Lift Arm
in the wear pad and does not rotate when tightened.
If the insert is loose in the wear pad, install a new
wear pad and threaded insert.
On 2 stage (2 section) machines, shim the inner

boom to the outer boom.
B
On 3 stage (3 section) machines, shim the
intermediate boom to the outer boom, then repeat the
procedure for the inner to the intermediate boom.
The wear pad bolts are not all the same. Make sure
you use the correct bolts for each wear pad. Refer to A
Body and Framework- Lift Arm (PIL 06-12).
The number of washers under the bolt changes C

depending on the shim thickness. Make sure you
install the correct number of washers for the
thickness of shims. Refer to Body and Framework-
Lift Arm, Technical data (PIL 06-12-30). A Intermediate lift arm
B Outer lift arm
Do not install spring washers. C Inner lift arm
Figure 47.
D
D Chamfer depth
06 - 46 9813/9400-1 06 - 46
12 - Lift Arm
24 - Shim
Figure 50. Figure 51.

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

F Shim F Shim
G Washer G Washer
1 Wear pad 1 Wear pad
2 Threaded insert 2 Threaded insert
Lower wear pads- Shimming Rear lower wear pads
Front lower wear pads 1. Rest the forks on the ground.
1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the lift arm rear cover. Refer to (PIL
06-06).
2. Follow all safety procedures. Refer to (PIL
01-03). 3. Measure the distances between lift arm lower
faces which must be in the limit given. Refer to
3. Raise the lift arm slightly so that forks are just off (PIL 06-12).
the ground.
4. If this dimension is less than the limit, then install
4. Measure the distances between the lift arm lower shims under the lower wear pads to restore the
faces which must be in the limit given. Refer to dimension.
Technical Data (PIL 06-12).
5. Raise the lift arm slightly so that forks are just off
5. If this dimension is less than the limit, then install the ground and place wedges under the inner lift
shims under the lower wear pads to restore the arm.
dimension.
6. Remove the wear pad bolts and add shims as
6. Rest the forks on the ground so that there is no required.
weight on the lower wear pads.
7. Measure the total thickness of shims under each
7. Remove the wear pad bolts and add shims as pad.
required.
8. Add or remove plain washers under the heads
8. Measure the total thickness of shims under each of wear pad bolts. Make sure that the thread
pad. engages sufficiently. Refer to (PIL 06-12).
9. Add or remove the correct number of plain 9. Do not install spring washers.
washers under the heads of wear pad bolts.
Make sure that the thread engages sufficiently. 10. Remove the wedges, install the shims again and
Use the correct number of washers. Refer to tighten the bolts to the specified torque value.
10. Do not install spring washers.
11. Install the shims again and tighten the bolts to the
06 - 47 9813/9400-1 06 - 47
12 - Lift Arm
24 - Shim

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

F Shim F Shim
G Washer G Washer
1 Wear pad 1 Wear pad
2 Threaded insert 2 Threaded insert
Top wear pads- Shimming Side wear pads- Shimming

The following procedure applies to both front and The following procedure applies to both front and
rear top wear pads. rear side wear pads.
1. Raise the lift arm until the inner lift arm is resting 1. Measure the distances between the lift arm side
on the lower wear pads. faces which must be in the limit given. Refer to
2. Measure the distances between the lift arm upper
faces which must be in the limit given. Refer to 2. If this dimension is less than the limit, install
(PIL 06-12-00). shims under the side wear pads to restore the
dimension.
3. If this dimension is less than the limit, install
shims under the top wear pads to restore the 3. Slacken the side wear pad bolts and install shims
dimension. as required. Divide number of shims equally each
side to ensure that inner lift arm runs centrally
4. Install or remove shims to obtain the correct within the outer lift arm.
vertical clearance.
4. Measure the total thickness of shims under each
5. Measure the total thickness of shims under each pad.
pad.
5. Add or remove the correct number of plain
6. Add or remove the correct number of plain washers under the heads of wear pad bolts.
washers under the heads of wear pad bolts. Make sure that the thread engages sufficiently.
Make sure that the thread engages sufficiently. Refer to (PIL 06-12-00).
Refer to Technical Data (PIL 06-12).
7. Install the shims again and tighten the bolts to the
8. Install the shims again and tighten the bolts to the specified torque value.
06 - 48 9813/9400-1 06 - 48
12 - Lift Arm
24 - Shim
Figure 54.
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert
Table 11. Torque Information

Item Description Torque
E For wear pads 98N·m
with M12 bolts
E For wear pads 58N·m
with M10 bolts
E 550-80 Ma- 56N·m
chines only
06 - 49 9813/9400-1 06 - 49
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-51
06 - 50 9813/9400-1 06 - 50
30 - Pivot Pins
00 - General
Introduction .................................................... 06-51 Pivot pins are a short shaft or pin that supports
Lubricate ........................................................ 06-52 something that turns. Pivot pins are installed in
Remove and Install ....................................... 06-52 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 - 51 9813/9400-1 06 - 51
30 - Pivot Pins
00 - General
Lubricate Remove and Install

Special Tools
Extension Ram Pivot Pin Description Part No. Qty.
Use another pivot pin to support the ram while
greasing the other pivot pin. Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
1. Make the machine safe. Refer to (PIL 01-03). look different.
2. Follow the general health and safety procedures. 1. Prepare the pivot pin for removal, remove the
Refer to (PIL 01-03). locking device e.g. pivot pin retaining bolt.
3. Remove the inner extension ram pivot pin and 2. Prepare the slide hammer kit.
apply waxoyl. Refer to (PIL 06-30).
4. Install the inner extension ram pivot pin.
2.1. Install the slide hammer onto the slide bar.
5. Remove the tilt ram pivot pin and coat with
waxoyl. Refer to (PIL 06-30). 2.2. Determine the thread size of the pivot pin
and then install the appropriate adaptor.
6. Install the tilt ram pivot pin. Use the spanner flats to securely install the
adaptor.
Figure 55.
2.3. Install an end stop onto the other end of the
adaptor (M20 thread size), make sure that
the adaptor threads are fully engaged.
2.4. Install the slide bar into the end stop. Make
sure that the threads are fully engaged.
2.5. Finally install the other end stop at the end
of the slide bar. The slide hammer kit is now
ready to use.
A B 3. To extract the pivot pin, slide the hammer along
the bar until it contacts the end stop. Repeat this
step until the pivot pin is released.
4. To remove the slide hammer kit, reverse steps 2
to 3.
A Inner extension ram pivot pin

B Tilt ram pivot pin
06 - 52 9813/9400-1 06 - 52
30 - Pivot Pins
00 - General
Figure 56. Typical Machine
A Adaptor
B End stop
C End stop
D Spanner flats
E Slide bar
F Slide hammer
06 - 53 9813/9400-1 06 - 53
42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ........................................................................................................................... 06-55
06 - 54 9813/9400-1 06 - 54
42 - Stabiliser
00 - General
Introduction .................................................... 06-55 The stabilisers are a safety device to stop the
Health and Safety .......................................... 06-56 machine tipping over when the lift arm is extended.
There are two stabiliser legs. The stabiliser legs

can be deployed by controls in the cab, to give
the machine added stability when the machine is
stationary.
06 - 55 9813/9400-1 06 - 55
42 - Stabiliser
00 - General
Health and Safety

WARNING The stability of the machine can
be reduced when you use the lift arm without
stabilisers. Before using the lift arm make sure the
stabilisers are set on stable ground.
WARNING You must be sitting in the operators
seat when operating the machines lift arm,
stabiliser or drive controls.
WARNING Bystanders could be crushed and
obstacles could be damaged if they are beneath
the stabilisers while they are being lowered.
Before lowering the stabilisers, make sure any
bystanders are clear of the machine. Also make
sure that there are no obstacles beneath the
stabilisers.
Notice: Before you extend the boom make sure
that the stabiliser legs are deployed to the ground
and the weight of the machine is supported.
06 - 56 9813/9400-1 06 - 56
49 - Step
49 - Step
Contents Page No.
06-49-00 General ........................................................................................................................... 06-59
06 - 57 9813/9400-1 06 - 57
Notes:
06 - 58 9813/9400-1 06 - 58
49 - Step
00 - General
00 - General
Remove and Install
Remove
2. Remove the bolts and washers (x4) that secure
the steps to the machine.
3. Remove the assembly from the machine.
Figure 57. Side Step
A Side step
B Bolts
Install
1. The installation procedure is the opposite of
step.
1.1. Tighten fasteners to the correct torque
value.
06 - 59 9813/9400-1 06 - 59
54 - Fender
54 - Fender
Contents Page No.
06-54-00 General ........................................................................................................................... 06-61
06 - 60 9813/9400-1 06 - 60
54 - Fender
00 - General
00 - General
Remove and Install
Top Guard Assembly 2.1. If the washers on top of the fender are
metal, discard them and obtain the correct
Remove new nylon shoulder washers.
1. Make the machine safe. Refer to (PIL 01-03). 3. Remove the lower saddle clamp.
2. Remove the nuts, bolts and washers. 4. Lift off the fender cover.
5. Inspect the fender for cracks, particularly around
the mounting holes.
Figure 58.
A
E B
A Bolts B Fender cover

C Lower saddle clamp D Nuts
E Washers
5.1. Also check all other fenders on the machine Figure 59.
for cracks.
5.2. If cracks are found, discard the fender and
install a new one.
Install
L
steps.
1.1. Make sure you install the correct nylon
shoulder washers. Do not reuse metal
washers (if they were installed originally).
L Nylon shoulder washer
06 - 61 9813/9400-1 06 - 61
54 - Fender
00 - General
1.2. Drill out the fender mounting holes to the 2. Remove the road wheel if greater access is
specified diameter and de-burr the hole if necessary. Refer to (PIL 27-29).
required.
3. Remove the top guard assembly.
1.3. Make sure the shoulder washers are 4. Remove the mounting arm bolts, nuts and
located correctly in the fender hole. washers.
1.4. Tighten the nuts to the specified torque 5. Remove the arm assembly.
value.
6. Remove the support bracket nuts.
Torque: 14N·m
7. Remove the bracket from the trunnion studs.
Complete Fender Assembly
Remove
Figure 60.
P
N
M
R
S
M Mounting arm nuts N Mounting arm washers

P Arm assembly Q Mounting arm bolts
R Bracket S Support bracket fastenings
Install Table 12. Torque table

1. The installation procedure is the opposite of the Item Value
removal procedure. Additionally do the following M 28N·m
step. S
(1)
139–154N·m
1.1. Tighten the bracket nuts to the correct S
(2)
28N·m
torque value. (1) 550-80 machines.
(2) Other machines.
06 - 62 9813/9400-1 06 - 62
57 - Counterweight
57 - Counterweight
Contents Page No.
06-57-00 General ........................................................................................................................... 06-65
06 - 63 9813/9400-1 06 - 63
Notes:
06 - 64 9813/9400-1 06 - 64
57 - Counterweight
00 - General
00 - General
Health and Safety

method and device.
CAUTION You can be injured if you use incorrect
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting
equipment that is strong enough and suitable for
the job. Make sure that lifting equipment is in good
condition and complies with all local regulations.
WARNING Make sure the machine cannot be
used with the counterweight removed. Make sure
the ignition key is removed and the battery is
isolated.
WARNING Make sure the machine cannot tip
over when this component (or components) is
(are) removed during this operation.
06 - 65 9813/9400-1 06 - 65
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-67

06-63-03 Machine .......................................................................................................................... 06-68
06-63-06 Engine ............................................................................................................................ 06-70
06-63-09 Axle ................................................................................................................................ 06-72
06-63-12 Gearbox .......................................................................................................................... 06-73
06-63-15 Operator Protective Structure ........................................................................................ 06-74
06 - 66 9813/9400-1 06 - 66
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 - 67 9813/9400-1 06 - 67
03 - Machine
03 - Machine
Machine Identification Plate Figure 61.
Your machine has an identification plate mounted in

one of two positions as shown. The serial numbers
of the machine and its major units are shown on the
plate.
The machine model and build specification is

indicated by the PIN (Product Identification Number)
The serial number of each major unit is also shown

on the unit itself. If a major unit is replaced by a
new one, the serial number on the identification plate
will be wrong. Either get a replacement identification
plate from your JCB Dealer or simply remove the
old number. This will prevent the wrong unit number
being quoted when replacement parts are ordered.
The machine and engine serial numbers can help
identify exactly the type of equipment you have.
Typical Product Identification Number

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 13. Typical PIN

JCB 5C3 8 N C H 1234567
Table 14.
Digit 1 to 3 World Manufacturer Identification
JCB United Kingdom
GEO Georgia, US
HAR Haryana, India
SOR Sorocaba, Brazil
GET Gatersleben, Germany
PUN Pune, India
SHA Shanghai, China
JBP JCB Branded Products
Digit 7 Engine Type

Table 15. 3 93kW
Digit 4 to 6 Machine Model 4 108kW
5C3 506-23 Toolcarrier 7 55
5C4 509-23 Toolcarrier 8 68kW
5C5 512-26 Toolcarrier
Table 17.
Table 16. Digit 8 Gearbox Model
Digit 7 Engine Type G 4 Speed (PS750)
JCB Dieselmax (Tier 4): H 4 Speed (PS760)
2 81kW J 6 Speed (PS760)
06 - 68 9813/9400-1 06 - 68
03 - Machine
Digit 8 Gearbox Model

M 4 Speed (SS700)
N 4 Speed (PS750
40KPH)
Table 18.
Digit 9
Random check letter. The check letter is used to
verify the authenticity of a machine's PIN
Table 19.
Digit 10
Year of manufacture. H = 2017, J = 2018 etc.
Table 20.
Digit 11 to 17
Machine serial number. Each machine has a
unique serial number.
06 - 69 9813/9400-1 06 - 69
06 - Engine
06 - Engine
The engine data labels are attached to the cylinder

block as shown.
Figure 62.
B
A C
A Engine data label - rocker cover B Engine identification number

C Stamp
The data label includes the engine identification

number.
Table 21. Example of the engine identification number
SH 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 22.
Digit 1-2 Engine Type
DA 4.8L naturally aspirated mechanical fuel injection (Tier 2)
DB 4.8L turbocharged mechanical fuel injection (Tier 2)
DC 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 2)
DE 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 2)
DD 4.8L turbocharged mechanical fuel injection (Tier 3)
DF 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 3)
DK 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
DH 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
DJ 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
FL 3L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
SEF >55kW)
SA 4.4L naturally aspirated mechanical fuel injection (Tier 2)
SB 4.4L turbocharged mechanical fuel injection (Tier 2)
SC 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 2)
SD 4.4L turbocharged mechanical fuel injection (Tier 3)
SE 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
06 - 70 9813/9400-1 06 - 70
06 - Engine
Digit 1-2 Engine Type

SF 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 3)
SH 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
SJ 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
SL 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
55kw)
Table 23. Explanation of the engine identification number

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

and year of manufacture of the engine are also
stamped on the crankcase. Refer to Figure 62.
06 - 71 9813/9400-1 06 - 71
09 - Axle
09 - Axle Figure 65. Front axle

A
For: 506-23 [T4F], 509-23 [T4F]
................................................... Page 06-72
For: 512-26 [T4F] ...................... Page 06-72
(For: 506-23 [T4F], 509-23 [T4F])

The axles have a serial number stamped on a data
plate as shown. B
Figure 63. Front axle
A Cover
B Data plate - front axle
A
Figure 66. Rear axle
A Data plate - front axle

Figure 64. Rear axle
C Data plate - rear axle
B Data plate - rear axle
(For: 512-26 [T4F])

The axles have a serial number stamped on a data
plate label as shown.
To view the front axle data plate remove the cover.

The plate will be visible through hole.
06 - 72 9813/9400-1 06 - 72
12 - Gearbox
12 - Gearbox Figure 68.

A
For: 506-23 [T4F], 509-23 [T4F]
................................................... Page 06-73
For: HM560 Variable Transmission
................................................... Page 06-73
(For: 506-23 [T4F], 509-23 [T4F])

The gearbox has a serial number stamped on a data
plate as shown. B
Figure 67. Power-shift Transmission
RATIO
SERIAL No
817/02980
A Dual Tech Variable Transmission
B Data plate
A
A Data plate
Unit Identification
The gearbox serial number is stamped on the
unit identification plate as shown. When you make
an order for parts replacement, always quote the
details on the unit identification plate. In the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.
06 - 73 9813/9400-1 06 - 73
15 - Operator Protective Structure
15 - Operator Protective Structure certification. If damage has occurred then an

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

WARNING You could be killed or seriously injured Structure) can be identified by referring to the
if you operate a machine with a damaged or cab identification plate. Work place (work site, job
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ site) risk assessment should facilitate the machine
FOGS has been in an accident, do not use the selection and the need for an machine with a ROPS.
machine until the structure has been renewed.
Modifications and repairs that are not approved Figure 69.
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification.
WARNING Machines with a ROPS, FOPS,FOGS
or TOPS are equipped with a seat belt. The
ROPS, FOPS,FOGS or TOPS is designed to give
you protection in an accident. If you do not wear
the seat belt you could be thrown off the machine
Data plate - ROPS/FOPS standards
and crushed. You must wear a seat belt when
using the machine. Fasten the seat belt before Figure 70.
starting the engine.
FOPS Data Plate

WARNING Do not use the machine if the falling
objects protection level provided by the structure
is not sufficient for the application. Falling objects
can cause serious injury. Data plate - ROPS/FOPS and OECD
(Organization for Economic Cooperation and
If the machine is used in any application where there Development) standards
is a risk of falling objects then a FOPS (Falling Object
Protective Structure) must be installed. For further Protection Offered by the Cab
information, contact your JCB dealer.
Definition of Category 1
The FOPS has a data plate attached. The data
plate indicates what level of protection the structure The Cab meets the requirements defined in EN
provides. 15695-1. This means that the air delivery and
filtration system does not provide a specified level
There are two levels of FOPS: of protection against hazardous substances but only
from external atmospheric conditions (e.g. rain, wind,
• Level I Impact Protection - impact strength snow etc.).
for protection from small falling objects
(e.g. bricks, small concrete blocks, hand
Definition of Category 2
tools) encountered in operations such as
highway maintenance, landscaping and other The Cab meets the requirements defined in EN
construction site services. 15695-1. This means that the air delivery and
• Level II Impact Protection - impact strength for filtration system provides protection against dust and
protection from heavy falling objects (e.g. trees, the minimum differential pressure. The necessary
rocks) for machines involved in site clearing, filtered fresh air flow rate can be obtained using A/
overhead demolition or forestry. C system and by adjusting the maximum fan speed
provided that doors, windows and hatches are closed
ROPS Data Plate and the recirculation device is deactivated.
WARNING Your machine may be installed with a
Roll-Over Protective Structure (ROPS) indicating Comfort and Safety Inside the Cab
that the purchaser specified the machine for use
in applications where there is risk of roll-over. The cab category 1 does not guarantee full protection
ROPS is a device to protect the operator in the against dust, aerosols and vapours.
event of roll-over. Any damage or modification
The cab category 2 cab offers protection against
to the structure may invalidate the ROPS
dust but only partially for aerosols and vapours:
for application of plant protection products (e.g.
06 - 74 9813/9400-1 06 - 74
15 - Operator Protective Structure
pesticides, fungicides, herbicides), refer to the

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

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

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

the spraying operation.
• Keep the cab interior clean.
• Do not enter the cab with contaminated shoes
and/or clothing.
• Keep all used personal protective equipment
outside the cab.
• Bring the wire harness of the remote spray
control box into the tractor cab.
• Remove the outside air delivery cab filter after
the spraying operation and store it in a dry
dust free room. Reserve it for the next spraying
operation; replace with a service part filter.
• Active carbon filters must be properly stored
in a sealed plastic bag to preserve their
functionality.
• Use only genuine JCB filters and ensure that
the filter is correctly installed.
• Check the condition of the sealing material and
have it repaired when required.
06 - 75 9813/9400-1 06 - 75
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-77
06 - 76 9813/9400-1 06 - 76
66 - Tools
00 - General
00 - General
Introduction
All tools must be kept in the toolbox (if installed) when

not in use.
06 - 77 9813/9400-1 06 - 77
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-79

06-69-03 Lift Arm ........................................................................................................................... 06-80
06 - 78 9813/9400-1 06 - 78
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.
Refer to: PIL 01-03-27.
06 - 79 9813/9400-1 06 - 79
03 - Lift Arm
03 - Lift Arm Figure 72.
Remove and Install

WARNING You could be killed or injured if the lift A
arm drops while you are working under it. Install
the lift arm maintenance strut as instructed before
doing any maintenance work with the lift arm
raised. Keep people away from the machine while
you install or remove the lift arm maintenance
strut.
WARNING Make sure that you use the correct
JCB maintenance strut for the machine. Make A Maintenance strut
sure that the safety strut is only used with the
correct JCB retaining bolt or securing device. 6. Install the maintenance strut.
Never substitute this bolt or securing device,
always use the correct JCB part. 7. Place the strut around the lift ram piston rod.
Secure it in position with the strap.
Make sure that the strut and bolt/securing device
is installed correctly. Never use a strut intended Figure 73.
for another machine. If in doubt, consult your JCB
dealer.
B
CAUTION You will have to climb onto the
machine to install or remove the strut. Take care,
especially if the machine is wet. Remove mud and
oil before climbing onto the machine. Do not use A
the exhaust as a handhold. It can burn you.
If you raise the lift arm to get access for maintenance,

you must install the maintenance strut on the lift arm.
Before you install the maintenance strut remove any
load on the forks and empty shovels or attachments. A Maintenance strut
B Lift arm
Figure 71.
8. To prevent any chance of the lift arm creeping
down and trapping your fingers, the lift arm
should be lowered onto the strut. Lower the arm
carefully, to prevent possible damage to the strut.
Stop as soon as the weight of the lift arm is on
the strut.
9. Disconnect the battery to prevent accidental
operation of the engine.
10. If necessary, put blocks against the two sides of
Lift arm raised the wheels before you get below the machine.
Installing the Maintenance Strut Removing the Maintenance Strut

1. Make the machine safe. 1. Raise the lift arm to take the weight off of the strut.
2. Retract the lift arm. 2. Stop the engine and remove the ignition key.
3. Raise the lift arm. 3. Remove the maintenance strut.
4. Stop the engine and remove the ignition key. 4. Secure the strut in its stowage position.
5. Remove the maintenance strut from its stowage 5. Lower the lift arm to the ground.
position.
06 - 80 9813/9400-1 06 - 80
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-83
06 - 81 9813/9400-1 06 - 81
Notes:
06 - 82 9813/9400-1 06 - 82
00 - General
00 - General
Check (Condition)
In addition to the operator check the extinguisher

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

leaks.
2. Make sure the fire extinguisher is correctly
attached.
3. Make sure that the gauge indicates that the
extinguisher is charged i.e. the needle is in the
green segment
3.1. If the needle is in or very near the red
segment at either end of the gauge, the
extinguisher must be serviced or replaced.
4. Make sure the safety pin is correctly installed.
Figure 74.
A Gauge
B Safety Pin
06 - 83 9813/9400-1 06 - 83
89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ........................................................................................................................... 06-85
06 - 84 9813/9400-1 06 - 84
89 - Window Guard
00 - General
00 - General Figure 75. Front screen guard
Remove and Install A E
Screen Guard B
Remove C
D
2. Follow all general health and safety procedures. A
3. Support the guard.
4. Remove the upper nuts, bolts and washers.
5. Remove the lower nuts and washers.
6. Remove the guard from the machine.
Installation
removal procedure.
F
G
H F
A Screen guard
B Washer
C Bolts
D Nut
E Mounting lug
F Washer
G Washer
H Nut
06 - 85 9813/9400-1 06 - 85
Notes:
06 - 86 9813/9400-1 06 - 86
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-6
09-09 Window
09-09-00 General ........................................................................................................................... 09-13
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-21
09-12-03 Seat Base ...................................................................................................................... 09-23
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-25
09-18 Door
09-18-00 General ........................................................................................................................... 09-29
09-18-03 Lock ................................................................................................................................ 09-32
09-18-12 Handle ............................................................................................................................ 09-33
09-27 Controls
09-27-36 Accelerator Pedal ........................................................................................................... 09-35
09-27-57 Park Brake ..................................................................................................................... 09-37
09-30 Trim Panel
09-30-03 Roof Trim ....................................................................................................................... 09-39
09-30-09 Dashboard ...................................................................................................................... 09-40
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-45
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-49
09-48 Floor mat
09-48-03 Front Floor mat .............................................................................................................. 09-51
9813/9400-1
2017-11-01
Acronyms Glossary
ECU Electronic Control Unit

HVAC Heating Ventilation Air Conditioning
LLMI Longitudinal Load Moment Indicator
TXV Thermal Expansion Valve
9813/9400-1
2017-11-01
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-6
09 - 1 9813/9400-1 09 - 1
Notes:
09 - 2 9813/9400-1 09 - 2
00 - General
00 - General Health and Safety

Health and Safety ........................................... 09-3 Raised Equipment
Component Identification ................................. 09-4 Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Lifting Equipment
equipment is in good condition and complies with all
local regulations.
09 - 3 9813/9400-1 09 - 3
00 - General
This cab is certified to category 1 according to There are different variants of hydraulic control
EN15695-1-2009. levers. The cab layout is the same except the control
levers.
Cab Layout
The layout shown below is for a typical machine.
Figure 76. Cab Layout - Dual lever control
A
A
P
P S
S
R
P
B
B
TT
C
C N
N
M
M
D
D
L
U
R
E
E
G
G
F
HH
J
A Steering wheel B Transmission Lever and Gear Selection

C Console switches D Steer mode selector
E Service brake pedal F Park brake lever
G Control locks H Immobiliser
J Hydraulic tow hitch K Load charts
L HVAC (Heating Ventilation Air Conditioning) M Console switches
N Ignition switch P Instrument panel
09 - 4 9813/9400-1 09 - 4
00 - General
R Inclinometer S LLMI (Longitudinal Load Moment Indicator)

T Load control system
Single lever control variant

The single lever control can be mounted on the right
side console, in the arm rest or in an adjustable
control pod.
Figure 77.
1
2
3
1 Hydraulic control lever

2 Transmission dump switch
3 Drive direction selection switch
09 - 5 9813/9400-1 09 - 5
03 - Cab Frame
03 - Cab Frame
Remove and Install
Working Under the Machine 9. Disconnect the engine accelerator cable (if
installed).
Make sure that any attachments on the machine are Refer to: PIL 09-27.
the ignition key, disconnect the battery. If the machine 10. Disconnect the accelerator pedal electrical
has wheels use blocks to prevent unintentional connectors (if installed).
movement. Refer to: PIL 09-27.
Air Conditioning Maintenance
11. Make sure that all wheels are blocked to prevent
The air conditioning system is a closed loop system movement of the machine. Release the park
and contains pressurised refrigerant. No part of the brake and disconnect the park brake cable.
system should be disconnected until the system
has been discharged by a refrigeration engineer Refer to: PIL 24-18.
or a suitably trained person. You can be severely 12. On machines with dual lever controls, disconnect
frostbitten or injured by escaping refrigerant. the control levers from the control valve
Notice: Make sure you label all hoses / pipes and connection rods.
electrical connectors (if installed) before removal to Refer to: PIL 30.
aid identification during subsequent installation.
13. On machines with parallel servo control levers,
Cab label and disconnect the hoses at the servo
control valves. Disconnect the control levers from
Remove the control valve connection rods.
Refer to: PIL 30.
Refer to: PIL 01-03. 14. Disconnect the manual steer mode valve cable
(if installed) from the lever.
2. Install the safety strut. Refer to: PIL 25.
15. Disconnect the chassis electrical harness and
3. Discharge the hydraulic pressure. cab earth strap.
Refer to: PIL 30-00-00. 16. Undo the fuel filler hose clip. Loosen the fuel tank
filler hose on fuel tank filler neck so that the two
4. Remove the battery cover and disconnect the
separate later.
battery.
17. Disconnect the braking system components.
5. Remove the bolts and remove the cab front
cover. 17.1. 550-80 and 560-80 Machines- For details
Refer to: PIL 09-27. of disconnecting the brake valve.
6. Disconnect all hydraulic hoses from the steering
unit. Cap all open hoses and ports to prevent fluid 17.2. On machines with cab mounted brake
loss and ingress of dirt. servo, disconnect the brake pipe and
servo hose. Cap all open hoses and pipes
7. Remove the heater cover (if installed). Undo the to prevent fluid loss and ingress of dirt.
hose clips and disconnect the heater hoses.
17.3. Disconnect brake pipe at the master
8. If applicable, once the system has been cylinder. Cap all open hoses and pipes to
discharged, disconnect the air conditioning prevent fluid loss and ingress of dirt.
hoses at the TXV (Thermal Expansion Valve).
Some machines are installed with a cab roof 18. Disconnect hitch cable (if installed).
mounted air conditioning condenser. Disconnect
19. For machines with manual transmission
the condenser hoses at the rear of the cab.
disconnect the cables to the gear lever.
09 - 6 9813/9400-1 09 - 6
03 - Cab Frame
Refer to: PIL 09-27. Refer to: PIL 24-03.

20. Unscrew and remove the cab mounting bolts. 1.3. Adjust the accelerator cable and pedal (if
installed).
21. Attach appropriate lifting equipment to the ROPS Refer to: PIL 09-27.
(Roll-Over Protective Structure).
1.4. Correctly connect and adjust the cables to
22. Carefully lift the cab from the machine, make sure the gear lever (if installed).
that all connections have been released and are
clear of any obstruction. Cap off fuel tank filler Refer to: PIL 09-27.
neck to prevent contamination. 1.5. If applicable, recharge the air conditioning
system.
Install
Refer to: PIL 12.
1. The installation procedure is the opposite of the 1.6. Check the hydraulic fluid level.
steps. Refer to: PIL 30-00.
1.7. Make sure that all cables are connected and
1.1. Tighten the cab mounting bolts to the correctly adjusted. Make sure that they are
correct torque value. routed and secured correctly.
Refer to: PIL 72.
1.8. Make sure that all electrical and hydraulic
1.2. Bleed the brakes. services operate correctly.
09 - 7 9813/9400-1 09 - 7
03 - Cab Frame
Figure 78.
B
J B
G
B
C
D
E
F
B
A Park brake cable B Cab mounting bolts

C Cab front cover D Steering unit
E Cab earth strap F Chassis electrical harness
G Hitch cable H Fuel tank filler neck
J Filler hose clip
09 - 8 9813/9400-1 09 - 8
03 - Cab Frame
Figure 79.
K
K
R
Z
W
X
K Dual lever controls M Transmission gear lever
09 - 9 9813/9400-1 09 - 9
03 - Cab Frame
O Manual steer mode lever P

R Heater cover (if installed) S Heater hose clips
T Air conditioning hoses at TXV U Servo hose clip
V Brake pipe W View- cab mounted servo
X View- master cylinder Y Brake pipe
Z Single lever control
09 - 10 9813/9400-1 09 - 10
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-13
09 - 11 9813/9400-1 09 - 11
Notes:
09 - 12 9813/9400-1 09 - 12
09 - Window
00 - General
Introduction .................................................... 09-13 The service procedures, explain how to correctly
Health and Safety .......................................... 09-14 remove and install panes of glass that are directly
Preparation .................................................... 09-14 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-16 out any service procedure, you must always refer to
the relevant safety precautions, Health and Safety.
1. Always wear safety glasses during removal and

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

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

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

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

5°C (41.0°F).
09 - 13 9813/9400-1 09 - 13
09 - Window
00 - General
Health and Safety Preparation

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

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

otherwise they may be absorbed into the old sealant
and ultimately prevent the new glass from bonding.
New Glass
1. Make sure that the new glass correctly fits the
frame aperture.
1.1. Put two spacer blocks on to the bottom part
of the frame aperture.
Special Tool: Rubber Spacer Blocks (Qty.:
2)
1.2. Install the new glass on the spacer blocks
- Always use glass lifters. Check that there
is an equal sized gap all round the edge
of the glass. Note: The spacer blocks are
rectangular in section to give two common
gap widths. If necessary they can be
trimmed to a smaller size to give an equal
sized gap around the glass. Important: The
glass edges must not touch the frame,
otherwise movement of the frame will chip
and eventually break the newly installed
glass.
Special Tool: Glass Lifter (Qty.: 2)
09 - 14 9813/9400-1 09 - 14
09 - Window
00 - General
4. Clean the glass.

4.1. Use surface cleaner to thoroughly clean
and prime the black ceramic ink band
printed on the glass (see Note). Use a lint
A Frame aperture free cloth to apply the cleaner, allow to
B Spacer blocks dry. Important: Do not touch the glass after
C Glass lifters cleaning with the surface cleaner.
2. After checking for size, remove the new glass Duration: 5min
and place it on a purpose made glass stand. Consumable: Surface Cleaning Fluid
Small panes of glass will need locating on a
600 x 700 mm x 15 to 19 mm thick plywood 4.2. If the glass does not have a black ceramic
board, sourced locally to fit the glass stand. It is ink band, paint a band on the glass using
recommended that an access hole is cut in the Black Primer. Make sure that the band
board to accommodate the glass lifter, making it measures the correct width and that the
easier and safer to handle small panes of glass. edge is a neat straight line.
The board should be covered with felt or carpet Dimension: 25mm
to give an anti-scratch surface. Resting the glass Consumable: Black Primer/Activator
on four spacer blocks will ensure clearance of
the cartridge nozzle tip during application of the Figure 83.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 81.
5. Install the Ultra Fast Adhesive cartridge into a

suitable applicator gun:
Special Tool: Static Oven (240V) (Qty.: 1)
Special Tool: Mobile Oven (12V) (Qty.: 1)
Special Tool: Cartridge Gun (Qty.: 1)
Consumable: Polyurethane Adhesive
5.1. Remove the aluminium disc cover from
3. Make sure the glass is positioned on the stand the base of the cartridge and discard the
the correct way up (i.e. with the black ceramic dessicant capsule.
ink band upwards) ready for application of primer
etc. 5.2. Make sure that the rolled edge of the
cartridge is not damaged - if necessary, the
edges should be pressed flat, otherwise it
09 - 15 9813/9400-1 09 - 15
09 - Window
00 - General
will be difficult to remove the cartridge from Remove and Install

the applicator gun.
Special Tools
5.3. Pierce the front nozzle end of the cartridge
to its maximum diameter. Description Part No. Qty.
Glass Lifter 892/00842 2
5.4. Install the pre-cut nozzle.
Glass Extractor 892/00846 1
5.5. Install the cartridge in the applicator gun. (Handles Only)
Note: Cold material will be very difficult to Nylon Spatula 892/00847 1
extrude. The cartridges must be pre-heated
Wire Starter 892/00848 1
in a special oven for 1 hour to a temperature
of 80°C (176°F). Pre-heating the cartridges Braided Cutting Wire 892/00849 1
makes the adhesive more workable and Rubber Spacer Blocks 926/15500 2
also brings the curing time down to 30 Cut-Out Knife 992/12800 1
minutes. 'L' Blades 992/12801 1
Figure 84.
Consumables
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
A 12.5mm
B 9mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10min
2.1. Laminated glass - leave installed until the
Figure 85. old sealant has been cut away, after which
it will be possible to lift the broken screen
away from its frame housing in one piece.
2.2. Toughened glass - remove as much of the
shattered glass as possible prior to cutting
out the old sealant.
3. Cut out the old sealant, leaving approximately 1
to 2 mm on the cab frame. There are several tools
and techniques for doing this:
3.1. Pneumatic Knife - This provides one of the
A Nozzle guide easiest methods of removing the sealant
7. After applying the adhesive, leave a small around laminated glass. The tool, powered
amount of sealant protruding from the nozzle. by compressed air, should be sourced
This will prevent any adhesive left in the cartridge locally. Press the handle to start the knife
from curing. blade oscillating. Important: This tool must
not be used on toughened glass. Insert the
knife blade into the sealant. Slowly move
the knife along the sealant with the blade
positioned as close to the glass as possible.
09 - 16 9813/9400-1 09 - 16
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 87.

the sealant will melt.
Figure 86.
3.2. Braided Cutting Wire and Handles - This

method uses a 3-core wire, a wire starter
tube and two handles. Insert the steel tube
into the old sealant on the inside of the
glass. Insert the braided cutting wire down
the centre of the steel tube. If necessary,
from the outside, cut out local sealant at the
point of the tube to gain access to the wire.
Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the A Wire starter
glass. Secure the end of the braided cutting B Braided cutting wire
wire (found on the outer side of the glass) in C Glass extractor (handles)
the special handle. Slowly remove the steel D Glass extractor (handles)
tube. Secure the second end of the braided 3.3. Cut-out Knife - The cut-out knife can be
cutting wire in the special handle. Move the used as a left handed or right handed tool.
cutting wire backwards and forwards in a Insert the knife blade into the sealant. Make
sawing motion and at the same time gently sure that the blade of the knife is against the
push or pull the wire to cut through the old glass. Use the 'pull-handle' to pull the knife
sealant. along and cut out the old sealant.
Special Tool: Wire Starter (Qty.: 1) Special Tool: 'L' Blades (Qty.: 1)
Special Tool: Glass Extractor (Handles Special Tool: Cut-Out Knife (Qty.: 1)
Only) (Qty.: 1)
Special Tool: Braided Cutting Wire (Qty.: 1) Figure 88.
A Glass
3.4. Craft Knife - The blades are replaceable.
Insert the knife blade into the sealant. Pull
the knife along and cut out the old sealant.
09 - 17 9813/9400-1 09 - 17
09 - Window
00 - General
Figure 89. glass. Make sure the two spacer blocks are in
position. Refer to Preparation - New Glass
2. Install the glass in the frame aperture:
2.1. Always use the glass lifting tools when
moving the glass. Use a lifting strap to hold
large panes of glass in position.
Special Tool: Glass Lifter (Qty.: 2)
Figure 91. Typical Machine
A Blades
3.5. Glass Replacement Kit - This kit is
designed for removal of one pane of glass.
The kit comprises: Cartridge Polyurethane
Adhesive (310ml), Primer/Activator (10ml),
Surface Cleaner Wipe, Abrasive Pad,
Applicator Nozzle, Wool Dauber, Cutting
Wire, Rubber Blocks.
Consumable: Glass Replacement Kit
4. Laminated glass - lift out the broken pane using
glass lifters. Toughened glass - remove the cut off 2.2. Sit the bottom edge of the glass on the
sealant and all remaining particles of shattered spacer blocks.
glass. Special Tool: Rubber Spacer Blocks (Qty.:
2)
5. If necessary, trim off the remaining old sealant
to leave approximately 1 to 2 mm on the upright Figure 92.
face of the cab frame aperture.
Figure 90.
A 1.5mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures. 2.3. Make sure that the glass is correctly
positioned, then gently press around the
6.2. The old sealant was inadvertently cut back edges of the glass and ensure full adhesive
to the cab frame during the glass/sealant contact is achieved. Do not press too hard
removal procedures. or too much adhesive will squeeze out.
Installing new Glass 3. Make the inside seal smooth:
1. If the internal trim strip is damaged, renew it (cut 3.1. Wearing surgical gloves, dip your finger in
to length as required) before installing the new a soapy water solution.
09 - 18 9813/9400-1 09 - 18
09 - Window
00 - General
3.2. Use your finger to make the inside seal

smooth.
4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
caution when wiping the inside of the new glass
- pushing too hard on the inside of the glass will
affect the integrity of the bonded seal.
Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
5.2. Large amounts of excess sealant should be
left to cure and then cut off with a sharp
knife. Note: On completion of the glass
replacement procedures, the sealant curing
time is 30 minutes. This means that the
machine can be driven and used after 30
minutes, but it must not be used during the
curing period of 30 minutes.
5.3. Clean the glass using a purpose made
glass cleaner.
Consumable: Hand Cleaner
Consumable: JCB Glass Cleaner
6. On completion of the glass installation
procedures tidy the work area:
6.1. Remove all broken glass from the cab area.
6.2. Remove the protective covers from the cab
seat and control pedestals.
6.3. Renew all safety and instructional labels so
that the new installation conforms with the
original cab installation.
09 - 19 9813/9400-1 09 - 19
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-21

09-12-03 Seat Base ...................................................................................................................... 09-23
09 - 20 9813/9400-1 09 - 20
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-21 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-22 correctly.
2. Check the seat is undamaged.
3. Check the seat mounting bolts are undamaged,
correctly installed and tight.
4. Make sure the seat is clear from unwanted
materials and hazards at all times.
09 - 21 9813/9400-1 09 - 21
12 - Operator Seat
00 - General
Remove and Install

method and device.
Remove
2. Disconnect the electrical connections to the seat.
3. Remove the bolts that attach the seat to the seat
base.
Figure 93.
A
A Bolt (x4)
4. Attach suitable lifting equipment to the seat.
5. Use the lifting equipment to remove the seat from
the machine.
Install
step.
1.1. Tighten the bolts to the correct torque value.
Refer to: PIL 72.
09 - 22 9813/9400-1 09 - 22
12 - Operator Seat
03 - Seat Base
03 - Seat Base
Remove and Install
Remove
1. Make the machine.
2. Remove the seat.
3. Fully move the seat slide adjustment backward,
then remove the front fixing bolts from the slide
rails.
4. Fully move the seat slide adjustment forward and
remove the rear fixing bolts from the slide rails.
5. Remove the slide adjustment assembly.
Install
removal procedure.
09 - 23 9813/9400-1 09 - 23
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-25
09 - 24 9813/9400-1 09 - 24
15 - Seat Belt
00 - General
WARNING When a seat belt is installed on your
Introduction .................................................... 09-25 machine replace it with a new one if it is damaged,
Check (Condition) .......................................... 09-26 if the fabric is worn, or if the machine has been in
an accident.
The seat belt is to protect the operator if the machine

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

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

flashing beacon which informs observers that the
operator has correctly connected the seat belt.
09 - 25 9813/9400-1 09 - 25
15 - Seat Belt
00 - General
Check (Condition)
WARNING When a seat belt is installed on your
machine replace it with a new one if it is damaged,
if the fabric is worn, or if the machine has been in
an accident.
WARNING If the seat belt does not 'lock' when
you check if the seat belt is operating correctly, do
not drive the machine. Get the seat belt repaired
or replaced immediately.
1. Make sure the seat belt can be adjusted.

2. Examine the seat belt for signs of fraying and
stretching.
3. Check that the stitching is not loose or damaged.
4. Check that the belt mounting bolts are
undamaged, correctly installed and tight.
5. Check that the buckle assembly is undamaged
and operates correctly.
09 - 26 9813/9400-1 09 - 26
18 - Door
18 - Door
Contents Page No.
09-18-00 General ........................................................................................................................... 09-29

09-18-03 Lock ................................................................................................................................ 09-32
09-18-12 Handle ............................................................................................................................ 09-33
09 - 27 9813/9400-1 09 - 27
Notes:
09 - 28 9813/9400-1 09 - 28
18 - Door
00 - General
00 - General
Remove and Install
Consumables 5.1. Use a thin punch and hammer to tap the

Description Part No. Size securing pin from the hinge assembles.
Extreme Performance 4003/1327 0.4kg 5.2. Remove the grub screw.
Moly Grease 4003/1326 12.5kg
6. Use a thin punch and hammer to tap the hinge
pin from the hinge assembles.
Remove
7. Do steps 4 and 5 for all other hinges on the door.
8. Carefully remove the door from the hinge
2. Follow the general health and safety procedures. assembly.
9. If necessary, remove the hinge assembly by
3. Divide the doors by releasing the locking handle removing the nuts from inside the cab.
(Two piece doors only- if installed).
10. Do procedures 3 to 7 for the lower part of the
4. Make sure that the door upper is supported door. (Two piece doors only- if installed).
correctly.
11. If necessary the door catch assembly can be
5. To remove the hinge pin securing device, removed by removing the nuts, bolts and locking
depending on your machine, do one of the plate.
following actions:
09 - 29 9813/9400-1 09 - 29
18 - Door
00 - General
Figure 94. Two piece door assembly

C
F E
A Locking handle B Hinge assembly

C Hinge pin D Door- upper
E Door- lower F Door catch assembly
G Securing pin (or grub screw)
09 - 30 9813/9400-1 09 - 30
18 - Door
00 - General
Install
steps.
1.1. Lubricate the door hinge. Refer to (PIL
75-06).
Consumable: Extreme Performance Moly
Grease
09 - 31 9813/9400-1 09 - 31
18 - Door
03 - Lock
03 - Lock
Remove and Install
09 - 32 9813/9400-1 09 - 32
18 - Door
12 - Handle
12 - Handle Figure 95.
Remove and Install A

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

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

lever.
5. Slightly tilt the handle unit to unhook the unit from
the door assembly. Retain the gasket and trim
plate.
E E
A Gasket
B Trim plate
C Latch assembly
D Handle- exterior
E Retaining screws
F Cover plate
Install
removal procedure.
09 - 33 9813/9400-1 09 - 33
27 - Controls
27 - Controls
Contents Page No.
09-27-36 Accelerator Pedal ........................................................................................................... 09-35

09-27-57 Park Brake ..................................................................................................................... 09-37
09 - 34 9813/9400-1 09 - 34
27 - Controls
36 - Accelerator Pedal
Remove and Install
Consumables
JCB Threadlocker 4101/0250 0.01L
and Sealer (Medium 4101/0251 0.05L
Strength)
Figure 96.
B B
E A
A Pedal assembly B Pedal bolts

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

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

connectors from the chassis harness.
09 - 35 9813/9400-1 09 - 35
27 - Controls
Install
step.
2. Apply JCB Threadlocker and Sealer to the
threads of the pedal bolts.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
09 - 36 9813/9400-1 09 - 36
27 - Controls
57 - Park Brake
57 - Park Brake Installation

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

switch location dowel with the hole in the
1. Make the machine safe. mounting bracket.
2. Put blocks under the wheels. Release the park
brake.
3. Remove the rubber gaiter.
4. Disconnect the electrical connector from the
switch connector.
5. Hold the switch and remove screw.
6. Remove the switch.
Figure 97.
A Rubber gaiter
B Switch
C Electrical connector
D Switch connector
E Screw
F Switch location dowel
G Hole in mounting bracket
09 - 37 9813/9400-1 09 - 37
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-03 Roof Trim ....................................................................................................................... 09-39

09-30-09 Dashboard ...................................................................................................................... 09-40
09 - 38 9813/9400-1 09 - 38
30 - Trim Panel
03 - Roof Trim
03 - Roof Trim
Remove and Install

Notice: Take care during the removal and
replacement of the roof liner. Make sure your
hands and clothes are clean. The roof liner is
easily damaged.
Remove
2. With the aid of one more person hold the roof
liner and remove the screws.
3. Lower the liner to get access to the electrical
connectors at the interior lights and audio
speakers (if installed).
4. Disconnect the electrical connectors from the
interior lights and audio speakers.
5. Remove the roof liner.
6. Put the roof liner into a clean plastic bag and keep
it in a safe place. The roof liner is damaged easily.
Figure 98.
A A A A
C
C
D D
B
A A A
A Screws
B Roof liner
C Interior lights
D Audio speakers
Install
1. The installation procedure is the opposite of
step.
1.1. If seals are attached to the panel, make
sure they are in good condition. If damaged,
replace the seals.
09 - 39 9813/9400-1 09 - 39
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
Remove Figure 99.
1. Make the machine safe. C C

2. Remove the steering wheel.
3. Remove the two button head screws 1. D B D
4. Remove the steering column lower surround.
5. Remove the two button head screws 2 and the
two screws 1.
6. Remove the steering column upper surround. 00: 00: 05
7. Remove the two screws 2 that hold the centre

display panel in place, disconnect all connections
and remove the panel.
8. If the steer mode select switch has a lockable
surround, then remove it as follows: A
8.1. Remove the two screws that secure the A Button head screw 1
steer mode select switch panel. B Button head screw 2
C Screw 1
8.2. Disconnect all connections and remove the D Screw 2
panel.
Figure 100.
8.3. Remove the steer mode control knob.
9. Remove the heater control panel.
10. Remove the radio (if installed).
E
11. Remove the right hand Instrument panel.
12. Remove the left hand switch panel.
13. Remove the centre display panel.
14. Remove the screw 3, screw 4, screw 5 and screw F
6 and then remove the upper right hand panel.
Take care not to damage the harness when you
move it through the hole in the panel.
15. The screw 5 is removed from the front of the
panel, i.e. the opposite side to that shown.
16. Remove the screw 7, screw 8 and screw 9.
E Steer mode select switch panel
17. Remove the lower left hand panel. F Steer mode control switch
09 - 40 9813/9400-1 09 - 40
30 - Trim Panel
09 - Dashboard
Figure 101.
G Q H
M
N
G Screw 3 H Screw 4
J Screw 5 K Screw 6
L Screw 7 M Screw 8
N Screw 9 P Lower left hand panel
Q Upper right hand panel
09 - 41 9813/9400-1 09 - 41
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 42 9813/9400-1 09 - 42
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-45
09 - 43 9813/9400-1 09 - 43
Notes:
09 - 44 9813/9400-1 09 - 44
00 - General
Introduction .................................................... 09-45 The safety labels are strategically placed around the
Health and Safety .......................................... 09-46 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 - 45 9813/9400-1 09 - 45
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 - 46 9813/9400-1 09 - 46
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-49
09 - 47 9813/9400-1 09 - 47
Notes:
09 - 48 9813/9400-1 09 - 48
36 - Steering Wheel
00 - General
00 - General 1.1. If the key becomes damaged during the

removal procedure, replace with a new key.
Remove and Install 1.2. Make sure that the steering wheel aligns
with the marks you made during removal.
1.3. If removed, install the foam collar. Attach
Remove the adhesive lined side to the column trim
panel before you install the steering wheel.
Refer to: PIL 01-03. Figure 103.
2. Mark the position of the steering wheel on the

splined shaft.
3. Take out the steering wheel centre cap from the
wheel.
G
4. Remove the steering wheel securing nut.
5. Remove the washer.
6. Remove the steering wheel away from the
splined shaft.
7. Make sure to retain the key.
8. Remove the foam collar (if installed).
Figure 102.
A
B
H
C
G Column trim panel
H Foam collar
D
A Steering wheel center cap

B Steering wheel securing nut
C Washer
D Key
E Steering wheel
F Shaft
Install
steps.
09 - 49 9813/9400-1 09 - 49
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-51
09 - 50 9813/9400-1 09 - 50
48 - Floor mat
03 - Front Floor mat
03 - Front Floor mat
Remove and Install
Remove
2. Remove the nuts and remove the pedal pads
from the machine.
3. Remove the bolts and the retaining plate.
4. Remove the screws and the kick strips.
5. Remove the trim retainers from the front section
of the mat.
6. Remove the mat from the machine.
Figure 104.
A
D E
C F
G D
A Pedal pads
B Nuts
C Kick strips
D Screws
E Bolts
F Retaining plate
G Trim retainers
Install
removal procedure.
09 - 51 9813/9400-1 09 - 51
Notes:
09 - 52 9813/9400-1 09 - 52
12 - Heating, Ventilating and
Air-Conditioning (HVAC)
Contents Page No.
12-00 Heating, Ventilating and Air-Conditioning (HVAC)

12-00-00 General ............................................................................................................................. 12-3
12-03 HVAC Unit
12-03-00 General ........................................................................................................................... 12-21
12-03-03 Evaporator ...................................................................................................................... 12-23
12-03-06 Pressure Switch ............................................................................................................. 12-24
12-03-09 Expansion Valve ............................................................................................................. 12-27
12-03-12 Blower Motor .................................................................................................................. 12-28
12-03-15 Thermostat ..................................................................................................................... 12-29
12-03-18 Heater Coil ..................................................................................................................... 12-31
12-04 Heater Unit
12-04-00 General ........................................................................................................................... 12-33
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-37
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-41
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-45
12-18 Filter
12-18-00 General ........................................................................................................................... 12-53
12-18-06 Fresh Air ........................................................................................................................ 12-54
12-21 Heater Valve
12-21-00 General ........................................................................................................................... 12-57
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-61
9813/9400-1
2017-09-08
Acronyms Glossary
FEAD Front End Accessory Drive

PAG Polyalkyline Glycol
RPM Revolutions Per Minute
TXV Thermal Expansion Valve
9813/9400-1
2017-09-08
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9813/9400-1 12 - 1
Notes:
12 - 2 9813/9400-1 12 - 2
00 - General
Introduction ...................................................... 12-3 To maintain optimum operator comfort in warm
Health and Safety ........................................... 12-4 climates or during seasons of high ambient
Technical Data ................................................. 12-5 temperature, the air conditioning system delivers
Component Identification ................................. 12-6 cool, dehumidified air into the cab. Cooling is
provided by passing the warm ambient air, together
Operation ......................................................... 12-9 with recirculated air, over an evaporator matrix in the
Fault-Finding .................................................. 12-12 air conditioning unit.
Discharge and Pressurise ............................. 12-15
Check (Operation) ......................................... 12-18 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Check (Pressure) .......................................... 12-18 changing from gas to liquid and back to gas again,
Adjust ............................................................ 12-19 as it is forced through the system. The major
components of the system are the:
• Compressor
• Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9813/9400-1 12 - 3
00 - General
Health and Safety • DO NOT steam clean refrigerant system

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

is used and that charging is done only by
qualified personnel. It is illegal to discharge
the refrigerant into the atmosphere but as
a precaution in case of accidental leakage,
discharging and charging of the vehicle
refrigerant system must be conducted in a well-
ventilated area.
• Containers of refrigerant should be stored in a
cool environment away from direct sunlight.
• DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least
0.5m from hoses).
12 - 4 9813/9400-1 12 - 4
00 - General
Technical Data
Table 24. Binary pressure switch settings

Item Specification
Low pressure 2bar (29.0psi)
High pressure 26bar (376.8psi)
Table 25. Thermostatic switch settings

Item Specification
Cut out 0.2–1.4°C (32.4–34.5°F)
Cut in 3.4–4.8°C (38.1–40.6°F)
Table 26. Refrigerant

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

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

(2) Systems with roof mounted condenser.
Table 27. Oil

Item Specification
Type PAG (Polyalkyline Gly-
col) oil
Charge amount
(3)
-
Complete system 0.0426L
Condenser remove and 0.0284L
install
Evaporator remove and 0.0568L
install
Hoses remove and in- 0.0085L
stall
Receiver drier remove 0.0142L
and install
Compressor remove and None- pre charged
install
(3) The quantity of oil replaced should be the same
as that taken out during `Recovery' procedure.
12 - 5 9813/9400-1 12 - 5
00 - General
Heater Only
Figure 105.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 28.
E Heater Control panel
(1)
Item Description
A Heater and ventilation (1) A typical heater control panel is shown. Refer to
unit (HV) the applicable Operator Manual for machine specific
controls.
B Heater valve
12 - 6 9813/9400-1 12 - 6
00 - General
Machines with Air Conditioning
Figure 106.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 29.
pack mounted)
Item Description H Condenser (roof mount-
A TXV (Thermal Expan- ed) (Available as an op-
sion Valve) tion on some machines).
B Evaporator matrix (1) Typical heater control panel shown. Refer to
C Compressor the correct operator manual for machine specific
D FEAD (Front End Acces- controls.
sory Drive)
Table 30. Component Locations
E Heater/air conditioning
control panel
(1)
HVAC System Location (All Ma-
F Heater/air conditioning chines)
vents HVAC (Heating Venti- Fixed to cab (RHS)
lation Air Conditioning)
unit
TXV Part of HVAC unit
12 - 7 9813/9400-1 12 - 7
00 - General
HVAC System Location (All Ma-

chines)
Evaporator matrix Part of HVAC unit
Compressor Fixed to engine (RHS)
Binary switch Fixed to pipe next to
compressor
Receiver drier Fixed to chassis inside
engine compartment
Condenser - cooling Part of machine cooling
pack mount pack inside engine com-
partment
Condenser - roof mount Fixed to a frame fixed at
the rear of the cab roof.
Includes electric cooling
fans
12 - 8 9813/9400-1 12 - 8
00 - General
Operation
Fresh air is supplied to the cab interior through the fan. In the condenser, the refrigerant changes state
cab air vents. The heater and ventilation unit (HV) to a high pressure, high temperature liquid but with
uses a blower fan to increase the air speed. The a lower heat content.
air can also be heated by the heat exchange matrix
housed within the HV unit. The refrigerant passes through the receiver drier,
which contains a desiccant to remove moisture from
On machines with air conditioning, the unit also the system. The receiver drier serves as a tank for
houses the air conditioning evaporator matrix to refrigerant and also includes a filter to remove foreign
become a combined HVAC (Heating Ventilation Air particles from the system.
Conditioning) unit. Refer to (PIL 12-03).
Figure 107.
The machine operator can control the air
temperature and speed from within the cab on the F
E
heater control panel. For operation of the heater
controls refer to the applicable Operator Manual.
The operator uses the fan speed switch to select

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

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

D
through which the refrigerant is circulated, its state
changing from gas to liquid and back to gas again, A Compressor
as it is forced through the system. B Condenser matrix
C Receiver drier
The major components of the system are as follows. D Binary pressure switch
E TXV
• Compressor F Evaporator matrix
• Condenser matrix
• Receiver drier The receiver drier can only hold a limited amount of
• Binary pressure switch moisture, additional moisture can lead to icing and
• TXV (Thermal Expansion Valve) ultimately blockage of the thermostatic expansion
• Evaporator matrix valve. If the air conditioning system has been left
open or has been leaking for a prolonged period of
Operate the air conditioning as described in the time, the desiccant will become saturated and the
operator manual. receiver drier will need to be replaced with new one.
Air conditioning system power is generated from The high temperature, high pressure refrigerant
the engine, through an electromagnetic clutch to is forced by compressor action into the TXV,
the compressor. Switches, connected in series, are which meters the amount of refrigerant entering
included in the clutch supply line, all must be closed the evaporator. In the TXV the refrigerant
for the clutch and therefore the air conditioning instantaneously expands to become a low pressure,
system to operate. low temperature liquid.
The compressor draws in low pressure refrigerant The refrigerant is drawn through the evaporator
gas from the suction line (evaporator to matrix by the suction of the compressor. The
compressor) and increases refrigerant pressure temperature of refrigerant is now considerably below
through compression. This process also increases that of the air being drawn across the evaporator
the refrigerant temperature. matrix by the blowers. Heat is transferred from the
ambient and re circulated air to the refrigerant,
High pressure refrigerant is forced from the causing the low pressure liquid to vaporise and
compressor to the condenser. Ambient air is drawn become a low pressure gas. Moisture in the air
across the condenser by the engine- driven cooling
12 - 9 9813/9400-1 12 - 9
00 - General
condenses on the evaporator matrix and is drained The low temperature, low pressure, high heat
away through condensate. content refrigerant gas, is now drawn by suction back
to the compressor, where the cycle is completed.
Cool de-humidified air is emitted through air vents
into the cab.
Figure 108.
X F Y
C E A
A Compressor B Condenser matrix

C Receiver drier D Binary pressure switch
E TXV F Evaporator matrix
X Refrigerant is in liquid state Y Refrigerant is in gas state
System control 2. The high and low level binary pressure switch
located in the pipework near to the compressor.
The system is a manual control type and is set to on This switch is not adjustable.
or off by switch. There is no automatic control of the
cab air temperature. 3. The freeze protection thermostat switch located
inside the HVAC unit. This switch is not
Refrigerated air will be heated by the heater matrix If adjustable.
the heater control is not set to ‘cold’.
When the air conditioning switch is set to on
You can control the system by activating and the refrigeration system is active. The system
deactivating the compressor electromagnetic clutch. operates within fixed temperature and pressure limits
When current is fed to the field coil of the compressor controlled by the freeze protection thermostat switch
clutch, a magnetic field develops between the field and the binary pressure switch. The system does not
coil and the armature which pulls the field coil, respond to changes in the cab air temperature.
complete with clutch assembly, onto the compressor
rotor. Since the clutch assembly is turned constantly If the compressor runs continuously condensate
by the crankshaft pulley drive belt, the compressor on the evaporator matrix will freeze and the
armature turns, starting the refrigeration cycle. system will not be effective. The freeze protection
thermostat switch has its sensor probe installed
Current is fed to the field coil through a series of in the evaporator matrix. When the temperature
switches. of the probe is near 0°C (32.0°F) the thermostat
switch contacts open. The compressor clutch
1. The manual air conditioning on/off switch in the disengages, closing down the refrigeration cycle.
control console. As the temperature of the probe increases the
12 - 10 9813/9400-1 12 - 10
00 - General
thermostat switch contacts close. The compressor

clutch engages and refrigeration re-starts.
Figure 109.
D Binary pressure switch G Manual air conditioning on/off switch

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

pressure limit or falls below the lower limit,
the contacts of the binary switch open and the
compressor clutch disengages, closing down the
refrigeration cycle.
12 - 11 9813/9400-1 12 - 11
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 31. Page 12-12
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 32. Page 12-12
Compressor clutch continually cuts out Table 33. Page 12-12
Poor performance- Compressor function tests Table 34. Page 12-13
Compressor not achieving 24 bar pressure Table 35. Page 12-13
No air conditioning Table 36. Page 12-13
Table 31. Poor performance (For system diagnosis using test gauges, refer to Check Operation, PIL
12-03)
Cause Remedy
Condenser matrix air flow restricted Remove debries from matrix using compressed air
HVAC (Heating Ventilation Air Conditioning) Unit air Refer to (PIL 12-18)
intake filter blocked
Compressor drive belt too slack Refer to (PIL 15-18)
Low system pressure Discharge and recharge the system
Table 32. Warm air or slightly cool air emitted from unit
Cause Remedy
Expansion valve stuck open or closed Renew expansion valve. Refer to (PIL 12-03)
Table 33. Compressor clutch continually cuts out

Cause Remedy
Condenser matrix blockage Remove debris from matrix or
Overcharging of refrigerant system Discharge and recharge the system. Refer to (PIL
12-00)
Blocked expansion valve or condenser Clear blocked component. Refer to (PIL 12-03)
Compressor fault Do compressor function tests. Refer to (PIL 12-03)
12 - 12 9813/9400-1 12 - 12
00 - General
Table 34. Poor performance- Compressor function tests

Cause Remedy
(1) Is the compressor rotation smooth? With the YES = Check (2), NO = Renew compressor
engine having been turned off for 5 minutes, turn
the compressor shaft by turning the armature plate
by hand. Check for smooth rotation. Grinding or
hanging during shaft rotation is caused by a broken
component within the compressor.
(2) Is the field coil receiving greater than 7.5 V? YES = Check (3), NO = Rectify electrical problem
This test should be conducted with the electrical
system on and clutch engaged. Unplug the electrical
connector and measure on the machine side.
(Reversing polarity will short diode resulting in blown
fuses).
(3) Is the field coil resistance between 3 and 4 ohms? YES = Check (4), NO = Renew compressor
Coil resistance out of this range will not engage
or will cause fused circuits to open. Unplug the
electrical connector, measure on compressor side.
(4) Is compressor capable of producing 24 bar or YES = Compressor is functioning correctly, No =
more? To check this do the pressure tests. Refer Follow the pressure fault finding table (Compressor
to (PIL 12-03). Excessive high pressure can be not achieving 24 bar pressure).
artificially produced by preventing air flow across
the condenser. Preventing air flow through the
condenser minimises heat removal from the system
resulting in high pressure.
Table 35. Compressor not achieving 24 bar pressure

Cause Remedy
Low refrigerant charge - possible leakage, suction TEST = Discharge and recharge the system,
and discharge pressure are low. ACTION = Repair leak & check system pressures
(Compressors with dirt/oil build up at hose
connections are most likely to have damaged 'O'
rings. Check for leaks and replace 'O' rings.
System high pressure side blockage - flow to the TEST = Check suction pressure is 0.35 bar or less,
compressor is stopped or limited. ACTION = Compressor is functioning correctly,
remove the system blockage.
Compressor failure - internal compressor damage. TEST = Suction pressure high, discharge pressure
low, do compressor function tests (See table 4),
Action = Renew compressor
Test performed below 10 ºC - Low ambient TEST = Move machine to area where temperature is
temperature limits pressure. higher, ACTION = Check system pressures
Table 36. No air conditioning

Cause Remedy
(1) Are the controls set correctly, i.e. air conditioning YES = Check (2), NO = Reset controls and retest
selected, heater control set to coldest position and
blower switched on?
(2) Is the air conditioning (evaporator) blower YES = Check (30), NO = Reset controls and retest
working?
(3) Is the compressor running (visual check of pulley/ YES = Check (10), NO = check (5)
clutch)?80 % or betetr
(4) Is the air conditioning fuse(s) blown? For details YES = Renew fuses and retest, NO = Check (9)
of the electrical circuit and connections, Refer to (PIL
33-00-50)
(5) Is there a 12V supply to the binary pressure YES = Check (6), NO = Check (7)
switch harness?
12 - 13 9813/9400-1 12 - 13
00 - General
Cause Remedy
(6) Does the compressor clutch engage with binary YES = Replace binary pressure switch assembly, NO
pressure switch assembly bypassed? = Check (8)
(7) Does the clutch engage with freeze thermostat YES = Renew freeze thermostat switch and retest,
switch bypassed? NO = Check all electrical connections.
(8) Is there a 12V supply at the compressor? YES = Renew the compressor clutch and re-test, NO
= Renew the compressor relay and re-test.
(9) Are blower switch and wiring OK? YES = Renew blower unit complete, NO = Renew
switch or wiring.
(10) Is the system correctly charged with refrigerant YES = Check (11), NO = Charge check required by
OK? refrigeration engineer or suitably trained person.
(11) Is condenser air flow blocked? YES = Clean condenser and radiator, NO = Check
(12).
(12) Is evaporator air flow blocked? YES = Clean/Replace HVAC Unit Air Intake filter.
Refer to (PIL 12-03), NO = If necessary replace the
evaporator. Call in refrigeration engineer or suitably
trained person.
12 - 14 9813/9400-1 12 - 14
00 - General
Discharge and Pressurise 10. Close the valves and remove all equipment.
Figure 110.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Refer to the Health and Safety section. Refer to: PIL

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

purity.
The JCB recommended Javac unit only recovers

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

A Low pressure hose (blue)
2. Make sure that the engine is OFF and the engine B High pressure hose (red)
is cool. C Hose (yellow)
D Filter
3. Remove the ignition key. E Javac unit
F Empty receiver bottle
4. Connect the manifold to the system with the blue
hose connected to the system low pressure port.
Do not connect the red hose. Make sure that both Evacuate
valves are closed.
This procedure follows on from the Recovery
5. Connect the yellow hose to the Javac unit filter. process and is necessary to make sure that the
system is correctly refilled with refrigerant. To avoid
6. Connect the filter to the Javac unit. leakage in the vacuum system itself, Do not use
extensions to the yellow hose (use standard 2 metre
7. Connect the Javac unit to an empty receiver length).
bottle. Weigh the bottle before and after filling to
assess the system capacity. Note: Do not fill the 1. Recover all refrigerant from the system, refer to
receiver bottle to more than 80% by weight. refrigerant recovery.
8. Switch on Javac unit and open the low pressure 2. Close all valves and connect the manifold.
manifold valve. Note: If the high pressure Connect the blue hose to the system low
warning light on the Javac unit comes on, throttle pressure port and the red hose to the high
back the manifold low pressure valve to provide pressure port.
a restriction.
3. Connect the yellow hose to the vacuum pump.
9. The Javac unit will automatically switch off when Note: If the Electronic vacuum gauge is used
a pressure balance exists between the system connected as shown. Refer to Electronic Vacuum
and the receiver bottle. Switch off Javac unit at Gauge for further information.
main switch, but leave the system connected.
Switch on after the specified time and the Javac 4. Open the manifold valves.
unit will restart if residual pressure remains.
5. Switch on the vacuum pump until 740mm (29
Duration: 10min in) mercury vacuum reads on both gauges.
12 - 15 9813/9400-1 12 - 15
00 - General
Note: achievable vacuum will vary with altitude. 6. Switch on the vacuum pump and open the high
Maximum gauge reading will be 25mm (1 in) less pressure side valve.
for every 305 metres (1000 feet) above sea level.
7. Unscrew the oil injector cap and add the specified
6. Maintain suction for approximately the specified quantity of refrigerant oil.
time. Note: If the vacuum falls rapidly the system
is leaking. Check all connections and reseal. If 8. When 740mm (29 in) mercury shows on the
the point of leakage is not obvious, recharge the vacuum gauge, open the oil injector valve to
system and test again. allow the oil into the system.
Duration: 30min 9. If more oil is needed repeat the above procedure.
The quantity of oil should be the same as that
7. Close the valves and remove all equipment. taken out during the Recovery procedure. Note:
Figure 111. Use only PAG oil in R-134a systems.
Figure 112.

B High pressure hose (red)
C Hose (yellow) F
D Vacuum pump
E Electronic vacuum gauge
B High pressure hose (red)
Re-lubricate C Hose (yellow)
D Vacuum pump
Re-lubrication is essential after recovering the
E Oil injector
system refrigerant, vacuuming and component
F Low pressure point
flushing. The system should be evacuated to a
vacuum of 740mm (29 in) of mercury before re-
lubricating. Charge
1. Make sure that the engine is OFF and the engine This procedure is the industry recommended
is cool. practice for refilling air conditioning systems with
refrigerant. Evacuate the system beforehand to
2. Remove the ignition key. 740mm (29 in) of mercury.
3. Close all valves and connect the manifold as 1. Close all valves and connect the manifold
shown, with the blue hose connected to the oil as shown. Connect the blue hose to system
injector and the red hose to the system high low pressure and the red hose to system
pressure port. high pressure. Connect the yellow hose to the
refrigerant cylinder.
4. Connect the yellow hose to the vacuum pump.
2. Invert the single valve cylinder on the scales and
5. Connect the other end of the oil injector to the zero the scale reading. Note: Some refrigerant
system low pressure point. cylinders have separate valves for gas and liquid.
12 - 16 9813/9400-1 12 - 16
00 - General
Be sure to connect to the liquid port when Figure 114.

following the above procedure. Note: Refrigerant
can be used either in gas or liquid form. If
recharging with gas follow the manufacturers
instructions and recharge only via the low
pressure port. Do not use liquid refrigerant at the
low pressure port.
3. Slowly open the high pressure valve and allow
the vacuum to draw-in refrigerant to the specified
weight for the system. Refer to Technical
Data. Add refrigerant until the scales indicate
the specified weight for the system or the
weight obtained when the system refrigerant
was previously recovered. Note: To speed up
the process a thermostatically controlled thermal
blanket can be used around the replenishing
cylinder.
4. Close all valves and remove the equipment.
Figure 113.
A396790
Table 37.
Gauge Reading Description
ATM/BAT Normal atmospheric
pressure reading. Bat-
tery condition.
15"/510mbar 381mm (15 in)Hg. Par-
tial vacuum- Vacuum
system is operating.
29"/980mbar 736mm (29 in)Hg. No
vacuum drawn- Possible
system leakage.
8000 8.0mm (0.31 in)Hg. Par-
tial vacuum - If the read-
ing does not progress
the system may have a
slow leak.
1000 1.0mm (0.039 in)Hg.
A Low pressure hose (blue) Deeper vacuum.
B High pressure hose (red) 600 0.6mm (0.023 in)Hg.
C Hose (yellow) Deep vacuum.
D Refrigerant cylinder 400 0.4mm (0.015 in)Hg.
E Scales Deep vacuum.
F Thermal blanket
200 0.2mm (0.0078 in)Hg.
Deep vacuum.
Electronic Vacuum Gauge
25 0.025mm (0.00098
The CPS VG100 vacuum gauge is an electronic type in)Hg. Pump Test. Max-
using LED's to indicate various states of vacuum. It imum sustainable vacu-
is used in place of or to supplement the gauge on the um.
vacuum pump. Before connecting into the system,
switch on to check that the first LED lights to show
that the battery is in good condition.
Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).
12 - 17 9813/9400-1 12 - 17
00 - General
Check (Operation) Check (Pressure)

The air conditioning system needs to be checked
regularly to make sure it operates efficiently and The air conditioning system is a closed loop system
safely. and contains pressurised refrigerant. No part of the
Before you do any service operation, carry out a has been discharged by a refrigeration engineer
basic service check as described below. or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
1. Start the engine and operate at fast idle speed of
1000 RPM (Revolutions Per Minute). WARNING! Leak testing of Air Conditioning systems
should only be carried out in well ventilated areas.
2. Switch on the air conditioning and set to
maximum cooling. The refrigerant is heavier than air and will leak
downwards from the defective component. Check in
3. The cab temperature should be above the a well ventilated area.
specified value.
Hose or pipe connections are likely leakage points of
Temperature: 20°C (68.0°F)
any refrigerant circuit.
4. At low ambient temperatures it may be necessary
to operate the heating system to prevent the air It is essential that an electronic leak detector is used
conditioning system switching off. to locate leaks accurately. However, if a leak detector
is not available, an approximate source can be found
5. Operate the engine at operating temperature for by applying soap solution to the suspect area.
five to ten minutes.
To test for leaks in the high pressure side of
6. Close the cab door and windows and allow the the system i.e. from the compressor output to the
internal temperature to stabilize. expansion valve, run the air conditioning for a few
minutes then switch off the engine and test for
7. Measure the temperature at the evaporator leakage using an electronic leak detector or soapy
outlets. The temperature should change as the water.
compressor clutch cycles in and out.
To test for leakage in the low pressure side of the
8. The outlet temperature with the clutch engaged, system, switch off the air conditioning and leave for
should be significantly below the ambient a new minutes before you do the test.
temperature (4°C to 10°C) which can raise upto
the specified value when the clutch disengages.
Tightening leaking hoses
Temperature: 6–8°C (42.8–46.4°F)
The refrigerant hoses have crimped ferrule end
9. Stop the engine when the tests are complete. fittings. The hose connectors have an O-ring seal
which compresses when the connection is tight and
Off-Season Operation create an air tight seal.
During the off-season, the air conditioning system Hoses are used to connect the inlets and outlets
should be operated for at least five minutes every of the compressor, condenser, receiver drier and
month to circulate the oil in the system to lubricate expansion valve (the evaporator coil is connected to
the fittings and seals. the expansion valve within the air conditioning unit
using rigid pipes).
When you operate the system, make sure of the
followings. If leakage is detected from a hose connector, either
by means of an electronic leak detector or soapy
• Engine idle speed is more than 1000 RPM. water, tighten the connector up and repeat the
• Ambient temperature is more than the specified leakage test. If leakage is still evident, it will be
value. 0°C (32.0°F) necessary to discharge the system and renew the
• Cab temperature is more than the specified connector O-ring seal.
value. 20°C (68.0°F)
• The engine is at normal operating temperature.
12 - 18 9813/9400-1 12 - 18
00 - General
Adjust
For compressor drive belt adjustment, please see

(PIL 15-18).
12 - 19 9813/9400-1 12 - 19
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-00 General ........................................................................................................................... 12-21

12-03-03 Evaporator ...................................................................................................................... 12-23
12-03-06 Pressure Switch ............................................................................................................. 12-24
12-03-09 Expansion Valve ............................................................................................................. 12-27
12-03-12 Blower Motor .................................................................................................................. 12-28
12-03-15 Thermostat ..................................................................................................................... 12-29
12-03-18 Heater Coil ..................................................................................................................... 12-31
12 - 20 9813/9400-1 12 - 20
03 - HVAC Unit
00 - General
00 - General 9.2. Remove the chassis side cover from the

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

10. Remove the bolt 1 and bolt 2 which secure the
Air Conditioning Maintenance HVAC unit to the machine.
The air conditioning system is a closed loop system
11. Carefully remove the unit sufficiently to access
and contains pressurised refrigerant. No part of the
the electrical harness connector at the rear.
has been discharged by a refrigeration engineer 12. The electrical harness connector is located
or a suitably trained person. You can be severely behind the unit and cannot be disconnected until
frostbitten or injured by escaping refrigerant. the unit is pulled away from the machine.
The heating and ventilation unit (HV) contains a 13. Disconnect the electrical connector.
blower unit and heat exchanger matrix. It is located
under the right front side of the cab. 14. Remove the assembly from the machine.
The HVAC (Heating Ventilation Air Conditioning) unit Figure 115.

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

2. Install the safety strut. E
3. To remove the HVAC unit it is necessary to A C B D
discharge the refrigerant from the system. A Heater valve
B Heater matrix
Refer to: PIL 12.
C TXV (If installed)
4. Drain the cooling system. D Bolt 1
E Bolt 2
Refer to: PIL 21. F Clip
G Cable
5. If installed, remove the cab side cover to get
access to the HVAC unit.
Install
6. Disconnect the heater hoses from the heater
valve and from the heater matrix. 1. The installation procedure is the opposite of the
7. Disconnect the HVAC hoses from the TXV (if steps.
installed).
1.1. Make sure that the TXV is installed correctly
8. Remove the clip and disconnect the cable from with the diaphragm, located below the
the heater valve. valve.
9. For 526-56 machines only:
9.1. Remove the cab frame from the machine.
12 - 21 9813/9400-1 12 - 21
03 - HVAC Unit
00 - General
Figure 116.
C TXV
J Diaphragm
1.2. Charge the HVAC system and check for
leaks.
Refer to: PIL 12.
1.3. Fill the cooling system and check for leaks.
Refer to: PIL 21.
12 - 22 9813/9400-1 12 - 22
03 - HVAC Unit
03 - Evaporator
03 - Evaporator
Introduction
The evaporator works in the opposite way as the

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

Ventilation Air Conditioning) unit.
12 - 23 9813/9400-1 12 - 23
03 - HVAC Unit
06 - Pressure Switch
06 - Pressure Switch Introduction

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

limits, the pressure switches will be closed and if the
thermostat and on/of switches are closed, current
will be supplied to the field coil of the clutch. Due
to the electromagnetic action the field coil clutch will
be pulled towards the compressor's clutch and the
refrigeration cycle will start.
12 - 24 9813/9400-1 12 - 24
03 - HVAC Unit
Check (Operation) Figure 117.
Binary Switch
The binary pressure switch is located in the
HVAC (Heating Ventilation Air Conditioning) system
pipework. Refer to: PIL 12-03.
Before testing the binary pressure switch, check the

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

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

system operates, one of the switches inside the
binary pressure switch assembly is faulty.
5. Install a new pressure switch assembly. If the
clutch still fails to operate, check the harness
electrical wiring for damage and open or short
circuits. A Binary pressure switch
B Harness connectors
12 - 25 9813/9400-1 12 - 25
03 - HVAC Unit
Remove and Install 4.1. If leaks are found, tighten the pressure
switch further until the leaking stops.
Remove
2. Discharge the HVAC (Heating Ventilation Air
Conditioning) system.
Refer to: PIL 12.
3. Remove the harness connectors.
4. Remove the screws and then remove the
pressure switch assembly.
Figure 118.
B
A
A Pressure switch
B Harness connectors
Install
1. Screw the pressure switch into the threaded port
and tighten sufficiently to form a gas tight seal.
2. Connect the harness connectors.
3. Charge the HVAC system.
Refer to: PIL 12.
4. Operate the HVAC system and check around the
pressure switch for leaks.
12 - 26 9813/9400-1 12 - 26
03 - HVAC Unit
09 - Expansion Valve
09 - Expansion Valve
Introduction
The purpose of the expansion valve is to remove

pressure from the liquid refrigerant and to allow the
refrigerant to change from liquid to vapour in the
evaporator. The expansion valve is located in the
HVAC unit.
12 - 27 9813/9400-1 12 - 27
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 38. Page 12-28
Blower does not operate Table 39. Page 12-28
Table 38. Blower operates on fan speed 3 only

Cause Remedy
Blower resistor defective. Install new resistor
Blower motor defective. Remove and install new blower motor unit.
Table 39. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 28 9813/9400-1 12 - 28
03 - HVAC Unit
15 - Thermostat
15 - Thermostat
Remove and Install
Remove 4. Remove the fixing bolts (x2) and then remove the
electrical connectors.
5. Carefully remove the thermostat and the
Refer to: PIL 01-03. thermostat sensor. Note the routing of the sensor
2. Install the safety strut. probe. Do not make sharp bends in the sensor
probe.
3. Remove the screws (x12) and take out the HVAC
(Heating Ventilation Air Conditioning) unit cover.
Figure 119.
H G
A
C E
D D
A Screws (x12) B HVAC unit cover

C Electrical connectors D Fixing bolt (x2)
E Sensor F Thermostat
G Protective sleeve H New sensor
12 - 29 9813/9400-1 12 - 29
03 - HVAC Unit
15 - Thermostat
Install
steps.
1.1. If a new thermostat is to be installed,
carefully remove the protective sleeve from
the new sensor. Do not make sharp bends
in the sensor probe.
1.2. Make sure that the HVAC cover sealing
gasket locates correctly.
12 - 30 9813/9400-1 12 - 30
03 - HVAC Unit
18 - Heater Coil
18 - Heater Coil
Introduction
The heater coil is a tube and fin construction, with the

inlet and outlet on one end of the coil. Hoses connect
the coil to the engine.
The heat energy for heating cab air comes from the
hot engine coolant. The heater systems are designed
to transfer heat energy from the engine coolant to the
air in the cab.
12 - 31 9813/9400-1 12 - 31
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-33
12 - 32 9813/9400-1 12 - 32
04 - Heater Unit
00 - General
00 - General Operation
Operation ....................................................... 12-33 For the heater unit operation, refer to HVAC (Heating
Fault-Finding .................................................. 12-34 Ventilation Air Conditioning)- general, refer to (PIL
12-00).
12 - 33 9813/9400-1 12 - 33
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 40. Page 12-34
Blower does not operate Table 41. Page 12-34
Table 40. Blower operates on fan speed(3) only

Cause Remedy
Blower resistor failed Replace the resistor.
Blower motor failed Replace the complete blower motor unit.
Table 41. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 34 9813/9400-1 12 - 34
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-37
12 - 35 9813/9400-1 12 - 35
Notes:
12 - 36 9813/9400-1 12 - 36
09 - Compressor
00 - General
Introduction .................................................... 12-37 The compressor is located at the front of the engine,
Remove and Install ....................................... 12-38 it is the heart of the air conditioning system since it
produces the refrigerant flow.
The compressor is driven by the engine drive belt.
Refer to Component Identification. Refer to: PIL

12-00-00.
12 - 37 9813/9400-1 12 - 37
09 - Compressor
00 - General
Remove and Install
Remove 5.1. Put a label on the hoses to help installation.

contamination.
6. Remove the high pressure hose to the
2. Discharge the air conditioning system refrigerant. compressor.
Refer to: PIL 12. 6.1. Put a label on the hoses to help installation.
3. Remove the FEAD (Front End Accessory Drive) 6.2. Plug all the open ports and hoses to prevent
belt. contamination.
7. Support the compressor and remove the
4. Disconnect the electrical harness connector from mount bolts that attach the compressor to the
the compressor and binary pressure switch. crankcase.
5. Remove the low pressure hose to the 8. Lift the compressor and remove from the
compressor. machine.
Figure 120.
E G
A B F
C D
J H
K B
A FEAD belt B Compressor

C Harness connector- binary pressure switch D Bolt
E Harness connector- compressor F High pressure hose
G Mount bolts H Low pressure hose
J Bolt K Cable ties
12 - 38 9813/9400-1 12 - 38
09 - Compressor
00 - General
Install
steps.
2. Replace the FEAD belt.
3. Recharge the air conditioning system refrigerant.
Refer to: PIL 12.
4. Check the air conditioning system for leaks and
correct operation.
12 - 39 9813/9400-1 12 - 39
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-41
12 - 40 9813/9400-1 12 - 40
12 - Receiver Drier
00 - General
Introduction .................................................... 12-41 The Receiver/Drier is a device that removes
Check (Condition) .......................................... 12-42 moisture from the refrigerant as well as filtering any
contaminants or particulates from it. It also acts as a
tank to store excess coolant.
Refer to Component Identification. Refer to: PIL

12-00-00.
12 - 41 9813/9400-1 12 - 41
12 - Receiver Drier
00 - General
Check (Condition) Figure 122.
1. Make the machine safe with the lift arm lowered.

2. Clean the sight glass on the top housing of the
receiver drier.
3. Check the sight glass.
3.1. Make sure that the sight glass is clear.
4. Check the pipe connections to the receiver drier
for signs of cracks or wear. 3. Clouded - Dessicant breakdown in the receiver
drier. Refer to Figure 123.
5. Make sure that the pipes are correctly clamped.
Figure 123.
5.1. If necessary, replace the pipes and clamps.
6. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
Sight glass indications

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

supply cool air. The indication then is that the
system is completely discharged of refrigerant.
Refer to Figure 121.
Figure 121.
2. Foam or bubbles - Refrigerant is low and needs

of charging. Some slight bubbling is to be
expected when R134a refrigerant is used. Refer
to Figure 122.
12 - 42 9813/9400-1 12 - 42
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-45
12 - 43 9813/9400-1 12 - 43
Notes:
12 - 44 9813/9400-1 12 - 44
15 - Condenser
00 - General
Introduction .................................................... 12-45 A condenser is a component used to condense
Clean ............................................................. 12-46 a substance from its gaseous to its liquid state,
Check (Condition) .......................................... 12-46 typically by cooling it. In so doing the latent heat is
Remove and Install ....................................... 12-47 given up by the substance, and will transfer to the
condenser coolant.
12 - 45 9813/9400-1 12 - 45
15 - Condenser
00 - General
Clean Check (Condition)
When you are cleaning take extra care not to damage 1. Inspect the condenser coil for a build of dirt. If
the condenser fins or tubes. Damaged fins must necessary, clean the condenser coil.
be straightened out to make sure of a good airflow Refer to: PIL 12-15-00.
through the coil.
2. Inspect the condenser fins or tubes for damage.
1. Make the machine safe. Straighten out the damaged fins and make sure
Refer to: PIL 01-03. of a good airflow through the coil.
2. Raise the grille at the rear of the machine. The working environment of the machine can build
up airborne particles on the condenser coil over a
3. Use compressed air or low pressure water to period of time. This restricts the airflow around the
back flow through the coil fins. Make sure that the condenser coil and reduces the heat dissipation from
fins are not damaged. the refrigerant to the air. This results in poor air
conditioning performance.
4. Start the HVAC (Heating Ventilation Air
Conditioning) system and check the cooling The heavy build up on the condenser coil leads to
performance. over pressurisation of the system. This can cause
the high pressure cut-out switch to operate and
switch off the system. The internal blockage of the
condenser coil can also operate the high pressure
cut-out switch.
12 - 46 9813/9400-1 12 - 46
15 - Condenser
00 - General
Remove and Install
CAUTION When working on the HVAC System 6. Remove the work light securing screws and
gloves, eye protection and protective clothing remove the lights and brackets from the machine.
must be worn. Refrigerant may be released which Make sure the work lights and harness are clear
can be harmful to your skin or eyes. of the condenser.
7. Remove the bolt securing the pipe clamp,
Roof Mounted Condenser remove the clamp.
The condenser matrix is mounted on the cab roof. 8. Disconnect the condenser harness connector.
Use the assistance of a refrigeration engineer or 9. Put a label on the pipes to help installation.
suitably trained person to remove the condenser
10. Disconnect the HVAC pipes at the pipe stubs on
matrix since the refrigerant needs to be drained from
the condenser.
the system.
11. Plug all the open ports and pipes to prevent
Remove contamination.
1. Make the machine safe. 12. To prevent damage to the condenser when you
Refer to: PIL 01-03. remove or install the pipes, hold the hexagon
flats on the pipe stubs with a spanner when you
2. Disconnect the battery. loosen or tighten the pipe nuts.
Refer to: PIL 33-03. 13. When you remove the components or hoses,
retain any lubricant within the component/pipe
3. Make sure that the HVAC (Heating Ventilation Air
and fill the system with the same amount of clean
Conditioning) system is fully discharged.
lubricant (PAG Oil).
Refer to: PIL 12.
14. Using lifting equipment support the weight of the
4. Support the protective cover and remove the condenser unit.
nuts. Lower the cover from the matrix.
15. Remove the nuts and carefully lift the condenser
5. Remove the cable ties to release the work light matrix from the machine.
harness if installed.
12 - 47 9813/9400-1 12 - 47
15 - Condenser
00 - General
Figure 124.
A F
D D
F
B
F
E
C
G J
K
L
L
M
M
L
M
P
L
A Condenser matrix B Protective cover

C Cover fasteners D Air conditioning pipes
E Cable ties F Condenser support bolts
G Work light harness H Pipe clamp bolt
J Pipe clamp K Condenser electrical connector
L Condenser support nuts M Bracket securing screws
N Condenser unit P Support bracket
12 - 48 9813/9400-1 12 - 48
15 - Condenser
00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe.
steps.
2. Open the engine compartment cover.
1.1. Recharge the HVAC system after
installation. Refer to: PIL 06-06.
Refer to: PIL 12. 3. Disconnect and remove the battery.
1.2. Operate the HVAC system and check for Refer to: PIL 33-00.
leaks.
4. Make sure that the HVAC system is fully
1.3. In the cab, set the HVAC system to discharged.
maximum cooling and check that cooled air
comes through the vents. Refer to: PIL 12.
5. Put a label on the hoses to help installation.
Cooling Pack Mounted Condenser
6. Disconnect the HVAC hoses at the pipe stubs on
The condenser matrix is mounted onto the cooling the side of the condenser.
pack in the engine compartment. If the condenser is
removed only to gain access to the cooling pack, this 7. Plug all the open ports and hoses to prevent
can be done without disconnecting the HVAC hoses contamination.
and with the system fully charged. Put the condenser
carefully on to one side with the hoses still connected 8. To prevent damage to the condenser when you
after you remove the nuts. Take care not to kink the remove or install the hoses, hold the hexagon
hoses. Do not allow the condenser to hang on the flats on the pipe stubs with a spanner when you
hoses unsupported. loosen or tighten the hose nuts.
Use the assistance of a refrigeration engineer or 9. When you remove the components or hoses,
suitably trained person to remove the condenser retain any lubricant within the component/hose
matrix since the refrigerant needs to be drained from and fill the system with the same amount of clean
the system. lubricant (PAG Oil).
10. Remove the nuts and carefully lift the condenser
matrix from the machine.
12 - 49 9813/9400-1 12 - 49
15 - Condenser
00 - General
Figure 125.
A C
B
C
A Condenser matrix B Pipe stub

C Nuts
12 - 50 9813/9400-1 12 - 50
15 - Condenser
00 - General
Install
steps.
1.1. Recharge the HVAC system after
installation.
Refer to: PIL 12.
1.2. Operate the HVAC system and check for
leaks.
1.3. In the cab, set the HVAC system to
maximum cooling and check that cooled air
comes through the vents.
12 - 51 9813/9400-1 12 - 51
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-53

12-18-06 Fresh Air ........................................................................................................................ 12-54
12 - 52 9813/9400-1 12 - 52
18 - Filter
00 - General
00 - General
Introduction
CAUTION The filter may be filled with dust. Wear
goggles and a face mask when removing the filter.
The air conditioning filter assemblies are designed to

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

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

cleaning/changing more often than detailed in the
maintenance schedule.
12 - 53 9813/9400-1 12 - 53
18 - Filter
06 - Fresh Air
06 - Fresh Air 1.1. Carefully install the new filter into the
housing.
Remove and Install 1.2. Make sure that the tab locates behind the
edge of the panel before you install the
CAUTION The filter may be filled with dust. Wear screw.
goggles and a face mask when removing the filter.
In dusty conditions the filter will require cleaning/

changing more often than detailed in the service
schedule.
Remove
1. Make the machine safe with the lift arm raised.
2. Install the safety strut.
3. Remove the screw and the cover to access the
filter.
4. Remove the filter.
Figure 126.
C
E
A Screw
B Cover
C Filter
D Tab
E Panel
Install
Do not try to clean the filter. If the filter gets clogged,
install a new one.

steps.
12 - 54 9813/9400-1 12 - 54
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-57
12 - 55 9813/9400-1 12 - 55
Notes:
12 - 56 9813/9400-1 12 - 56
21 - Heater Valve
00 - General
00 - General
Remove and Install
The cab heater valve is part of the heater assembly 5. Align the marks on the control cable outer and
installed on the external part of the cab. the valve body.
6. Remove the clip 1.
Remove
7. Be careful, when you remove the hoses from the
valve, some amount of engine coolant will leak.
8. Loosen the clip 2 and remove the hoses from the
2. Remove the ignition key. valve.
3. If the engine is hot let it cool for one hour. 9. Disconnect the control cable from the valve lever.
4. Secure the heater hoses with clamps.
Figure 127.
A
C
D
E
G
H
B
B
F
A Cab heater valve B Heater hoses

C Control cable outer D Valve body
E Clip 1 F Clip 2
G Control cable H Valve lever.
12 - 57 9813/9400-1 12 - 57
21 - Heater Valve
00 - General
Install
steps.
1.1. Align the marks on the control cable outer
and valve body and then install a new clip 1.
1.2. Check the level of the engine coolant.
After installation
1. Start the engine and operate the cab heater at
the maximum temperature.
2. Operate the engine for the specified time.
Duration: 5min
3. Stop the engine and check for any coolant leaks.
12 - 58 9813/9400-1 12 - 58
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-61
12 - 59 9813/9400-1 12 - 59
Notes:
12 - 60 9813/9400-1 12 - 60
96 - Pipe
00 - General
Introduction .................................................... 12-61 The refrigeration pipes are responsible for carrying
Check (Condition) .......................................... 12-62 the refrigerant ( liquid and gas) around the closed
loop air conditioning system. There are usually 4
pipes that connect the system components:
• Suction Line-Evaporator to Compressor, the

low pressure refrigerant gas line.
• Discharge Line-Compressor to Condensor, the
high pressure, hot gas line coming out of the
compressor.
• Condenser drain line-Condensor to Receiver
drier
• Liquid line-Receiver drier to Evaporator
12 - 61 9813/9400-1 12 - 61
96 - Pipe
00 - General
Check (Condition)
2. Check all the visible pipes and connectors.
3. Look for areas where the hoses flex or are
fastened, clamped, connected, bent or go
through panels. All these areas are potential
wear and damage points.
4. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
5. Tighten the pipes and adaptors to the correct
torque value.
12 - 62 9813/9400-1 12 - 62
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-43
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-47
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-55
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-63
15-12-03 Main Bearing .................................................................................................................. 15-72
15-12-06 Front Oil Seal ................................................................................................................. 15-74
15-12-09 Rear Oil Seal ................................................................................................................. 15-77
15-12-12 Pulley .............................................................................................................................. 15-81
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-83
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-93
15-18-03 Drive Belt ....................................................................................................................... 15-96
15-18-21 Tensioner ...................................................................................................................... 15-100
15-21 Oil Filter
15-21-00 General ......................................................................................................................... 15-103
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-111
15-24-09 Dust Valve .................................................................................................................... 15-114
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-117
15-30 Valve
15-30-00 General ......................................................................................................................... 15-121
15-30-12 Valve Spring ................................................................................................................. 15-130
15-30-24 Stem Seal .................................................................................................................... 15-131
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-133
15-33-06 Big-End Bearing ........................................................................................................... 15-137
15-36 Piston
15-36-00 General ......................................................................................................................... 15-143
15-36-03 Piston Ring ................................................................................................................... 15-155
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-157
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-159
15-42-06 Rocker Cover ............................................................................................................... 15-168
9813/9400-1
2017-10-31
15-42-09 Push Rod ..................................................................................................................... 15-170
15-42-21 Tappet ........................................................................................................................... 15-172
15-42-24 Tappet Cover ................................................................................................................ 15-174
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-177
15-48 Grid Heater
15-48-00 General ......................................................................................................................... 15-183
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-187
15-51-03 Crankshaft Gear ........................................................................................................... 15-192
15-51-06 Camshaft Gear ............................................................................................................. 15-195
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-196
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-199
15-51-22 Rear Case .................................................................................................................... 15-202
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-207
15-54-03 Housing ........................................................................................................................ 15-211
15-54-09 Gear Ring ..................................................................................................................... 15-214
15-54-12 Drive Plate .................................................................................................................... 15-215
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-219
15-63 Mount
15-63-00 General ......................................................................................................................... 15-227
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-231
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-237
15-72-03 Pulley ............................................................................................................................ 15-243
15-72-06 Voltage Regulator ......................................................................................................... 15-244
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-247
15-75-03 Solenoid ....................................................................................................................... 15-255
15-75-06 Brush Gear ................................................................................................................... 15-256
15-80 Glow Plug
15-80-00 General ......................................................................................................................... 15-259
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-263
15-84-03 Crankshaft Position ...................................................................................................... 15-274
15-84-06 Camshaft Position ........................................................................................................ 15-278
15-84-09 Knock ........................................................................................................................... 15-282
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-285
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-288
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-291
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-294
15-84-19 Exhaust Temperature ................................................................................................... 15-297
15-84-24 Fuel Temperature ......................................................................................................... 15-300
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-303
15-84-29 Foot Throttle Control .................................................................................................... 15-306
15-84-33 Coolant Temperature .................................................................................................... 15-310
15-84-42 Engine Oil Temperature ............................................................................................... 15-313
15-84-43 Engine Oil Level ........................................................................................................... 15-316
9813/9400-1
2017-10-31
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-319
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-322
15-86 Solenoid
15-86-00 General ......................................................................................................................... 15-327
15-86-09 Cold Start Advance ...................................................................................................... 15-328
15-87 Switch
15-87-00 General ......................................................................................................................... 15-333
15-87-03 Engine Oil Pressure ..................................................................................................... 15-334
15-87-09 Cold Start ..................................................................................................................... 15-337
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-343
9813/9400-1
2017-10-31
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
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
HPV High Pressure Valve
IMV Inlet Metering Valve
LMS Loadall Monitoring System
MAF Mass Air Flow
NOx Nitrogen Oxide
PTO Power Take-Off
SCR Selective Catalytic Reduction
TDC Top Dead Centre
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
VGT Variable Geometry Turbocharger
9813/9400-1
2017-10-31
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/9400-1 15 - 1
Notes:
15 - 2 9813/9400-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-7 engine assembly. For specific engine technical
Technical Data ................................................. 15-8 information refer to the technical data section.
Component Identification ................................. 15-9
Make sure that the correct engine service tools,
Operation ....................................................... 15-14 consumables and torque figures are used when you
Diagram ......................................................... 15-18 perform service procedures.
Fault-Finding .................................................. 15-19
Drain and Fill ................................................. 15-29 Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
Clean ............................................................. 15-29 damage is expected as a matter of course.
Check (Condition) .......................................... 15-30
Check (Leaks) ............................................... 15-31 It is expected that components will be cleaned and
Check (Pressure) .......................................... 15-31 lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
Remove and Install ....................................... 15-34 excessive loss of hydraulic fluid, engine oil and
Store and Recommission .............................. 15-38 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 9813/9400-1 15 - 3
15 - Engine
00 - Engine
00 - General
Figure 128.
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 9813/9400-1 15 - 4
15 - Engine
00 - Engine
00 - General
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 129.
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 9813/9400-1 15 - 5
15 - Engine
00 - Engine
00 - General
Figure 130.
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 9813/9400-1 15 - 6
15 - Engine
00 - Engine
00 - General
Health and Safety accordance with local regulations. Use authorised

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
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 correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 7 9813/9400-1 15 - 7
15 - Engine
00 - Engine
00 - General
Technical Data
Table 42.
Description SJ Engine DJ Engine
Engine Variants Turbocharged with intercooler and Turbocharged with intercooler and
exhaust after treatment system exhaust after treatment system
Emission compliance US-EPA Tier 4 Final, EU Stage IV US-EPA Tier 4 Final, EU Stage IV
Rated speed 2200 rpm 2200 rpm (108kW), 2050 rpm
(129kW)
Weight (Dry) (Dry weight-No cooling fan drive) (Dry weight-No cooling fan drive)
496kg 496kg
Number of cylinders 4 4
Nominal bore size 103mm 106mm
Stroke 132mm 135mm
Cylinder arrangement In line In line
Combustion Cycle 4-stroke 4-stroke
Firing order 1-3-4-2 1-3-4-2
Displacement 4.399L 4.765L
Compression ratio 16.7: 1 16.7: 1
Engine Compression Compression variance between Compression variance between
each cylinder should be no greater each cylinder should be no greater
than 3.5bar (50.7psi) than 3.5bar (50.7psi)
Direction of rotation (viewed from Clockwise Clockwise
front {crankshaft pulley} end)
Valves 4 per cylinder 4 per cylinder
Valve clearances measured at the
tappet end of the rockers (mea-
sured cold)
- Inlet 0.15–0.21mm 0.15–0.21mm
- Exhaust 0.43–0.49mm 0.43–0.49mm
Lubricating oil pressure (Depen- 1.6–6.5bar (23.2–94.2psi) 1.6–6.5bar (23.2–94.2psi)
dent on engine temperature and
speed)
Fuel filter type Screw-on canister (with drain facil- Screw-on canister (with drain facil-
ity) ity)
Oil pressure relief valve setting 6bar (87.0psi) 6bar (87.0psi)
Oil pressure switch setting 0.6bar (8.7psi) falling 0.6bar (8.7psi) falling
Oil pump
(1)
Integral unit with relief valve Integral unit with relief valve
Combustion system Common rail direct Injection Common rail direct Injection
High pressure fuel pump High pressure with electronically High pressure with electronically
controlled fuel metering controlled fuel metering
(1) The oil pump is a non-serviceable part
15 - 8 9813/9400-1 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 131. Left hand Side
24
23 9
2
8
1
15
10
4
20
17
14 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
15 - 9 9813/9400-1 15 - 9
15 - Engine
00 - Engine
00 - General
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 Lubrication oil dipstick 16 Low duty PTO (Power Take-Off) (blanking
cover if no device is installed)
17 Low pressure fuel line (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 (if installed) 24 Intake throttle
15 - 10 9813/9400-1 15 - 10
15 - Engine
00 - Engine
00 - General
Figure 132. Right Hand Side

6
11 14
8
2
16
3
17
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) (not
installed on <55kW Engines)
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 - 11 9813/9400-1 15 - 11
15 - Engine
00 - Engine
00 - General
15 Oil drain plug (sump) 16 Coolant take off for cab heater
17 Coolant take off for SCR (Selective Catalytic
Reduction) system (not installed on <55kW
Engines)
Figure 133. 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 (Front End Accessory Drive) tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
11 VGT (not installed on <55kW Engines) 12 Coolant temperature sensor
15 - 12 9813/9400-1 15 - 12
15 - Engine
00 - Engine
00 - General
Figure 134. 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 (not installed on <55kW Engines) 8 VGT actuator (not installed on <55kW
Engines)
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
15 - 13 9813/9400-1 15 - 13
15 - Engine
00 - Engine
00 - General
Operation
The Four Stroke Cycle - 4 Cylinder It is important to note that number 1 cylinder is firing
Engine and about to start its power stroke. Rotating the
crankshaft a further full rotation would position the
This section describes the cycle sequence, for the 4 pistons as described but the engine would be at a
cylinder engine. different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons
in numbers 1 and 4 cylinders are at top dead centre The stages in the four stroke cycle for each cylinder
and pistons in numbers 2 and 3 cylinders are at are as follows:
bottom dead centre.
Table 43. The Four Stroke Cycle

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

number 1 cylinder will be next to fire. Number 3
A cylinder is said to be firing, when the fuel / air cylinder is starting its compression stroke and is next
mixture ignites and the piston is about to start its in the cycle, followed by cylinders 4 and 2.
power stroke.
The firing order is therefore; 1, 3, 4, 2.
15 - 14 9813/9400-1 15 - 14
15 - Engine
00 - Engine
00 - General
Figure 135.
CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
15 - 15 9813/9400-1 15 - 15
15 - Engine
00 - Engine
00 - General
Four Stroke Cycle revolution of the crankshaft, thus, in one cycle of a

four stroke engine, the crankshaft revolves twice.
Induction
Figure 136.
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the 3

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

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

both temperature and pressure. The high pressure 746030
generated propels the piston downward turning the 1 Induction stroke
crankshaft and producing energy. 2 Compression stroke
3 Power stroke
Exhaust 4 Exhaust stroke
A Camshaft
Once the piston has reached the bottom of its travel, B Camshaft lobe - Inlet valve operation
the exhaust valves open and momentum stored C Camshaft lobe - Exhaust valve operation
in the flywheel forces the piston up the cylinder BDC Bottom dead centre
expelling the exhaust gases. TDC TDC (Top Dead Centre)
In a running engine these four phases are
continuously repeated. Each stroke is half a
15 - 16 9813/9400-1 15 - 16
15 - Engine
00 - Engine
00 - General
Figure 137.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
15 - 17 9813/9400-1 15 - 17
15 - Engine
00 - Engine
00 - General
Diagram
Electrical Operation and Schematics signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
The schematic diagram shows a typical system. CAN (Controller Area Network)bus to tell the Engine
For machine specific schematics, refer to electrical ECU that the transmission is in Neutral.
system- general, refer to (PIL 33-00).
The engine ECU provides power to the engine
The schematic is shown with the ignition switch compartment fusebox to energise the start relay, the
set to position III and the transmission set to N. A fuel pump relay, the starter motor and the fuel pump.
Figure 138.
Charge
D+
W
A
ECU
F
M
D
+VE -VE
3
4
5 H
1 6
2 7 M
E 8
9 K
10
J
C ECU
+VE G -VE
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU
15 - 18 9813/9400-1 15 - 18
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 44. Page 15-19
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 45. Page 15-20
Engine - Will Not Crank or Cranks Slowly Table 46. Page 15-20
Engine - Starts Then Stops Table 47. Page 15-21
Engine - Poor Running Table 48. Page 15-21
Engine - Poor Running at Idle Table 49. Page 15-22
Engine - Noise Excessive Table 50. Page 15-23
Engine - Compression Knocks Table 51. Page 15-23
Engine - Reduced Power Output Table 52. Page 15-24
Engine - Will Not Reach Maximum RPM Table 53. Page 15-25
Engine - RPM Surges Table 54. Page 15-25
Engine - Vibration Excessive Table 55. Page 15-26
Engine - Exhaust Smoke Excessive (Black Smoke) Table 56. Page 15-26
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 57. Page 15-27
Engine - Will Not Shut Off Table 58. Page 15-27
Lubricating Oil - Consumption Excessive Table 59. Page 15-27
Lubricating Oil - Contaminated Table 60. Page 15-28
Lubricating Oil - Pressure Low Table 61. Page 15-28
Lubricating Oil - Pressure High Table 62. Page 15-28
Table 44. 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.
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.
15 - 19 9813/9400-1 15 - 19
15 - Engine
00 - Engine
00 - General
Table 45. 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: 0.133bar (1.9psi)
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 46. Engine - Will Not Crank or
Cranks Slowly
ECM or electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at the ECM and sensors.
Table 46. 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.
15 - 20 9813/9400-1 15 - 20
15 - Engine
00 - Engine
00 - General
Table 47. Engine - Starts Then Stops

Cause Remedy
Engine starting under load. Check for added loading from malfunctioning
accessories or driven units, brakes dragging and
other changes in vehicle loading. Disengage the
hydraulic controls.
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump.
Fuel is waxing due to extremely cold weather. Verify by inspecting the fuel filter. Clean the system
and use acclimatised fuel.
pump and injectors.
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return lines are not obstructed and
ECM or Electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at theECM and sensors.
Table 48. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 49. 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.
15 - 21 9813/9400-1 15 - 21
15 - Engine
00 - Engine
00 - General
Cause Remedy
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 49. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
install new ones.
system.
inadequate). fuel to the injection pump.
restriction.
pump and injectors.
clearances.
15 - 22 9813/9400-1 15 - 22
15 - Engine
00 - Engine
00 - General
Table 50. 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 56. 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.
Table 51. 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.
15 - 23 9813/9400-1 15 - 23
15 - Engine
00 - Engine
00 - General
Table 52. 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.
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
15 - 24 9813/9400-1 15 - 24
15 - Engine
00 - Engine
00 - General
Table 53. 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 54. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
system.
15 - 25 9813/9400-1 15 - 25
15 - Engine
00 - Engine
00 - General
Table 55. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 49. 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 56. 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.
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
15 - 26 9813/9400-1 15 - 26
15 - Engine
00 - Engine
00 - General
Table 57. 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 58. 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 59. 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.
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.
15 - 27 9813/9400-1 15 - 27
15 - Engine
00 - Engine
00 - General
Table 60. 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 61. 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 62. Lubricating Oil - Pressure High

Cause Remedy
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Engine running too cold. Check and if necessary replace the engine
thermostat.
Oil pump pressure relief valve stuck closed. Replace oil pump assembly.
15 - 28 9813/9400-1 15 - 28
15 - Engine
00 - Engine
00 - General
Drain and Fill Clean

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

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

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

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

2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
15 - 29 9813/9400-1 15 - 29
15 - Engine
00 - Engine
00 - General
9. When the pressure washing is complete move Check (Condition)

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

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

working on the high pressure fuel system. Refer to:
PIL 18-00-00.
15 - 30 9813/9400-1 15 - 30
15 - Engine
00 - Engine
00 - General
Check (Leaks) Check (Pressure)

Special Tools
Before you start the machine, do a check for oil leaks: Description Part No. Qty.
Servicemaster 721/10855 1
Electronic Test Cable
2. Get access to the engine compartment (if Pressure Gauge (0-40 892/00278 1
applicable) Bar)
Servicemaster 892/01033 1*
3. Check the engine and the area below for oil Electronic Test Kit 892/01174
leaks. Data Link Adaptor
4. Close the engine cover (if applicable). (DLA) Kit
Digital Hydraulic 998/11051 1
5. If necessary, contact your JCB dealer. Pressure Test Kit
*Unless otherwise stated, you can use any of the
tools shown.
This test is used to diagnose suspected poor

compression in one or more of the engine cylinders.
Use ServiceMaster to control the test.
Engine Compression Test

1. Connect the Servicemaster tool to the machine,
refer to (PIL 33-57).
Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
Special Tool: Servicemaster Electronic Test
Cable (Qty.: 1)
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:
15 - 31 9813/9400-1 15 - 31
15 - Engine
00 - Engine
00 - General
• The correct engine oil has been used, refer to Figure 139.
Consumable Products, Oil (PIL 75-03).
• 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.
4. Install a suitable adaptor into the vacant pressure A
switch port (M10 x 1.5mm thread) and a pressure
test gauge. Make sure that the gauge has a
sealing washer as shown.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1)
A Oil pressure switch

B Sealing washer
5. Start the engine and allow a few seconds to
gain oil pressure, increase the engine revs to
the rated speed. Record the pressure gauge
reading, refer to Technical Data (PIL 15-00), for
the recommended circuit pressure.
6. Remove the pressure gauge and install the
pressure switch.
15 - 32 9813/9400-1 15 - 32
15 - Engine
00 - Engine
00 - General
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

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
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.
• Damaged oil pump - oil pressure will be high at
low oil temperature but fall when oil becomes
hotter.
15 - 33 9813/9400-1 15 - 33
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 140.
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 - 34 9813/9400-1 15 - 34
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 - 35 9813/9400-1 15 - 35
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 - 36 9813/9400-1 15 - 36
15 - Engine
00 - Engine
00 - General
Figure 141. 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 - 37 9813/9400-1 15 - 37
15 - Engine
00 - Engine
00 - General
Store and Recommission
Engines should be stored in the original shipping If an engine is to be placed into storage, all external
packaging. Damaged or disturbed packaging should signs of surface coating damage or corrosion should
be made weatherproof immediately. be cleaned and re-coated. Electrical connectors and
components should be coated with a protective
If an engine is shipped with oil, it should be stored in spray.
the correct (upright) position.
The DEF (Diesel Exhaust Fluid) tank should be at
If an engine is shipped dry of oil, after 6 months it least 20% full before being placed in to storage.
should be filled with oil to the correct level and re-
inhibited, refer to hot test description. Capping Engine Openings
All floor stock engines should be stored under cover All openings on the engine must be suitably capped
in dry conditions and not subjected to extreme to prevent ingress of water and contamination by
variations in temperature or humidity. foreign particles.
Figure 142.
13
5
3
4
14
16
12
11
2
10
8 15
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
15 - 38 9813/9400-1 15 - 38
15 - Engine
00 - Engine
00 - General
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 16 SCR (Selective Catalytic Reduction) coolant
feed spigot (if installed)
12 Month Revalidation Procedure Table 64. Oil Pressure Switch Set Points
1. Pre-inspection: Oil pressure switch >0.6bar (8.7psi)

closed
1.1. Inspect packaging for signs of damage. Oil pressure switch open <0.6bar (8.7psi)
1.2. Inspect the caps for signs of damage.
OEM Commissioning Check on Engine
1.3. Inspect openings for signs of water or dirt Installation After More Than 12 Months
ingress.
1.4. Inspect the engine for signs of external 1. Flush the coolant system with proprietary
corrosion. flushing solution.
1.5. Inspect the engine for signs of fluid leaks. 2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
1.6. Check that the DEF tank level is above the
specified level. 3. Hot test engine according to the hot test profile.
Percentage: 20% Refer to Table 65.
2. From storage: 4. Drain engine oil and replace engine oil filter.
2.1. Remove the air intake caps. 5. Refill with the correct oil and inhibit the cooling
system using the correct product.
2.2. Make sure the engine oil level is correct.
6. Drain the DEF tank.
2.3. Using a suitable power supply at the correct
voltage, crank the engine over. 7. Fill the DEF tank with clean good quality DEF.
2.4. During cranking, check that the oil pressure Leave to stand for the specified time period.
switch opens using a multimeter. The switch Duration: 72h
is closed when there is no or low oil
pressure and opens when oil pressure 8. Record details of work as required.
reaches a set point. After three separate 20
second cranking periods, If the oil pressure Hot Test Description
switch does not open (indicating no, or
WARNING When using cleaning agents, solvents
low oil pressure), contact your JCB engine
or other chemicals, you must adhere to
dealer.
the manufacturer's instructions and safety
2.5. Recap all engine openings. precautions.
2.6. Coat any exposed bare metal with a
suitable product. All engines despatched from JCB will have been
subjected to a hot test (checking items such as oil
2.7. Electrical connectors and components pressure, engines speeds, torque values etc.) and
should be coated with a protective spray if therefore the interior surfaces will have been coated
exposed. with engine oil.
2.8. Cover in weatherproof packaging.
All coolant galleries are coated with CRODAFLUID
2.9. Place in storage, under cover on level PA75 corrosion inhibitor.
ground or shelving.
2.10. Record details of work as required. Stored engines will require re-inhibiting every 12
months, this will include hot testing the engine using
2.11. Do not expose to extremes of temperature a dynamometer. The hot test profile is:
or humidity.
Notice: Do not operate the starter motor for more
than 20s at one time. Let the starter motor cool for
at least 2min.
15 - 39 9813/9400-1 15 - 39
15 - Engine
00 - Engine
00 - General
Table 65. 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 - 40 9813/9400-1 15 - 40
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-43
15 - 41 9813/9400-1 15 - 41
Notes:
15 - 42 9813/9400-1 15 - 42
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-43 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-44 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 143.
A
A Crankcase
B Crankshaft
15 - 43 9813/9400-1 15 - 43
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 66. Crankcase and Bedplate Data

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

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

Diameter of second oversize bore 104–104.02mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92–92.02mm 92–92.02mm
Number 5 105–105.02mm 105–105.02mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047–88.09mm 88.047–88.09mm
Number 5 100.047–100.09mm 100.047–100.09mm
Camshaft bore
Numbers 1 to 4 60.04–60.07mm 60.04–60.07mm
Number 5 (bush) 60.29–60.32mm 60.29–60.32mm
Permissible wave profile wt < 10m (2.5 distance) wt < 10m (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 - 44 9813/9400-1 15 - 44
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-47
15 - 45 9813/9400-1 15 - 45
Notes:
15 - 46 9813/9400-1 15 - 46
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-47 The cylinder head is located above the cylinders
Technical Data ............................................... 15-48 on top of the crankcase. It closes in the top of the
Component Identification ............................... 15-49 cylinder, forming the combustion chamber. This joint
Remove and Install ....................................... 15-50 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 - 47 9813/9400-1 15 - 47
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 67. Cylinder Head Data

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

- Side to side 0.03mm
Valve recess depth
- Inlet 0.85mm
- Exhaust 0.85mm
Valve seat angle
- Inlet 120(inclusive)
- Exhaust 90(inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10m 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 - 48 9813/9400-1 15 - 48
15 - Engine
06 - Cylinder Head
00 - General
Figure 144.
C
A Cylinder head
B Cylinder head gasket
C Cylinder head bolts
15 - 49 9813/9400-1 15 - 49
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 0.4L 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 - 50 9813/9400-1 15 - 50
15 - Engine
06 - Cylinder Head
00 - General
Figure 145.
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 - 51 9813/9400-1 15 - 51
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 68.
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 40N·m
at X.
- second stage torque 75N·m
3. Make sure that all items are clean and free from - third stage torque 75N·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 - 52 9813/9400-1 15 - 52
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-55
15 - 53 9813/9400-1 15 - 53
Notes:
15 - 54 9813/9400-1 15 - 54
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-55 The bedplate acts as the main strength component
Remove and Install ....................................... 15-56 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 146.
1
1 Bedplate
2 Crankcase
15 - 55 9813/9400-1 15 - 55
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 0.4L 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 - 56 9813/9400-1 15 - 56
15 - Engine
09 - Bedplate
00 - General
Figure 147.
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 - 57 9813/9400-1 15 - 57
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 148.
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 - 58 9813/9400-1 15 - 58
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 - 59 9813/9400-1 15 - 59
15 - Engine
09 - Bedplate
00 - General
Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.
7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, Before removal
the crankcase, NOT the bedplate. The sealant in reverse order.
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Table 69. Torque Table
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1) Item Torque Value
1-10 (1st Stage) 50N·m
8. Locate the holes in the templates A and B using 1-10 (2nd Stage) 115N·m
four fixing bolts at positions Y. Use the templates
15 - 60 9813/9400-1 15 - 60
15 - Engine
09 - Bedplate
00 - General
Item Torque Value

1-10 (Final Stage) 180°
11 24N·m
15 - 61 9813/9400-1 15 - 61
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-63

15-12-03 Main Bearing .................................................................................................................. 15-72
15-12-06 Front Oil Seal ................................................................................................................. 15-74
15-12-09 Rear Oil Seal ................................................................................................................. 15-77
15-12-12 Pulley .............................................................................................................................. 15-81
15 - 62 9813/9400-1 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-63 Figure 149.
Technical Data ............................................... 15-64
Operation ....................................................... 15-66
Check (Condition) .......................................... 15-67
A
A Crankcase
B Crankshaft
15 - 63 9813/9400-1 15 - 63
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 70.
Main bearing journal diameter (x4)
- min 87.98mm
- max 88mm
Main rear bearing journal diameter (x1)
- min 99.98mm
- max 100mm
Connecting rod bearing journal diameter
- min 72.98mm
- max 73mm
Maximum wear and ovality on journals
(1)
Crankshaft induction hardness 55 HRc min on surface

Thrust washer width
- min 2.44mm
- max 2.5mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
(1) No visible damage/wear or marks
15 - 64 9813/9400-1 15 - 64
15 - Engine
12 - Crankshaft
00 - General
Figure 150.
A
A Crankcase
B Crankshaft
15 - 65 9813/9400-1 15 - 65
15 - Engine
12 - Crankshaft
00 - General
Operation
Lubrication transfer to cross drillings in the crankshaft to feed

each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
diameter of the upper main bearing shell allows oil engine.
Figure 151.
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 - 66 9813/9400-1 15 - 66
15 - Engine
12 - Crankshaft
00 - General
1. Check the main bearing surfaces for damage and

excessive wear.
Figure 152.
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 153.
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 - 67 9813/9400-1 15 - 67
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 0.4L 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 - 68 9813/9400-1 15 - 68
15 - Engine
12 - Crankshaft
00 - General
Figure 155.
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 156. Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
D
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
steps.
2. Make sure that all items are clean and free from
3. If removed or a new crankcase is being installed
D Main bearing shells then install cooling J jets as follows:
5. It is recommended that the bearing shells are

replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
15 - 69 9813/9400-1 15 - 69
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 - 70 9813/9400-1 15 - 70
15 - Engine
12 - Crankshaft
00 - General
Figure 159.
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 - 71 9813/9400-1 15 - 71
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-72 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-73 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 160.
A Main bearing
B Crankshaft
15 - 72 9813/9400-1 15 - 72
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 - 73 9813/9400-1 15 - 73
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 161.

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 162.
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
162.
15 - 74 9813/9400-1 15 - 74
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 162.
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 163.
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
163. G
Dimension: -0.5 -0/+0.5mm
C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
15 - 75 9813/9400-1 15 - 75
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 - 76 9813/9400-1 15 - 76
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install
Special Tools Figure 165. 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 164. 24mm Hub
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
15 - 77 9813/9400-1 15 - 77
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 166.
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 167.
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 - 78 9813/9400-1 15 - 78
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 168.
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 169.
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 - 79 9813/9400-1 15 - 79
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 - 80 9813/9400-1 15 - 80
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1. This procedure requires service parts. Make 1)
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
you start the service work. Figure 171.

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 170.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 73.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·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 - 81 9813/9400-1 15 - 81
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-83
15 - 82 9813/9400-1 15 - 82
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-83
Technical Data ............................................... 15-85
Operation ....................................................... 15-87
Check (Condition) .......................................... 15-88
Figure 172.
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
15 - 83 9813/9400-1 15 - 83
15 - Engine
15 - Camshaft
00 - General
4 Tappets 5 Push rods

15 Inlet valves 16 Exhaust valves
15 - 84 9813/9400-1 15 - 84
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 74. Camshaft Data

Camshaft journal diame-
ter
- 4 off 59.99–59.97mm
- 1 off 60.25–60.22mm
Camshaft lobe wear lim-
its
Inlet lift 7.161–7.271mm
Exhaust lift 7.2–7.31mm
Camshaft bore diameter
- 4 off 60.07–60.04mm
- 1 off 60.32–60.29mm
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 - 85 9813/9400-1 15 - 85
15 - Engine
15 - Camshaft
00 - General
Figure 173.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700

3 Camshaft 3a Camshaft lobes
4 Tappets 5 Push rods
15 Inlet valves 16 Exhaust valves
15 - 86 9813/9400-1 15 - 86
15 - Engine
15 - Camshaft
00 - General
Operation
As the crankshaft rotates the camshaft also rotates, during the cycle it follows that the camshaft is driven
driven by a gear on the crankshaft. The inlet and at half crankshaft (engine) speed.
exhaust valves are opened by lobes on the camshaft
in time with the cycle. Lubrication
The diagrams show the position of the camshaft at Oil is fed from the main gallery via a drilling to the
each part of the four stroke cycle, refer to Engine- camshaft bearing. A groove around the diameter of
General, Operation. Refer to: PIL 15-00-00. the bearing and connecting the cross drilling ensures
that oil is always fed to the centre drilling. Oil is then
It can be seen that for a complete cycle the camshaft transferred to the remaining camshaft bearings by
revolves once. Since the crankshaft revolves twice further cross drillings in the shaft. The cam lobes and
tappets are 'splash' lubricated.
Figure 174.
1 Main gallery 2 Camshaft bearing

3 Groove 4 Centre drilling
15 - 87 9813/9400-1 15 - 87
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 175.
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 - 88 9813/9400-1 15 - 88
15 - Engine
15 - Camshaft
00 - General
Figure 176. 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 178.
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 177. 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 - 89 9813/9400-1 15 - 89
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 - 90 9813/9400-1 15 - 90
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-93

15-18-03 Drive Belt ....................................................................................................................... 15-96
15-18-21 Tensioner ...................................................................................................................... 15-100
15 - 91 9813/9400-1 15 - 91
Notes:
15 - 92 9813/9400-1 15 - 92
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-93 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-94 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-94 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 - 93 9813/9400-1 15 - 93
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 179. 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 180. 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 - 94 9813/9400-1 15 - 94
15 - Engine
18 - Engine Belt
00 - General
Figure 181. C - With air conditioning com-

pressor, cooling fan pulley installed
C
6
4
5
3
7
Figure 182. 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 - 95 9813/9400-1 15 - 95
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-96 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-97 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-97 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-98 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 - 96 9813/9400-1 15 - 96
15 - Engine
18 - Engine Belt
03 - Drive Belt
Health and Safety Check (Condition)

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

2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 183.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 97 9813/9400-1 15 - 97
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A Remove

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct 1. Make the machine safe. Refer to (PIL 01-03).
tension.
3. Use a socket of the specified size to locate
on to the hexagon spigot nut, carefully rotate
the tensioner against the spring force in the
direction shown. Do not use excessive force or
the tensioner will be damaged.
Dimension: 16mm
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 - 98 9813/9400-1 15 - 98
15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 184.
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 - 99 9813/9400-1 15 - 99
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 75. Torque Values

4. Remove the drive belt, refer to (PIL 15-18). Item Nm
2 24
Figure 185.
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 - 100 9813/9400-1 15 - 100

15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ......................................................................................................................... 15-103
15 - 101 9813/9400-1 15 - 101

Notes:
15 - 102 9813/9400-1 15 - 102

15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................. 15-103 The oil filter is a spin on type which screws on and
Health and Safety ........................................ 15-104 off the oil filter head.
Component Identification ............................. 15-105
Operation ..................................................... 15-107
Check (Level) .............................................. 15-107
Remove and Install ..................................... 15-108
15 - 103 9813/9400-1 15 - 103

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 - 104 9813/9400-1 15 - 104

15 - Engine
21 - Oil Filter
00 - General
Figure 186.
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 - 105 9813/9400-1 15 - 105

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 - 106 9813/9400-1 15 - 106

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 187.
draining. These features help protect the engine from
oil starvation on start up. B
A Dipstick
B Oil filler point
15 - 107 9813/9400-1 15 - 107

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: 30s
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: 10s
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: 10s
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 - 108 9813/9400-1 15 - 108

15 - Engine
21 - Oil Filter
00 - General
Figure 188.
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 - 109 9813/9400-1 15 - 109

15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ......................................................................................................................... 15-111

15-24-09 Dust Valve .................................................................................................................... 15-114
15 - 110 9813/9400-1 15 - 110

15 - Engine
24 - Air Filter
00 - General
Introduction .................................................. 15-111 Engine performance and durability will be severely
Health and Safety ........................................ 15-112 affected if the quality of the air intake is poor.
Check (Condition) ........................................ 15-112
Remove and Install ..................................... 15-113 A dirty and blocked air cleaner element will reduce
the amount of air entering the combustion chamber
which can cause engine mis-firing, black smoke and
low output power.
A dirty and blocked air filter can also lead to abrasion

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

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

installed.
15 - 111 9813/9400-1 15 - 111

15 - Engine
24 - Air Filter
00 - General

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

with a vacuum switch. The switch will detect if there
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual
indicator.
15 - 112 9813/9400-1 15 - 112

15 - Engine
24 - Air Filter
00 - General
Remove and Install Figure 189.
B
Do not attempt to wash or clean the elements, they
must only be renewed.
A new inner element must be installed at least

every other time the outer element is changed. As
a reminder, mark the inner element with marker pen
each time the outer element is changed.
F
Remove E
D
3. Depress the clips and lift off the cover.
4. Remove the outer element. Take care not to tap
or knock the element.
5. If the inner element is to be changed, lift up pulls
and remove the inner element.
G
C
B Clips
C Cover
D Outer element
E Inner element
F Housing
G Air holes
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that dust valve is at the bottom.
15 - 113 9813/9400-1 15 - 113

15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve
Check (Condition)
• Check the dust valve for rips/tears.
• Check there are no obstructions.
• Check that the dust valve is free of dirt and dust.
• Check that the dust valve securely attached to
the air filter housing.
15 - 114 9813/9400-1 15 - 114

15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ......................................................................................................................... 15-117
15 - 115 9813/9400-1 15 - 115

Notes:
15 - 116 9813/9400-1 15 - 116

15 - Engine
00 - General
Introduction .................................................. 15-117 Depending on the specification, the engine may be
Component Identification ............................. 15-118 installed with open loop, filtered open loop or a closed
Operation ..................................................... 15-119 loop CCV (Crankcase Ventilation) system.
15 - 117 9813/9400-1 15 - 117

15 - Engine
00 - General
Figure 190. 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 - 118 9813/9400-1 15 - 118

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 191.
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 - 119 9813/9400-1 15 - 119

15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ......................................................................................................................... 15-121

15-30-12 Valve Spring ................................................................................................................. 15-130
15-30-24 Stem Seal .................................................................................................................... 15-131
15 - 120 9813/9400-1 15 - 120

15 - Engine
30 - Valve
00 - General
Introduction .................................................. 15-121 The valve train system opens and closes the
Technical Data ............................................. 15-122 valves with correct timing in relation to the piston
Component Identification ............................. 15-123 movements.
Operation ..................................................... 15-125
Each push rod has one end in a valve tappet and the
Adjust .......................................................... 15-125 other end under a rocker arm, or as applicable. The
Remove and Install ..................................... 15-128 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 - 121 9813/9400-1 15 - 121

15 - Engine
30 - Valve
00 - General
Technical Data
Table 77. Inlet and Exhaust Valve Data

Max lift Inlet 9.64mm @ 101° ATDC
Max lift Exhaust 9.84mm @ 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 6.928–6.943mm
- Exhaust 6.918–6.933mm
Valve spring free length 51.1mm
Valve guide bore diame-
ter
- min 6.958mm
- max 6.973mm
Valve face angle
- Inlet 60.5°
- Exhaust 45.17°
Valve length 131.9–132.4mm
Valve sealing Stem seal with sealing
washer
Valve head depth (below
cylinder head surface)
- Inlet 0.89–1.39mm
- Exhaust 0.95–1.45mm
Valve rim thickness 2.98–3.38mm
Valve Clearances (en-
gine cold)
- Inlet 0.15–0.21mm
(1)
(1)
(1) The values refer to the tappet adjuster end of the

valve rockers.
15 - 122 9813/9400-1 15 - 122

15 - Engine
30 - Valve
00 - General
Figure 192.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700

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 - 123 9813/9400-1 15 - 123

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

17 Valve stem
Cross Sectional View
Figure 193.
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 - 124 9813/9400-1 15 - 124

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 - 125 9813/9400-1 15 - 125

15 - Engine
30 - Valve
00 - General
Figure 194. Figure 196. 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 195. 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 - 126 9813/9400-1 15 - 126

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 - 127 9813/9400-1 15 - 127

15 - Engine
30 - Valve
00 - General
Remove and Install Figure 199. 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 200.
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 201.
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 - 128 9813/9400-1 15 - 128

15 - Engine
30 - Valve
00 - General
Figure 202. 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 203. 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 - 129 9813/9400-1 15 - 129

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

15 - 130 9813/9400-1 15 - 130

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

15 - 131 9813/9400-1 15 - 131

15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ......................................................................................................................... 15-133

15-33-06 Big-End Bearing ........................................................................................................... 15-137
15 - 132 9813/9400-1 15 - 132

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-133 The connecting rod connects the piston to the
Technical Data ............................................. 15-134 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-134 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-135
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-135 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-136 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 - 133 9813/9400-1 15 - 133

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 78. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 77–77.01mm
ameter
Connecting rod side
clearance
min 0.05mm
max 0.4mm
Big end bearings
Width 32.5–33mm
Thickness (at centre) 1.99–1.981mm
Small end bearings
Inside diameter 40.034–40.02mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 134 9813/9400-1 15 - 134

15 - Engine
33 - Connecting Rod
00 - General

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

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 135 9813/9400-1 15 - 135

15 - Engine
33 - Connecting Rod
00 - General

15 - 136 9813/9400-1 15 - 136

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

Introduction .................................................. 15-137 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-138 bearings at the big-end of the connecting rod.
15 - 137 9813/9400-1 15 - 137

15 - Engine
33 - Connecting Rod

Special Tools
1. Check the bearing shell surfaces for signs of Description Part No. Qty.
Torque Wrench 993/70111 1
2. Measure the crank pin diameters to confirm they (10-100Nm)
are within service limits. Refer to Technical Data
(PIL 15-00-00). Before Removal
3. Renew any parts that are worn or not within the 1. This procedure requires service parts. Make
specified tolerances. sure you have obtained the correct service parts
before you start. Refer to Parts Catalogue.
injectors. Refer to (PIL 18-96).
5. Remove the rocker cover. Refer to (PIL 15-42).
6. Remove the fuel injectors. Refer to (PIL 18-18).
7. Drain the oil from the engine. Refer to (PIL
15-21).
8. Remove the oil sump. Refer to (PIL 15-45).
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
The connecting rod and the big-end bearing cap

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 138 9813/9400-1 15 - 138

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

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

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear. Refer to Check Condition
(PIL 15-12).
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
15 - 139 9813/9400-1 15 - 139

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

bearing cap. Lubricate the bearing shell with
clean engine oil. Install the big-end bearing cap
to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
1)
Figure 206.
T3
T3 Angle gauge (obtain locally)

5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
6. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
Figure 207.
0° +90°
After Installation
1. Carry out the procedures listed in Before
Removal in reverse order.
Table 79.
Item Torque Value
2 - 1st Stage 35N·m
2 - 2nd Stage 65N·m
2 - Final Stage 90°
15 - 140 9813/9400-1 15 - 140

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-143

15-36-03 Piston Ring ................................................................................................................... 15-155
15 - 141 9813/9400-1 15 - 141

Notes:
15 - 142 9813/9400-1 15 - 142

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-143 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-144 expanding combustion gases in the combustion
Component Identification ............................. 15-145 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-146 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-147
Calibrate ...................................................... 15-147 The pistons are cast from aluminium alloys for
Remove and Install ..................................... 15-149 increased strength and improved fatigue life.
Disassemble and Assemble ........................ 15-152
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 - 143 9813/9400-1 15 - 143

15 - Engine
36 - Piston
00 - General
Technical Data
Table 80.
Engine 444 - SE Engine 444 - excluding SE en- 448, 672
gine
Gudgeon pin bore diame-
ter
- min. 4.0008mm 40.01mm 42.008mm
- max. 40.013mm 40.015mm 42.013mm
Piston ring clearance
- Top ring Half keystone ring Full keystone ring Full keystone ring
- Middle ring 0.11–0.07mm 0.125–0.08mm 0.125–0.08mm
- Bottom (oil) ring 0.09–0.05mm 0.09–0.05mm 0.09–0.05mm
Piston ring gap
- Top ring 0.3–0.5mm 0.3–0.4mm 0.3–0.4mm
Piston height above 0.0375–0.3385mm 0.00025–0.36825mm
(1)
0.00025–0.36825mm
(1)
crankcase (cold)
Piston groove width
- Top ring 3.108–3.133mm 3.114–3.134mm 3.114–3.134mm
Piston skirt - 102.853–102.871mm 105.851–105.869mm
Piston pin - 39.994–40mm 41.994–42mm
(1) Nominal measurement is 0.03325mm
15 - 144 9813/9400-1 15 - 144

15 - Engine
36 - Piston
00 - General
Figure 208.
C
D
E
A F
F
A Piston
B Connecting rod
C Oil control ring
D Piston ring - compression No.1
E Piston ring - compression No.2
F Retaining circlips
G Piston pin
15 - 145 9813/9400-1 15 - 145

15 - Engine
36 - Piston
00 - General
Operation
The groove around the diameter of the upper main top of the pistons. Oil spray also enters the small end
bearing shells allows oil transfer to an oil jet located bearing bushes via a feed hole on the top of each
in the crankcase bearing saddle. Jets are installed at connecting rod.
the main bearing positions.
Note: On turbocharged engines additional J-jets are
The jets spray oil directly to the under side of the installed. Oilways connect the J-shaped jets fixed to
pistons effectively transferring heat away from the the crankcase at the underside of each cylinder bore.
Figure 209.
1 1
6
2
5
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft 6 J shaped jets
15 - 146 9813/9400-1 15 - 146

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

1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
Piston Height Measurement Above
diameter, piston pin bore and the clearance in Cylinder Block- DTI Method
the piston ring grooves to confirm they are within
service limits. In the event of sufficient liquid entering the engine, a
hydraulic lock can occur. This may result in bending
Refer to: PIL 15-36-00. of one or more of the connecting rods. Bending of the
connecting rod(s) can occur even when the engine is
2. Check the piston pin for signs of damage and cranked by the starter motor.
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston. Bending of the connecting rod may be very slight and
Refer to: PIL 15-36-00. can be checked by carrying out this procedure prior
to a full strip down:
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged 1. With the cylinder head removed, make sure the
or worn the connecting rod must be renewed as a surface of the engine block and piston are clean.
complete assembly.
2. Zero a DTI (Dial Test Indicator) on the top face
of the cylinder block adjacent to the area on the
piston to be measured. The aim of the procedure
is to use the DTI to take a measurement across 2
locations on the piston that are on the axis of the
gudgeon pin. This will be towards the front and
rear of the engine.
3. Rotate the engine and bring the piston up until
it is 3mm below the engine block face. Carefully
reposition the zeroed DTI above the area of the
piston to be measured.
4. Rotate the engine to bring the piston up to
exactly TDC (Top Dead Centre) and record the
measurement at position 1.
5. Repeat steps 2 to 4 for position 2.
6. Calculate the average of the 2 readings to give
a figure of the piston height above the cylinder
block.
7. Compare the reading obtained to the technical
data.
7.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
7.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
8. Repeat steps 2 to 7 to check all connecting rods/
pistons.
9. If any connecting rods are bent, strip the engine
and check for further damage.
10. If the engine is serviceable, any connecting rod
that is bent must be replaced.
15 - 147 9813/9400-1 15 - 147

15 - Engine
36 - Piston
00 - General
Figure 210. DTI Measurement 5. Calculate the average of the 2 readings to give
D a figure of the piston height above the cylinder
block.
C
5.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
5.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
B Refer to: PIL 15-36-00.
6. Repeat steps 1 to 5.2 to check all connecting
rods/pistons.
Figure 211. Straight Edge Measurement
G
F
E
A Gudgeon pin axis

B Line of measurement above gudgeon pin axis K
C Piston measurement point 1
D Piston measurement point 2
L
Piston Height Measurement Above
Cylinder Block- Straight Edge Method
If a DTI is not available, a calibrated straight E Straight edge
edge may be used to take a measurement. The F Measurement position 1
measurement will be less accurate. G Measurement position 2
H Cylinder block- top face
1. With the cylinder head removed, make sure the J Gudgeon pin axis
surface of the engine block and piston are clean. K Piston
L Connecting rod
2. Rotate the engine until the piston to be measured
is at TDC.
3. Position the straight edge on top of the piston
along the axis of the gudgeon pin.
4. Use feeler gauges to measure the gap between
the cylinder block face and underside of the
straight edge on both sides, position 1 and
position 2.
15 - 148 9813/9400-1 15 - 148

15 - Engine
36 - Piston
00 - General
Remove and Install
Before Removal 3. Get access to the engine.
The following procedure is for one piston and 4. Disconnect and remove the fuel pipes from the
connecting rod assembly. Note that each assembly injectors. Refer to (PIL 18-96).
must be replaced in the same cylinder bore. Label 5. Remove the rocker cover. Refer to (PIL 15-42).
each piston and connecting rod assembly to make
sure it is installed in the correct position on assembly. 6. Remove the fuel injectors. Refer to (PIL 18-18).
1. This procedure requires service parts. Make sure 7. Remove the cylinder head assembly. Refer to
that you have obtained the correct service parts (PIL 15-06).
before you start. Refer to Parts Catalogue.
8. Remove the oil sump. Refer to (PIL 15-45).
the engine has been running, let it cool before 9. Remove the big end bearing caps. Refer to (PIL
you start the service work. 15-33-06).
15 - 149 9813/9400-1 15 - 149

15 - Engine
36 - Piston
00 - General
Figure 212.
X
1
1 Piston 2 Piston ring

3 Connecting rod X Longest side of connecting rod
15 - 150 9813/9400-1 15 - 150

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 - 151 9813/9400-1 15 - 151

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

To avoid damage or distortion to the rings, use a
1. Clamp the connecting rod in a vice. Take care not suitable piston ring expander tool. Note that the
to damage the connecting rod. oil control ring is installed with a spiral wire. Pull
the wire apart and remove it.
2. It is recommended that the piston rings are
renewed. If they are to be reused, label the 3. Remove the circlips and push out the piston pin.
rings to ensure they are installed in the correct
positions and the correct way up on assembly. 4. Use a suitable cleaning agent, clean the carbon
deposits from the piston.
15 - 152 9813/9400-1 15 - 152

15 - Engine
36 - Piston
00 - General
Figure 213.
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 - 153 9813/9400-1 15 - 153

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 - 154 9813/9400-1 15 - 154

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 - 155 9813/9400-1 15 - 155

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-157
15 - 156 9813/9400-1 15 - 156

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 157 9813/9400-1 15 - 157

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-159

15-42-06 Rocker Cover ............................................................................................................... 15-168
15-42-09 Push Rod ..................................................................................................................... 15-170
15-42-21 Tappet ........................................................................................................................... 15-172
15-42-24 Tappet Cover ................................................................................................................ 15-174
15 - 158 9813/9400-1 15 - 158

15 - Engine
00 - General
Introduction .................................................. 15-159 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-160 system consisting of rocker arms and a shaft.
Operation ..................................................... 15-162 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-163 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-164 raised and lowered by a rotating lobe of the camshaft
Disassemble and Assemble ........................ 15-166 via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 159 9813/9400-1 15 - 159

15 - Engine
00 - General
Technical Data
Table 81. Rocker Levers, Rocker Shafts and Tappets Data

Valve clearances measured at the valve bridge piece
tip of the rockers (measured cold):
- Inlet 0.19–0.27mm
Rocker clearances measured at the adjusting screw
tip of the rockers (measured cold):
- Inlet 0.15–0.2mm
Rocker lever bore diameter
- min 26.058mm
- max 26.092mm
Rocker shaft diameter
- min 26.003mm
- max 26.021mm
Tappets stem diameter
- min 19.975mm
- max 19.985mm
Tappet bore diameter
- min 20mm
- max 20.021mm
Tappet height (maximum) 55.25mm
15 - 160 9813/9400-1 15 - 160

15 - Engine
00 - General
Figure 214.
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 - 161 9813/9400-1 15 - 161

15 - Engine
00 - General
Operation
When the camshaft lobe raises the outside of the rocker arm is permitted to return due to the camshafts
rocker arm, the inside presses down on the valve rotation, the inside rises to allow the valve spring to
stem to open the valve. When the outside of the close the valve.
Figure 215.
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 - 162 9813/9400-1 15 - 162

15 - Engine
00 - General
Check (Condition)
1. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Measure
the rocker shaft diameter and rocker bearing
bushes to confirm they are within service limits.
Refer to Technical Data. Note: The rocker
bearing bushes are not renewable. If a rocker
bearing bush is damaged or worn the rocker
must be renewed as a complete assembly.
2. Make sure that all oil-ways and cross drillings in
the rocker shaft, rocker arms and pedestals are
clear and free from debris. Use an air line to blow
through cross drillings.
15 - 163 9813/9400-1 15 - 163

15 - Engine
00 - General
Remove and Install
1. Make sure that the engine is safe to work on. If 3. Disconnect and remove the fuel pipes from the
the engine has been running, let it cool before fuel injectors, refer to Fuel pipes (PIL 18-96).
Figure 216.
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 - 164 9813/9400-1 15 - 164

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

Item Nm
2 24
3 24
15 - 165 9813/9400-1 15 - 165

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

15-42).
1. Remove the rocker cover. Refer to (PIL 15-42).
Figure 217.
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 - 166 9813/9400-1 15 - 166

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 - 167 9813/9400-1 15 - 167

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

15-00).
Figure 218.
A Rocker cover B Bolts

C Gasket D Injector seals
15 - 168 9813/9400-1 15 - 168

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 - 169 9813/9400-1 15 - 169

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

Introduction .................................................. 15-170 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-171 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 - 170 9813/9400-1 15 - 170

15 - Engine
09 - Push Rod
Remove and Install

15 - 171 9813/9400-1 15 - 171

15 - Engine
21 - Tappet
21 - Tappet Figure 220.
Remove and Install

B
Before Removal
1. Drain the oil from the engine.
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 219. The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
Figure 221.
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 - 172 9813/9400-1 15 - 172

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 222. 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 - 173 9813/9400-1 15 - 173

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 84. 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 223.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 174 9813/9400-1 15 - 174

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-177
15 - 175 9813/9400-1 15 - 175

Notes:
15 - 176 9813/9400-1 15 - 176

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-177 The lubrication system distributes oil around the
Component Identification ............................. 15-178 engine by a system of galleries and drillings in the
Remove and Install ..................................... 15-179 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 - 177 9813/9400-1 15 - 177

15 - Engine
45 - Oil Sump
00 - General
Figure 224.
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 - 178 9813/9400-1 15 - 178

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 0.31L 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 225.
1 Oil sump 1a Integral suction tube

1b Integral baffle plates 2 Oil sump fixing bolts (x20)
3 Oil pick up seal
15 - 179 9813/9400-1 15 - 179

15 - Engine
45 - Oil Sump
00 - General
Installation Figure 227.
1. Lightly smear the new oil pick up seal with oil and X
install into the bedplate as shown.
Figure 226.
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: 4mm 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 228.

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: 5min
2 Bolts
Y No bolts to be installed at this position (x6)
15 - 180 9813/9400-1 15 - 180

15 - Engine
45 - Oil Sump
00 - General
After Replacing
1. Allow the sealant to cure for
Duration: 20min
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 - 181 9813/9400-1 15 - 181

15 - Engine
48 - Grid Heater
48 - Grid Heater
Contents Page No.
15-48-00 General ......................................................................................................................... 15-183
15 - 182 9813/9400-1 15 - 182

15 - Engine
48 - Grid Heater
00 - General
Operation ..................................................... 15-183 The system aids engine starting by heating the air
Diagram ....................................................... 15-185 in the induction manifold through an electrical grid
heater. Operation of the system is fully automatic and
is controlled by the engine ECU (Electronic Control
Unit).
The power to the grid heater is supplied by a primary

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

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

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

2. Warning light illuminated (grid heater on)- engine
not ready to start.
Figure 229.
B
A
G
C D
E
F
A Coolant expansion tank B Warning light- grid heater on
15 - 183 9813/9400-1 15 - 183

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

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

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

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

ignition key to off position, the grid heater will come
on while the starter motor is engaged.
15 - 184 9813/9400-1 15 - 184

15 - Engine
48 - Grid Heater
00 - General
Diagram
Figure 230.
FUSE
A C
D
FUSE
F
G
A Primary fuse link B Engine compartment fuse

C Cold start relay D Grid heater element
E Engine ECU (Electronic Control Unit) F +VE
G -VE
15 - 185 9813/9400-1 15 - 185

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-187

15-51-03 Crankshaft Gear ........................................................................................................... 15-192
15-51-06 Camshaft Gear ............................................................................................................. 15-195
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-196
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-199
15-51-22 Rear Case .................................................................................................................... 15-202
15 - 186 9813/9400-1 15 - 186

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-187 The timing gears are located inside a case at the
Component Identification ............................. 15-188 flywheel end of the engine.
Operation ..................................................... 15-189
Check (Condition) ........................................ 15-191 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 - 187 9813/9400-1 15 - 187

15 - Engine
51 - Timing Gear
00 - General
Figure 231.
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 - 188 9813/9400-1 15 - 188

15 - Engine
51 - Timing Gear
00 - General
Operation
All the gears are driven via the crankshaft gear as • Oil pump gear-The lubrication oil pump is driven
follows: directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
• Camshaft gear-The camshaft is driven at half gear via idler gear.
crankshaft speed. • Low Duty Power Take-Off (PTO) Gear (if
• High pressure fuel pump gear-The high installed)-driven by the camshaft gear.
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
Figure 232.
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)
15 - 189 9813/9400-1 15 - 189

15 - Engine
51 - Timing Gear
00 - General
G Low duty PTO device gear (if installed)
15 - 190 9813/9400-1 15 - 190

15 - Engine
51 - Timing Gear
00 - General
Check (Condition)
1. Inspect the gears for wear or damage. If one or
more of the gears are worn or damaged, replace
them.
15 - 191 9813/9400-1 15 - 191

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 - 192 9813/9400-1 15 - 192

15 - Engine
51 - Timing Gear
Figure 233.
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 - 193 9813/9400-1 15 - 193

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 - 194 9813/9400-1 15 - 194

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 - 195 9813/9400-1 15 - 195

15 - Engine
51 - Timing Gear
09 - Fuel Injection Pump Gear
Remove and Install
Note: The illustrations show the engine inverted. If 2. Loosely install the high pressure fuel pump and
the drive gear components are being removed prior fixing nut, retain the gear.
to crankshaft or camshaft removal the engine must
be inverted. If the gear components only are being 3. Remove the starter motor. Refer to (PIL 15-75).
removed (for inspection/renewal) then the engine
need not be inverted. 4. Remove the flywheel. Refer to (PIL 15-54).
Before Removal 15-54).
1. Remove the high pressure fuel injection pump.
15 - 196 9813/9400-1 15 - 196

15 - Engine
51 - Timing Gear
Figure 234.
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 - 197 9813/9400-1 15 - 197

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

15 - 198 9813/9400-1 15 - 198

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
Remove and Install
The illustrations show the engine inverted. If the 2. Remove the starter motor. Refer to (PIL 15-75).
drive gear components are being removed prior to
crankshaft or camshaft removal the engine must 3. Remove the flywheel. Refer to (PIL 15-54).
be inverted. If the gear components only are being
removed (for inspection / renewal) then the engine 4. Remove the flywheel housing. Refer to (PIL
need not be inverted. 15-54-03).
Before Removal
15 - 199 9813/9400-1 15 - 199

15 - Engine
51 - Timing Gear
Figure 235.
1 Z
6
5 W
4 W
X
2
Y
3
1
2
1 High duty PTO idler gear 2 Idler gear hub

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

screws and lift out the hub.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub. DO NOT remove the crankshaft Inspect
gear.
1. Check the idler gear teeth and idler gear bearing
2. Lift the High duty PTO (Power Take-Off) idler bush for signs of damage or excessive wear.
gear from the hub.
15 - 200 9813/9400-1 15 - 200

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 - 201 9813/9400-1 15 - 201

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 - 202 9813/9400-1 15 - 202

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 236.
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 - 203 9813/9400-1 15 - 203

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 88. 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 - 204 9813/9400-1 15 - 204

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-207

15-54-03 Housing ........................................................................................................................ 15-211
15-54-09 Gear Ring ..................................................................................................................... 15-214
15-54-12 Drive Plate .................................................................................................................... 15-215
15 - 205 9813/9400-1 15 - 205

Notes:
15 - 206 9813/9400-1 15 - 206

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-207 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-208 systems, where the energy source is not continuous.
Remove and Install ..................................... 15-209 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 - 207 9813/9400-1 15 - 207

15 - Engine
54 - Flywheel
00 - General
Figure 237.
1 Flywheel
2 Flywheel gear ring
15 - 208 9813/9400-1 15 - 208

15 - Engine
54 - Flywheel
00 - General
Remove and Install
1. This procedure requires service parts. Make Removal

before you start. The flywheel is installed with a 1. Remove the bolts and withdraw the flywheel from
crankshaft position sensor target disc. DO NOT the crankshaft hub. The bolts MUST NOT be
remove the target disc. If the disc is defective the reused. Discard the bolts.
flywheel must be replaced.
Figure 238.
3 1 2
1
T3
1 Flywheel 2 Flywheel fixing bolts (x8)

3 Flywheel location dowel Y Angle tightening mark
15 - 209 9813/9400-1 15 - 209

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 - 210 9813/9400-1 15 - 210

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 - 211 9813/9400-1 15 - 211

15 - Engine
54 - Flywheel
03 - Housing
Figure 239.
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 - 212 9813/9400-1 15 - 212

15 - Engine
54 - Flywheel
03 - Housing
Installation After Installation

Anaerobic sealant will not start to cure whilst it 1. Install a new crankshaft rear oil seal.
is open to the atmosphere, however when air is
excluded (for instance when the two parts are 2. Install the flywheel.
put together) it will immediately start to harden. 3. Install the starter motor.
Make sure that all the necessary tools, bolts
etc. are readily available prior to assembling the Table 90. Torque Values
components. The parts must be installed and torque
tightened within5min with a maximum permissible Item Nm
time of 15min 4 47
5 24
removal procedure. Additionally do the following 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: 15min
8. Install the access cover and use the bolts to
secure. Tighten the bolts to the correct torque
value. Refer to Table 90.
15 - 213 9813/9400-1 15 - 213

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an oven
Before Removal to make sure that the heat is applied evenly
around the circumference. Do not heat the gear
1. This procedure requires service parts. Make ring above
sure you have obtained the correct service parts Temperature: 200°C (391.7°F)
before you start.
3. When sufficiently heated, install the gear ring into
2. Remove the flywheel from the crankshaft hub. position over the flywheel. Make sure that the
gear ring is installed the correct way around.
Figure 240.
X After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 214 9813/9400-1 15 - 214

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

Introduction .................................................. 15-215 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-216 bolted to the engine flywheel and a coupling clamped
to the input shaft of the wheel drive pump. Both are
contained within the engine bell housing and rear
support frame to which the wheel drive pump is fixed.
Figure 241.
B
A Drive plate
B Coupling (PIL 2731)
15 - 215 9813/9400-1 15 - 215

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 91. Torque Values

Item Nm
Consumables
Description Part No. Size C 23
Strength)
Remove
1. Make the machine safe with the lift arm and cab
raised. Refer to (PIL 01-03).
2. Remove the Wheel drive pump and coupling,
3. Remove the bolts, remove the drive plate from
the flywheel.
Install
removal procedure. additionally do the following
steps.
2. Make sure that the drive plate is installed with
the flat face against the flywheel and the boss is
facing outwards.
3. Coat the threads of the bolts with JCB
Threadlocker and Sealer and tighten to the
(Medium Strength)
Figure 242.
A Drive plate
C Bolts
E Boss
15 - 216 9813/9400-1 15 - 216

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-219
15 - 217 9813/9400-1 15 - 217

Notes:
15 - 218 9813/9400-1 15 - 218

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-219 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-220 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-222 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 - 219 9813/9400-1 15 - 219

15 - Engine
60 - Oil Pump
00 - General
Figure 243.
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 - 220 9813/9400-1 15 - 220

15 - Engine
60 - Oil Pump
00 - General
Figure 244.
10
10 CCV Anti drain back valve
15 - 221 9813/9400-1 15 - 221

15 - Engine
60 - Oil Pump
00 - General
Check (Condition)
1. Check the oil pump internal parts for signs of
2. Use feeler gauges to measure the inner and
outer rotor clearance, and the rotor end float to
confirm they are within service limits.
15 - 222 9813/9400-1 15 - 222

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 245.
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 - 223 9813/9400-1 15 - 223

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 - 224 9813/9400-1 15 - 224

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-227
15 - 225 9813/9400-1 15 - 225

Notes:
15 - 226 9813/9400-1 15 - 226

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-227 Engine mounts support the engine and in some
Remove and Install ..................................... 15-228 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 - 227 9813/9400-1 15 - 227

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 - 228 9813/9400-1 15 - 228

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-231
15 - 229 9813/9400-1 15 - 229

Notes:
15 - 230 9813/9400-1 15 - 230

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-231
Oil Cooler Assembly
Operation ..................................................... 15-232 The oil cooler and filter are incorporated in a housing
Check (Condition) ........................................ 15-233 that is bolted to the side of the crankcase. The
Remove and Install ..................................... 15-233 housing allows transfer of lubricating oil from the
crankcase to the oil cooler and filter head.
Some installations have a remote oil filter head. The
oil cooler housing incorporates feed and return ports
for hose connections to the filter head. A remote
oil filter head is used when access to the engine is
restricted.
Oil Cooler Matrix

The oil cooler matrix is a non-serviceable part and
must not be removed from the housing. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 231 9813/9400-1 15 - 231

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

Figure 246. 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 247.
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 - 232 9813/9400-1 15 - 232

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 248.
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 - 233 9813/9400-1 15 - 233

15 - Engine
69 - Oil Cooler
00 - General
ECM to prevent ingress of oil and coolant. Tie the Table 93. 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 249.
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 - 234 9813/9400-1 15 - 234

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 94. Torque Values
cooler matrix. Item Nm
2. Remove and discard the two sealing O-rings. A 23
3. Remove the sealing gasket.

Figure 250.
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 - 235 9813/9400-1 15 - 235

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-237

15-72-03 Pulley ............................................................................................................................ 15-243
15-72-06 Voltage Regulator ......................................................................................................... 15-244
15 - 236 9813/9400-1 15 - 236

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-237 The alternator is a three phase generator having a
Health and Safety ........................................ 15-238 rotating field winding and static power windings.
Technical Data ............................................. 15-238
Component Identification ............................. 15-239 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) ........................................ 15-239 warning light to the field winding. This creates
Remove and Install ..................................... 15-241 a magnetic field which supplements the residual
Disassemble and Assemble ........................ 15-242 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 - 237 9813/9400-1 15 - 237

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

• Ensure that the battery negative terminal is Technical data may differ between machine variants
connected to the earthing cable. and installations. For full data relating to the
• Never make or break connections to the battery alternator refer to the applicable parts information.
or alternator, or any part of the charging circuit
whilst the engine is running. Disregarding this
instruction will result in damage to the regulator
or rectifying diodes.
• Main output cables are 'live' even when the
engine is not running. Take care not to earth
connectors in the moulded plug if it is removed
from the alternator.
• During arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables installed, remove the
cables).
• If slave starting is necessary, connect the
second battery in parallel without disconnecting
the vehicle battery from the charging circuit.
The slave battery may then be safely removed
after a start has been obtained. Take care to
connect batteries positive to positive, negative
to negative.
15 - 238 9813/9400-1 15 - 238

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

Figure 251.
Charging Circuit Test
1. Make sure that all the battery and alternator
D connections are in place, secure and making
good metal - to - metal contact, especially the
earth connections to chassis and engine.
2. Adjust the alternator drive belt tension if
necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If
the oil pressure warning remains on stop the
engine Immediately and investigate the engine
A Alternator lubrication system.
B Regulator and brush assembly
C Drive pulley Check 1
D Tie bolts
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
If they operate normally, check the warning light bulb

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

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

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 252.
Check 2
The following checks should be made using an
analogue (moving pointer) type Multimeter.
15 - 239 9813/9400-1 15 - 239

15 - Engine
72 - Alternator
00 - General
1. Stop the engine and turn the ignition switch to 4. Alternatively, operate the starter for a few
OFF. moments with the ESOS (Engine Shut-Off
Solenoid) fuse removed.
2. Withdraw the alternator plug and connect the
Multimeter between the large terminals and 5. Install an open type shunt between the battery
earth. With the Multimeter set to measure, positive lead and the battery positive terminal.
Voltage: 12V Current: 100A
Figure 253. 6. Connect a Multimeter positive lead to machine
side of the shunt and negative lead to battery side
of the shunt.
7. Connect the leads to the Multimeter and set the
Multimeter to the relevant range as follows.
8. AVO 2002
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
2.1. The Multimeter should show battery 8.3. Right side slider to DC (Direct Current)
voltage. voltage.
2.2. If the reading is zero, check the cables 8.4. Left side slider,Refer to Figure 254.
for continuity, particularly at the starter
9. AVO 2003
terminals.
9.1. Red lead to amps socket (A) on the
3. If the voltage is correct, check the alternator.
Multimeter.
Alternator Charging Test 9.2. Black lead to negative on Multimeter.
Figure 254. 9.3. Right side slider to DC voltage

9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
1. Make sure that all battery and alternator conditions. These are listed in the order of
connections are in place, secure and making probability.
good metal to metal contact, especially the earth
connections to chassis and engine. 12.1. Defective suppression capacitor.
2. Make sure that the alternator drive belt tension is 12.2. Dirty slip rings or worn brushes.
correctly adjusted. 12.3. Defective regulator.
3. If the battery is in a fully charged condition, before 12.4. Defective rectifier.
commencing the test switch on the working lights
for 12.5. Open or short circuited field (rotor)
windings.
Duration: 3min
15 - 240 9813/9400-1 15 - 240

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

windings.
13. To check for a fault, disconnect the capacitor and Figure 255. Alternator location
repeat the charging test. Renew the capacitor if
necessary.
14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
assembly. Check the condition of the brushes
and, if necessary, clean the slip rings using extra-
fine glass paper. The regulator may only be
renewed.
15. Faults with the rectifier, rotor and stator may be
checked only by removing and dismantling the
alternator for further testing. Remove
1. Disconnect the negative (-) lead followed by the
positive (+) lead from the battery terminals.
2. Remove the alternator (accessory) drive belt.
3. Disconnect the electrical leads from the
alternator terminals. Label the leads to make
sure that they are installed in the correct positions
on assembly.
4. Undo the alternator securing bolts and lift the
alternator away from the cylinder block mounting.
Figure 256.
A
A Alternator
B Securing bolts
Inspect
1. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 241 9813/9400-1 15 - 241

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

removal procedure. Additionally do the following Voltage Regulator and Brushes
steps.
1. The voltage regulator and brush set is a
2. It is not necessary to adjust the position of the combined assembly. Refer to (PIL 15-72-06).
alternator in order to tension the drive belt, as
the accessory drive belt arrangement is self-
tensioning. Drive Pulley
3. Tighten the alternator securing bolts to the 1. Refer to (PIL 15-72-03).
4. Make sure you reconnect the electrical leads to
the alternator in the correct positions and tighten
to the correct torque.
Table 95. Alternator securing bolt torque

Item Torque Value
A 47N·m
B 47N·m
Figure 257.
Table 96. Alternator electrical connection torque

Item Torque Value
B+ 9–13N·m
L 2.7–3.8N·m
W 2.7–3.8N·m
15 - 242 9813/9400-1 15 - 242

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).
15 - 243 9813/9400-1 15 - 243

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).
15 - 244 9813/9400-1 15 - 244

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-247

15-75-03 Solenoid ....................................................................................................................... 15-255
15-75-06 Brush Gear ................................................................................................................... 15-256
15 - 245 9813/9400-1 15 - 245

Notes:
15 - 246 9813/9400-1 15 - 246

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-247 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-248 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-248 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-249 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-249 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-251 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-253 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 - 247 9813/9400-1 15 - 247

15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Refer to Electrical System- General, Technical Data
and lower the loader arm. Stop the engine and (PIL 33-00).
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
15 - 248 9813/9400-1 15 - 248

15 - Engine
75 - Starter Motor
00 - General

Figure 258. Before carrying out the multimeter tests, check
the battery condition and make sure that all the
1 applicable electrical connections are clean and tight.
Make sure that the starter motor fixing bolts are
tightened to the correct torque.
To prevent the engine starting during the tests make

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

a multimeter. Unless otherwise stated, the readings
must be taken with the ignition switch held in the
start position (HS) and the controls set to enable
the starter motor. The readings are shown for both
12V and 24V systems. The highest values are for
machines with 24V systems. Identify the applicable
3 system before carrying out the tests.
1 Solenoid Do not operate the starter motor for more than 20s at
2 Brush gear one time. Let the starter motor cool for at least 2min
3 Tie bolts between starts.
1. Connect the multimeter across the battery

terminals.
Figure 259.
1.1. Reading in start position approximately

Voltage: 10V
Voltage: 20V
1.2. Minimum permissible reading in start
position
Voltage: 9.5V
Voltage: 18V
1.3. A low reading probably indicates a fault in
the starter motor.
2. Connect the multimeter between the starter main
terminal and the commutator end bracket. In the
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5V
Voltage: 1V
15 - 249 9813/9400-1 15 - 249

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

B Commutator end bracket (Starter earth B Starter earth connection
connection) C Solenoid terminal
2.1. Minimum permissible reading in start D Start relay feed
position E Start relay switched output
H Battery positive and solenoid connection
Voltage: 9V
Voltage: 17V 4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
2.2. If the reading is within this limit, continue to
and earth.
3. If the reading is outside the limit, proceed
to 4. 4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage
3. Connect the multimeter between the solenoid increases to
terminal and a good earth. Minimum permissible
reading in start position Voltage: 8V
Voltage: 16V
Voltage: 8V
Voltage: 16V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 261. or in the wiring between the solenoid, starter
switch, and the start relay, if the reading
between terminal and earth is less than
Voltage: 8V
Voltage: 16V
5. Connect the multimeter between battery
negative and starter earth connection. The
reading in the start position should be practically
zero, maximum permissible reading
Voltage: 0.25V
Figure 263.
C Solenoid terminal
4. If the reading is less than specified, connect
the multimeter between the start relay switched
output and earth. A fault is indicated with the
wiring from the start relay to the solenoid if the
reading increases to
Voltage: 8V
Voltage: 16V
B Starter earth connection
15 - 250 9813/9400-1 15 - 250

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

permissible voltage, a high resistance in the
earth lead or connections is indicated.
Figure 266.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter A
switch off, the voltmeter should indicate battery E
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading B
Voltage: 0.25V
Figure 264.
D
C
A Electrical lead (Terminal 30)
B Security cover
C Starter motor
D Bolt (x3)
E Electrical lead (Terminal 50)
A Starter main terminal Remove

7. If the reading is above the maximum permissible 1. Make the machine safe.
voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the Refer to: PIL 01-03.
multimeter between the battery positive and 2. Make sure the engine is safe to work on. If the
solenoid connection. If the multimeter now reads engine has been running, make sure that the
zero with the switch closed, the fault is in the engine has cooled sufficiently before you start
solenoid. work.
Figure 265. 3. Disconnect the battery negative lead followed by
the positive lead from the battery terminals.
4. Remove the security nut and bolt, remove the
security cover (if installed).
5. Disconnect the electrical leads from the starter
motor terminals. Label the leads to make sure
they are installed in the correct positions on
assembly.
6. Undo the bolts (x3) and withdraw the starter
motor from the flywheel housing.
H Battery positive and solenoid connection Inspection

8. Finally install the engine stop fuse. 1. Check the drive pinion splines for damage and
excessive wear.
2. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 251 9813/9400-1 15 - 251

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

Item Nm
A 15 ± 3
D 47 ± 4
E 3.6 ± .6
15 - 252 9813/9400-1 15 - 252

15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor (PIL15-75). For cover.
cleaning and checking purposes only, dismantle the
1.6. Carefully install the commutator end cover,
motor as follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 253 9813/9400-1 15 - 253

15 - Engine
75 - Starter Motor
00 - General
Figure 267.
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 - 254 9813/9400-1 15 - 254

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

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

the complete starter motor (PIL15-75).
15 - 255 9813/9400-1 15 - 255

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 (PIL15-75).
15 - 256 9813/9400-1 15 - 256

15 - Engine
80 - Glow Plug
80 - Glow Plug
Contents Page No.
15-80-00 General ......................................................................................................................... 15-259
15 - 257 9813/9400-1 15 - 257

Notes:
15 - 258 9813/9400-1 15 - 258

15 - Engine
80 - Glow Plug
00 - General
Introduction .................................................. 15-259 A glow plug is a heating device used to help
Operation ..................................................... 15-260 start diesel engines. In cold weather, diesel engines
Remove and Install ..................................... 15-260 can be difficult to start because the mass of the
crankcase and cylinder head absorb the heat of
compression, preventing ignition due to the higher
surface to volume ratio.
The glow plug is a pencil shaped piece of metal with

a heating element at the tip. The heating element,
when electrified, heats due to its electrical resistance.
15 - 259 9813/9400-1 15 - 259

15 - Engine
80 - Glow Plug
00 - General
The glow plugs are controlled by the ECM (Engine The glow plugs for cylinders 1,3 and 4 can be
Control Module). The ECM takes signals from engine removed without the need to remove any other
sensors such as the engine coolant temperature components. The glow plug for cylinder 2 requires
sensor to determine whether the glow plugs are the removal of the turbocharger to gain access. Refer
required and for how long. The glow plugs will be to (PIL 18-35).
activated when the ambient temperature is below
0°C (32.0°F). The glow plugs will be deactivated by Remove
the ECM after a predetermined time period.
3. Disconnect the electrical connector.
Figure 268.
B
A
A Electrical connector
B Glow plug
4. Remove the glow plug from the cylinder head.
Install
step.
2. Tighten the glow plug to the correct torque value.

Item Nm
B 15 ± 2
15 - 260 9813/9400-1 15 - 260

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-263

15-84-03 Crankshaft Position ...................................................................................................... 15-274
15-84-06 Camshaft Position ........................................................................................................ 15-278
15-84-09 Knock ........................................................................................................................... 15-282
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-285
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-288
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-291
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-294
15-84-19 Exhaust Temperature ................................................................................................... 15-297
15-84-24 Fuel Temperature ......................................................................................................... 15-300
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-303
15-84-29 Foot Throttle Control .................................................................................................... 15-306
15-84-33 Coolant Temperature .................................................................................................... 15-310
15-84-42 Engine Oil Temperature ............................................................................................... 15-313
15-84-43 Engine Oil Level ........................................................................................................... 15-316
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-319
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-322
15 - 261 9813/9400-1 15 - 261

Notes:
15 - 262 9813/9400-1 15 - 262

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-263 The engine sensors continually send signals to the
Technical Data ............................................. 15-264 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-266 control the smooth running of the engine and related
Fault-Finding ................................................ 15-268 components.
Check (Operation) ....................................... 15-273 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 - 263 9813/9400-1 15 - 263

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

Sensor (TMAP)
Atmospheric Output voltage +/- V
pressure bar V
Table 99.
(psi)
Crankshaft Position Sensor 0.98 -0.025/ 1.84 0.05
Type Hall effect. +0.025
(14.2 -0.4/+0.4)
Table 100. Table 103.

Camshaft Position Sensor Knock Sensor
Type Hall effect. Type Piezo crystal.
Fixing screw tightening 24N·m
torque
Table 101.
Fixing screw thread di- M8
Coolant Temperature Sensor ameter
Type Temperature dependant resis-
tance. Table 104.
Tightening 22N·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 °C Resistance Ω +/- % Rotational range 75°
(°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 105.
Table 102.
Rail Pressure Sensor
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) Type The rail pressure sensor
is integral with the com-
Fixing screw 22N·m max mon rail.
tightening
torque
Table 106.
Fixing screw M6
thread diameter High Pressure Rail Fuel Valve
Supply voltage 5V Type The HPV (High Pressure
Temperature Sensor Valve) is integral with
the common rail.
Type Temperature dependant resistor.
Temperature v Resistance Table Table 107.
Temperature °C Resistance Ω +/- %
Fuel Temperature Sensor
(°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 108.
30 (86.0) 1,715 4.12 Oil Pressure Switch
Pressure Sensor Set pressure 0.6bar (8.7psi) falling.
Type Piezo-resistive Switch mode Normally open.
Atmospheric Pressure v Voltage Max pressure 27.5bar (398.5psi)
15 - 264 9813/9400-1 15 - 264

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

Max working pressure 13.8bar (200.0psi)
Tightening torque 23N·m max.
Thread diameter M12 x 1.5.
15 - 265 9813/9400-1 15 - 265

15 - Engine
84 - Sensor
00 - General
Engine Sensors and Actuators
Figure 269.
B
P
F
G
H
J
K
A Coolant temperature sensor (PIL 15-84) B Turbocharger actuator (not installed on 55Kw
engines) (PIL 18-36)
D TMAP (Temperature Manifold Air Pressure) (PIL E Fuel temperature sensor (PIL 15-84)
15-84)
F Fuel inlet metering valve (PIL 18-18) G Camshaft position sensor (PIL 15-84)
H Crankshaft position sensor (PIL 15-84) J Oil temperature sensor (PIL 15-84)
K Oil pressure switch (PIL 15-84) P Inter cooler outlet temperature sensor (PIL
15-84)
15 - 266 9813/9400-1 15 - 266

15 - Engine
84 - Sensor
00 - General
Figure 270.
M
C
C Exhaust manifold pressure sensor (PIL 15-84) L Fuel pressure relief valve (HPV) (PIL 15-84)
M EGR (Exhaust Gas Recirculation) actuator (PIL N Exhaust manifold temperature sensor (PIL
18-27) 15-84)
O Oil level switch (optional) (PIL 15-84)
15 - 267 9813/9400-1 15 - 267

15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 109. Page 15-268
Water in Fuel Sensor Fault Table 110. Page 15-268
Knock Sensors Table 111. Page 15-269
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 112. Page 15-270
Crankshaft Position Sensor Table 113. Page 15-270
Camshaft Position Sensor Table 114. Page 15-271
TMAF (Temperature and Mass Air Flow) Sensor Table 115. Page 15-272
Table 109. 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 110. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
15 - 268 9813/9400-1 15 - 268

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 111. 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 - 269 9813/9400-1 15 - 269

15 - Engine
84 - Sensor
00 - General
Table 112. 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 113. 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 - 270 9813/9400-1 15 - 270

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 114. 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 - 271 9813/9400-1 15 - 271

15 - Engine
84 - Sensor
00 - General
Table 115. 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 - 272 9813/9400-1 15 - 272

15 - Engine
84 - Sensor
00 - General
Check (Operation)
1. Check the applicable fuse. Refer to (PIL 33-09).
2. Check the display for related fault codes. Refer
to (PIL 33-57).
3. Using Servicemaster perform the required
diagnostic tests. Refer to (PIL 33-57).
4. Check the sensor condition, make sure the
sensor or housing is not damaged, broken,
contaminated or subjected to excess heat. If
necessary replace sensor and make sure the
damage can not reoccur.
5. Check the condition of sensor to harness
connection, make sure the seals are in place,
check for signs of corrosion or contamination.
Repair/replace as necessary
6. Check the sensor location and make sure it is
mounted correctly. Where applicable check the
sensor is tightened to the correct torque. Refer to
the applicable sensor procedure for details.
7. Check the sensor is of the correct type and
specification. If incorrect replace with correct
sensor. Refer to the applicable sensor procedure
for details.
8. Disconnect the sensor, check sensor voltage
supply at the harness connector (Refer
to the applicable sensor Technical Data
and Component Identification procedures.
Alternatively refer to engine electrical
schematic). If the voltage supply is faulty,
disconnect all other sensors in turn until voltage
supply returns. Trace the supply fault and rectify.
9. Check the sensor resistance. Refer to the
applicable sensor Technical Data. If sensor is out
of specification replace.
10. Disconnect the harness from the engine ECM
(Engine Control Module) and inspect. Check
seals are in place, check for signs of corrosion or
contamination.
11. Check the harness continuity. Check the
machine and engine earth contacts. Repair /
replace as necessary
15 - 273 9813/9400-1 15 - 273

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

Introduction .................................................. 15-274 The crankshaft position sensor is a device used
Operation ..................................................... 15-275 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-276 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-276 (Engine Control Module) to control the ignition
system timing and other engine parameters.
15 - 274 9813/9400-1 15 - 274

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 271.
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 - 275 9813/9400-1 15 - 275

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 272.
A
D
C
A Crankshaft position sensor

B Electrical connector
C Bolt
D Guard
15 - 276 9813/9400-1 15 - 276

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

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

Item Nm
C 8
15 - 277 9813/9400-1 15 - 277

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

Introduction .................................................. 15-278 The camshaft position sensor is a device that detects
Operation ..................................................... 15-279 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-280 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-280 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
15 - 278 9813/9400-1 15 - 278

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 273.
TDC 2 3
5
4
C1 C2
D1 D2 6

3 Camshaft target wheel 4 Crankshaft position sensor
5 Crankshaft mounted target wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse - injector solenoid coil D1-D2 Fuel Injection
TDC TDC (Top Dead Centre)
15 - 279 9813/9400-1 15 - 279

15 - Engine
84 - Sensor

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
crankcase.
Figure 274.
A
B
A Camshaft position sensor

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

item. If the sensor is defective it must be replaced.
15 - 280 9813/9400-1 15 - 280

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

Item Nm
C 8
15 - 281 9813/9400-1 15 - 281

15 - Engine
84 - Sensor
09 - Knock
09 - Knock Introduction
Introduction .................................................. 15-282 There are two knock sensors fixed to the side of the
Operation ..................................................... 15-283 crankcase with a centre mounted bolt. One sensor is
Check (Operation) ....................................... 15-283 situated between cylinders 1 and 2, and the second
Remove and Install ..................................... 15-284 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 275. Knock sensor locations
A
B
A Knock sensor - cylinders 1 and 2

B Knock sensor - cylinders 3 and 4
15 - 282 9813/9400-1 15 - 282

15 - Engine
84 - Sensor
09 - Knock
Operation Check (Operation)
The knock sensors detect pre-ignition (knock) by 1. For the full inspection and testing procedure,
means of sensing engine vibration. The vibration refer to the help files in ServiceMaster.
signal is sent to the engine ECM (Engine Control
Module)where the ECM will adjust the fuel timing to
give optimum performance, economy and driveability
and prevent engine damage. The voltage signal is
proportional to engine vibration/acceleration.
15 - 283 9813/9400-1 15 - 283

15 - Engine
84 - Sensor
09 - Knock
Remove and Install 3. Tighten the bolt to the correct torque value.
Torque: 22–26N·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 276.
B C
A Knock sensor
C Bolt
Install
steps.
2. Make sure that the sensor mates fully with the
adjacent face on the crankcase.
15 - 284 9813/9400-1 15 - 284

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

Introduction .................................................. 15-285 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-286 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-286 cylinder 3 and 4 exhaust outlet ports.
Figure 277. Exhaust manifold
temperature sensor location
15 - 285 9813/9400-1 15 - 285

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 1–4.5V.
15 - 286 9813/9400-1 15 - 286

15 - Engine
84 - Sensor
Remove and Install

Special Tools
Deep Socket 892/12351 1
Before Removal
Figure 278.
A
N
A Exhaust manifold temperature sensor
Remove
2. Disconnect the electrical connector at the
exhaust manifold temperature sensor.
3. Use the special tool to remove the sensor from
the exhaust manifold.
Special Tool: Deep Socket (Qty.: 1)
4. Discard the sealing washer.
The exhaust manifold temperature sensor is a non-

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

Item Nm
N 45
15 - 287 9813/9400-1 15 - 287

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

Introduction .................................................. 15-288 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-289 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-289 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-290 (Engine Control Module) Controlled engine.
The sensor is mounted in the rear section of the

rocker cover.
Figure 279.
C Exhaust manifold pressure sensor
15 - 288 9813/9400-1 15 - 288

15 - Engine
84 - Sensor
The exhaust manifold pressure sensor measures For the full inspection and testing procedure, refer to
the exhaust pressure from the engine. To attain an the help files in ServiceMaster.
accurate and stable reading, the take-off point is
piped from the exhaust manifold between cylinders
3 and 4. This is fed to a sample chamber where the
sensor is screwed directly into the pressure path. The
analogue voltage signal is 0.5–4.5V.
15 - 289 9813/9400-1 15 - 289

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 280.
P1
1 Exhaust manifold pressure sensor

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

it must be renewed.
Install
steps.
15 - 290 9813/9400-1 15 - 290

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 .................................................. 15-291 sensor is mounted in a port on top of the inlet
Operation ..................................................... 15-292 manifold. It measures the inlet manifold boost air
Check (Operation) ....................................... 15-292 pressure and temperature. The sensor incorporates
a piezo-resistive element and resistor.
Figure 281.
D TMAPsensor
15 - 291 9813/9400-1 15 - 291

15 - Engine
84 - Sensor
The TMAP (Temperature Manifold Air Pressure) 1. Remove oil and sludge contamination from the
sensor measures the inlet manifold boost air sensor.
pressure and temperature. The sensor produces an
analogue signal voltage proportional to air pressure. 2. Carefully inspect the sensor. If it is defective,
replace it.
15 - 292 9813/9400-1 15 - 292

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 120. Torque Values
the engine has been running, let it cool before Item Nm
you start the service work. C 3.3
inlet manifold.
Figure 282.
A
C B
D
A TMAP (Temperature Manifold Air Pressure)
C Bolt
D O-ring seal
Remove
3. Remove the bolt.
4. Remove the sensor from the inlet manifold
together with O-ring.
The TMAP sensor is a non-serviceable item. If the

sensor is defective, it must be replaced.
Install
steps.
2. Make sure that the sealing O-ring is correctly
installed.
15 - 293 9813/9400-1 15 - 293

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 .................................................. 15-294 measures the amount of air coming in to the engine
Operation ..................................................... 15-295 and the air temperature. It is mounted between the
Check (Operation) ....................................... 15-295 air filter and turbo charger.
Remove and Install ..................................... 15-296 Figure 283.
15 - 294 9813/9400-1 15 - 294

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 284.
1 Air flow sensor area

2 Temperature sensor area
15 - 295 9813/9400-1 15 - 295

15 - Engine
84 - Sensor
Remove and Install Install

Do not install a TMAF sensor which has been
Before Removal dropped or damaged. Replace it with a new one.
1. Make sure that the engine is safe to work on. If 1. The installation procedure is the opposite of the
the engine has been running, let it cool before removal procedure. Additionally do the following
you start the service work. step.
2. Get access to the TMAF (Temperature and Mass 2. Tighten the screws to the correct torque value.
Air Flow) sensor
3. Clean the area around the sensor to prevent
Item Nm
contamination entering the engine.
2 5
Remove
Figure 285.
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 286.
1 Air flow temperature sensor area

2 Temperature sensor area
15 - 296 9813/9400-1 15 - 296

15 - Engine
84 - Sensor
19 - Exhaust Temperature
19 - Exhaust Temperature Introduction

Introduction .................................................. 15-297 The exhaust temperature sensor is located in the
Operation ..................................................... 15-298 exhaust system just before the SCR (Selective
Check (Operation) ....................................... 15-298 Catalytic Reduction) catalyst.
15 - 297 9813/9400-1 15 - 297

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 - 5V
The resistance values specified are correct at 20°C
(68.0°F).

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: 5V
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 ± 1,228Ω
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.
15 - 298 9813/9400-1 15 - 298

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 287.
3. Tighten the retaining screw to the correct torque
value.

Item Nm
2 44
2
1
1 Exhaust temperature sensor

2 Retaining nut
2. Undo the retaining screw.
15 - 299 9813/9400-1 15 - 299

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

Introduction .................................................. 15-300 The fuel temperature sensor is an integral part of
Operation ..................................................... 15-301 the fuel injection high pressure pump, refer to (PIL
Check (Operation) ....................................... 15-301 18-18).
Figure 288.
E Fuel temperature sensor
15 - 300 9813/9400-1 15 - 300

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 - 301 9813/9400-1 15 - 301

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 - 302 9813/9400-1 15 - 302

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

Introduction .................................................. 15-303 The fuel rail pressure sensor measures the fuel
Operation ..................................................... 15-304 pressure in the common rail.
Check (Operation) ....................................... 15-304
A Fuel rail pressure sensor
15 - 303 9813/9400-1 15 - 303

15 - Engine
84 - Sensor
The fuel rail pressure sensor measures the fuel For the full inspection and testing procedure, refer to
pressure in the fuel rail. This allows the ECM (Engine the help files in ServiceMaster.
Control Module) to control the IMV (Inlet Metering
Valve) to deliver the correct amount of fuel to the high
pressure fuel pump. This keeps the fuel pressure in
the fuel rail constant at all engine RPM (Revolutions
Per Minute).
15 - 304 9813/9400-1 15 - 304

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 - 305 9813/9400-1 15 - 305

15 - Engine
84 - Sensor
29 - Foot Throttle Control
29 - Foot Throttle Control Technical Data

Technical Data ............................................. 15-306
Operation ..................................................... 15-307
Throttle Position Sensor
Remove and Install ..................................... 15-308 Figure 290. Throttle Pedal Movement
A
B
Table 123.
Pedal Position Voltage Output
A Signal 1 = 0 Signal 2 = 5
B Signal 1 = 2 Signal 2 = 3
C Signal 1 = 5 Signal 2 = 0
15 - 306 9813/9400-1 15 - 306

15 - Engine
84 - Sensor
Operation
The throttle pedal sensor (TPS) converts the

movement from the pedal into an electrical signal
for interpretation by the Engine ECU (Electronic
Control Unit), variflow pump ECU hi(if installed) or
the hydraulic control ECU.
The the movement of the throttle pedal is transmitted

from the footplate to the roller and the swing arm
on the throttle position sensor (TPS) unit. A variable
resistor within the TPS unit changes the voltage
output in relation to the position of the pedal.
Two signals are output from the unit, a track 1 signal

and a track 2 signal. One signal varies the voltage by
the angle below the foot pedal pad. The other signal
varies the voltage by the angle above the foot pedal
pad. Both signals will always add up to 5V. Refer to
engine- sensor, refer to (PIL 15-84).
Figure 291.
B
A
C
D
A Throttle position sensor unit

B Throttle pedal
C Swing arm
D Roller
15 - 307 9813/9400-1 15 - 307

15 - Engine
84 - Sensor
Remove and Install
Consumables 4. Remove the floor mat from the cab.

JCB Threadlocker 4101/0250 0.01L chassis harness, from below the cab.
Strength) 6. Remove the socket head bolts.
Remove 7. Make sure you keep the spacer plate (if

installed).
1. Park the machine and make it safe. Refer to (PIL
01-03). 8. Remove the nut to release the clip and the
connector from the floor.
2. Follow the general safety precautions. Refer to
(PIL 01-03). 9. Slowly remove the pedal assembly from inside
the cab.
3. Make sure that the engine cannot be started.
10. Pull the connector through the hole in the floor.
Figure 292.
D
B B
E
A
F
A Pedal assembly B Socket head bolts

C Spacer plate D Nut
E Connector F Hole in the floor
15 - 308 9813/9400-1 15 - 308

15 - Engine
84 - Sensor
Install
1. The installation is the opposite of the removal
procedure.
2. When you install do the following steps also:
2.1. Apply sealant to the thread of the bolts.
(Medium Strength)
15 - 309 9813/9400-1 15 - 309

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

Introduction .................................................. 15-310 The coolant temperature sensor is located on the
Operation ..................................................... 15-311 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-311
A
A Coolant temperature sensor
15 - 310 9813/9400-1 15 - 310

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 - 311 9813/9400-1 15 - 311

15 - Engine
84 - Sensor

Item Nm
1 16
Before Removal
2. Drain the coolant, refer to (PIL 21-00).
Figure 294.
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 - 312 9813/9400-1 15 - 312

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

Introduction .................................................. 15-313 The engine oil temperature sensor is mounted in a
Operation ..................................................... 15-314 port on the oil cooler housing adjacent to the engine
Check (Operation) ....................................... 15-314 oil dipstick.
Figure 295. Engine oil tem-
perature sensor location
A Engine oil temperature sensor
15 - 313 9813/9400-1 15 - 313

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 - 314 9813/9400-1 15 - 314

15 - Engine
84 - Sensor

Item Nm
Special Tools
Description Part No. Qty. 1 21
Before Removal
Figure 296.
B
A Sealing washer
B Engine oil temperature sensor
Remove
2. Disconnect the electrical connector at the engine
oil temperature sensor.
the oil cooler housing.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The engine oil temperature sensor is a non-

it must be renewed.
Install
steps.
3. Use the special tool to tighten the engine oil
temperature sensor to the correct torque value.
15 - 315 9813/9400-1 15 - 315

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

Introduction .................................................. 15-316 The engine oil level sensor is used to warn the
Operation ..................................................... 15-317 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-317 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-318 mounted on the engine oil sump.
15 - 316 9813/9400-1 15 - 316

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 - 317 9813/9400-1 15 - 317

15 - Engine
84 - Sensor
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
1. Make the machine safe. engine has cooled sufficiently before you start.
Figure 297.
A
C
B
D
E
A Engine oil level sensor B Oil level sensor float

C Bolts (x2) D Clip
E Oil Sump
Remove
2. Drain the engine oil.
4. Remove the oil sump.
5. Remove the bolts (x2) securing the oil level
sensor float to the oil sump.
6. Remove the clip.
7. Remove the oil level sensor.
The engine oil level sensor is a non-serviceable item.

If the sensor is faulty or damaged it must be replaced.
Install
steps.

Item Nm
C 10 ± 1
15 - 318 9813/9400-1 15 - 318

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

Introduction .................................................. 15-319 The intercooler outlet sensor is located in the air
Operation ..................................................... 15-320 intake on the inlet manifold.
Check (Operation) ....................................... 15-320
P Intercooler outlet sensor
15 - 319 9813/9400-1 15 - 319

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 - 320 9813/9400-1 15 - 320

15 - Engine
84 - Sensor
Remove and Install
Before Removal
Figure 299.
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 - 321 9813/9400-1 15 - 321

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

Introduction .................................................. 15-322
Operation ..................................................... 15-323
Introduction
Remove and Install ..................................... 15-324 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 300.
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 - 322 9813/9400-1 15 - 322

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 5min
before both NOx sensors are fully operational.
These two signals are then compared to determine
the conversion efficiency of the catalyst.
Figure 301.
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 - 323 9813/9400-1 15 - 323

15 - Engine
84 - Sensor
Remove and Install Remove

Consumables Figure 302.
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 - 324 9813/9400-1 15 - 324

15 - Engine
84 - Sensor
Figure 303. 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.
6.3. 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 - 325 9813/9400-1 15 - 325

15 - Engine
86 - Solenoid
86 - Solenoid
Contents Page No.
15-86-00 General ......................................................................................................................... 15-327

15-86-09 Cold Start Advance ...................................................................................................... 15-328
15 - 326 9813/9400-1 15 - 326

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 - 327 9813/9400-1 15 - 327

15 - Engine
86 - Solenoid
09 - Cold Start Advance
09 - Cold Start Advance Introduction

Introduction .................................................. 15-328 The cold start advance solenoid consists of an
Check (Condition) ........................................ 15-329 electrical solenoid and a valve which allows extra
Remove and Install ..................................... 15-330 fuel to spray into the inlet manifold at specific
temperatures for starting purposes. The fuel is
supplied to this valve by the electric fuel pump.
Under cold starting conditions, the solenoid is

energised that opens the fuel valve allowing jets of
fuel to spray into the inlet manifold and mix with the
incoming air, thus richening the air/fuel mixture to
help in cold starting conditions.
15 - 328 9813/9400-1 15 - 328

15 - Engine
86 - Solenoid
Check (Condition)
1. If a faulty solenoid is suspected, perform tests to
confirm its serviceability.
15 - 329 9813/9400-1 15 - 329

15 - Engine
86 - Solenoid
Remove and Install

Figure 304.
2
1 Cold start advance solenoid 2 Fuel injection pump

3 O-ring - cold start advance solenoid
Removal Install
1. Disconnect the electrical connector at the cold 1. Replacement is the reversal of the removal
start advance solenoid. procedure.
2. Remove the solenoid cartridge from the fuel 2. Install a new O-ring seal.
injection pump body.
3. Discard the O-ring seal. Cap all open ports to
prevent ingress of dirt and debris. 4. Start the engine and check for fuel leaks.
The cold start advance solenoid is a non-serviceable Table 129. Torque Values
item. If the solenoid is faulty or damaged it must be Item Nm
renewed. It is essential that the correct solenoid is
1 15
installed.
15 - 330 9813/9400-1 15 - 330

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-00 General ......................................................................................................................... 15-333

15-87-03 Engine Oil Pressure ..................................................................................................... 15-334
15-87-09 Cold Start ..................................................................................................................... 15-337
15 - 331 9813/9400-1 15 - 331

Notes:
15 - 332 9813/9400-1 15 - 332

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 - 333 9813/9400-1 15 - 333

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

Introduction .................................................. 15-334 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-335 oil cooler housing.
Check (Operation) ....................................... 15-335
A
A Engine oil pressure switch
15 - 334 9813/9400-1 15 - 334

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 - 335 9813/9400-1 15 - 335

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

item. If the switch is faulty or damaged it must be
renewed.
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the
Torque: 16N·m
15 - 336 9813/9400-1 15 - 336

15 - Engine
87 - Switch
09 - Cold Start
09 - Cold Start Introduction

Introduction .................................................. 15-337 The cold start switch will send a signal to turn on the
Check (Condition) ........................................ 15-338 cold start advance solenoid at specific temperatures
Remove and Install ..................................... 15-339 to help in cold starting conditions.
15 - 337 9813/9400-1 15 - 337

15 - Engine
87 - Switch
09 - Cold Start
Check (Condition)
1. If a faulty switch is suspected, use a suitable
multimeter to check that the correct supply
voltage is present at the switch electrical
connector.
2. Carry out tests on the machine electrical circuits
to check for possible wiring faults. The fault may
be caused by failure of other components within
the electrical system.
15 - 338 9813/9400-1 15 - 338

15 - Engine
87 - Switch
09 - Cold Start
Remove and Install
The engine cold start switch is a non-serviceable Before Removal

item. If the engine cold start switch is faulty or
damaged it must be renewed. 1. Make sure that the engine is safe to work on. If
2. Drain the coolant. Refer to (PIL 21-00).
Figure 306.
2
1 Engine cold start switch 2 Crankcase

3 Sealing washer - switch
15 - 339 9813/9400-1 15 - 339

15 - Engine
87 - Switch
09 - Cold Start
Removal
1. Disconnect the electrical connector at the engine
cold start switch.
2. Remove the engine cold start switch from the
crankcase.
3. Discard the O-ring. Cap the open ports to prevent
ingress of dirt.
Install
steps.
2. Install a new sealing washer.
3. Tighten the engine cold start switch to the correct
torque value.
After Installation
1. Fill the cooling system with the recommended
coolant mixture. Refer to (PIL 21-00).

Item Nm
1 16
15 - 340 9813/9400-1 15 - 340

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-343
15 - 341 9813/9400-1 15 - 341

Notes:
15 - 342 9813/9400-1 15 - 342

15 - Engine
90 - Air Intake
00 - General
00 - General
Check (Condition)
15 - 343 9813/9400-1 15 - 343

Notes:
15 - 344 9813/9400-1 15 - 344

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-17
18-06 Level Sender
18-06-00 General ........................................................................................................................... 18-25
18-09 Filter
18-09-00 General ........................................................................................................................... 18-29
18-09-03 Filter Element ................................................................................................................. 18-34
18-09-09 Pre-Filter Element .......................................................................................................... 18-36
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-39
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-42
18-15 Filler
18-15-00 General ........................................................................................................................... 18-45
18-18 Injection
18-18-00 General ........................................................................................................................... 18-47
18-18-03 Injector ............................................................................................................................ 18-62
18-18-07 Injector Seal ................................................................................................................... 18-67
18-18-12 Rail ................................................................................................................................. 18-69
18-18-15 Pump .............................................................................................................................. 18-71
18-18-27 High Pressure Rail Valve ............................................................................................... 18-78
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-83
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-89
18-24-03 Inlet Manifold .................................................................................................................. 18-91
18-24-04 Outlet Manifold ............................................................................................................... 18-95
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ......................................................................................................................... 18-101
18-27-03 Actuator ........................................................................................................................ 18-108
18-30 Selective Catalytic Reduction (SCR)
18-30-00 General ......................................................................................................................... 18-111
18-30-03 Tank .............................................................................................................................. 18-118
18-30-06 Filter ............................................................................................................................. 18-127
18-30-09 Tank Sensor ................................................................................................................. 18-131
18-30-12 Pump Supply Module ................................................................................................... 18-135
18-30-15 Dosing Metering Module .............................................................................................. 18-141
18-30-18 Catalyst ........................................................................................................................ 18-144
18-30-24 Coolant Valve ............................................................................................................... 18-147
18-30-30 Intake Throttle .............................................................................................................. 18-150
18-30-36 Mixer Reactor ............................................................................................................... 18-154
9813/9400-1
2017-10-05
18-30-90 Hose ............................................................................................................................. 18-156
18-35 Turbocharger
18-35-00 General ......................................................................................................................... 18-159
18-36 Variable Geometry Turbocharger (VGT)
18-36-00 General ......................................................................................................................... 18-167
18-36-03 Actuator ........................................................................................................................ 18-174
18-39 Fuel Cooler
18-39-00 General ......................................................................................................................... 18-177
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-181
18-96-03 High Pressure Pipe ...................................................................................................... 18-183
18-96-06 Low Pressure Pipe ....................................................................................................... 18-186
9813/9400-1
2017-10-05
Acronyms Glossary

CPA Connector Position Assurance
EAT Exhaust After Treatment
HPV High Pressure Valve
IMV Inlet Metering Valve
NOx Nitrogen Oxide
PPE Personal Protective Equipment
PWM Pulse Width Modulation
VGT Variable Geometry Turbocharger
WIF Water in Fuel
9813/9400-1
2017-10-05
Notes:
9813/9400-1
2017-10-05
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/9400-1 18 - 1
Notes:
18 - 2 9813/9400-1 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for
Health and Safety ........................................... 18-4 engine damage due to the use of incorrect or
Technical Data ................................................. 18-4 contaminated fuel is much greater with common
Component Identification ................................. 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Operation ......................................................... 18-6 and cleanliness requirements, refer to Consumable
Fault-Finding .................................................... 18-9 Products Refer to: PIL 75-00-00. Technical Data,
Discharge and Pressurise ............................. 18-11 Fuel, Acceptable and Unacceptable Fuels and
Clean ............................................................. 18-11 Cleanliness Requirements.
Check (Pressure) .......................................... 18-13 For information about the fuel injection system. Refer
Bleed ............................................................. 18-15 to: PIL 18-18.
Common Rail Fuel Injection

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

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

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

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

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

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9813/9400-1 18 - 3
00 - General

Fuel Table 131. 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 - 0.65bar (9.4psi)
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Fuel return restriction - 0.22bar (3.2psi)
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 9813/9400-1 18 - 4
00 - General
Figure 307.
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 9813/9400-1 18 - 5
00 - General
Operation
The fuel system is central to the performance and Some fuel flows through the pump at all times to
efficiency of the engine, distributing an accurate provide internal lubrication and cooling. This fuel
amount of fuel to each cylinder at exactly the right bleeds back to tank via the bleed-off fuel lines.
time.
Pressurised fuel from the high pressure pump
Fuel is drawn from the fuel tank by the electric passes into the common fuel rail. The high pressure
lift pump integral via the 5 micron pre-filter/water pump is capable of pressurising the fuel in the rail
separator. (The fuel lift pump is integral with the pre- up to 2000 bar. The ECM controlled IMV is used to
filter/water separator assembly.) control the amount, and therefore pressure of the fuel
in the common rail.
Fuel is pressurised at low pressure by the electric
lift pump and passes through an engine mounted 2 In some operating conditions the inlet metering valve
micron fuel filter on its way to the inlet on the high is not able to reduce the rail pressure quickly enough
pressure pump. (if the operator goes from full throttle to no throttle
suddenly for example). In these circumstances the
Important: Use of the correct fuel grade, together rail pressure is dumped to the bleed off line using the
with effective filtration and decontamination of the ECM controlled electric HPV (High Pressure Valve).
fuel is essential. The high pressure pump, injectors
and engine can be damaged beyond repair by High pressure fuel pipes connect the injectors to
contaminated fuel or use of incorrect fuel. the common fuel rail. The injectors are electrically
controlled and incorporate a small solenoid valve.
The high pressure fuel injection pump is a rotary type
and is gear driven by the engine. The pump consists Injection timing is determined by the ECM. Electrical
of two sections, the transfer pump and high pressure data from several sensors is continually monitored
pump. Fuel is first pressurised to about 6 bar by the and processed by the ECM to determine when, how
transfer pump. A constant pressure is maintained much and to which cylinder fuel must be injected.
regardless of engine speed by the regulating valve.
The injectors inject fuel in response to a supply
Fuel is transferred to the high pressure pump via of electrical current from the ECM. So precise is
the IMV (Inlet Metering Valve). The metering valve the control that several injections of fuel occur
controls the amount of fuel transferred depending on during each firing stroke for maximum efficiency and
the engine operating parameters (throttle position, minimum emissions. During fuel injection some fuel
coolant temperature etc.). The metering valve is bleeds off the injectors and back to tank via bleed off
controlled by the ECM (Engine Control Module). lines.
18 - 6 9813/9400-1 18 - 6
00 - General
Figure 308.
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 9813/9400-1 18 - 7
00 - General
2d Fuel high pressure pump (high pressure 2e Pressure regulating valve (transfer section)
section)
3 Common fuel rail 3b HPV
4 High pressure fuel lines 5 Bleed off fuel lines
6 Fuel injectors 13 Fuel filter
14 Pre-filter/water separator 15 Electric fuel lift pump
16 Fuel tank
Table 132. 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 9813/9400-1 18 - 8
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 133. Page 18-9
Fuel/Oil- Leaking from Exhaust Manifold Table 134. Page 18-9
General Fuel System Faults Table 135. Page 18-10
Exhaust Gas Recirculation Table 136. Page 18-10
Table 133. 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 134. 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 9813/9400-1 18 - 9
00 - General
Table 135. 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 136. 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 9813/9400-1 18 - 10
00 - General
Discharge and Pressurise Clean

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

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 11 9813/9400-1 18 - 11
00 - General
• Gases - Air, sulphur dioxide etc. which can Maintenance Environment, Common
create corrosive compounds if dissolved in the Rail Fuel Injection
fluid.
Depending on circumstances engine maintenance
These contaminants can appear during may be required in various working environments.
manufacture, assembly, operation and maintenance. Obviously procedures are best carried out in a
dedicated workshop equipped with a suitable clean
The main filter is rated at 2 micron = 0.002 mm
room, but in practice this is not always possible.
(0.0007874 in). The pre-filter is rated at 5 micron.
Listed are a few typical comparisons of micron size: Maintenance procedures requiring removal or
replacement of fuel system components, particularly
Figure 309.
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 9813/9400-1 18 - 12
00 - General
• Erect clean plastic sheeting to shelter the Check (Pressure)

engine from the wind and the possibility of
debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit When it is necessary to check the fuel rail pressure
when working on the fuel system. If it becomes function on a faulty vehicle, it is often difficult to
contaminated with mud, move away from the decide which component of the system has failed.
engine and change into a new suit. It is essential to keep in mind the principles of the
• Use clean latex gloves (non-powdered). function of the Common Rail Fuel system:
• Before you start work make sure that all the
required replacement parts and tools are on Table 137.
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 9813/9400-1 18 - 13
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 311. 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 310. 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 9813/9400-1 18 - 14
00 - General
Bleed
WARNING Do not open the high pressure fuel bleed automatically when the lift pump is operated.
system with the engine running. Engine operation Make sure that as much air is removed from the fuel
causes high fuel pressure. High pressure fuel as possible before the engine is started.
spray can cause serious injury or death.
Do not try to bleed the high pressure fuel system by
WARNING Bleeding of the high pressure fuel loosening high pressure pipe connections even when
system by opening the high pressure lines is not the engine is stopped. To bleed the fuel system follow
required. High fuel pressure can persist for a the steps below.
period of time when the engine has stopped. High
pressure fuel spray can cause serious injury or 1. Turn on the ignition key to start the fuel lift pump.
death.
2. Do not start the engine. Allow the pump to run for
The engine installation contains an electrically the specified time.
operated fuel lift pump. The system is designed to Duration: 30s
Figure 312.
A Fuel lift pump (The installation position and pump

may differ on your machine)
3. Turn off the ignition key to stop the fuel lift pump. 5. Start the engine and make sure it runs smoothly.
3.1. Wait for the specified time and turn the
ignition key to start the pump.
3.2. Do not start the engine. Allow the pump to
run for the specified time.
Duration: 30s
4. Do the step 3 for two more times before you start
the engine.
18 - 15 9813/9400-1 18 - 15
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-17
18 - 16 9813/9400-1 18 - 16
03 - Tank
00 - General
Introduction .................................................... 18-17 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-18 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel
tank. Therefore, you must fill the fuel tank after you
operate the engine.
Drain the water and sediment from any fuel storage

tank at the recommended service intervals.
18 - 17 9813/9400-1 18 - 17
03 - Tank
00 - General
Clean
The diesel tank must be drained if there is a chance

the fuel is contaminated or it has been filled with the
incorrect fuel.

2. Drain the diesel tank.
3. Drain the fuel from the low pressure fuel pipes.
4. Replace the fuel filters.
5. Refill the tank to the specified level with clean
diesel.
Percentage: 25%
6. Start the engine and leave it to run for the
specified time period.
Duration: 10min
7. Stop the engine.
8. Drain the water separator and the main fuel filter.
9. If there was any water or other liquid in the water
separator, repeat 6 to 8.
18 - 18 9813/9400-1 18 - 18
03 - Tank
00 - General
Remove and Install
Remove 5. Remove the access panel in the cab floor. Refer

to (PIL 06-06-39).
Some machines have a DEF (Diesel Exhaust Fluid)
tank installed if the machine has SCR (Selective 6. Remove the side step. Refer to (PIL 06-49).
Catalytic Reduction) system installed. The DEF tank 7. Remove the batteries. Refer to (PIL 33-03-00).
is a separate component but is installed within the
area of the fuel tank. When the fuel tank is removed, 8. Remove the cab exterior front and rear panels.
the DEF tank remains in place. The fuel tank must be Refer to (PIL 06-06-12) and (PIL 06-06-15).
removed before removing the DEF tank.
9. Disconnect the fuel filler neck and breather pipe
The fuel tank has to be removed before the DEF tank from the fuel tank. Take precautions to prevent
can be removed. the ingress of debris. Make sure that you do not
confuse this with the DEF tank filler.
The removal and installation procedure of all fuel
tanks is similar. Some illustrations may differ from 10. Put a label on the hoses to the fuel sender to help
your machine. installation.
1. Make the machine safe. Refer to (PIL 01-03). 11. Plug all the open ports and hoses to prevent
contamination.
2. Make sure there is sufficient clearance under the
machine to remove the fuel tank before you begin 12. Disconnect the fuel sender electrical connector.
work.
13. Disconnect the tank breather pipe at the outer
3. Remove the fuel tank drain plug and drain the side. Remove the cable tie securing it to the
fuel tank. outrigger. Stow the pipe so that it does not get
damaged during tank removal.
4. Install the drain plug and tighten to the correct
torque value. 14. Remove the bolt 1 and bolt 2.
Figure 313. Fuel Tank Drain Plug
W
W Fuel tank drain plug
18 - 19 9813/9400-1 18 - 19
03 - Tank
00 - General
Figure 314. Fuel Tank T4F

B A A C
E D
F
G
J
K
L
A Fuel pipes (sender unit) B Electrical connection (sender unit)

C Bolt 1 (pipe retaining bracket) D Bolt 2 (primary fuses bracket)
E Cable tie (breather pipe) F Breather pipe connection (outer side)
G Fuel filler neck hose clip H Fuel filler breather hose clip
J Nut 1 (tank support- front side) K Nut 2 (tank support- rear side)
L Fuel tank support bracket M Top view of tank (with cab removed for clarity)
N View of tank from LH side of machine (cut away
to show detail)
15. Make sure that there are no other wires, pipes or 16. Support the tank from below, make sure that the
hoses clipped to the tank that may be damaged load is spread evenly. Remove nut 1 and nut 2
when you lower the tank.
18 - 20 9813/9400-1 18 - 20
03 - Tank
00 - General
and washers from the tank support bracket and Figure 316.
remove it.
17. Tilt the tank and pull it towards you slightly to
allow the protrusion on the rear of the tank to
clear the bracket on the chassis.
Figure 315.
T
P S
P Protrusion on inner side of the tank.

18. Lower the tank carefully. Make sure that any fuel
U
tank or DEF tank connections do not get trapped
or damaged during the tank removal.
19. To remove the DEF tank. Refer to (PIL18-30-03).
Install
steps. L V
1.1. Remove the front side fuel tank support bolt L Tank support bracket
before installing the tank. R Fuel tank support bracket
S Fuel tank support bolt (front side)
T Spacer
U O-ring (spacer retention)
V Locknut and washer
1.2. Set the spacer on the fuel tank support
bolt so there is approximately the specified
clearance between the spacer and the
underside of the head of the bolt. The
spacer is held in position by an O-ring
installed on the bolt.
1.3. Make sure that you do not install the
fuel tank support bolt without the spacer
installed correctly on the bolt.
1.4. Make sure that all foam and rubber mats
and seals on the tank are in good condition.
Install new parts if they are defective.
1.5. Install the front side fuel tank support bolt.
1.6. Install the tank. When you install the tank,
tilt it to allow the protrusion on the rear of the
tank to fit above the bracket on the chassis.
18 - 21 9813/9400-1 18 - 21
03 - Tank
00 - General
1.7. If required, reposition the rear side tank

support bracket bolt so it protrudes
correctly.
1.8. Install the fuel tank support bracket and
locking nuts and washers (use new locking
nuts).
1.9. Make sure that the DEF tank and
connections are not damaged during this
procedure.
1.10. Make sure that hoses or wires are not
twisted or trapped.
1.11. Tighten the fuel tank support bracket nuts
1.12. Reinstall all pipework, electrical
connectors, brackets, cable ties and the
filler neck. Make sure that no hoses are
twisted or trapped.
1.13. Make sure that all connections are tight
and correctly secured.
1.14. Fill the fuel tank with clean fuel.
1.15. Bleed the fuel system. Refer to (PIL
18-00).
1.16. Check for leaks. Refer to (PIL 18-00).
1.17. Install all access panels. Refer to (PIL
06-06).

Item Nm
W 9
TBA
TBA
18 - 22 9813/9400-1 18 - 22
06 - Level Sender
06 - Level Sender
Contents Page No.
18-06-00 General ........................................................................................................................... 18-25
18 - 23 9813/9400-1 18 - 23
Notes:
18 - 24 9813/9400-1 18 - 24
06 - Level Sender
00 - General
00 - General
Remove and Install
Notice: Do not allow dirt to enter the fuel system. 3. Isolate the battery. Refer to (PIL 33-03-03).
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a 4. Remove the cab floor access plate, Refer to (PIL
component has been disconnected, for example 06-06-39).
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow 5. Make sure that the area around the sender unit
these instructions will lead to dirt entering the is clean. Make sure that no debris can enter the
fuel system. Dirt in the fuel system will seriously fuel tank.
damage the fuel injection equipment and could be 6. Disconnect the fuel feed and return hoses and
expensive to repair. plug the ends. Mark each hose before you
disconnect them to make sure they are correctly
Remove replaced.
1. Make the machine safe. Refer to (PIL 01-03). 7. Disconnect the fuel sender electrical connector.
2. Make sure that the tank contains no more than

the specified amount of fuel.
Percentage: 75%
Figure 317. Diesel Fuel Tank (Cab removed for clarity)

D A C B
A Diesel fuel sender unit B Diesel fuel pipes

C Sender electrical connector D Diesel fuel tank
8. Remove the screws from the annular ring that

secures the sender unit to the fuel tank.
18 - 25 9813/9400-1 18 - 25
06 - Level Sender
00 - General
Figure 318. Sender Unit

E
D
D Diesel Fuel Tank
E Screw (x6)
9. Manoeuvre the fuel sender to remove it from the
tank.
Install
steps.
1.1. Make sure that no debris enters the fuel
tank or fuel system.
1.2. Tighten all fasteners to the correct torque
value.
1.3. Renew the sender unit O-ring seal.
1.4. Bleed the fuel system. Refer to (PIL
18-00-00).
1.5. Make sure there are no leaks. Refer to (PIL
18-00-00).

Item Nm
E 5
18 - 26 9813/9400-1 18 - 26
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-29

18-09-03 Filter Element ................................................................................................................. 18-34
18-09-09 Pre-Filter Element .......................................................................................................... 18-36
18 - 27 9813/9400-1 18 - 27
Notes:
18 - 28 9813/9400-1 18 - 28
09 - Filter
00 - General
Introduction .................................................... 18-29 The fuel filter consists of a paper element folded in
Component Identification ............................... 18-30 such a way as to give a very large surface area. It is
Operation ....................................................... 18-31 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-31 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 29 9813/9400-1 18 - 29
09 - Filter
00 - General
Figure 319.
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 - 30 9813/9400-1 18 - 30
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 - 31 9813/9400-1 18 - 31
09 - Filter
00 - General
Remove and Install Remove - Disposable Type

Description Part No. Qty. E
Spanner - HP Fuel 334/G5933 1 C
Filter
Fuel Filter Removal 892/01383 1
Tool (4 cyl)
D
Before Removal
2. Get access to the filter.
A
2.1. On some machines the filter is located on
the engine. Other machines have remotely
located filters. There may be more than
one filter. Refer to the relevant service point
information for details.
2.2. There are different types of filters. Refer to B
the correct procedure. A Filter
B Drain tap
3. Thoroughly clean the outside of the filter housing C Low pressure fuel line
and around the filter head. D Screw
E Low pressure fuel line
4. Loosen the drain tap and allow the water / fuel to
drain into a suitable container. 1. Remove the low pressure fuel lines.
5. On machines with a fuel shut-off valve, set the 1.1. Put a label on the hoses to help installation.
valve to isolate the fuel supply.
Figure 320. 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: 24N·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 - 32 9813/9400-1 18 - 32
09 - Filter
00 - General
Remove - Element Type

Figure 322.
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: 35N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
18 - 33 9813/9400-1 18 - 33
09 - Filter
03 - Filter Element
03 - Filter Element Remove - Disposable Type

Figure 324.
Remove and Install E
Special Tools C
Spanner - HP Fuel 334/G5933 1
Filter
Fuel Filter Removal 892/01383 1 D
Tool (4 cyl)
Before Removal
you start the service work. A
2. Get access to the filter.
2.1. On some machines the filter is located on
the engine. Other machines have remotely
located filters. There may be more than
one filter. Refer to the relevant service point B
information for details. A Filter
B Drain tap
2.2. There are different types of filters. Refer to
C Low pressure fuel line
the correct procedure.
D Screw
3. Thoroughly clean the outside of the filter housing E Low pressure fuel line
and around the filter head.
1. Remove the low pressure fuel lines.
4. Loosen the drain tap and allow the water / fuel to
1.1. Put a label on the hoses to help installation.
drain into a suitable container.
5. On machines with a fuel shut-off valve, set the contamination.
valve to isolate the fuel supply.
2. Release the filter strap retaining screw and lift the
Figure 323. filter upward.
A
Install - Disposable Type
1. Make sure that the filter is in the correct position
to enable connection of the fuel lines.
2. Install the filter strap.
B
2.1. Tighten the filter strap to the correct torque
value.
Torque: 24N·m
A Fuel filter element 3. Install the low pressure fuel lines.

B Drain tap
3.1. Make sure they are installed at the correct
ports.
18 - 34 9813/9400-1 18 - 34
09 - Filter
03 - Filter Element
Remove - Element Type

Figure 325.
C
A Filter head
B Filter element
C Drain tap
1. Use the applicable service tool to unscrew the
filter element from the filter head (anticlockwise).
Special Tool: Fuel Filter Removal Tool (4 cyl)
(Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.: 1)
Install - Element Type

1. Lubricate the element seals with clean fuel and
install a new filter element.
1.1. Make sure that the filter flange touches the
filter head.
1.2. Use the applicable service tool to tighten to
Torque: 35N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
18 - 35 9813/9400-1 18 - 35
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-36 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-37 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 36 9813/9400-1 18 - 36
09 - Filter
09 - Pre-Filter Element

Remove removal procedure. Additionally do the following
steps.
2. Install a new filter element and secure in position
2. Get access to the filter. with the locking ring.
3. On machines with a fuel shut off valve, set the 3. Make sure that the water in fuel electrical
valve to isolate the fuel supply. connector is correctly installed.
4. Drain the water separator bowl. 4. On machines with a fuel shut-off valve, set the
valve to connect the fuel supply.
5. Disconnect the water in fuel sensor.
6. Release the locking ring and remove water
separator bowl. Any fuel and water mix drained
must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
7. Release the locking ring and remove the filter
element, discard the element.
Figure 326.
E
A Filter Element
B Filter element locking ring
C Water separator bowl locking ring
D Water separator bowl
E Water in fuel electrical connector
18 - 37 9813/9400-1 18 - 37
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-39

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-42
18 - 38 9813/9400-1 18 - 38
00 - General
Introduction .................................................... 18-39 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-40 lift pump is a sealed integral electrical unit. The
Clean ............................................................. 18-40 assembly is a non-serviceable component. If any
Remove and Install ....................................... 18-41 part is defective, replace the complete pump, filter
and separator assembly.
Figure 327.
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 - 39 9813/9400-1 18 - 39
00 - General
Drain and Fill Clean

1. Obey all fuel system health and safety
information.
Draining the Water Separator
Refer to: PIL 18-00-00. 1. Make the machine safe. Refer to (PIL 01-03).
2. Make the machine safe. 2. Get access to the filter.

Refer to: PIL 01-03. 3. If there is water but no sediment, open the tap
to drain the water. If there is any sediment in
3. Drain off any water in the filter element by turning the bowl replace the fuel filter element. Do not
the tap. disconnect the electrical connector (if installed).
4. Drain off any water in the water separator bowl 4. Tighten the drain tap when all the water is
by turning the tap. Do not disconnect the water drained.
in fuel electrical connector (if installed).
Figure 329.
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 328. Typical Engine
A
B
B
A Tap
B Bowl
A Fuel filter
B Drain tap
18 - 40 9813/9400-1 18 - 40
00 - General
Remove and Install
Refer to Fuel and Exhaust system - Filter - Pre-Filter

Element. Refer to: PIL 18-09.
18 - 41 9813/9400-1 18 - 41
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-42 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-43 filter water bowl. A warning light will illuminate in
the instrument panel to indicate that water has
accumulated in the fuel filter water bowl and must be
drained.
18 - 42 9813/9400-1 18 - 42
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 330.
A 1
1 Fixing screw
2 Electrical connections
A Water in fuel sensor
Install
removal procedure.
18 - 43 9813/9400-1 18 - 43
15 - Filler
15 - Filler
Contents Page No.
18-15-00 General ........................................................................................................................... 18-45
18 - 44 9813/9400-1 18 - 44
15 - Filler
00 - General
00 - General Install
step.
Fuel Filler Pipe 1.1. Make sure that no debris enter the fuel or
DEF system.
Remove Figure 331.
1. Make sure that the fuel level is below the level of
the top of the fuel tank. E
D
2. Remove the cab rear access cover plate. Refer
to (PIL 06-06-14).
3. Make sure that the area is clean to prevent the C
contamination of the tank with debris. B
4. Loosen the clip securing the filler pipe to the fuel

tank.
5. Loosen the clip securing the filler pipe to the filler
A
neck.
A
6. Remove the filler pipe.
7. If needed, Install a plug over the tank to prevent A
the ingress of debris.
Install
removal procedure.
Fuel Filler Neck

A Studs / nuts (location)
Remove B Exterior view of filler assembly
C Rear view of filler moulding assembly
The fuel filler neck incorporates apertures for diesel D Diesel fuel filler neck
fuel and DEF (Diesel Exhaust Fluid). E DEF filler aperture
Make sure that the area around these components

is scrupulously clean. Make sure debris do not
contaminate the fuel or DEF system. Make sure that
there is no cross contamination between diesel fuel
and DEF. Refer to (PIL 15-30).
1. Remove the diesel fuel pipe from the filler neck

see 1
2. Remove the DEF pipe from the filler neck and
install a plug on to the open DEF pipe. Refer to
(PIL 15-30).
3. Remove the diesel fuel and DEF filler caps. Make
sure they are stored in a clean location.
4. Remove the securing nuts from the filler neck
moulding assembly.
5. Remove the filler neck moulding assembly.
18 - 45 9813/9400-1 18 - 45
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-47

18-18-03 Injector ............................................................................................................................ 18-62
18-18-07 Injector Seal ................................................................................................................... 18-67
18-18-12 Rail ................................................................................................................................. 18-69
18-18-15 Pump .............................................................................................................................. 18-71
18-18-27 High Pressure Rail Valve ............................................................................................... 18-78
18 - 46 9813/9400-1 18 - 46
18 - Injection
00 - General
Introduction .................................................... 18-47 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-48 injectors via high pressure fuel pipes.
Operation ....................................................... 18-49
Fault-Finding .................................................. 18-52 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
Check (Operation) ......................................... 18-59 the tubes are formed with conical nipples for sealing
Calibrate ........................................................ 18-61 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 - 47 9813/9400-1 18 - 47
18 - Injection
00 - General
Figure 332.
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 - 48 9813/9400-1 18 - 48
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 333.
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 - 49 9813/9400-1 18 - 49
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 335.
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 334. 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 - 50 9813/9400-1 18 - 50
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 - 51 9813/9400-1 18 - 51
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 140. Page 18-52
Injector Trim Codes Table 141. Page 18-52
Open Circuit Injector Table 142. Page 18-53
Injection Bank Table 143. Page 18-53
Short Circuit Injector Table 144. Page 18-54
Engine Low on Power Table 145. Page 18-54
Injector Calibration Table 146. Page 18-55
Open Circuit Injector Table 147. Page 18-55
High Pressure Injection Diagnostics Table 148. Page 18-56
Fuel Rail Pressure Calibration Table 149. Page 18-56
IMV Table 150. Page 18-57
HPV Table 151. Page 18-57
Table 140. 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 141. 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 - 52 9813/9400-1 18 - 52
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 142. 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 143. 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 - 53 9813/9400-1 18 - 53
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 144. 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 145. 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 - 54 9813/9400-1 18 - 54
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 146. 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 147. 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 - 55 9813/9400-1 18 - 55
18 - Injection
00 - General
Table 148. 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 149. 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 - 56 9813/9400-1 18 - 56
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 150. 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 151. 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 - 57 9813/9400-1 18 - 57
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 - 58 9813/9400-1 18 - 58
18 - Injection
00 - General
Check (Operation) Figure 338. Injector leak off test kit
Special Tools
Servicemaster 721/10855 1
Electronic Test Cable
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
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 /
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 - 59 9813/9400-1 18 - 59
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 - 60 9813/9400-1 18 - 60
18 - Injection
00 - General
Calibrate
Since the injector operating components are by recorded in code form and attached to the injector
necessity very small, even the most advanced body.
manufacturing techniques do not ensure consistent
injection cycle characteristics between injectors. The codes for each injector installed to the engine are
programmed into the ECM (Engine Control Module).
For example, small variations in the metering orifice The operating software in the ECM uses the data
sizes will alter the time durations for the start and to adjust the control of the injector solenoid coil
stop of fuel injection. The small dimensions involved accordingly. The injector is therefore effectively re-
mean that only a tiny variation will alter the orifice calibrated by the ECM.
area by a relatively large percentage.
It follows that if injectors are removed they must
For this reason it is necessary to individually test and always be installed in their original positions. If
record the operating characteristics of each injector new injectors are installed the ECM must be
assembly at the factory. The results of the test are reprogrammed with the new injector codes.
Figure 339.
18 - 61 9813/9400-1 18 - 61
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-62 The fuel Injectors are electronically controlled and
Component Identification ............................... 18-63 incorporate a small solenoid valve. The injectors are
Check (Operation) ......................................... 18-63 supplied with pressurised fuel by the high pressure
Remove and Install ....................................... 18-64 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 340.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 62 9813/9400-1 18 - 62
18 - Injection
03 - Injector
Component Identification Check (Operation)

Special Tools
Figure 341. Description Part No. Qty.
Injector Leak-off Test 892/12350 1
N Kit ((Electronic Engine))
H
Injector Cap Kit 892/12359 1
G
The injectors can be tested using Servicemaster
D F diagnostics and by means of a leak off test. To test
M for a defective injector first use Servicemaster to
diagnose the problems with the high pressure fuel
E injection equipment, specifically when the engine
does not start.
C
Leak Off Test
J
The leak off test kit must be installed on the engine
and the ServiceMaster must be used to test the
engine.
1. Operate the engine until it reaches its normal

operating temperature.
2. Stop the engine. Remove the bleed off pipe at
B each injector. Refer to (PIL 18-96). Cap the open
connectors on the pipes with the caps in the
A injector leak off test kit.
Special Tool: Injector Leak-off Test Kit
((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
3. Connect the test pipes to the leak off ports on the
L four injectors.
4. Position the four plastic bottles as upright as
possible. Keep the test equipment clear of
A Multi-point injector nozzle components that get hot when the engine is
B Needle operated.
C Spacer
5. Connect a test pipe to the leak off ports on the
D Nut
High Pressure valve outlet. Cap the open pipe.
E Valve
F Solenoid coil 6. Make sure it is safe to start the engine.
G Valve spring
H Calibration dowel 7. Use ServiceMaster to control the tests. Refer to
J Injector spring Fuel Injection - Check Operation (PIL 18-18).
L Electrical connector
M Return port (bleed off) 7.1. Fuel System Diagnostic Test (Cranking
N High pressure port and filter element Only).
7.2. Fuel System Diagnostic Tests (Engine
Running).
8. Examine the fuel levels in the test bottles. If the
difference between any of the levels is more than
10 ml. this indicates that there are one or more
defective injectors.
9. Remove the test equipment and replace the
bleed off pipes. Refer to (PIL 18-96).
18 - 63 9813/9400-1 18 - 63
18 - Injection
03 - Injector
Figure 342. Remove and Install

B
The following procedure is for one injector, the
A procedures are identical for all injectors.
Note: The original injector calibration codes are

located on a label on the rocker cover.
A
Before Removal
A
A 4. Remove the fuel bleed off fuel pipes. Refer to

6. Record which injector is for which cylinder. The
injectors must be installed in the same positions.
Note: If a fuel injector is defective, it must be

replaced.
Remove
1. Remove the injector clamp retaining bolt and lift
the clamp away.
A Injectors (x4)
B HP valve
18 - 64 9813/9400-1 18 - 64
18 - Injection
03 - Injector
4 X 1 5
2
1 Injector
2 Injector clamp
3 Retaining bolt
4 Injector sleeve
X Injector bleed-off port 6
2. Remove and discard the sealing washer. Label
the injector to make sure it is installed in its
original cylinder. Put a clean protective cap over
the nozzle of the injector. 7
3. Remove and discard the O-ring.
5 Protective cap
6 Protective cap
7 Sealing washer
Install
Important: The fuel injectors are not interchangeable
between cylinders or other engines. Make sure you
install the injectors in the same positions. If a new
or different injector is installed, the engine electronic
control unit (ECU) must be re-programmed. Refer to
(PIL 33-45), Engine Electronic Control Unit, Vehicle
Set Up Data.
When new or different injectors are installed, record

the calibration code. Record which cylinder the
injector is installed into. Refer to (PIL 33-45), Engine
Electronic Control Unit, Vehicle Set Up Data.
18 - 65 9813/9400-1 18 - 65
18 - Injection
03 - Injector
Figure 345. Table 152. Torque Values

Item Nm
A 3 28
4 39
D
C
A Correction factor (20 characters)

B Manufacturers reference
C JCB part number
D Injector serial number
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
or surface contamination will cause the injector
sealing O-ring to fail.
3. Install a new O-ring.
4. Install a new sealing washer.
5. Make sure that the injector is installed in the
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the
engine. Make sure the injector is pushed fully into
the cylinder head.
6. Tighten the injector clamp bolt to the correct
torque value.
After Installation
1. Replace the rocker cover, refer to (PIL 15-42).
2. Renew the high pressure fuel pipes, Refer to Fuel
Pipes (PIL 18-96).
3. Replace the low pressure fuel pipes, Refer to
4. Start the engine and check for fuel leaks.
18 - 66 9813/9400-1 18 - 66
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 346.
A Rocker cover B Bolts

C Gasket D Injector seals
18 - 67 9813/9400-1 18 - 67
18 - Injection
07 - Injector Seal
Remove Figure 348.
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 347.
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 - 68 9813/9400-1 18 - 68
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-69 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-70 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 349.
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 - 69 9813/9400-1 18 - 69
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 153. 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 - 70 9813/9400-1 18 - 70
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-71 The high pressure fuel injection pump is a rotary
Component Identification ............................... 18-72 type device that pumps fuel into the cylinders of
Operation ....................................................... 18-72 the engine. The pump is driven indirectly from the
Remove and Install ....................................... 18-74 crankshaft by gears refer to (PIL 15-51).
18 - 71 9813/9400-1 18 - 71
18 - Injection
15 - Pump

Figure 351. 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.
13 The rotor rotates inside an eccentric liner. The
6 vanes are held in contact with the liner by springs.
5 Fuel is drawn into the pump chamber at port X,
pressurised by the decreasing volume inside the
chamber and expelled at port Y. Fuel pressure
4 2 11 generated by the transfer pump is limited to a
1 Fuel injection pump specified pressure by an integral pressure regulating
2 Pump fixing nuts (x3) valve. This pressure is maintained regardless of
3 Injection pump gear cover engine speed.6bar (87.0psi)
4 Inlet metering valve electrical connector
5 Fuel temperature sensor electrical connector Figure 352.
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 - 72 9813/9400-1 18 - 72
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 354.
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 353.
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 - 73 9813/9400-1 18 - 73
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)
Tamperproof 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 - 74 9813/9400-1 18 - 74
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 - 75 9813/9400-1 18 - 75
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 360.
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: Tamperproof Cover Removal Tool
(Qty.: 1)
18 - 76 9813/9400-1 18 - 76
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 154. Torque Values
on the pump.
Item Nm
4. Install a new high pressure fuel pipe, remove 2 24
the protective caps from the ports, refer to Fuel 3 70
Pipes- Remove and Install, refer to (PIL 18-96). 9 65
5. Connect the electrical connectors at the IMV and
the fuel temperature sensor.
6. Replace the fuel filter, refer to (PIL 18-09).
18 - 77 9813/9400-1 18 - 77
18 - Injection
27 - High Pressure Rail Valve
27 - High Pressure Rail Valve Introduction

Introduction .................................................... 18-78 The HPV (High Pressure Valve) is an integral part
Operation ....................................................... 18-79 of the common fuel rail assembly, If the valve
Check (Operation) ......................................... 18-79 is defective replace the complete common rail
Remove and Install ....................................... 18-80 assembly. (Refer to PIL 18-18).
Figure 363. High pressure valve location
Figure 364.
A HPV
B Solenoid coil
18 - 78 9813/9400-1 18 - 78
18 - Injection
In certain operating conditions, the HPV (High For the full inspection and testing procedure, refer to
Pressure Valve) controls the fuel pressure inside the the help files in ServiceMaster.
common rail.
When the valve opens, fuel is bled from the rail back
to the fuel tank, reducing the fuel pressure inside the
fuel rail. The valve is actuated by a solenoid coil and
features proportional control. The fuel flow through
the valve is proportional to the current supplied to
the coil. The current value is controlled by the ECM
(Engine Control Module) using PWM (Pulse Width
Modulation).
During normal engine operation, the fuel pressure is

controlled solely by the IMV (Inlet Metering Valve),
In some operating circumstances, the IMV is unable

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

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

by altering the control of the HPV to ensure the
engine performance is sufficient to limp home.
18 - 79 9813/9400-1 18 - 79
18 - Injection
Remove and Install
This part is a non-serviceable component, if it

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
18 - 80 9813/9400-1 18 - 80
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-83
18 - 81 9813/9400-1 18 - 81
Notes:
18 - 82 9813/9400-1 18 - 82
21 - Fuel Pump
00 - General
Introduction .................................................... 18-83 The fuel lift pump is a sealed electrical unit integral
Technical Data ............................................... 18-85 with the fuel pre-filter and water separator.
Operation ....................................................... 18-86
Check (Operation) ......................................... 18-86 The fuel lift pump is a non-serviceable component.
If any part is defective, replace the complete pump,
Remove and Install ....................................... 18-87 filter and separator assembly.
Figure 365.
A Fuel lift pump

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

from a 24V supply by means of an in-line voltage
reducer.
18 - 83 9813/9400-1 18 - 83
21 - Fuel Pump
00 - General
Figure 366.
A
A Lift pump motor

B Voltage reducer
C In-line electrical connector
D Harness electrical connector
18 - 84 9813/9400-1 18 - 84
21 - Fuel Pump
00 - General
Technical Data
Table 155.
Component Value
Operating pressure 0.8bar (11.6psi)
Expected minimum free 2.5L/min
flow delivery
Table 156. 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 - 85 9813/9400-1 18 - 85
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 2min if no fuel is present.
1. Make the machine safe, refer to (PIL 01-03).
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: 5L
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: 1min
Flowrate: 2.5L/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 24s. A fuel pump flow test can be carried
out during this period of time. Minimum expected fuel
flow. 1L in 24s.
Alternatively use the JCB engine diagnostic tool

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5s delay the pump runs for a
period of 24s.
18 - 86 9813/9400-1 18 - 86
21 - Fuel Pump
00 - General
Remove and Install
Remove 4. Disconnect the WIF (Water in Fuel) sensor

harness connector.
5. Make sure to mark label on the fuel pipes to aid
The fuel lift pump is installed on the loader tower. in the installation.
This procedure is also similar for the machines with
6. Disconnect the fuel pipes at the fuel lift pump by
lift pumps installed on the side of the fuel tank.
means of the quick release connectors.
1. Make the machine safe. Refer to (PIL 01-03). 7. Disconnect the drain hose at drain tube.
2. Disconnect the battery. 8. Support the fuel lift pump and remove the bolts.
3. Disconnect the fuel lift pump harness connector. 9. Remove the fuel lift pump together with its pre-
filter/separator from the machine.
Figure 367.
D
C
A B E
H
F
A WIF sensor harness connector B Fuel pipe

C Fuel lift pump harness connector D Fuel lift pump
E Fuel pipe F Bolt
G Drain tube H Pre-filter/Seperator
J Fuel pipe
Install
removal procedure.
Table 157. Colour code

Fuel pipe Colour
E Blue
J Red
18 - 87 9813/9400-1 18 - 87
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-89

18-24-03 Inlet Manifold .................................................................................................................. 18-91
18-24-04 Outlet Manifold ............................................................................................................... 18-95
18 - 88 9813/9400-1 18 - 88
24 - Exhaust
00 - General
Introduction .................................................... 18-89 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-90 away from the controlled combustion inside the
Check (Condition) .......................................... 18-90 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 - 89 9813/9400-1 18 - 89
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 - 90 9813/9400-1 18 - 90
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-91 The inlet manifold (or intake manifold) supplies
Component Identification ............................... 18-92 combustion air to the cylinders in compression
Check (Condition) .......................................... 18-92 ignition engines or the air/fuel mixture for spark
Remove and Install ....................................... 18-93 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 - 91 9813/9400-1 18 - 91
24 - Exhaust
03 - Inlet Manifold

Figure 368. 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 - 92 9813/9400-1 18 - 92
24 - Exhaust
03 - Inlet Manifold
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on. If
1. This procedure requires service parts. Make you start the service work.
before you start, refer to Parts Catalogue. 3. Get access to the engine.
4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 369.
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 - 93 9813/9400-1 18 - 93
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 - 94 9813/9400-1 18 - 94
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-95 Figure 370.
Component Identification ............................... 18-96 A B
Check (Condition) .......................................... 18-96
A Exhaust manifold
B Manifold gasket and heat shield
18 - 95 9813/9400-1 18 - 95
24 - Exhaust

Figure 371. 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 - 96 9813/9400-1 18 - 96
24 - Exhaust
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on. If
1. This procedure requires service parts. Make you start the service work.
before you start, refer to Parts Catalogue. 3. Get access to the engine.
4. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 372.
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 - 97 9813/9400-1 18 - 97
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 - 98 9813/9400-1 18 - 98
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ......................................................................................................................... 18-101

18-27-03 Actuator ........................................................................................................................ 18-108
18 - 99 9813/9400-1 18 - 99
Notes:
18 - 100 9813/9400-1 18 - 100

00 - General
Introduction .................................................. 18-101 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................. 18-102 a technique that re-circulates a portion of the
Operation ..................................................... 18-103 exhaust gases back into the combustion chamber.
Check (Condition) ........................................ 18-104 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 - 101 9813/9400-1 18 - 101

00 - General
Figure 373.
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 160. Colour Code Key

Colour System
Blue Coolant Flow 1
Red Recirculated Gas Flow
Green Air Flow
Yellow Coolant flow 2
18 - 102 9813/9400-1 18 - 102

00 - General
Operation Figure 376.
1. Exhaust gases enter the exhaust manifold.

Figure 374.
4. Exhaust gases enter the mixer tube.

Figure 377.
2. The exhaust gases travel through the
intermediate EGR (Exhaust Gas Recirculation)
cooler.
Figure 375.
5. The exhaust gases are mixed with new air and

re-enter the engine.
Figure 378.
3. The exhaust gases enter the main cooler which
reduces the heat.
18 - 103 9813/9400-1 18 - 103

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 - 104 9813/9400-1 18 - 104

00 - General
Remove and Install

Figure 379.
C
B D
E
A
F
G

C EGR (Exhaust Gas Recirculation) actuator D EGR valve
E EGR Intermediate Cooler F Main Plate Cooler
G Mixer Tube
18 - 105 9813/9400-1 18 - 105

00 - General
Remove 8. Remove the four bolts that retain the heat-shield

to the EGR control module.
1. Remove the EGR cooler hose (LHS viewed from
the rear of the engine). 9. Remove the bolt from the cooler pipe.
2. Remove the two EGR cooler bracket assembly 10. Remove the cooler connections (four banjo
bolts. fittings and copper washers) from the EGR
control module and electrical harness connector.
3. Carefully remove the main EGR cooler.
11. Remove the three small bolts that fix the control
4. Remove the EGR cooler hose (RHS viewed from module to the EGR valve.
the rear of the engine).
12. Remove the two bolts that fix the EGR bracket to
5. Remove the four nuts fixing the EGR tube in tube 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 380.
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 - 106 9813/9400-1 18 - 106

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 161. Torque Values
the correct order, 1 to 4 as shown in 2 stages.
Item Nm
Figure 381. 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 - 107 9813/9400-1 18 - 107

03 - Actuator
03 - Actuator Introduction
Introduction .................................................. 18-108 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ..................................... 18-109 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 - 108 9813/9400-1 18 - 108

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 - 109 9813/9400-1 18 - 109

30 - Selective Catalytic Reduction (SCR)
Contents Page No.
18-30-00 General ......................................................................................................................... 18-111

18-30-03 Tank .............................................................................................................................. 18-118
18-30-06 Filter ............................................................................................................................. 18-127
18-30-09 Tank Sensor ................................................................................................................. 18-131
18-30-12 Pump Supply Module ................................................................................................... 18-135
18-30-15 Dosing Metering Module .............................................................................................. 18-141
18-30-18 Catalyst ........................................................................................................................ 18-144
18-30-24 Coolant Valve ............................................................................................................... 18-147
18-30-30 Intake Throttle .............................................................................................................. 18-150
18-30-36 Mixer Reactor ............................................................................................................... 18-154
18-30-90 Hose ............................................................................................................................. 18-156
18 - 110 9813/9400-1 18 - 110

00 - General
Introduction .................................................. 18-111 To meet Tier 4 emission standards, this machine has
Health and Safety ........................................ 18-112 EAT (Exhaust After Treatment) using SCR (Selective
Technical Data ............................................. 18-113 Catalytic Reduction) technology. In SCR technology
Component Identification ............................. 18-114 a liquid called DEF (Diesel Exhaust Fluid) is injected
into the exhaust gases.
Check (Condition) ........................................ 18-115
DEF is specified in standards DIN 70070 and ISO
22241. Most commonly known trademarks of DEF
are:
• AdBlue
• Air1
• Greenox
The SCR system consists of the engine control

system, An exhaust muffler containing the SCR
catalyst and the DEF injection system. These are
connected together by a CAN (Controller Area
Network)bus, refer to (PIL 33-45).
The engine control system is mounted on the engine.

It controls the normal functions of the engine as well
as the SCR system. For further information refer to
the SCR control module (PIL 33-45).
The DEF consumption depends upon the duty cycle

of the engine. The DEF tank and pipes are heated
so that the system works in low temperatures. If DEF
freezes, it is automatically defrosted when the engine
is started. The freezing point of DEF with 32.5%
urea concentration is -11 °C. The only maintenance
required in normal use is the DEF filter change for
the supply module. Refer to DEF Filter (PIL 18-30).
The SCR is equipped with on-board diagnostic

systems which will warn the operator or limit the
usage of the machine if any problems occur in the
system; for example leakages or blocking of lines.
Make sure that genuine DEF is used (DIN 70070 or

ISO 22241 certified). Do not dilute DEF or mix it with
other substances, it may damage the catalyst.
When filling the DEF tank, make sure that you use
the DEF filler and not the fuel filler. Even small
amounts of DEF in the fuel tank may damage the
system. If there is any possibility that fuel has been
contaminated with DEF, the engine must not be
started before emptying and cleaning the fuel tank.
Make sure that no other substances can get in to
the DEF tank. If there is any possibility that the DEF
tank could have been misfiled or contaminated do
not start the engine. Drain and clean the tank before
refilling with clean, good quality DEF. Refer to (PIL
18-30-03).
Supplementary admixtures or additives are not

allowed. Do not dilute DEF or mix it with other
substances as it may damage the catalyst. If the DEF
18 - 111 9813/9400-1 18 - 111

00 - General
quality sensor detects a problem, it will cause the Health and Safety
engine to run at reduced power.
Be careful when handling DEF. It is aggressive to Diesel Exhaust Fluid (DEF)

some materials and corrosive to some metals. DEF If large quantities of DEF have been swallowed
becomes crystalline when in contact with air. In case a doctor should be called immediately. Do not
of a spillage, rinse with plenty of water and dry with induce vomiting unless directed to do so by medical
a clean cloth. personnel. Never give anything by mouth to an
unconscious person. Avoid prolonged or repeated
skin contact. After contact with skin wash thoroughly
with plenty of soap and water. If irritation develops
seek medical advice. Avoid contact with eyes,
skin and clothing. Wear chemical resistant gloves,
overalls and safety goggles complying with an
approved standard. If in contact with eyes, rinse
immediately with plenty of clean water. If irritation
occurs seek medical attention. Always wash hands
and arms thoroughly after handling before eating,
drinking, smoking or using the lavatory. DEF is
corrosive to some metals such as copper and
its alloys. Use only recommended storage and
dispensing systems. DEF solution is very polluting
to surface water and groundwater. DEF may not
be removed by oil separators so it is important to
isolate drainage from the dispensing area to prevent
pollution in the event of a spill. Store below 30
degrees C in a segregated, approved and labelled
area. Keep container closed.
Notice: No warranty liability whatsoever will be
accepted for failure of the emissions control system
where the failure is attributed to the quality and grade
of the diesel exhaust fluid (DEF) used.
Notice: No warranty liability whatsoever will be
accepted for failure of the emissions control system
where the failure is attributed to contamination of the
diesel exhaust fluid (DEF).
18 - 112 9813/9400-1 18 - 112

00 - General
Technical Data
Table 162.
Description Data
Recommended DEF (Diesel Exhaust Fluid) 32.5% Urea, 67.5% Water (Must meet Standards
ISO 22241 and DIN70070)
18 - 113 9813/9400-1 18 - 113

00 - General
Figure 382.
G
E
F
L
D
L L
C J
A
K
O
A
M
P
B
A NOx (Nitrogen Oxide) sensor upstream B NOx sensor downstream

C Dosing metering module D SCR (Selective Catalytic Reduction) dosing
control module
E Pump supply module F Coolant valve
G Tank sensor H Heated DEF (Diesel Exhaust Fluid) hoses
I SCR catalyst J DEF tank
K Harness to ECM (Engine Control Module) L Engine coolant hoses
M Exhaust gas in (dirty) N Exhaust gas out (clean)
O Mixer reactor P Exhaust temperature sensor
18 - 114 9813/9400-1 18 - 114

00 - General
Special Tools
Meter (hydrometer) 333/H5664 1
Kit Vacuum Pump 998/10424 1
A
It may be necessary to obtain a sample of DEF
(Diesel Exhaust Fluid) if contamination is suspected
or to check the operation of the DEF quality sensor.
This procedure must be carried out in clean

conditions, make sure that no contamination of any
kind is allowed to enter the DEF tank.
Make sure that all test equipment is scrupulously

clean. Any contamination can make test results
inaccurate. A DEF Filler cap
This procedure does not apply to T4F machines Figure 384.

installed with engines under 55kW.
1. Make the machine safe. Refer to (PIL 01-03). B
2. Follow the general health and safety procedures.

3. Make sure that you wear the correct
PPE (Personal Protective Equipment) for the
procedure. Refer to (PIL 01-03).
4. Make sure that the area around the DEF filler
cap is scrupulously clean. The location of the
DEF filler may vary according to your machine.
Consult the operators manual.
B Hexagonal key
5. For 506, 507, 509, 510, 512 and 514 machines,
do the following: Figure 385.
5.1. Use the correct hexagonal key to remove
the screws (x3) that attach the cap and
strainer to the machine.
5.2. Remove the blue cap and strainer assembly
by rotating counterclockwise and remove it
from the tank.
18 - 115 9813/9400-1 18 - 115

00 - General
C DEF Cap and strainer assembly

6. For all other machines, unlock and remove the
DEF tank cap.
6.1. Remove the strainer by rotating it
counterclockwise and remove from the tank Figure 389. DEF Strainer (Other machines)
filler neck.
6.2. Make sure that any contamination retained D
in the strainer does not enter the tank.
Figure 387. DEF Filler location (Other machines)
D DEF Strainer
7. Assemble the JCB sampling kit and feed the
hose in to the DEF tank through the filler neck.
Special Tool: Kit Vacuum Pump (Qty.: 1)
8. Make sure the hose is fully inserted in to the
bottom of the DEF tank.
9. Pump and fill the sample bottle with the required
amount of DEF.
A DEF Cap
18 - 116 9813/9400-1 18 - 116

00 - General
Figure 390. DEF Sampling Kit Special Tool: Meter (hydrometer) (Qty.: 1)
13. The float should rise so that the DEF level is
within the green area on the scale. If the DEF
level is not within the green area it suggests that
the DEF is of poor quality or is contaminated.
F Figure 392.
J
K
E
J Hydrometer
K Hydrometer reading
14. DEF should have a urea concentration of the
specified range.
E Sample bottle
F Vacuum pump Percentage: 31.8–33.2%
10. Install the strainer and filler cap and make sure 15. Further DEF quality tests are available. Refer to
that the cap is locked. JCB Technical service.
11. Examine the DEF sample: 16. Dispose of the DEF sample correctly. Do not pour
it back in the tank.
11.1. Contaminated DEF will appear cloudy.
11.2. Clean DEF should be clear and colourless.
Figure 391.
E
G H
E DEF Test bottle

G Contaminated DEF sample
H Clean DEF sample
12. Carefully place the sample into the JCB
hydrometer to test the quality of the DEF.
18 - 117 9813/9400-1 18 - 117

03 - Tank
03 - Tank Introduction
Introduction .................................................. 18-118 The DEF (Diesel Exhaust Fluid) tank stores the
Drain and Fill ............................................... 18-119 DEF. It is very important that only clean DEF is
Clean ........................................................... 18-120 used. Use of any other fluid will contaminate and
Remove and Install ..................................... 18-122 potentially cause damage to the SCR (Selective
Catalytic Reduction) system.
18 - 118 9813/9400-1 18 - 118

03 - Tank
Drain and Fill 3. Position a container of suitable size under the

drain plug.
Special Tools
Description Part No. Qty. 4. Use the special tool to remove the drain plug and
let the DEF drain out.
DEF Tank Drain Tool 334/E9120 1
Special Tool: DEF Tank Drain Tool (Qty.: 1)
CAUTION Make sure you do not over tighten the
DEF tank drain plug. Use the correct tools and 5. Make sure the drain plug is kept scrupulously
tighten carefully to the correct torque. Do not use clean.
any thread sealants of any kind. Make sure the 6. Dispose of any unused DEF according to local
drain plug is clean before installation. regulations.
The SCR (Selective Catalytic Reduction) tank level 7. Make sure that the drain plug is clean before you
must be checked and filled every time the main diesel install it. Do not use any thread sealants of any
tank is filled. The machine must not be run with the kind.
tank empty.
8. Tighten the drain plug to the correct torque value.
The tank must never be filled with anything other than Do not over tighten the drain plug.
the DEF (Diesel Exhaust Fluid) specified in Technical
Data. Refer to (PIL 18-30). Fill
The DEF tank is a separate tank located within 1. Make sure that the area around the filler is clean
the area of the diesel tank. The drain plug can be to prevent SCR system contamination. Make
accessed from underneath the machine in the area sure the drain plug is correctly installed.
of the diesel tank. Make sure you identify the correct
drain plug. 2. Remove the DEF tank filler cap.
3. Fill the tank with clean DEF.
Drain
4. Install the DEF tank filler cap.
Figure 393.
Item Description Nm
A A Drain plug 9
H
A DEF Tank
H DEF Drain plug
18 - 119 9813/9400-1 18 - 119

03 - Tank
Clean 2. Fill the DEF tank with clean water from an open
ended low pressure hose pipe.
Special Tools
Description Part No. Qty. 3. Drain the DEF tank.
DEF Tank Drain Tool 334/E9120 1 4. Repeat steps 2 and 3.
Data Link Adaptor 892/01174 1
(DLA) Kit 5. Fill the DEF tank with clean good quality DEF.
DEF Diagnostic Test Kit 892/12461 1
Cleaning the DEF tank
Consumables
Description Part No. Size The DEF tank should be cleaned when there is
a chance that the system has been contaminated
Traffic Film Remover 4006/2120 20L or there is DEF contamination or quality warnings
993/99174 200L present.
If the DEF (Diesel Exhaust Fluid) tank requires 1. Disconnect the DEF pressure hose from the
cleaning, for example due to filling with diesel fuel by dosing metering module. Install a cap to the
mistake, it may be possible to clean the tank without dosing metering module to prevent dirt ingress.
removing the tank or tank sensor from the machine.
2. Connect the extension tube to the DEF pressure
Do not use a high pressure washer, jet or steam hose.
cleaning equipment with the tank sensor installed as Special Tool: DEF Diagnostic Test Kit (Qty.: 1)
this may cause damage to the internal components.
Make sure that any unused or contaminated DEF is 3. Insert the end of the DEF extension hose into a
disposed of in accordance with the local authority clean container with enough traffic film remover
regulations. solution DEF to completely cover the end of
the extension hose. Traffic film remover solution
Flushing the DEF tank should be made with a ratio of 1L of traffic film
remover for every 5L of clean water.
The DEF tank should be flushed when there is a Consumable: Traffic Film Remover
chance that dirt may have entered the system or
there is an insufficient DEF flow rate with no other 4. Connect Servicemaster and perform the DEF
symptoms. emptying routine. This will draw traffic film
remover from the container through the DEF
1. Drain the DEF tank. return hose and into the contaminated DEF tank.
Special Tool: DEF Tank Drain Tool (Qty.: 1) Make sure that the traffic film remover in the
container remains above the end of the extension
Figure 394. pipe at all times.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
1)
A Special Tool: DEF Tank Drain Tool (Qty.: 1)
6. Install the DEF tank drain plug. Tighten to the
7. Add the required amount of traffic film remover
into the tank through the filler cap to the ratio of 1L
of traffic film remover for every 5L of clean water.
Consumable: Traffic Film Remover
8. Fill the DEF tank with clean water from an open
9. Leave the solution to stand.
Duration: 20min
A Drain plug
10. Where possible, agitate the solution to make sure
all internal surfaces of the tank are cleaned.
18 - 120 9813/9400-1 18 - 120

03 - Tank
11. Clean the DEF filler cap with water and traffic film Figure 395.
remover solution. Rinse thoroughly afterwards
with clean water.
13. With the DEF tank drain plug removed,
thoroughly rinse the DEF tank through the filler
cap with clean water from an open ended low
pressure hose pipe.
15. Fill the DEF tank with clean water from an open
18. Fill the DEF tank with clean good quality DEF.
A
19. Place the dosing metering module pressure line
extension tube end into a clean container and A DEF quality sensor
perform the maximum pump flow DEF dosing
32. Install the tank sensor unit.
quantity test routine within Service Master.
20. Replace the DEF filter and the DEF pre-filter If contamination warnings remain, the DEF tank and
located in the pump supply module. Refer to (PIL tank sensor unit may have to be replaced.
18-30-06).
21. Perform the maximum pump flow DEF dosing Item Nm
quantity test routine within Service Master. 2 9
22. Disconnect the test equipment.
23. Install the dosing metering module. Make sure
the metal gasket is replaced.
24. Start the engine.
25. Switch off the engine.
Duration: 1min
26. Start the engine. All faults and warnings should
be cleared.
27. If contamination warnings remain further
cleaning will be required. Carry out 28 to 32.
28. Remove the tank sensor. Refer to (PIL 18-30-09).
29. With the DEF tank drain plug removed, use a
pressure washer to rinse the inside of the DEF
tank.
30. Clean the tank sensor unit with water and traffic
film remover solution.
31. Carefully wipe the DEF quality sensor lens and
mirror with a clean, disposable soft wipe. Make
sure that you do not to scratch or damage the
quality sensor.
18 - 121 9813/9400-1 18 - 121

03 - Tank
Remove and Install
For: 512-26 [T4F] .................... Page 18-122 4. Drain the DEF (Diesel Exhaust Fluid) tank,
For: 506-23 [T4F], 509-23 [T4F], 512-26 removal must only be done when the tank is
[T4F] ........................................ Page 18-125 empty. Refer to (PIL 18-30-03).
5. The DEF tank must be kept free of contaminants.
(For: 512-26 [T4F]) Do not re-use the drained DEF.
Before Removal 6. Any unused DEF should be disposed of

according to local regulations.
7. Do not allow contaminants to enter the DEF tank.
2. Follow all the general health and safety Make sure that contamination does not enter the
procedures. Refer to (PIL 01-03). pipes or fittings.
3. Remove the fuel tank. Refer to (PIL 18-03).
18 - 122 9813/9400-1 18 - 122

03 - Tank
Remove
Figure 396.
B A
D
A DEF tank B Chassis outrigger

C Tank securing bolts (x3) D Tank mounting points
18 - 123 9813/9400-1 18 - 123

03 - Tank
A DEF Tank
B DEF Tank filler neck hose clip
A DEF Tank
B Check valve
2. Disconnect the tank sensor. Prevent
contamination entering the fittings and hoses.
3. Disconnect the tank filler neck. Refer to Figure
397.
4. Disconnect the tank breather.
5. Remove the check valve. Refer to Figure 398.
6. Disconnect any additional fittings or pipe work.
7. Cap all open ports to prevent contamination.
8. Remove the securing strap on top of the tank.
9. Remove the DEF tank securing bolts.
10. Remove the DEF tank.
18 - 124 9813/9400-1 18 - 124

03 - Tank
Install Remove
1. The installation procedure is the opposite of the Figure 399.
steps. F G
1.1. Tighten the tank securing bolts to the
correct torque value. Make sure that the
compression spacers are installed to the
DEF tank bolts. D
1.2. Make sure that the check valve is installed
correctly. E
Item Nm
C 21
(For: 506-23 [T4F], 509-23 [T4F], 512-26 A

[T4F])
C
Before Removal
B
4. Drain the DEF tank, removal must only be done
when the tank is empty. Refer to (PIL 18-30-03). C
B
5. The DEF tank must be kept free of contaminants.
Do not re-use the drained DEF.
6. Any unused DEF should be disposed of
according to local regulations.
7. Do not allow contaminants to enter the DEF tank.
Make sure that contamination does not enter the
pipes or fittings.
A DEF tank
B Tank securing strap bolts (x3)
C Check valve
D Breather pipe
E Filler pipe
F Hose connections
G Electrical connector
2. Disconnect the tank sensor. Prevent
contamination entering the fittings and hoses.
3. Disconnect the tank filler neck.
4. Disconnect the tank breather.
5. Disconnect any additional fittings or pipe work.
6. Cap all open ports to prevent contamination.
7. Remove the securing strap on top of the tank.
18 - 125 9813/9400-1 18 - 125

03 - Tank
8. Remove the DEF tank.
Install
steps.
1.1. Tighten the tank strap securing bolts to the
1.2. Make sure that the check valve is installed
correctly.

Item Nm
C 21
18 - 126 9813/9400-1 18 - 126

06 - Filter
06 - Filter Introduction
Introduction .................................................. 18-127 The DEF (Diesel Exhaust Fluid) filter is located in the
Remove and Install ..................................... 18-128 pump supply module. It is designed to filter all the
contamination that is generated through use to the
required level of cleanliness.
It is important that the filter is changed in accordance

with the machine maintenance schedule. Use only
the correct specification filters.
18 - 127 9813/9400-1 18 - 127

06 - Filter
Remove and Install
Remove 4. Remove and discard the pressure equalising

element.
1. Perform the DEF (Diesel Exhaust Fluid)
emptying routine using ServiceMaster. Figure 401.
2. Get access to the DEF supply module.

3. Remove the filter cover.
Figure 400.
D B
B Pressure equalising element

A 5. Use the filter extraction tool to remove the filter
from the supply module. The filter extraction tool
is supplied with each new filter.
5.1. Insert the split end into the filter element.
Gently rotate the tool to position it in the
A Filter cover correct position. Then rotate the tool in a
D Supply module clockwise motion to engage the tool with the
filter.
18 - 128 9813/9400-1 18 - 128

06 - Filter
Figure 402.
D
C
E C
E
C
F
E
E
G
C Filter element D Supply module

E Filter extraction tool F Extraction tool- not engaged with filter
G Extraction tool- engaged with filter ready for
removal
6. Place a suitable tool through the slot in the end of

the filter extraction tool and pull hard to remove
the filter element.
7. Discard the filter element.
18 - 129 9813/9400-1 18 - 129

06 - Filter
Figure 403.
C Filter element
Install
1. Lubricate the 0-rings with distilled water or DEF.
2. Install a new filter element into the supply
module.
3. Install a new pressure equalising element.
4. Install the filter cover, tighten to the correct torque
value.

Item Nm
3 22.5
18 - 130 9813/9400-1 18 - 130

09 - Tank Sensor
09 - Tank Sensor Introduction

Introduction .................................................. 18-131 The tank sensor is mounted in the DEF (Diesel
Operation ..................................................... 18-132 Exhaust Fluid) tank.
Clean ........................................................... 18-132
18 - 131 9813/9400-1 18 - 131

09 - Tank Sensor
Operation Clean
The tank sensor has a number of functions: Refer to (PIL 18-30-03).
• To measure the level of DEF (Diesel Exhaust

Fluid) inside the tank.
• To confirm the DEF quality meets the
requirements of the SCR (Selective Catalytic
Reduction) system.
• To defrost the DEF inside the tank.
• To measure the temperature of the DEF inside
the tank to inform when heating is required.
The tank sensor uses the CAN (Controller Area

Network)bus system to communicate with the DCU
(Dosing Control Unit).
18 - 132 9813/9400-1 18 - 132

09 - Tank Sensor
Remove and Install machine and its application you may need to
rotate the head unit as it is removed from the tank
to prevent it fouling. Do not use excessive force.
Make sure you have read and fully understand this Do not put force the pipe on to the spigots.
procedure before you begin.
17. The DEF quality sensor works by measuring the
The actual appearance of the component may differ DEF opacity. Make sure the lens is kept clean
from the illustration shown below. and is not touched.
18. Make sure you cap the DEF tank to prevent the
Remove ingress of debris.
1. Make the machine safe. Refer to (PIL 01-03). Figure 404.
2. Follow the general health and safety procedures. 3
Refer to (PIL 01-03). 2 1
3. Isolate the battery. Refer to (PIL 33-03).
4. Remove the ignition key to make sure that no 4
one attempts to start the machine during this
procedure.
5
6. Make sure there is no pressure in the engine
cooling system. Carefully loosen the cap on the
expansion tank and let the pressure release from
the system.
7. Open the cab door and remove the kick strip.
8. Remove the floor mat and access panel. Refer
to (PIL 06-06-39).
9. Locate the head unit. Make sure the area around
the head unit and the lens are clean to prevent 6
contamination of the SCR (Selective Catalytic
Reduction) system.
10. Record the angular position of the sensor relative 1 Pipe spigots- engine coolant hoses
to the DEF (Diesel Exhaust Fluid) tank. 2 Pipe spigots- DEF hoses
11. Remove the DEF hoses and the silver DEF line 4 Worm drive clip
from the retaining guide. Make sure that the 5 Tank level sensor
hoses are capped correctly. 6 DEF quality sensor
12. Clamp the coolant hoses within the specified
distance of the quick connectors.
Install
Length/Dimension/Distance: 152mm 1. The installation procedure is the opposite of the
13. Remove the coolant hoses from the head unit. steps.
Make sure the hoses are capped correctly.
1.1. Do not put force on the pipe spigots when
14. Remove the electrical harness connector from installing.
the bracket and then separate the female and
male part. 1.2. Align the sensor at the correct angular
position relative to the DEF tank, as
15. Remove the jubilee clip. recorded in Removal.
16. Remove the head unit and place it in a clean 1.3. Make sure that the tank sensor is seated
plastic bag to prevent contamination whilst it correctly and not touching the sides of the
is removed from the tank. Depending on the tank.
18 - 133 9813/9400-1 18 - 133

09 - Tank Sensor
1.4. Make sure that any spilt DEF is removed.

1.5. Make sure the coolant level is correct. Refer
to (PIL 21-00-00).
1.6. Run the machine for the specified time with
the throttle fully engaged to ensure that the
head unit is working correctly and that there
are no error codes present in the right hand
instrument panel.
Duration: 2min
18 - 134 9813/9400-1 18 - 134

12 - Pump Supply Module
12 - Pump Supply Module Introduction

Introduction .................................................. 18-135 The SCR (Selective Catalytic Reduction) pump
Operation ..................................................... 18-136 supply module has a number of functions:
Clean ........................................................... 18-138
Remove and Install ..................................... 18-139 • Provide the stable DEF (Diesel Exhaust Fluid)
system pressure.
• Provide clean DEF to the dosing metering
module.
• Emptying (purging) of the pressure line to
protect the dosing metering module against
damage due to ice expansion or crystallization.
• Thawing of the DEF inside the pump supply
module.
• Diagnosis of motor speed and temperature
inside the pump supply module.
• Prevention of dosing metering module flooding.
18 - 135 9813/9400-1 18 - 135

Operation
The supply module pumps DEF (Diesel Exhaust • Inlet: DEF enters the pump supply module from
Fluid) from the tank into the dosing metering module the tank.
at a stable pressure of 5bar (72.5psi). There are three • Outlet: DEF is pumped into the dosing metering
spigots which the DEF hoses are connected to: module.
• Backflow: DEF returns to the tank.
Figure 406.
1
7
2
1 Pump supply module 2 DEF inlet spigot

3 DEF outlet spigot 4 DEF backflow spigot
5 Bolts (x3) 6 DEF filter
18 - 136 9813/9400-1 18 - 136

The pump supply module contains the DEF filter.

There is also a course mesh filter within the DEF inlet
spigot. A heater is integrated into the pump supply
module to defrost the DEF in freezing conditions.
After a machine shutdown, the pump supply module

will recover DEF from the system and return it to
the tank. This helps to prevent DEF crystallising
when the machine is not in use. This function can
also be activated using ServiceMaster to purge the
system of DEF before carrying out service work.
This is controlled by the SCR (Selective Catalytic
Reduction)ECU (Electronic Control Unit) and takes
approximately 30s to complete. During this time it is
important that the battery isolator is not removed /
disconnected otherwise damage to the SCR system
can result.
18 - 137 9813/9400-1 18 - 137

Clean
The pump supply module has a mesh filter to prevent

any large particles or contaminants entering the
module. This is located within the inlet spigot.
Remove
Figure 407.
A Inlet spigot
B Clip
C Pump supply module
1. Get access to the pump supply module.
2. Disconnect the inlet DEF (Diesel Exhaust Fluid)
hose. Make sure that you clean up any spilled
DEF immediately.
3. Remove the clip.
4. Carefully pull the inlet spigot to remove it from the
pump supply module.
Clean
1. Rinse the spigot with clean water to remove any
debris in the filter.
2. If rinsing is not sufficient, the inlet spigot must be
replaced. Do not attempt to force debris out of
the filter as this may cause damage.
Install
1. Installation is the reverse of the removal
procedure.
18 - 138 9813/9400-1 18 - 138

Remove and Install
This component is not serviceable, if the component 2. Get access to the pump supply module.
fails replace the complete module.
3. Ensure that the area around the pump supply
module is clean to prevent contamination of the
Before Removal SCR (Selective Catalytic Reduction) system.
Remove
Figure 408.
1
7
2
1 Pump supply module 2 DEF (Diesel Exhaust Fluid) inlet spigot
18 - 139 9813/9400-1 18 - 139

3 DEF outlet spigot 4 DEF backflow spigot

5 Bolts (x3) 6 DEF filter
1. Perform the DEF emptying routine using

ServiceMaster.
2. Disconnect the DEF hoses from the spigots (x3).
3. Install caps to all open ports to prevent dirt
ingress and contamination of the SCR system.
5. Install a cap on to the electrical connector to
prevent dirt ingress and corrosion.
6. Undo the bolts (x3).
7. Remove the pump supply module from the
machine.
Install
1. Installation is the reversal of the removal
procedure.

Item Nm
5 19
18 - 140 9813/9400-1 18 - 140

15 - Dosing Metering Module
15 - Dosing Metering Module Introduction

Introduction .................................................. 18-141 The dosing metering module injects the required
Operation ..................................................... 18-142 amount of DEF (Diesel Exhaust Fluid) into the
Remove and Install ..................................... 18-142 exhaust gas. It is mounted on the mixer before the
SCR (Selective Catalytic Reduction) catalyst.
18 - 141 9813/9400-1 18 - 141

The dosing metering module is controlled by the Before Removal

SCR (Selective Catalytic Reduction) control module.
The SCR control module uses information from the 1. Make sure that the engine is safe to work on. If
upstream and downstream NOx (Nitrogen Oxide) the engine has been running, let it cool before
sensors to determine the quantity of DEF (Diesel you start the service work.
Exhaust Fluid) needed to reduce the nitrogen
emissions to the required level. The SCR control 2. Get access to the dosing metering module.
module will then send a signal to the dosing metering
module which will inject DEF in to the exhaust gases. 3. Ensure that the area around the dosing metering
module sensor is clean to prevent contamination
The dosing metering module has engine coolant of the SCR (Selective Catalytic Reduction)
flowing through it so that the DEF is prevented from system.
freezing when the machine is used in cold conditions.
Remove
Figure 409.
1 Coolant hoses
2 DEF (Diesel Exhaust Fluid) hose
3 Bolts (x3)
ServiceMaster.
2. Drain the engine coolant.
3. Disconnect and cap the coolant hoses.
4. Disconnect and cap the DEF hose.
18 - 142 9813/9400-1 18 - 142

5. Disconnect and cap the electrical connector.

6. Undo the bolts (x3).
7. Remove the dosing metering module from the
mixer. Discard the metal gasket.
8. Install the caps on the mixer and the dosing
metering module.
The dosing metering module is a non-serviceable

item. If it is damaged or faulty it must be replaced.
Do not attempt to disassemble the dosing metering
module, any evidence of tampering will result in
warranty claims being rejected.
Install
Figure 410.
A Dosing metering module

B Metal gasket
1. Installation is the reversal of the removal
procedure.
2. Replace the metal gasket.
4. Fill the engine cooling system.

Item Nm
3 8
18 - 143 9813/9400-1 18 - 143

18 - Catalyst
18 - Catalyst Introduction
Introduction .................................................. 18-144 The SCR (Selective Catalytic Reduction) catalyst is
Remove and Install ..................................... 18-145 the location where the DEF (Diesel Exhaust Fluid)
reacts with the exhaust gases to reduce the amount
of NOx (Nitrogen Oxide) emissions.
DEF consists of water and urea. When injected into

the exhaust gases, the heat converts the DEF into
ammonia and carbon dioxide. The ammonia reacts
with the NOx in the exhaust gases to convert them
into nitrogen and water.
It is the catalytic surfaces within the catalyst that

allow the reaction to take place. In order for optimum
conversion, the SCR catalyst temperature needs to
be greater than 200°C (391.7°F).
The SCR catalyst is located in the exhaust system.
18 - 144 9813/9400-1 18 - 144

18 - Catalyst
Remove and Install Remove

CAUTION The exhaust pipe becomes extremely Figure 411. Typical Catalyst without Insulation
hot when the engine is running and will remain so
for some time after the engine is stopped. If you 2
touch the hot pipe you could be severely burned.
This component is not serviceable, if the component

fails replace the catalyst.
The actual appearance may differ from the illustration

shown below. This section is provided for general
information.
Some machines may have an insulation jacket

installed on the SCR (Selective Catalytic Reduction)
catalyst. If the insulation is installed, it must not be
removed. If the insulation becomes damaged it must
be replaced.
Before Removal
2. Get access to the SCR catalyst. 3
3. Ensure that the area around the head unit
system.
1
1 Exhaust clamp
2 Catalyst straps
3 Catalyst
18 - 145 9813/9400-1 18 - 145

18 - Catalyst
Figure 412. Typical Catalyst with Insulation
1
3
1 Exhaust clamp
2 Catalyst straps
3 Catalyst with insulation jacket
1. Remove the exhaust clamps. There is one at
each end of the catalyst.
2. Loosen the catalyst straps.
3. Remove the catalyst from the machine.
Install
removal procedure.
2. Tighten the exhaust clamps to the correct torque
value. Check whether the clamp is a standard
joint (1a) or a sealing ring joint (1b).

Item Nm
1a 10
1b 14
18 - 146 9813/9400-1 18 - 146

24 - Coolant Valve
24 - Coolant Valve Introduction

Introduction .................................................. 18-147 The coolant valve (or coolant solenoid) controls the
Operation ..................................................... 18-148 flow of engine coolant into the heat exchanger in the
Remove and Install ..................................... 18-148 head unit.
It is used to defrost DEF (Diesel Exhaust Fluid) in

the DEF tank. It is a normally closed solenoid valve
that will open when the temperature drops below a
calibrated level.
The coolant is taken directly from a port on the

crankcase. The coolant valve will close once the
temperature rises above the calibrated level.
The coolant valve is machine mounted, the location

will depend on the machine and its application.
Figure 413.
18 - 147 9813/9400-1 18 - 147

24 - Coolant Valve

Special Tools
The coolant valve is controlled by the DCU (Dosing Description Part No. Qty.
Control Unit). When the head unit in the DEF (Diesel Data Link Adaptor 892/01174 1
Exhaust Fluid) tank detects that the temperature (DLA) Kit
is below the calibrated level, the coolant valve will
open to allow engine coolant to flow through a heat CAUTION Antifreeze can be harmful. Obey the
exchanger on the heat unit. This warms the DEF manufacturer's instructions when handling full
to defrost and prevent it from freezing. Once the strength or diluted antifreeze.
temperature has reached the calibrated level the
coolant valve will close to prevent the DEF from
overheating. Before removal
2. Get access to the coolant valve.
Remove
Figure 414.
4 2
1 3 3 1
1 Coolant hose connections

3 Bolts (x4)
4 Coolant valve
1. Drain the engine coolant.
2. Disconnect the coolant hoses from the hose
connections. Make sure that you clean up any
spilled coolant.
3. Cap all open ports.
5. Remove the bolts (x4).
6. Remove the coolant valve from the machine.
Install
steps.
2. Make sure that the coolant valve is in the correct
orientation. The coolant hoses have different
18 - 148 9813/9400-1 18 - 148

24 - Coolant Valve
sized connectors so that it cannot be installed

incorrectly.
3. Tighten the bolts (x4) to the correct torque figure.
4. Fill the engine cooling system with the specified
engine coolant. Refer to (PIL 75-09-03).
5. Connect the Servicemaster diagnostic tool.
1)
6. Check for active fault codes. Make sure any
existing fault codes are erased and do not return.
6.1. Diagnose and repair any faults that return
before continuing.
7. Select the aftertreatment system in the service
master diagnostic tool and identify the coolant
valve image and the status indicator next to it.
Refer to the helpfiles.
9. Check that the status indicator of the coolant
valve changes from red to green. If the ambient
temperature is above the specified limit, the
indicator will return to red after a short period of
time.
10. Continue to run the engine and allow it to reach
operating temperature and for the after treatment
system to start dosing.
11. Check for active fault codes. Make sure any
existing fault codes are erased and do not return.
11.1. Diagnose and repair any faults that return
before continuing.
12. Disconnect the Servicemaster diagnostic tool.

Item Nm
3 10
18 - 149 9813/9400-1 18 - 149

30 - Intake Throttle
30 - Intake Throttle Introduction

Introduction .................................................. 18-150 The intake throttle is used to aid engine warm up
Operation ..................................................... 18-151 so that the SCR (Selective Catalytic Reduction)
Remove and Install ..................................... 18-152 system can reach operating temperature as quickly
as possible. It can also be used to aid SCR
regeneration.
The intake throttle is mounted on the intake manifold

after the grid heater (if installed).
Figure 415.
18 - 150 9813/9400-1 18 - 150

Operation
The intake throttle is controlled by the ECM (Engine

Control Module) It works by restricting the amount
of air entering the engine so that there is a
higher fuel to air ratio. This causes the engine
temperatures to rise quickly and therefore enables
the SCR (Selective Catalytic Reduction) system to
reach optimum operating temperature as quickly as
possible.
Once the SCR system has reached the operating

temperature, the throttle returns to the fully open
position and airflow in to the engine will return to
normal.
The Intake throttle can also be used to aid SCR

catalyst regeneration by restricting the air into the
engine during running to raise the temperature in the
engine and exhaust system.
The intake throttle is controlled automatically by the

ECM with no need for operator intervention.
18 - 151 9813/9400-1 18 - 151

Remove and Install
Before Removal 2. Get access to the intake throttle.
1. Make sure that the engine is safe to work on. If 3. Ensure that the area around the intake throttle
the engine has been running, let it cool before is clean to prevent contamination of the SCR
you start the service work. (Selective Catalytic Reduction) system.
Remove
Figure 416.
6
4
1
2 3
1 Temperature sensor connector 2 Throttle valve connector

3 Intake throttle 4 Throttle adaptor
5 O-rings (x2) 6 Bolts (x4)

A B
A
A CPA (Connector Position Assurance) tab A CPA tab

B connector latch
18 - 152 9813/9400-1 18 - 152

1. Disconnect the temperature sensor.

2. Disconnect the throttle valve.
2.1. Carefully pull back the CPA tab.
2.2. Depress the connector latch and pull
the connector whilst supporting the wiring
harness.
3. Disconnect the air intake hose.
4. Remove the bolts (x4) and remove the intake
throttle from the engine.
5. Separate the intake throttle from the throttle
adaptor.
Install
Do not use any grease or lubricants on the O-
rings, doing so can cause contamination of the SCR
system.
1. Make sure that all the sealing surfaces are clean

and flat.
2. Replace the O-rings (x2).
3. Install the intake throttle and adaptor plate on to
the engine.
4. Install the screws (x4), tighten to the correct
torque value.
5. Connect the temperature sensor.
6. Connect the throttle valve.
6.1. Push the connector until it is firmly seated
and an audible click is heard.
6.2. Carefully push the CPA tab in.

Item Nm
5 8
18 - 153 9813/9400-1 18 - 153

36 - Mixer Reactor
36 - Mixer Reactor Introduction

Introduction .................................................. 18-154 The mixer reactor is where the DEF (Diesel
Operation ..................................................... 18-155 Exhaust Fluid) is injected and mixed with the
exhaust gases. The mixer is mounted between the
exhaust manifold and the SCR (Selective Catalytic
Reduction) catalyst. The mixer is shaped to create
a vortex which helps to mix the DEF evenly with the
exhaust gases for optimum NOx (Nitrogen Oxide)
conversion in the SCR catalyst.
18 - 154 9813/9400-1 18 - 154

36 - Mixer Reactor
Operation
The mixer reactor is where the DEF (Diesel Exhaust

Fluid) is injected and mixed with the exhaust gases.
The atomizer integrated in the mixer reactor aids the
thermolytic process to convert the DEF to NH3. The
90° bend in the mixer reactor optimizes the mass
flow within the reactor and thereby assists the NH3
conversion.
18 - 155 9813/9400-1 18 - 155

90 - Hose
90 - Hose Introduction
Introduction .................................................. 18-156 The DEF (Diesel Exhaust Fluid) hoses carry the
Remove and Install ..................................... 18-157 supply of DEF from the tank to the supply module and
on to the dosing module, and back to the DEF tank.
The DEF hoses are insulated and contain heating

elements in order to defrost DEF when machines
are used in temperatures below -8°C (17.6°F). The
heating elements are controlled by the DCU (Dosing
Control Unit) through 3 relays for individual heater
control, and a single master relay for diagnostic
purposes.
Figure 419.
18 - 156 9813/9400-1 18 - 156

90 - Hose
Remove and Install 5. Press the tabs on the quick connector and at the
same time pull the connector to disconnect the
hose.
Before Removal 6. Install caps to all open ports to prevent dirt
1. Make sure that the engine is safe to work on. If ingress and contamination of the SCR system.
you start the service work. Install
2. Get access to the DEF (Diesel Exhaust Fluid) 1. Installation is the reversal of the removal
hose. procedure.
3. Ensure that the area around the DEF hose
(Selective Catalytic Reduction) system.
Remove
Figure 420.
3
1 Quick connector
3 DEF hose
ServiceMaster. Refer to (PIL 33-57).
3. Remove any clamps or supports securing the
DEF hose to the machine.
4. Locate the quick connectors at the ends of the
DEF hose.
Figure 421.
1 Quick connector
3 DEF hose
18 - 157 9813/9400-1 18 - 157

35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ......................................................................................................................... 18-159
18 - 158 9813/9400-1 18 - 158

35 - Turbocharger
00 - General
Introduction .................................................. 18-159 The turbocharger (turbo) is a turbine driven forced
Component Identification ............................. 18-160 induction device that makes an engine more efficient
Check (Condition) ........................................ 18-161 and helps to produce more power for its size.
Check (Operation) ....................................... 18-162
Engine exhaust gasses drive a turbine, which in turn
Remove and Install ..................................... 18-163 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 - 159 9813/9400-1 18 - 159

35 - Turbocharger
00 - General
Figure 422.
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 - 160 9813/9400-1 18 - 160

35 - Turbocharger
00 - General
1. Visually inspect for leaks at the turbocharger.

Make sure 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 423. 5.3. Make sure that the shaft end float is within
the specified limits. Refer to Turbocharger,
4.3. Make sure that the turbine shaft running

clearance is within the specified limits.
Refer to Turbocharger, Technical Data (PIL
18-35).
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.
18 - 161 9813/9400-1 18 - 161

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 - 162 9813/9400-1 18 - 162

35 - Turbocharger
00 - General
Remove and Install
Figure 425.
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
1. This procedure requires service parts. Make sure 5. Drain the cooling system.
start, refer to Parts Catalogue. Remove
2. Make sure that the engine is safe to work on. 1. Disconnect the air induction hose at the inlet
If the engine has been running, make sure the manifold and turbocharger. Remove the hose.
engine has cooled sufficiently before you start.
2. Remove the pipe clip. Undo fixing bolts and
3. Remove the ignition key. remove the oil drain pipe. Note that the pipe pulls
18 - 163 9813/9400-1 18 - 163

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 - 164 9813/9400-1 18 - 164

36 - Variable Geometry Turbocharger (VGT)
Contents Page No.
18-36-00 General ......................................................................................................................... 18-167

18-36-03 Actuator ........................................................................................................................ 18-174
18 - 165 9813/9400-1 18 - 165

Notes:
18 - 166 9813/9400-1 18 - 166

00 - General
Introduction .................................................. 18-167 The VGT (Variable Geometry Turbocharger) is
Component Identification ............................. 18-169 the next generation in turbocharger technology.
Operation ..................................................... 18-170 The turbocharger uses variable vanes to control
Check (Condition) ........................................ 18-171 exhaust flow and to introduce EGR (Exhaust Gas
Recirculation) to reduce emission in diesel engines.
Check (Operation) ....................................... 18-171 The turbocharger is bolted to the outlet port of the
Remove and Install ..................................... 18-172 exhaust manifold.
The turbo uses heat and energy from the waste

exhaust gases to drive a turbine which in turn drives
the compressor to pull new air at high pressure
into the cylinders. The extra volume of air allows
more fuel to be injected increasing the engine power
output.
This has the effect of lowering the combustion

temperature and reduces formation of NOx gases.
The air is compressed to a minimum pressure of

1 bar (14.5 lb/in2) depending upon engine speed
and load. The turbocharger spins at up to 100,000
rpm and reaches temperatures approaching 700 ºC
(1292 ºF); it is essential, therefore, that a good supply
of oil reaches it at all times. The oil not only lubricates
the turbocharger but also carries away excess heat.
External oil feed pipe connected to a port on the
crankcase supplies oil to the turbocharger bearing.
Oil returns to the engine oil sump via an external
drain pipe. Integral oil seals prevent oil escaping to
the compressor and turbine ends of the turbocharger.
18 - 167 9813/9400-1 18 - 167

00 - General
Figure 426.
B
A VGT
B VGT actuator
18 - 168 9813/9400-1 18 - 168

00 - General
Figure 427.
B
C
D
A E
F
G

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
18 - 169 9813/9400-1 18 - 169

00 - General
Operation Figure 430.
1. Exhaust gases move through the scroll volume

spread across a slot and over the louvres turning
the turbine and out of the outlet.
Figure 428.
4. The angle of the airflow can be adjusted as it

strikes the adjustable louvres to change the turbo
performance.
Figure 431.
2. The louvre ring sits inside the turbine housing

with the turbine spinning in the centre.
Figure 429.
3. The outer ring is adjusted by the actuator.
18 - 170 9813/9400-1 18 - 170

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 171 9813/9400-1 18 - 171

00 - General
Remove and Install
Before Removal 3. Remove the ignition key.
1. This procedure requires service parts. Make sure 4. Get access to the engine.
start, refer to Parts Catalogue. 5. Drain the cooling system. Refer to (PIL 21-00).
2. Make sure that the engine is safe to work on. If 6. Remove the EGR (Exhaust Gas Recirculation)
the engine has been running, let it cool before valve. Refer to (PIL 18-27).
Figure 432.
10
7
6
2
8
9 9
3
4
14
17
16 19 11
20
15 12
18
13
1 Turbocharger 2 Gasket
3 Studs M8 4 Lock nut
18 - 172 9813/9400-1 18 - 172

00 - General
5 Studs M10 6 Pipe adaptor (oil drain connection)

7 Gasket drain pipe 8 O-Ring
9 Bolt M6 10 Clip
11 Oil drain pipe 12 Gasket drain pipe
13 Bolts M8 14 Oil feed pipe
15 Pipe clip 16 Banjo bolts M12
17 Copper Washer 18 W Clip
19 Banjo bolts M16 20 Copper Washer M16
Remove 2. Test the VGT (Variable Geometry Turbocharger)

boost pressure.
1. Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose. Table 174. Torque Values
2. Undo the bolts and remove the oil drain pipe. Item Nm
Note that the pipe pulls off the pipe adaptor, 4 24
leaving the adaptor in place. Cap the open ports 9 10
to prevent ingress of dirt. Discard the O-ring and 13 24
the gasket.
16 36
3. Remove the pipe clips. Undo the banjo bolts at 19 21
each end of the oil feed pipe, remove the pipe.
Cap the open ports to prevent ingress of dirt.
Discard the sealing washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold- Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard gasket.
Install
steps.
2. Check the condition of the turbocharger. Refer to
(PIL 18-35).
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all O-rings, sealing washers and gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat-shield.
6. Tighten the nuts, bolts and banjo bolts to the
After Installation
1. Start the engine and check for exhaust leaks.
18 - 173 9813/9400-1 18 - 173

03 - Actuator
03 - Actuator Install
steps.
Special Tools
Description Part No. Qty. 2. Perform the VGT (Variable Geometry
Data Link Adaptor 892/01174 1 Turbocharger) position learn routine using
(DLA) Kit Servicemaster. Refer to the engine Helpfiles.
Before Removal 1)
1. Make the machine safe. Refer to (PIL 01-03). Table 175. Torque Values
2. Make sure that the engine is safe to work on. If Item Nm
the engine has been running, let it cool before B 10
you start the service work. C 13
Remove
Figure 433.
D A
A Actuator
B Actuator linkage
C Nuts (x4)
D Electrical connector
2. Disconnect the actuator linkage from the
actuator.
3. Disconnect the coolant hoses. Plug all the open
ports and hoses to prevent contamination. Make
sure that any spills or residual coolant is cleaned
up immediately.
4. Remove the nuts (x4) and remove the actuator
from the turbocharger housing.
18 - 174 9813/9400-1 18 - 174

39 - Fuel Cooler
39 - Fuel Cooler
Contents Page No.
18-39-00 General ......................................................................................................................... 18-177
18 - 175 9813/9400-1 18 - 175

Notes:
18 - 176 9813/9400-1 18 - 176

39 - Fuel Cooler
00 - General
00 - General
Remove and Install
Remove 5. Open the engine compartment cover. Refer to

(PIL 06-06).
6. Disconnect the fuel hoses from the matrix at the
2. Follow the general health and safety procedures. quick release couplings.
7. Support the matrix.
3. Switch off the engine before working in the
engine compartment. Remove ignition key or 8. Remove the nuts.
isolate battery to prevent the engine from being
started. Refer to (PIL 33-03). 9. Remove the fuel cooler matrix from the machine.
4. If the engine is hot let it cool for one hour.
Figure 434.
B
B C
A Quick release couplings B Nuts

C Matrix
18 - 177 9813/9400-1 18 - 177

39 - Fuel Cooler
00 - General
Install
steps also.
1.1. Bleed the fuel system. Refer to fuel system-
general, refer to (PIL 18-00).
1.2. After installation, start the engine and check
for fuel leaks.
18 - 178 9813/9400-1 18 - 178

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-181

18-96-03 High Pressure Pipe ...................................................................................................... 18-183
18-96-06 Low Pressure Pipe ....................................................................................................... 18-186
18 - 179 9813/9400-1 18 - 179

Notes:
18 - 180 9813/9400-1 18 - 180

96 - Fuel Pipe
00 - General
Introduction .................................................. 18-181 Fuel at rail pressure is continuously supplied to
Health and Safety ........................................ 18-182 the injectors via high pressure fuel pipes. The high
Component Identification ............................. 18-182 pressure fuel injector pipes consist of thick walled,
seamless steel tubing. The ends of the tubes are
formed with conical nipples for sealing in the sealing
cones on the common rail and on the injector at port.
It is essential that the pipes are maintained and

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

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

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
18 - 181 9813/9400-1 18 - 181

96 - Fuel Pipe
00 - General

WARNING Do not open the high pressure fuel
system with the engine running. Engine operation Figure 435.
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 - 182 9813/9400-1 18 - 182

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 437.
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 438.
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 436.
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 - 183 9813/9400-1 18 - 183

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 439.
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: 27N·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: 27N·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 - 184 9813/9400-1 18 - 184

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: 27N·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: 27N·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 - 185 9813/9400-1 18 - 185

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 440.

B
Remove and Install
A
Before Removal A
Obey all fuel system health and safety information.
Refer to Fuel System, Health and Safety (PIL 18-00). C
Low Pressure Fuel Pipes

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

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

Before Removal
Obey all fuel system health and safety information.
1. Make sure that the engine is safe to work on. The

engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine, Clean (PIL
15-00).
3. Remove the protective cover as follows.
18 - 186 9813/9400-1 18 - 186

96 - Fuel Pipe
06 - Low Pressure Pipe
3.1. Push out the plastic segments. Figure 442.

3.2. Remove the screws and lift off the cover.
Figure 441.
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 441.
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 - 187 9813/9400-1 18 - 187

Notes:
18 - 188 9813/9400-1 18 - 188

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 .......................................................................................................................... 21-23
21-03-09 Transmission Oil Cooler ................................................................................................. 21-24
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-29
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-43
21-09 Pump
21-09-00 General ........................................................................................................................... 21-49
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-55
21-21 Inlet
21-21-00 General ........................................................................................................................... 21-61
21-93 Hose
21-93-00 General ........................................................................................................................... 21-65
9813/9400-1
2017-09-20
Acronyms Glossary
CAC Charge Air Cooler

9813/9400-1
2017-09-20
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/9400-1 21 - 1
Notes:
21 - 2 9813/9400-1 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Component Identification ................................. 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Operation ......................................................... 21-7 quickly and then maintain it.
Fault-Finding .................................................... 21-8
Drain and Fill ................................................. 21-10
Check (Condition) .......................................... 21-10
Check (Leaks) ............................................... 21-11
Check (Level) ................................................ 21-11
21 - 3 9813/9400-1 21 - 3
21 - Cooling System
00 - Cooling System
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 176.
cap, hot coolant can spray out and burn you. Radiator cap pressure 1bar (14.5psi)
Make sure that the engine is cool before you work setting
on the cooling system.
Thermostat Wax element with by-
CAUTION Antifreeze can be harmful. Obey the pass blanking
manufacturer's instructions when handling full Thermostat operating
strength or diluted antifreeze. temperature:
- Nominal temperature 96°C (204.7°F)
- Start to open tempera-94–98°C (201.1–
ture 208.3°F)
- Full open temperature 110°C (229.8°F)
- Travel (fully open) 9mm
Fan drive type FEAD (Front End Acces-
sory Drive) belt
Fan belt (FEAD) adjust- Automatic belt tensioner
ment
Fan belt (FEAD) type Multigroove belt
Coolant Temperature Refer to PIL 15-84
Switch/Sender range
Coolant pump (non-ser- Bolt on, belt driven unit
viceable part)
21 - 4 9813/9400-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 443.
11
14
10
8
9
7
16 7
17
15
12
13 7
6
4 5
1 Coolant pump 2 Drive belt

3 Pump cavity (crankcase) 4 Pump outlet gallery (crankcase)
5 Oil cooler cavity (crankcase) 6 Coolant gallery (crankcase)
7 Cylinder cooling jackets (crankcase) 8 Link galleries (crankcase to cylinder head)
9 Thermostat housing (cylinder head) 10 Thermostat (cylinder head)
11 Top hose connection port (cylinder head) 12 By-pass gallery (cylinder head and crankcase)
13 Bottom hose connection port (crankcase) 14 Port for coolant temperature sensor and
switch unit
15 Cab heater coolant supply 16 Cab heater coolant return
21 - 5 9813/9400-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
17 Port for coolant supply to SCR (Selective

Catalytic Reduction) dosing system and DEF
(Diesel Exhaust Fluid) tank (if applicable)
21 - 6 9813/9400-1 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Operation
The coolant pump is driven via a pulley and front end

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

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

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

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

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

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

enables coolant to circulate through a heater matrix
when the thermostat is open or closed, ensuring fast
heater warm up. The coolant returns to the engine
through port 16.
Engine coolant is delivered to the SCR (Selective

Catalytic Reduction) system and DEF (Diesel
Exhaust Fluid) tank through port 17 irrespective of
the thermostat position. This defrosts the DEF as
quickly as possible in cold conditions so that the
emissions control system can work effectively. The
supply comes direct from the coolant pump outlet.
21 - 7 9813/9400-1 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 177. Page 21-8
Coolant - Over Temperature. Table 178. Page 21-8
Coolant - Under Temperature. Table 179. Page 21-9
Coolant - Contaminated. Table 180. Page 21-9
Table 177. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
DEF (Diesel Exhaust Fluid) tank heater circuit The coolant to DEF tank heater circuit has not bled
bleeding. correctly after work has been carried out. When this
(1)
circuit bleeds, the coolant level will drop until the

circuit has bled fully. Check the level until it stabilises.
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 178. 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. Check/replace the EGR cooler. Check for signs of
(1)
coolant leaking into combustion chamber.

SCR (Selective Catalytic Reduction) system leak. Check for signs of engine coolant in the DEF and
(1)
DEF in the engine coolant. Check the dosing

metering module and the head unit for leaks.
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.
(1) If installed
Table 178. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 177. 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 over filled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of antifreeze. Remove part of the coolant from cooling system and
replace with water.
21 - 8 9813/9400-1 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
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.
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 block blocked.
ECM (Engine Control Module) (if installed) or Check the electronic fault codes. Check the electrical
electrical sensor fault. connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
Table 179. 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 180. 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 177. Coolant - Loss.
gasket, cylinder head and crankcase.
SCR system leak.
(2)
See Also: Table 177. Coolant - Loss.
(2) If installed
21 - 9 9813/9400-1 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Condition)

Consumables
Description Part No. Size 1. Visually inspect the engine and related cooling
components for:
Antifreeze HP/ 4006/1101 5L
Coolant ASTM D6210 4006/1120 20L 1.1. Leaks.
Concentrate 4006/1103 200L 1.2. Cracked, burnt or perished hoses.
The graphic shows a typical engine cooling system, 1.3. Hose clips are in good condition and
the system you are working on may look slightly torqued to the correct value.
different.

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 444.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 10 9813/9400-1 21 - 10
21 - Cooling System
00 - Cooling System
00 - General
Check (Leaks) Check (Level)
Before you start the machine, inspect the system for 1. Make the machine safe.
leaks. Refer to: PIL 01-03.
1. Make the machine safe. Refer to (PIL 01-03). 2. Get access to the coolant expansion tank.
2. Get access to the cooling pack. 3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
3. Check the cooling system for leaks. cap and top up to the level indicated.
4. If necessary, contact your JCB dealer. 4. Install the filler cap and make sure it is tight.
5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
21 - 11 9813/9400-1 21 - 11
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-13

21-03-03 Radiator .......................................................................................................................... 21-23
21-03-09 Transmission Oil Cooler ................................................................................................. 21-24
21 - 12 9813/9400-1 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-13 The cooling pack contains the following major
Component Identification ............................... 21-14 components:
Clean ............................................................. 21-17
Check (Condition) .......................................... 21-17 • Radiator.
• Cooling fan.
Remove and Install ....................................... 21-18 • CAC (Charge Air Cooler).
Disassemble and Assemble .......................... 21-22 • Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 13 9813/9400-1 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
21 - 14 9813/9400-1 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 445.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
21 - 15 9813/9400-1 21 - 15
21 - Cooling System
03 - Cooling Pack
00 - General
Table 181.
Item Description
A Air cleaner / fuse box
support bolts
B Fuel sedimentor and
pump
C Air to air inter cooler ma-
trix
D Hydraulic oil cooler ma-
trix (if installed)
E Fixing points
F Hydraulic hoses- Fan
Motor/Oil Cooler
G Solenoid valve- re-
versible fan (if installed)
H Fan speed sensor
J Proportional fan speed
control solenoid
K Engine coolant radiator
matrix
L Radiator top hose con-
nection
M Inter cooler inlet hose
connection
N Fixed Speed Cooling fan
and hydraulic motor as-
sembly (55KW engines)
P Variable Speed Cooling
fan and hydraulic motor
assembly (81, 93 and
108 KW engines)
Q Inter cooler outlet hose
connection
R Radiator bottom hose
connection
21 - 16 9813/9400-1 21 - 16
21 - Cooling System
03 - Cooling Pack
00 - General
If the radiator tubes/fins get clogged the radiator will 1. Make the machine safe. Refer to (PIL 01-03).
be less efficient.
2. Let the engine cool.
3. Get access to the cooling pack. Refer to (PIL
2. Open the engine cover. Refer to (PIL 06-06-06). 21-03)
3. Remove the undershield. Refer to (PIL 4. Check the hoses, radiator and fan for:
06-06-30).
4.1. Condition.
4. Use a soft bristle brush to remove all unwanted 4.2. Damage.
material from the rear of the radiator.
4.3. Security.
5. Release the fastener and pull the condenser
away from the radiator. 5. If necessary, Replace the system hoses/radiator.
6. Use the soft bristle brush to remove all unwanted

material from both sides of condenser and
the front of the radiator. Then push back the
condenser and lock in position with the fastener.
7. Make sure that the loosened material is removed
out of the engine compartment.
21 - 17 9813/9400-1 21 - 17
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install
Although it is possible to remove individual 11. Plug all the open ports and hoses to prevent
components it is quicker and easier to remove contamination.
the complete sub assembly, particularly if access
is necessary for engine overhaul or removal and 12. Disconnect the hydraulic hoses from the chassis.
replacement for example.
13. Plug all the open ports and hoses to prevent
contamination.
Disassembly
14. On 527-56 machines, the fan motor hydraulic
1. Make the machine safe. Refer to (PIL 01-03). hoses are connected to the bulkhead plate.
2. Make sure that the engine and hydraulic system Figure 446.
are cool before you start the removal procedure.
3. Remove the engine cover and side console
assembly. Refer to (PIL 06-06).
4. Put a label on the fuel lines, hoses and electrical
connectors to help installation.
5. Disconnect the fuel lines and electrical connector
from the fuel separator or remove the fuel
separator bolts, the fuel line clips and tie the
assembly safely out of the way.
6. Disconnect the radiator bottom hose and drain S T
the coolant.
7. Disconnect the radiator top hose. S Bulkhead plate
T Fan motor hydraulic hoses
8. Disconnect the fan motor electrical connections
(if installed). 15. Disconnect the intercooler inlet and outlet hoses.
9. For 81 kW, 93 kW and 108 kW Machines. 16. Support the cooling pack assembly, remove the
fusebox bolts and the fixing bolts.
9.1. Disconnect the electrical connectors from
the fan motor direction control valve (if 17. Carefully lift and move the assembly away from
installed), control solenoid and the speed the machine.
sensor.
10. Disconnect the transmission cooler hoses from
the chassis.
21 - 18 9813/9400-1 21 - 18
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 447.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
21 - 19 9813/9400-1 21 - 19
21 - Cooling System
03 - Cooling Pack
00 - General
Table 182.
Item Description
A Fusebox support bolts
B Fuel separator and pump
C Air to air intercooler matrix
(1)
D Hydraulic oil cooler matrix (if installed)

(1)
E Fixing points
F Hydraulic hoses- Fan Motor/Oil Cooler
G Solenoid valve- reversible fan (if installed)
H Fan speed sensor
J Proportional fan speed control solenoid
K Engine coolant radiator matrix
(1)
L Radiator top hose connection

M Intercooler inlet hose connection
N Fixed Speed Cooling fan and hydraulic motor assem-
bly (55KW engines)
P Variable Speed Cooling fan and hydraulic motor as-
sembly (81, 93 and 108 KW engines)
Q Intercooler outlet hose connection
R Radiator bottom hose connection
(1) The engine coolant radiator, transmission oil cooler and air to air inter cooler matrix are all integral part. If
any part of the assembly has failed the complete unit must be replaced.
Install 1.1. Tighten the clamps to the correct torque

value.
steps.
Figure 448.
U
U
U Clamp
1.2. Fill the engine cooling system with the 1.3. Operate the engine and check the fan motor
correct type of coolant. Refer to (PIL 21-00). speed.
21 - 20 9813/9400-1 21 - 20
21 - Cooling System
03 - Cooling Pack
00 - General
1.4. Check the hydraulic fluid level. Refer to (PIL

30-00-00).
1.5. Check the transmission oil level and top up
as necessary.

Item Description Nm
U Clamp 5.5
21 - 21 9813/9400-1 21 - 21
21 - Cooling System
03 - Cooling Pack
00 - General
With the cooling pack removed from the machine

disassemble the components as necessary.
• Remove the transmission oil cooler. Refer to

(PIL 21-03-09).
• Remove the cooling fan motor. Refer to (PIL
21-05).
• Remove the hydraulic oil cooler. Refer to (PIL
21-03-12).
• Remove the fuel cooler. Refer to (PIL 18-39-00).
• Remove the air conditioning condenser. Refer
to (PIL 12-15-00).
21 - 22 9813/9400-1 21 - 22
21 - Cooling System
03 - Cooling Pack
03 - Radiator
03 - Radiator
Introduction
The radiator is a device in the cooling system that

removes heat from the coolant passing through it,
allowing the coolant to remove heat from the engine.
21 - 23 9813/9400-1 21 - 23
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Component Identification

Diagram ......................................................... 21-26
Figure 449. DTVT Oil Cooler
B
D
F
H
C
A Cooled oil (to the mechanical gearbox part of B Hot oil (from the mechanical gearbox part of the
the transmission) (IN port) transmission) (OUT port)
C Hydraulic system oil from fan return D Hydraulic oil return to tank
E Check valve- (installed on the underside of the F Heat exchanger- (transmission mechanical
front chassis torsion box). gearbox oil to hydraulic oil system)
G Mounting plate H Hydraulic oil from air blast cooler (not
transmission oil)
J Hydraulic oil to air blast cooler (not transmission
oil)
21 - 24 9813/9400-1 21 - 24
21 - Cooling System
03 - Cooling Pack
Figure 450. DTVT Oil Cooler

B
A
A Oil cooler
B Securing bolt
C Clamp
21 - 25 9813/9400-1 21 - 25
21 - Cooling System
03 - Cooling Pack
Diagram
Figure 451. DTVT Oil Cooler (Mechanical gearbox oil to hydraulic oil cooler)
A
2
3
6
7
8
D
B C
A DTVT Mechanical gearbox oil (Not hydrostatic B To hydraulic oil tank

oil)
C Fan return D To air blast cooler
E From air blast cooler 1 End fitting code table
2 Straight female fitting 3 90° Female fitting
4 135° Female fitting 5 Straight male fitting
6 Pipe code table 7 Steel tube
8 Hose
21 - 26 9813/9400-1 21 - 26
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-29
21 - 27 9813/9400-1 21 - 27
Notes:
21 - 28 9813/9400-1 21 - 28
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-29 The product is equipped with a hydraulically driven
Technical Data ............................................... 21-30 fan motor to provide air flow though the cooling pack.
Operation ....................................................... 21-33 Some products may have either a fixed speed fan or
a variable speed hydraulic fan.
Disassemble and Assemble .......................... 21-41 On some products, the fan may be reversible to
assist with the removal of debris from the cooling
pack.
21 - 29 9813/9400-1 21 - 29
21 - Cooling System
05 - Fan Motor
00 - General
Technical Data
For: 506-23 [T4F], 509-23 [T4F], 512-26

[T4F], JCB Tier 4F Engine 4 Cyl
................................................... Page 21-30
For: 512-26 [T4F] ...................... Page 21-31
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F], JCB Tier 4F Engine 4 Cyl)
Fixed Speed Fan Motor (55 KW Engines)

Table 184.
Type: Gear motor
Direction of rotation: Clockwise
Motor Displacement: 19 cc/rev
Fan speed (at maximum engine RPM (Revolutions TBA
Per Minute)):
Maximum pressure setting: 55bar (797.1psi)
Colour code (see sticker): Red
Variable Speed fan Motor (75 KW

Engines)
For information about fan motor control system, refer
to cooling system- fan motor, refer to (PIL 21-05).
Table 185.
Type: Gear motor
Direction of rotation: Bi-directional. Oil flow from port 'A' to port 'B' will ro-
tate the shaft in a clockwise direction when viewed
on the end of the shaft. Oil flow from port 'B' to port
'A' will rotate the shaft in an anti-clockwise direction
when viewed on the end of the shaft.
Motor displacement: 15 cc/rev
Fan speed (at maximum RPM): 3500 RPM
Maximum pressure setting: 210bar (3,043.5psi)
Colour code (see sticker): Black
Variable Speed fan Motor (81, 93 and 108

KW Engines)
For information about fan motor control system, refer
to cooling system- fan motor, refer to (PIL 21-05).
Table 186.
Type: Gear motor
Direction of rotation: Bi-directional (When reversing solenoid is energised
= anticlockwise. When reversing solenoid is de-ener-
gised = clockwise)
Motor displacement: 11 cc/rev
Fan speed (at maximum RPM): Variable
Colour code (see sticker): Green
21 - 30 9813/9400-1 21 - 30
21 - Cooling System
05 - Fan Motor
00 - General
(For: 512-26 [T4F])
Fixed Speed Fan Motor (55 KW Engines)

Table 187.
Type: Gear motor
Fan speed (at maximum engine RPM): TBA
Maximum pressure setting: 55bar (797.1psi)
Colour code (see sticker): Red
Fixed Speed fan Motor (81 KW Engines)

Table 188.
Type: Gear motor
Fan speed (at maximum engine RPM): TBA
Colour code (see sticker): Black
21 - 31 9813/9400-1 21 - 31
21 - Cooling System
05 - Fan Motor
00 - General
(For: 506-23 [T4F], 509-23 [T4F], JCB Tier 4F Engine 4 Cyl)
Figure 452.
E
G
A Cooling pack B Fan supply hydraulic pump section (Variflow

pump shown for illustration purposes, the fan
system operation is identical for gearpump
machines).
C Right hand cluster ECU (Electronic Control Unit) D Fan speed sensor
E Hydraulic cooling fan motor F Fan direction solenoid (if installed)
G Fan speed proportional solenoid
21 - 32 9813/9400-1 21 - 32
21 - Cooling System
05 - Fan Motor
00 - General
Operation
Fixed speed Schematic diagram
The schematic diagram shows an general overview Figure 453.

of the system. Your machine may have a triple pump D F
installed but the system will be similar.
C
The cooling fan motor is hydraulically driven. The
motor turns the cooling fan and air is drawn through
E
the radiators in the machine cooling pack.
Hydraulic oil from the pump supplies the fan motor

and pilot pressure supply valve.
The pressure relief valve prevents component

damage.
A Main pump
B Hydraulic tank
C Pump pressure supply
D Fan motor case drain line
E Fan motor pressure relief valve
F Fan motor
21 - 33 9813/9400-1 21 - 33
21 - Cooling System
05 - Fan Motor
00 - General
Table 189. Colour key-Oil flow and pressure to inform the right hand instrument ECU of the
ambient air temperature.
Full pressure
The ECU varies the speed of the fan motor according
Exhaust to the temperature signals, the fan will be at a higher
speed in high temperatures and a lower speed in low
temperatures.
Neutral
The ECU generates the correct PWM (Pulse Width
Modulation) signal for operation of the fan speed
proportional solenoid.
Variable speed
The proportional solenoid operates as a pressure
The engine cooling pack is cooled by a hydraulically reducing valve. The supply to the fan motor is at a
powered cooling fan motor. pressure in relation to the ambient temperature.
The fan speed is controlled by the right hand The fan speed sensor sends a signal to the ECU to
instrument ECU (Electronic Control Unit). record current fan speed.
The engine air temperature sensor sends a signal A reversible fan option is provided where an operator
over the machine CAN (Controller Area Network)bus switch energises the fan direction solenoid to reverse
the direction of the fan.
21 - 34 9813/9400-1 21 - 34
21 - Cooling System
05 - Fan Motor
00 - General
Schematic diagram
Figure 454.
G H
B
C
A Hydraulic tank B Hydraulic variflow pump assembly

C Hydraulic gear pump (Fan supply) D Oil cooler
E Fan speed proportional solenoid F Fan direction solenoid (if installed)
G Fan motor housing H Fan motor
21 - 35 9813/9400-1 21 - 35
21 - Cooling System
05 - Fan Motor
00 - General
Table 190. Colour key-Oil flow and pressure

Full pressure
Exhaust
Neutral
21 - 36 9813/9400-1 21 - 36
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Fixed Speed Fan (If Installed) If the performance is below that specified, the
motor should be renewed. Renewal of individual
Your machine may be installed with a fixed or components such as gears, bearings and housings
variable speed fan. Removal and installation of both will not result in a permanent cure. If the motor
types of fan are shown. performance is satisfactory, but there is external
leakage, it should be dismantled for re-sealing
Before you remove the fan motor, check its purposes only.
performance.
Figure 455.
21 - 37 9813/9400-1 21 - 37
21 - Cooling System
05 - Fan Motor
00 - General
A Fan retaining nut B Motor retaining bolts

C Fan bracket securing bolts D Feed and return hoses
E Case drain hose
Remove If the performance is below that specified, the motor

should be renewed.
1. Make the machine safe. Refer to (PIL 01-06)
Remove
2. Install the safety strut. Refer to (PIL 06-69).
30-00). 2. Follow the general health and safety procedures.
4. Mark the hydraulic feed and return hoses to help
identification when you install. 3. Install the safety strut. Refer to (PIL 06-69).
5. Disconnect and plug the feed and return hoses. 4. Discharge the hydraulic pressure. Refer to (PIL
30-00).
6. Disconnect and plug the case drain hose.
5. Mark the electrical connectors to help in
7. Remove the fan guard. identification when you install.
8. Undo the fan bracket securing bolts (x4) and lift 6. Disconnect the harness from the solenoid
the fan and motor assembly from the machine. electrical connector.
9. Prevent the fan from turning, release the tab 7. Disconnect the harness from the speed sensor
washer and then undo the fan retaining nut. electrical connector.
10. Withdraw the fan from the motor shaft. Retain the 8. If installed, disconnect the harness from the
drive key (not shown). direction solenoid.
11. Undo the motor retaining bolts and remove the 9. Mark the hydraulic hoses to help in identification
motor. when you install.
Install 10. Disconnect and plug the feed hose and return
hose.
removal procedure. Additionally do the following 11. If installed, disconnect and plug the case drain
steps. hose.
1.1. Tighten all the fastening nuts and bolts to 12. Support the motor and the fan.
13. Remove the bolts.
1.2. Make sure all hoses are attached to the
correct ports. The case drain hose (if 14. Remove the fan bracket, the fan and then the
installed) must be fed in to a tank line motor from the machine.
otherwise damage to the motor will occur.
15. Stop the fan from turning.
1.3. Check and adjust the hydraulic fluid level.
16. Remove the tab washer and then remove the nut.
Table 191. Torque Settings 17. Remove the fan from the motor shaft. Keep the
Item Value drive key.
A 36N·m 18. Remove the motor/ control pack retaining nuts.
B 28N·m
19. Remove the motor from the bracket.
C 47N·m
Variable Speed Fan (If Installed)

Before you remove the fan motor, check its
performance.
21 - 38 9813/9400-1 21 - 38
21 - Cooling System
05 - Fan Motor
00 - General
Figure 456.
A
A
J H
E
B G
K
A D F
A
A Bolts B Case drain hose

C Feed hose D Return hose
E Motor retaining nuts F Solenoid electrical connector
G Speed sensor electrical connector H Bracket
J Direction solenoid K Fan nut
21 - 39 9813/9400-1 21 - 39
21 - Cooling System
05 - Fan Motor
00 - General
Install 1.2. The case drain hose (if installed) must be

fed into a tank line otherwise the motor can
1. The installation procedure is the opposite of the be damaged.
steps. 1.3. Replace the tab washer located on the fan
nut.
1.1. Make sure all hoses are attached to the 1.4. Check the hydraulic fluid level. Refer to (PIL
correct ports. 30-00).
Table 192. Torque settings

Item Value
B 27N·m
C 48N·m
D 48N·m
K 36N·m
21 - 40 9813/9400-1 21 - 40
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 41 9813/9400-1 21 - 41
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-43
21 - 42 9813/9400-1 21 - 42
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-43 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-44 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 - 43 9813/9400-1 21 - 43
21 - Cooling System
06 - Expansion Tank
00 - General
Remove and Install
Consumables 5. Open the engine compartment cover. Refer to

Description Part No. Size (PIL 06-06).
JCB Threadlocker 4101/0250 0.01L 6. Drain the engine coolant. Refer to (PIL 21-00).
Strength) 7. Remove the bolts.
Remove 8. Remove the expansion tank cover.
1. Make the machine safe. Refer to (PIL 01-03). 9. Disconnect the coolant level sensor electrical
connector (if installed).
Refer to (PIL 01-03). 10. Loosen the hose clips and disconnect the hoses
from the expansion tank.
3. Switch off the engine before working in the
engine compartment. Remove the ignition key or 11. Support the expansion tank.
isolate battery to prevent the engine from being 12. Remove the expansion tank from the bracket.
started. Refer to (PIL 33-03).
4. If the engine is hot, let it cool for one hour.
21 - 44 9813/9400-1 21 - 44
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 457.
D A
E F E E
A Hose clips B Hoses

C Tank cover D Expansion tank
E Bolts F Bracket
21 - 45 9813/9400-1 21 - 45
21 - Cooling System
06 - Expansion Tank
00 - General
Install
steps.
1.1. Apply sealant to the bolts.
(Medium Strength)
value.
1.3. Fill the engine cooling system with the
correct type of coolant. Refer to (PIL 21-00).
1.4. When the installation procedure is
complete, start the engine and check for
coolant leaks.

Item Description Nm
E Bolts 5
21 - 46 9813/9400-1 21 - 46
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-49
21 - 47 9813/9400-1 21 - 47
Notes:
21 - 48 9813/9400-1 21 - 48
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-49 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-50 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-50
Remove and Install ....................................... 21-51 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 49 9813/9400-1 21 - 49
21 - Cooling System
09 - Pump
00 - General

Figure 458. The coolant pump is driven via a pulley and front end
1 accessory drive belt, the pump draws coolant from
2 the pump cavity. The coolant is pumped through the
outlet gallery to the oil cooler cavity in the left-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.
For cooling system operation. Refer to (PIL 21-00).
1 Coolant pump
2 Drive pulley
3 Impeller
21 - 50 9813/9400-1 21 - 50
21 - Cooling System
09 - Pump
00 - General
Before Removal
1. Make sure that the machine is safe. If the engine
has been running, let it cool before you start the
service work. Refer to (PIL 01-03).
3. Drain the coolant.
4. Remove the coolant pump drive belt.
Remove
2
1. Remove the fixing screws. 1
2. Remove the coolant pump assembly.
3. Remove and discard the sealing O-ring.
1 Coolant pump assembly

2 Fixing screws
The pump is a non-serviceable item. If the pump is

faulty or damaged it must be renewed.
Install
steps.
2. Make sure that the mating face on the crankcase
is clean and free from damage.
3. Install a new sealing O-ring.
4. Tighten the screws to the correct torque value.
21 - 51 9813/9400-1 21 - 51
21 - Cooling System
09 - Pump
00 - General
Figure 460.
P1
P1 Sealing O-ring
After Installation
1. Install the coolant pump drive belt.
2. Refill the engine with the recommended coolant
mixture.

Item Nm
2 24
21 - 52 9813/9400-1 21 - 52
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-55
21 - 53 9813/9400-1 21 - 53
Notes:
21 - 54 9813/9400-1 21 - 54
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-55 The thermostat is located between the engine and
Component Identification ............................... 21-56 the radiator. The function of the thermostat is to block
Operation ....................................................... 21-56 the flow of coolant to the radiator until the engine has
Check (Condition) .......................................... 21-57 warmed up to a sufficient temperature.
Check (Operation) ......................................... 21-58 When the engine is cold, no coolant flows through
Remove and Install ....................................... 21-58 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 - 55 9813/9400-1 21 - 55
21 - Cooling System
12 - Thermostat
00 - General

Figure 461. 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 462.
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 1mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1mm
21 - 56 9813/9400-1 21 - 56
21 - Cooling System
12 - Thermostat
00 - General
diameter orifice allows trapped air to be expelled Check (Condition)

from the system.
Figure 463. 1. If the thermostat is suspected of being faulty,

7 3 perform a thermostat test, refer to Thermostat
- Check Operation (PIL 21-12) to confirm its
serviceability. Note that the thermostat is a non-
8 11 serviceable 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 1mm diameter orifice
21 - 57 9813/9400-1 21 - 57
21 - Cooling System
12 - Thermostat
00 - General
A period of 3–5min before the thermostat valve starts Before Removal

to operate is normal because of the time required to
heat soak the thermostat. 1. Make sure that the engine is safe to work on. If
1. Make sure that the engine is safe to work on. If you start the service work.
you start the service work. 2. Get access to the engine.
2. Remove the thermostat housing and the 3. Drain the coolant. Refer to (PIL 21-03-03).
thermostat. Refer to (PIL 21-12).
Figure 465.
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 464.
1
Figure 464.
4. Use a thermometer to measure the temperature

of the coolant.
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the
movement of the valve plate should be evident.
1 Radiator hose
6. Record the start to open temperature, the fully 2 Fixing bolts
open temperature and the amount of valve lift
travel when fully open. Compare this with the Remove
data in Technical Data (PIL 21-00).
1. Disconnect the radiator hose at the thermostat
housing.
2. Remove the fixing bolts and lift off the housing.
3. Lift out the thermostat.
21 - 58 9813/9400-1 21 - 58
21 - Cooling System
12 - Thermostat
00 - General
Figure 466.
3 4
3 Thermostat
4 Seal
4. If the thermostat is suspected of being faulty,
perform tests to confirm its serviceability.
Note The thermostat is a non-serviceable item. If the

thermostat is faulty or damaged it must be renewed.
Install
steps.
2. Inspect the seal for damage or splits. If necessary
renew the seal. Locate the seal correctly as
shown.
3. Make sure you install the thermostat the right way
up.
5. Reconnect the radiator hose at the housing.
After Installation
1. Fill the cooling system with the recommended
coolant mixture.

Item Nm
2 24
21 - 59 9813/9400-1 21 - 59
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-61
21 - 60 9813/9400-1 21 - 60
21 - Cooling System
21 - Inlet
00 - General
00 - General Figure 467.
Remove and Install

1
Before Removal
the engine has been running, let it cool before 1
1
3. Drain the coolant. Refer to (PIL 21-03-03). 2
The housing may be orientated differently to that
shown in the illustration, depending on the engine
installation.
Remove
1. Disconnect the radiator hose at the inlet housing.
2. Undo the bolts and lift off the housing.
X 6.8
1 Inlet housing
2 Fixing bolts
6 Sealing Ring
X Locating tab - sealing ring
Install
steps.
2. Make sure that the sealing ring is undamaged.
If necessary install a new seal. Make sure that
the seal is correctly located in its groove on the
housing. Note the locating tab.
4. Reconnect the radiator hose at the housing.
After Installation
1. Refill the engine with the recommended coolant
mixture.
21 - 61 9813/9400-1 21 - 61
21 - Cooling System
21 - Inlet
00 - General

Item Nm
2 24
21 - 62 9813/9400-1 21 - 62
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-65
21 - 63 9813/9400-1 21 - 63
Notes:
21 - 64 9813/9400-1 21 - 64
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-65 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-66 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-66 between the engine and the radiator/cooling pack.
21 - 65 9813/9400-1 21 - 65
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 - 66 9813/9400-1 21 - 66
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ........................................................................................................................... 24-13
24-03-01 Master Cylinder .............................................................................................................. 24-39
24-03-06 Priority Charge Valve ..................................................................................................... 24-42
24-03-09 Brake Valve .................................................................................................................... 24-46
24-03-39 Piston ............................................................................................................................. 24-50
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-56
24-03-46 Vacuum Pump ................................................................................................................ 24-59
24-03-50 Light Switch .................................................................................................................... 24-63
24-03-57 Pressure Sensor ............................................................................................................ 24-67
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-77
24-18-03 Switch ............................................................................................................................. 24-92
24-18-06 Cable .............................................................................................................................. 24-93
24-18-15 Pad ............................................................................................................................... 24-103
24-18-18 Caliper .......................................................................................................................... 24-104
24-18-21 Disc .............................................................................................................................. 24-111
24-18-48 Actuator ........................................................................................................................ 24-121
24-36 Trailer Brake
24-36-00 General ......................................................................................................................... 24-125
9813/9400-1
2017-08-02
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
ISO International Organization for
Standardization
SRS Smooth Ride System
TBV Trailer Brake Valve
9813/9400-1
2017-08-02
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/9400-1 24 - 1
Notes:
24 - 2 9813/9400-1 24 - 2
24 - Brake System
00 - Brake System
00 - General

Health and Safety ........................................... 24-3 Brake Fluid
Technical Data ................................................. 24-5 Use of incorrect brake fluid will cause serious
Component Identification ................................. 24-7 damage to the seals of the braking system. This will
Fault-Finding .................................................... 24-8 result in brake failure.
Discharge and Pressurise ............................. 24-10 Service Brake Bleeding
Check (Level) ................................................ 24-10 Before bleeding the service brake system, park on
level ground and set the park brake to on. Put blocks
on both sides of the wheels on one axle to prevent
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If
you do not take these precautions the machine could
run over you.
Park Brake Maintenance
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the
machine could run over you.
movement.
Brake Dust
Brake pads generate dust, which if inhaled may
endanger health. Wash off the caliper assemblies
before commencing work. Clean hands thoroughly
after completing the work.
Brake Dust
Brake shoes generate dust, which if inhaled
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Put blocks on all wheels to prevent the machine
rolling.
WARNING! Do not use the machine with any part of
its brake system disconnected or inoperative. When
24 - 3 9813/9400-1 24 - 3
24 - Brake System
00 - Brake System
00 - General
the test has been completed, make sure all brake

system components are installed and the system is
operating correctly.
WARNING! Before testing the park brake make sure
the area around the machine is clear of people.
WARNING! If the machine starts to move during the
park brake test, immediately apply the foot brake and
reduce the engine speed.
WARNING! If the machine starts to move during the
service brake test, immediately reduce the engine
speed and apply the park brake.
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
WARNING! Oil on the brake disc will reduce brake
effectiveness. Keep oil away from the brake disc.
Remove any oil from the disc with a suitable solvent.
Read and understand the solvent manufacturer's
safety instructions. If the pads are oily, install with the
new pads.
WARNING! Faulty brakes can kill. If you have to
top up the brake reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
WARNING! The park brake must not be used to
slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will
be reduced. Whenever the park brake has been used
in an emergency the brake friction components must
be renewed and the other components inspected.
Notice: Over adjustment or failure to disengage the
park brake properly will cause excessive wear of the
park brake mechanism.
24 - 4 9813/9400-1 24 - 4
24 - Brake System
00 - Brake System
00 - General
Technical Data
For: 506-23 [T4F], 509-23 [T4F]

..................................................... Page 24-5
For: 512-26 [T4F] ........................ Page 24-5
..................................................... Page 24-6
(For: 506-23 [T4F], 509-23 [T4F])
Single axle service brakes system

Table 197. Service brake
Type Single circuit, oil immersed multi-plate disc.
Actuation Hydraulic.
Hydraulic, servo assisted.
(1)
Location Front axle, centre mounted (2 brake packs).

(1) Machines with turbo inter-cooled engines.
Table 198. Master cylinder

Type Master cylinder.
Master cylinder with remote servo unit.
(1)
No. of Cylinders 1
Diameter 31.75mm
Stroke 39mm
Displacement Minimum- 2835 cc.
(1) Machines with turbo inter-cooled engines.
Table 199. Servo unit

Type Vacuum assisted hydraulic valve.
Vacuum cylinder diameter 175mm
Hydraulic cylinder diameter 22.2mm
Brake vacuum pressure 0.8–1bar (11.6–14.5psi)
Minimum oil displacement 23.6 cc
Stroke 61mm
Table 200. Park brake

Type Independent disc (with manually adjusted calliper)
park brake in the drive to the front axle.
Actuation Cable operated.
Location Mounted on the gearbox.
Disc diameter 279.4mm
(For: 512-26 [T4F])

Table 201. Service Brakes- Power Brake System
Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic
Location Front and Rear Axle, centre mounted (2 brake packs
per axle).
Charge valve cut in pressure 80bar (1,159.4psi)
Charge valve cut out pressure 115bar (1,666.7psi)
24 - 5 9813/9400-1 24 - 5
24 - Brake System
00 - Brake System
00 - General
Friction plates (6 per brake pack):

Outside diameter 254mm
Inside diameter 176mm
Facing area (per plate) 0.02634m²
Annular Brake piston Area 0.006597m²
Table 202. Park Brake

Type Oil-immersed multi-plate brake pack.
Actuation Cable
Location Gearbox (acts through drive to front axle)

Table 203. Service Brakes- Power Brake System (JCB Axle)
Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic
Location Front axle, centre mounted.
Friction plates (per side) 5
Outside diameter 222mm
Inside diameter 160mm
Friction plate thickness (new) 3.76–3.92mm
Counter plate thickness (new) 3.8–3.9mm

Type Oil-immersed multi-plate brake pack.
Actuation Cable
Location Gearbox (acts through drive to front axle)
24 - 6 9813/9400-1 24 - 6
24 - Brake System
00 - Brake System
00 - General
(For: 512-26 [T4F])
Figure 468.
E
D
F
A Brake friction plates in centre case B Foot brake pedal

C Parking brake lever D Power brake valve
E Handbrake F Brake accumulator
24 - 7 9813/9400-1 24 - 7
24 - Brake System
00 - Brake System
00 - General
Fault-Finding
(For: 512-26 [T4F], HM560 Variable

Transmission)
Fault
Pedal travel excessive. Table 205. Page 24-8
Poor braking (not pulling to one side) Table 206. Page 24-8
Pedal hard to operate Table 207. Page 24-8
Pedal touches floor under constant pressure Table 208. Page 24-9
Brakes not releasing. Table 209. Page 24-9
Excessive brake noise from brake packs in operation (Due to the metal to Table 210. Page 24-9
metal contact of oil immersed brakes, limited noise can be heard which is
consistent with this type of design- this is normal).
Fluid escaping from axle breather (Noise is similar to the sound made by an Table 211. Page 24-9
air horn. Noise is possible after hydraulic oil change).
Table 205. Pedal travel excessive.

Cause Remedy
Air in the brake circuit. Bleed the brakes. Refer to (PIL 24-03-00)
Fluid leaks. Check the brake pipes and hoses for leaks, rectify as
required.
Friction and counter plates in poor condition, or worn Check the axle brake pack plates for wear, distortion
beyond limits. Brake piston binding. or damage. Check the axle brake piston operation.
Refer to (PIL 27-20/21)
Table 206. Poor braking (not pulling to one side)

Cause Remedy
Axle oil level low, or incorrect oil type. Check the axle for leaks. Fill the axle with clean oil of
the correct type. Refer to (PIL 75-03).
Brake valve faulty. Check the brake pressure. Refer to (PIL 24-03). If
necessary, install a new brake valve.
Charge valve faulty. Check the charge pressure. If necessary, install a
new charge valve.
Table 207. Pedal hard to operate

Cause Remedy
Tightness at pedal pivot. Inspect pedal pivot. Free-off/lubricate.
Fluid contamination/seal damage. Flush system and renew all hydraulic seals. Bleed
the brake system. Refer to (PIL 24-03).
Misaligned push rod/pedal. Check and rectify as required.
Kinked or crushed brake pipes. Check/renew brake pipework.
Brake valve faulty. Check the brake pressure. If necessary, install a new
charge valve.
Charge valve faulty. Check the charge pressure. If necessary, install a
new charge valve.
24 - 8 9813/9400-1 24 - 8
24 - Brake System
00 - Brake System
00 - General
Table 208. Pedal touches floor under constant pressure

Cause Remedy
Fluid leaks. Check the brake pipes and hoses for leaks, rectify as
required.
Internal fluid leaks Brake piston seal leakage.
Damage to brake valve. Check brake valve condition/operation. Refer to the
Power Brake Valve topic
Table 209. Brakes not releasing.

Cause Remedy
Brake pedal(s) does not return properly. (1) Check the area around the brake pedal is free of
obstructions. (2) Check the operation of the pedal
return spring. Check for tightness of pedal pivot,
lubricate pivot if required. (3) Check the pedal stop
bolt is adjusted correctly.
Brake valve faulty. (1) Check the brake pressure. (2) Check tank line
pressure after brake actuation. (3) If necessary,
renew the brake valve.
Kinked or crushed brake pipes or hoses. Inspect the brake pipes and hoses for damage.
Renew as required.
Refer to (PIL 24-03) and (PIL 24-39).
Friction and counter plates are not free on splines or Check the friction and counter plates for free
dowels. movement. Renew if required - BOTH sides of axle.
Table 210. Excessive brake noise from brake packs in operation (Due to the metal to metal contact of
oil immersed brakes, limited noise can be heard which is consistent with this type of design- this is
normal).
Cause Remedy
Axle oil level low, or incorrect oil type. Check the axle for leaks. Fill the axle with clean oil of
the correct type.
Table 211. Fluid escaping from axle breather (Noise is similar to the sound made by an air horn. Noise
is possible after hydraulic oil change).
Cause Remedy
Brake piston seals in poor condition, or damaged. Renew the piston seals- Both sides of axle. Refer to
(PIL 24-39).
Air in the system. Pump the pedals several times. Bleed the system.
24 - 9 9813/9400-1 24 - 9
24 - Brake System
00 - Brake System
00 - General
Discharge and Pressurise Check (Level)
(For: 512-26 [T4F], HM560 Variable (For: 506-23 [T4F], 509-23 [T4F])
Transmission) WARNING Faulty brakes can kill. If you have
WARNING Before proceeding with the bleed to top up the brake reservoir frequently, get the
procedure it is important to make sure that the brake system checked by your JCB Dealer. Do
park brake is engaged and that one pair of wheels not use the machine until the fault has been put
is chocked on both sides. right.
Machines installed with main hydraulic system power system. See Fluids, Capacities and Lubricants for
assisted brakes have an accumulator installed in the correct fluid. The fluid can harm your skin.
the braking circuit. The accumulator stores enough Wear rubber gloves. Cover cuts or grazes.
energy for a limited number of assisted brake pedal
operations when the engine is not running. The brake fluid tank is in the panel in front of the cab.
Pull the release knob to open the panel.
To make sure that the pressure in the braking system
is discharged, carry out the following procedure. Figure 469.
2. Make sure the battery is not disconnected during
this operation.
3. Make sure the ignition key is set to the on position
but with the engine stopped.
4. Operate the brake pedal for the specified number
of cycles. Number of cycles = 30.
5. Check the brake system pressure display on the
dashboard display screen.
A
6. If the brake system pressure displayed is greater
than zero, keep pressing the brake pedal until A Knob
zero pressure is displayed.
7. Set the ignition key to the off position and remove
the ignition key. Make sure you do not start 2. Check the brake fluid level. The correct fluid level
the engine as the brake system will be re- is marked on the tank.
pressurised and the process will need to be
repeated. 3. If necessary, add more fluid:
8. Isolate the battery before carrying out additional

service work on the machine. Refer to (PIL
33-03).
24 - 10 9813/9400-1 24 - 10
24 - Brake System
00 - Brake System
00 - General
Figure 470.
A
A Tank cap
B Tank
3.1. Remove the tank cap.
3.2. Add the recommended fluid slowly.
3.3. Replace the tank cap.
3.4. Clean any spilt fluid.
24 - 11 9813/9400-1 24 - 11
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ........................................................................................................................... 24-13

24-03-01 Master Cylinder .............................................................................................................. 24-39
24-03-06 Priority Charge Valve ..................................................................................................... 24-42
24-03-09 Brake Valve .................................................................................................................... 24-46
24-03-39 Piston ............................................................................................................................. 24-50
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-56
24-03-46 Vacuum Pump ................................................................................................................ 24-59
24-03-50 Light Switch .................................................................................................................... 24-63
24-03-57 Pressure Sensor ............................................................................................................ 24-67
24 - 12 9813/9400-1 24 - 12
24 - Brake System
03 - Service Brake
00 - General
Introduction .................................................... 24-13 The service brake is used to stop the machine when
Component Identification ............................... 24-14 it is in motion.
Operation ....................................................... 24-20
Operation (Hydraulic) .................................... 24-21 The service brake is a hydraulic system. The
machine operator applies pressure to the brake
Operation (Electrical) ..................................... 24-22 pedal in the cab.
Diagram ......................................................... 24-23
Check (Pressure) .......................................... 24-26 The pedal is connected to the master cylinder which
Bleed ............................................................. 24-28 supplies hydraulic pressure to the applicable brake
units to apply the brakes.
The brake packs are located in the axle- some
machines have front and rear brakes whilst some
machines only have front axle brakes.
24 - 13 9813/9400-1 24 - 13
24 - Brake System
03 - Service Brake
00 - General
For: Dana 213 Series ................ Page 24-14

For: 506-23 [T4F], 509-23 [T4F]
................................................... Page 24-15
For: 512-26 [T4F] ...................... Page 24-16
................................................... Page 24-17
(For: Dana 213 Series)

No information available at time of writing.
Figure 471. Dana 223 Axle Service Brakes

6
2 5 7
8
4
9
10
11
23 12
13
14
15
24 16
17
18
19
20
27 22 21
28
2 O-ring 1 4 O-ring 2
5 Bleed screw 6 Cap
7 Adaptor 8 Seal
9 Piston seal and anti-extrusion ring 1 10 Piston seal and anti-extrusion ring 2
11 Piston 12 Spring
13 Adjusting screw 14 Steel disc 1
15 Friction disc 1 16 Steel disc 2
17 Flange- brake disc pack 18 Friction disc 2
19 Steel disc 3 20 Friction disc 3
21 Pin screw 22 Stroke regulation bush
23 Intermediate disc 24 Cylinder
27 Distance piece 28 Shims
24 - 14 9813/9400-1 24 - 14
24 - Brake System
03 - Service Brake
00 - General
(For: 506-23 [T4F], 509-23 [T4F]) An electrical switch is fitted to the pedal assembly for
operation of the rear facing brake lights.
Auto 4-wheel braking
The front axle integral brake packs are multi-disc
plates that are immersed in oil. The brake packs To achieve 4-wheel braking, engage the 4WD (Four
are actuated hydraulically by a single foot pedal and Wheel Drive). In this way all 4 wheels are effectively
master cylinder. braked via the machine transmission.
On machines with servo assisted brakes, the When 2WD (Two Wheel Drive) is selected, operating
assistance is provided by means of an engine driven the brake pedal will automatically select 4-wheel
vacuum pump and remotely mounted servo unit drive. This gives increased braking effect. The
which is located on the front of the cab. transmission will switch back to 2- wheel drive when
the brake pedal is released.
The brake hydraulic fluid tank is situated outside the
cab, below the front windscreen.
Figure 472.
G
E
B
A
C
C A
A Front axle integral brake pack B Foot pedal

C Master cylinder D Exhauster (vacuum) pump (the location of
the pump will differ depending on the engine
installed)
E Servo unit F Brake fluid tank
G Brake light electrical switch
24 - 15 9813/9400-1 24 - 15
24 - Brake System
03 - Service Brake
00 - General
(For: 512-26 [T4F])
Figure 473. Power Brake System
C
B
E F
D
A Front Axle B Charge Valve

C Accumulator D Brake Valve
E Brake Pedal F Rear Axle
24 - 16 9813/9400-1 24 - 16
24 - Brake System
03 - Service Brake
00 - General
Figure 474. Power Brake System- Dual Tech Variable Transmission Machines
A
B
A B
C
F
333/D7974-4
A Direction of view B Direction of view

C Direction of view D Brake accumulator
E Connections to power brake valve (power brake F Connection to front axle
valve not shown)
24 - 17 9813/9400-1 24 - 17
24 - Brake System
03 - Service Brake
00 - General
F
G
F Connection to front axle G Front axle (with integral disc brakes)

H Pedal lever and brake valve assembly
A
C D
F
H
E
J
333/D7974-4
24 - 18 9813/9400-1 24 - 18
24 - Brake System
03 - Service Brake
00 - General
A Power brake valve B Port N

C Port B D Port D
E Front steering ram F SRS (Smooth Ride System) Pressure
transducer
G Tee adaptor H To trailer brake valve
J Blanking cap K To CPV
L Brake Accumulator
Other pipes are shown for reference only.
24 - 19 9813/9400-1 24 - 19
24 - Brake System
03 - Service Brake
00 - General
Operation

The front axle integral brake packs are an oil
immersed, multi disc type. The hydraulic supply to
operate the service brakes is supplied by the engine
driven hydraulic cooling fan gearpump. The pressure
from the hydraulic pump is regulated by the charge
valve. The charge valve provides a constant supply
of oil at a preset charge pressure to the brake valve
and brake accumulator. When the brake pedal is
pressed, the brake valve directs the oil in the charge
circuit to the brake piston housings in the front axle.
The resulting brake pressure is proportional to the

pedal movement. The brake accumulator stores
pressure in the charge circuit, so that there is a
limited supply for the brakes when the engine is
stopped. A pressure sensor located on the charge
valve senses the stored pressure and sends a signal
to the centre warning display.
Before any work is done to the front axle or

braking system, the brake hydraulic system must be
discharged. Refer to discharge and pressurise, (PIL
24-00-00).
24 - 20 9813/9400-1 24 - 20
24 - Brake System
03 - Service Brake
00 - General
Operation (Hydraulic)
(For: 512-26 [T4F])
Overview
Refer to Diagram, (PIL 24-03-00)
Figure 477.
D
A
F
C
G
A Rear axle B Brake accumulator

C Charge valve D Sensor
E Brake valve F Front axle
G Centre warning display
1. The hydraulic supply to operate the service 4. The brake accumulator stores pressure in the
brakes is supplied by the engine-driven hydraulic charge circuit, so that there is a limited supply
cooling fan gearpump. for the brakes when the engine is stopped.
The brake hydraulic system must be discharged
2. The pressure from the hydraulic pump is before the braking system is worked on. Refer to
regulated by the charge valve. The charge valve discharge and pressurise, (PIL 24-00-00).
provides a constant supply of oil at a preset
charge pressure to the brake valve and brake 5. A pressure sensor located on the charge valve
accumulator. senses the stored pressure and sends a signal
3. When the brake pedal is pressed, the brake valve
directs the oil in the charge circuit to the brake 6. A sensor is shown which is used in the
piston housings in the front axle and rear axle. transmission disconnect system. Refer to (PIL
The resulting brake pressure is proportional to 33-33-15).
the pedal movement.
24 - 21 9813/9400-1 24 - 21
24 - Brake System
03 - Service Brake
00 - General
Operation (Electrical)
(For: 512-26 [T4F]) The schematic shown is for illustration purposes

only. For electrical details of individual devices refer
Brake Pressure Display to the Harness Drawings (PIL 33-12) or Electrical
Schematics (PIL 33-00-50).
Refer to (PIL 33-00-50), (PIL 33-12), (PIL 33-00-90),
(PIL 33-09) and (PIL 33-59).
Figure 478.
B - J1
ECU
ECU
IGN +VE
A Centre Warning Display B Hydraulic control ECU (Electronic Control Unit)-

connector J1
C Brake pressure charge sensor
1. The brake pressure charge sensor is located

on the charge valve. The output voltage varies
according to the pressure in the brake charging
system. The output voltage is transmitted to the
centre warning display. The brake pressure is
displayed on screen.
2. The hydraulic control ECU provides the supply
and earth for the sensor.
3. A pressure sensor located on the charge valve
senses the stored pressure and sends a signal
24 - 22 9813/9400-1 24 - 22
24 - Brake System
03 - Service Brake
00 - General
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................... Page 24-23
For: 512-26 [T4F] ...................... Page 24-25
(For: 506-23 [T4F], 509-23 [T4F])

Hose and pipework- Machines with trailer brakes
Figure 479.
B
D
E
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
E T-piece F Check valve
G Trailer brake valve
24 - 23 9813/9400-1 24 - 23
24 - Brake System
03 - Service Brake
00 - General
Hose and pipework- Machines without trailer brakes
Figure 480.
D
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
24 - 24 9813/9400-1 24 - 24
24 - Brake System
03 - Service Brake
00 - General
(For: 512-26 [T4F])
Figure 481.
C
D
A B
F E
H
G
A Front axle B Rear axle

C Trailer brake valve (optional) D Variable displacement pump + gear pump
E Pressure sender F Brake valve
G Charge valve H Hydraulic tank
24 - 25 9813/9400-1 24 - 25
24 - Brake System
03 - Service Brake
00 - General
Check (Pressure) 6. Open the Loadall Diagnostics program.

7. Enable the connection between the PC/Laptop
by pressing the Start Diagnostics button or select
(For: 512-26 [T4F], HM560 Variable Start Diagnostics from the File Menu.
Transmission)
Figure 483.
WARNING Before working on the brake system,
make sure that the machine is on solid level
ground. Put blocks on all wheels to prevent the
machine rolling.
Checking the Brake Charge Pressure Figure 484.
The maximum stored pressure achieveable is as

stated in technical data, Refer to Technical Data, (PIL
24-03-06).
This is factory set inside the charge valve and cannot

be adjusted.
There is no test point in the circuit. To measure

the charge pressure it will be necessary to connect
the machine to a computer/laptop with the current
Servicemaster software. Refer to (PIL 33-57).
The brake system charge valve cycles the charge

pressure between pre-set limits to ensure the brake
accumulator is filled with pressure.
1. Make sure that the hydraulic fluid is at working 8. When the program is open select the Hydraulics
temperature. ECU (Electronic Control Unit) tab at the top of the
2. Make the machine safe. Refer to (PIL 01-03). page.
3. Follow the health and safety procedures. Refer 9. On the left hand side click the box to open
to (PIL 01-03). the “brake system”. For details of Servicemaster
display icons/keys refer to (PIL 33-57).
4. Discharge the braking system pressure. Refer to
(PIL 30-00-00). 10. Operate the engine for a minimum of two minutes
and occasionally press the brake pedals. This
5. Connect the machine to a computer/laptop with makes sure that the brake system charge valve
up to date Servicemaster software. Open the has filled the accumulator.
Loadall tool set.
11. With the engine running, check the reading on
Figure 482. the Servicemaster screen pressure gauge. The
charge pressure will be between the Cut-in and
Cut-out values stated. Refer to (PIL 24-03-06).
12. Press the brake pedal repeatedly and check
that the charge pressure is maintained within
the minimum and maximum limits. Refer to (PIL
24-03-09).
Checking the Brake Supply Pressure

The brake to axle supply pressure is as stated
in technical data, Refer to Technical Data, (PIL
24-03-09).
There is no test point in the circuit. To measure the

brake supply pressure, it will be necessary to connect
1 Loadall Diagnostic Program
24 - 26 9813/9400-1 24 - 26
24 - Brake System
03 - Service Brake
00 - General
the machine to a computer/laptop with the current Figure 487.

Servicemaster software.
For details of connection and use of Servicemaster

software. Refer to (PIL 33-57).
1. Make sure the hydraulic fluid is at working

temperature.
3. Follow the general care and safety procedures.
4. Discharge the braking system pressure. Refer to
(PIL 30-00-00).
5. Connect the machine to a computer/laptop with
up to date Servicemaster software. Open the
Loadall tool set.
8. When the program is open select the Hydraulics
Figure 485. ECU tab at the top of the page.
9. On the left hand side click the box to open
the “brake system”. For details of Servicemaster
display icons/keys refer to (PIL 33-57).
10. Operate the engine for a minimum of two minutes
and occasionally press the brake pedals. This
makes sure that the brake system charge valve
has filled the accumulator.
11. With the engine running, check the reading on
the Servicemaster screen pressure gauge.
1 Loadall Diagnostic Program

6. Open the Loadall Diagnostics program.
7. Enable the connection between the PC/Laptop
by pressing the Start Diagnostics button or select
Start Diagnostics from the File Menu.
Figure 486.
24 - 27 9813/9400-1 24 - 27
24 - Brake System
03 - Service Brake
00 - General
Bleed Figure 489. Servo unit
For: 506-23 [T4F], 509-23 [T4F]

................................................... Page 24-28
For: 512-26 [T4F] ...................... Page 24-28
................................................... Page 24-30
(For: 506-23 [T4F], 509-23 [T4F])
Single axle service brake system

WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn
cause brake failure.
1. Make the machine safe. Refer to (PIL 01-03). B

2. Follow all the care and safety procedures. Refer
to (PIL 01-03).
3. Fill the tank with correct fluid. Refer to operators
manual.
4. Make sure that the fluid level does not fall under
the Minimum mark when you do the bleeding
procedure.
5. Bleed the brake system in the applicable
sequence as follows:
5.1. Machines without servo brakes- Bleed at B Bleed point on servo unit
the point on the front axle.
6. Attach a tube to the applicable bleed screw.
Figure 488. Front axle
7. Make sure that the free end of the tube is put fully
into the fluid in a suitable container.
8. Open the bleed screw and apply one rapid full
stroke of the brake pedal followed by three rapid
short strokes from the halfway pedal position.
After the third short stroke, allow the pedal to
A return quickly to its stop.
9. Continue to bleed the air normally until all the air
is removed. Push the pedal fully and close the
bleed screw.
10. Top up the tank to the full mark.
A Bleed point on front axle (For: 512-26 [T4F])

5.2. Machines with servo brakes- Bleed at the WARNING Before proceeding with this procedure
point on the servo unit and the point on the make sure that the park brake is engaged and that
front axle. one pair of wheels is blocked on both sides.
The procedures are the same for the front and rear
axle.

24 - 28 9813/9400-1 24 - 28
24 - Brake System
03 - Service Brake
00 - General
3. Operate the engine for the specified time and Figure 490. Front Axle
occasionally press the brake pedal. This makes
sure that the brake system charge valve has filled A A
the accumulator and removed any air from the
charge circuit.
Duration: 2min
4. Make sure you keep the engine running while
bleeding the system.
5. Bleed each brake in turn:
5.1. Attach a tube to the relevant bleed screw on
the axle centre casing. Put the free end of
the tube into a suitable container to collect
the hydraulic fluid.
5.2. Get an assistant to gradually press the A Bleed screw
brake pedal, then carefully open the bleed
screw. When the bleed screw is open, oil will Figure 491. Rear Axle
flow through the bleed tube at a high rate
and pressure. Make sure the tube is secure.
5.3. Continue bleeding until all air is expelled. A
Close the bleed screw then release the
brake pedal. As the brake system uses the
hydraulic system fluid, there may be small
traces of air suspended in the fluid which
can be discounted.
6. Repeat step 5 for the opposite brake.
7. Make sure that all bleed screws are correctly
tightened.
8. Repeat steps 3 to 7 for the other axle.
9. On completion, check the brake circuit for leaks
and correct operation.
10. Check the hydraulic system fluid level. Refer to
(PIL 30-00).
11. Check the brake pressure. Make sure that when
the brake pedals are at rest (fully back against
their stops) the brake pressure to the brake packs
is zero.
A Bleed screw
24 - 29 9813/9400-1 24 - 29
24 - Brake System
03 - Service Brake
00 - General
(For: HM560 Variable Transmission) Figure 492. Front Axle

WARNING Before proceeding with this procedure
make sure that the park brake is engaged and that
one pair of wheels is blocked on both sides.

2. Follow the health and safety procedures. Refer A
to (PIL 01-03).
3. Operate the engine for the specified time and
occasionally press the brake pedal. This makes
sure that the brake system charge valve has filled
the accumulator and removed any air from the
charge circuit.
A Bleed screw
Duration: 2min
4. Make sure you keep the engine running while
bleeding the system.
5. Bleed each brake in turn.
5.1. Attach a tube to the relevant bleed screw on
the axle centre casing. Put the free end of
the tube into a suitable container to collect
the hydraulic fluid.
5.2. Get an assistant to gradually press the
brake pedal, then carefully open the bleed
screw. When the bleed screw is open oil will
flow through the bleed tube at a high rate
and pressure. Make sure the tube is secure.
5.3. Continue bleeding until all air is expelled.
Close the bleed screw then release the
brake pedal. As the brake system uses the
machines hydraulic system fluid, there may
be small traces of air suspended in the fluid
which can be discounted.
6. Repeat step 5 for the opposite brake.
7. Make sure that all bleed screws are correctly
tightened.
8. On completion, check the brake circuit for leaks
and correct operation.
9. Check the hydraulic system fluid level. Refer to
(PIL 30-00).
10. Check the brake pressure. Make sure that when
the brake pedals are at rest (fully back against
their stops) the brake pressure to the brake packs
is zero.
24 - 30 9813/9400-1 24 - 30
24 - Brake System
03 - Service Brake
00 - General
Disassemble and Assemble Figure 494.
For: 506-23 [T4F], 509-23 [T4F]

................................................... Page 24-31
(For: 506-23 [T4F], 509-23 [T4F])

Refer to driveline, axle, general, dissasemble and
assemble, (PIL 27-20-00).

Consumables
JCB High Strength 4102/0551 0.05L 4. Remove the screws from the counter plate. Refer
Threadlocker to Figure 495.
JCB Hydraulic Fluid OP 4002/2001 5L Figure 495.
46 4002/2005 20L
4002/2003 200L
Strength)
1. Sling the axle arm to be removed and connect it

to a hoist. Loosen and remove the screws. Refer
to Figure 493.
Figure 493.
12 Spring
13 Counter plate screws
5. Remove the pin screws. Refer to Figure 496.
Figure 496.
31 Screws
2. Remove the arm together with brakes and axle
shafts; lay down the arm vertically.
3. Release pressure. Refer to Figure 494.
21 Pin screws
6. Note down their order of assembly and remove
the counter plate. Refer to Figure 497.
24 - 31 9813/9400-1 24 - 31
24 - Brake System
03 - Service Brake
00 - General
23 Counter plate 2 O-ring
7. Loosen the studs in an alternate manner and 10. Slowly introduce low-pressure compressed air
remove them. Refer to Figure 498. through the connection port for the service brake,
in order to extract the piston. Refer to Figure 501.
Figure 498.
Figure 501.
11 Piston
8. Remove the cylinder. Refer to Figure 499.
11. Make sure you hold the piston back, as it may be
Figure 499. suddenly ejected and damaged. Refer to Figure
501.
12. Note down the order of assembly. Refer to Figure
502.
Figure 502.
24 Cylinder
9. The O-rings must be replaced each time the unit
is disassembled. Refer to Figure 500.
24 - 32 9813/9400-1 24 - 32
24 - Brake System
03 - Service Brake
00 - General
13. Remove braking discs noting down the order and Figure 505.
direction of assembly. Refer to Figure 503.
Figure 503.
16 Braking disc (x3) 14 Friction disc

15 Friction disc
14. If discs are not to be replaced, make sure you 16 Friction disc
avoid changing their position. Refer to Figure 17 Flange
503. 18 Disc
19 Disc
15. Remove the flange complete with the discs. 20 Disc
Refer to Figure 504. Refer to Figure 505.
16. Remove distance piece, braking discs and
Figure 504. shims, noting down direction of assembly. Refer
to Figure 506.
Figure 506.
27 Braking discs
28 Shim stack
17. Measure the thickness of the friction discs. If one
or more discs measure less than the minimum
value replace the complete brake disc pack,
including the metal discs.
Assemble
1. Replace the O-rings and anti-extrusion rings
on all pistons. The O-rings always have to be
assembled from the pressure facing side.
2. Install O-ring and anti-extrusion ring onto the
piston.
24 - 33 9813/9400-1 24 - 33
24 - Brake System
03 - Service Brake
00 - General
3. Lubricate the piston and the O-rings with the Figure 509.
correct lubricant and install the unit into the
cylinder. Refer to Figure 507.
Consumable: JCB Hydraulic Fluid OP 46
Figure 507.
2 O-ring
6. Engage the cylinder with the drive head. Refer to
Figure 510.
7. Insert the screws and tighten them alternately.
11 Piston
24 Cylinder 8. Lock the cylinder.
4. Using a plastic hammer, ram the piston into the Figure 510.
cylinder. Lightly hammer all around the edge in
an alternate sequence. Refer to Figure 508.
Figure 508.
9. Tighten the studs to the specified torque. Refer

to Figure 511.
11 Piston
24 Cylinder Torque: 30–35N·m
5. Check the condition and position of the cylinder’s Figure 511.

O-ring.Refer to Figure 509.
24 - 34 9813/9400-1 24 - 34
24 - Brake System
03 - Service Brake
00 - General
10. Insert the stroke automatic regulation springs 13. Apply locking fluid to the thread of the adjustment
and place them in line with the intermediate disc. screw. Refer to Figure 515.
Refer to Figure 512. Consumable: JCB Threadlocker and Sealer
Figure 512. (Medium Strength)
14. Tighten with torque wrench to the specified
setting.
Torque: 10–15N·m
Figure 515.
22 Stroke automatic regulation springs

23 Intermediate disc
11. Insert the intermediate disc. Refer to Figure 513.
Figure 513.
15. Fit the pin screws. Apply threadlocker to the

thread. Tighten to the specified torque.
Torque: 5–7N·m
Consumable: JCB High Strength Threadlocker
Figure 516.
12. Fit the reversal springs and the intermediate disc.
Figure 514.
16. Take the dimension from the surface of the

intermediate disc to the cover sealing surface
with the specified pressure introduced. Refer to
Figure 517.
Pressure: 30bar (434.8psi)
12 Reversal spring
13 Pin screw
24 - 35 9813/9400-1 24 - 35
24 - Brake System
03 - Service Brake
00 - General
X Dimension measurement- piston under pressure 28 Shim stack

17. Put the brake disc pack including the distance 20. Install the friction disc on the flange from arm
piece under a press. Apply the specified load and side. Refer to Figure 520. Refer to Figure 505.
measure the dimension. Refer to Figure 518.
Weight/Force: 1,000kg Figure 520.
Figure 518.
18 Friction disc
V Dimension measurement- brake pack under 21. Install the metal disc on the flange from the arm
load side.
18. Calculate the thickness of shim required to set Figure 521.

the disc pack gap to the specified gap. Refer to
Table 212.
19. Insert the measured shim stack under the
distance piece.
19 Metal disc
22. Install the friction disc on the flange from arm side
and insert the group on the u-joint.
24 - 36 9813/9400-1 24 - 36
24 - Brake System
03 - Service Brake
00 - General
Figure 522. 26. Tighten to the specified torque.

Torque: 30–35N·m
Figure 525.
17 Flange
18 Friction disc
19 Metal disc
20 Friction disc
23. Insert the flange and the remaining discs. 27. Check the condition and position of the cylinder’s
O-ring. Refer to Figure 526.
Figure 523.
Figure 526.
1
24. Check the alignment of the last disc and the 28. Check the condition and position of the arm’s O-
flange. ring; install the complete arm. Refer to Figure
Figure 524. 527.
Figure 527.
25. Apply JCB Locking Fluid to the studs.

Consumable: JCB Threadlocker and Sealer 29. Cross tighten the nuts in two stages.
(Medium Strength) Torque: 200–221N·m
24 - 37 9813/9400-1 24 - 37
24 - Brake System
03 - Service Brake
00 - General
Figure 528.
Shim Calculation (Example)

Table 212.
Axle arm brake housing 74mm
(1)
reference depth
Intermediate disc depth 29mm
(1)
measurement X
Disc pack thickness 42.33mm
(1)
measurement V
Disc pack gap measure- 1.25mm
(1)
ment required
Shim stack thickness re- 1.42mm
(1)
quired (74 - (29 + 42.33

+ 1.25)) = 1.42
(1) All dimensions for illustration purposes only.

No information available at time of writing.
24 - 38 9813/9400-1 24 - 38
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Remove and Install

(For: 506-23 [T4F], 509-23 [T4F])
The master cylinder is a non-serviceable part. If it is
defective, it must be replaced with a new one.
Remove
30-00).
4. For machines with power brake system,
Discharge the brake system pressure. Refer to
(PIL 24-00).
5. Remove the retaining clip.
Figure 529. Single axle brak-
ing system- Master cylinder
A C
B
E
F G E
A Retaining clip
B Clevis pin
C Brake pedal lever bracket
D Operating rod
E Nut
F Bolt
G Master cylinder
6. Remove the clevis pin to disconnect the master
cylinder operating rod from the brake pedal lever
bracket.
24 - 39 9813/9400-1 24 - 39
24 - Brake System
03 - Service Brake
Figure 530. Twin axle brak- Figure 531.

ing system- Master cylinder
A C
D F
H
F
E
G
J
K
A Retaining clip
B Clevis pin
C Brake pedal lever bracket
D Operating rod
E Nut H Cab front cover
F Bolt J Plastic feed pipe
G Master cylinder K Master cylinder output hose
7. Get access to the master cylinder hydraulic 10. Plug the cylinder port and blank off the hose (or
connections which are located behind the cab pipe) to prevent ingress of dirt.
front cover.
11. Machines with twin axle service brakes have
8. Disconnect the plastic feed pipe from the brake three master cylinder securing bolts. Machines
fluid tank and then either blank off the pipe or with single axle service brakes have two securing
drain the tank. bolts.
9. Disconnect the master cylinder output hose (or 12. Support the master cylinder.
pipe as applicable).
13. Remove the nuts and the bolts.
14. 'Remove the master cylinder from the machine.
Install
steps.
1.1. Once the master cylinder is installed and
the pipework connected make sure the
brake fluid tank level is correct. Refer to (PIL
24-00).
1.2. Bleed the brake system. Refer to (PIL
24-00).
1.3. Check the operation of the brake light
switch and adjust if necessary. Refer to (PIL
24-03-50).
24 - 40 9813/9400-1 24 - 40
24 - Brake System
03 - Service Brake
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 41 9813/9400-1 24 - 41
24 - Brake System
03 - Service Brake
06 - Priority Charge Valve
06 - Priority Charge Valve Technical Data

Technical Data ............................................... 24-42 For: 512-26 [T4F] ...................... Page 24-42
Component Identification ............................... 24-43 For: HM560 Variable Transmission
................................................... Page 24-42
Diagram ......................................................... 24-45
(For: 512-26 [T4F])
Table 213. Charge Valve
Charge pressure
(brakes)
(1)
Cut-in 85bar (1,231.9psi)

Cut-out 115bar (1,666.7psi)
(1) The charge pressure may briefly peak at 120bar
(1,739.1psi)

Table 214. Charge Valve
Charge pressure
(brakes)
Cut-in 120bar (1,739.1psi)
Cut-out 155bar (2,246.4psi)
24 - 42 9813/9400-1 24 - 42
24 - Brake System
03 - Service Brake
For: 512-26 [T4F] ...................... Page 24-43

................................................... Page 24-44
(For: 512-26 [T4F])

Figure 532. Charge Valve
N
R
F B
P
B Tank port
F Pressure sensor port
N Tank return port
P Inlet port
R Outlet port to brake valve/accumulator
24 - 43 9813/9400-1 24 - 43
24 - Brake System
03 - Service Brake
Figure 533. Priority Valve
A D E
B
F
C
G
A Port R (Accumulator) B Port P (From pump)

C Port N (Tank) D Port A (Priority flow)
E Port F (Accumulator pressure switch) F Port LS (Load sense signal)
G Port B (Fan motor)
24 - 44 9813/9400-1 24 - 44
24 - Brake System
03 - Service Brake
Diagram
Figure 534. DTVT Priority Valve

B A C
A Port A (Priority flow) B Port B (Exceeding flow)

C Port LS (Load sense signal) D Port N (Tank)
E Port R (Accumulator) F Port F (Accumulator pressure switch)
G Port P (Pump)
24 - 45 9813/9400-1 24 - 45
24 - Brake System
03 - Service Brake
09 - Brake Valve
09 - Brake Valve Technical Data

Technical Data ............................................... 24-46
(For: 512-26 [T4F])
Diagram ......................................................... 24-49 Table 215. Brake Valve Operating Pressure
Input (charge pressure) 80–115bar (1,159.4–
1,666.7psi)
Output (brake pressure) 0.46bar (6.7psi)
Accumulator pre-charge 70bar (1,014.5psi)
(nitrogen gas) at 20ºC
Weight 2.2kg
24 - 46 9813/9400-1 24 - 46
24 - Brake System
03 - Service Brake
09 - Brake Valve
For: 512-26 [T4F] ...................... Page 24-47

................................................... Page 24-48
(For: 512-26 [T4F])

Figure 535. Brake Valve
R
B Outlet port to brake packs
N Tank return port
R Inlet port (charge pressure)
24 - 47 9813/9400-1 24 - 47
24 - Brake System
03 - Service Brake
09 - Brake Valve
Figure 536. Dual Tech Variable Transmission Machines- Brake Valve
A C
N
B
334/F5148-1
A Brake valve B Outlet port to brake packs

C Spool position sensor N Tank return port
R Inlet port (charge pressure)
24 - 48 9813/9400-1 24 - 48
24 - Brake System
03 - Service Brake
09 - Brake Valve
Diagram
Figure 537. Dual Tech Variable Transmission- Brake Valve
1
2
3
4
5
6
B Outlet port to brake packs N Tank return port

R Inlet port (charge pressure) 1 Electrical connection
2 Electrical connection 3 Electrical connection
4 Electrical connection 5 Electrical connection
6 Electrical connection
24 - 49 9813/9400-1 24 - 49
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-50
Technical Data ............................................... 24-51
Brake Piston Seal Leakage
Check (Leaks) ............................................... 24-51 The most common reason for internal piston seal
Disassemble and Assemble .......................... 24-55 leakage is a build-up of axle contamination. It is
caused as a result of excessive brake wear caused
by extended service periods.
Two types of internal leakage can occur within the

axle or hub:
• Low Pressure Leaks- Seal damage, or scoring

to seal component surfaces, caused by a build-
up of metal particles.
• High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
Do the low pressure leak test first. Low pressure

leaks are difficult to find using a high pressure test.
The seals and other components can distort and form
a seal under pressure.
Do the low pressure or high pressure leak test

without disassembling the axle. Refer to brakes-
service brake, refer to (PIL 24-03).
Make sure that you do the leak test only when the
axle is cold.
24 - 50 9813/9400-1 24 - 50
24 - Brake System
03 - Service Brake
39 - Piston
Technical Data Check (Leaks)

For: 506-23 [T4F], 509-23 [T4F]
Refer to brakes- general, refer to (PIL 24-00). ................................................... Page 24-51
For: 512-26 [T4F] ...................... Page 24-53
(For: 506-23 [T4F], 509-23 [T4F])

Special Tools
Pressure Gauge (0-40 892/00278 1
Bar)
Consumables
JCB Hydraulic Fluid HP 4002/0501 1L
15 4002/0503 5L

machine rolling.
WARNING Do not use the machine with any part
of its brake system disconnected or inoperative.
When the test has been completed, make sure all
brake system components are installed and the
system is operating correctly.
The most common reason for internal piston seal

leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service
periods.

axle or hub:
1. Low Pressure Leaks- Seal damage, or scoring to

seal component surfaces, caused by a build-up
of metal particles.
2. High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
The low pressure leak test should be performed

first. Low pressure leaks are difficult to find using a
high pressure test- seals and other components can
distort and form a seal under pressure.
The following procedures explain how to check for

low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.

2. Disconnect the brake piston feed pipe (or hose,
as applicable) at port 1.
contamination.
24 - 51 9813/9400-1 24 - 51
24 - Brake System
03 - Service Brake
39 - Piston
4. Completely remove the pipe and install a plug at Figure 539.

port 2.
5. Fill both brake piston housings with JCB Light
Hydraulic Fluid through the port 1 and port 3.
X
Consumable: JCB Hydraulic Fluid HP 15
Figure 538.
D
A
E
B C
F
E Port 4
A Port 1 F Brake piston port
B Pipe X Brake fluid level line
C Port 2
D Port 3 7. Test for a high pressure leak as follows:
6. Test for a low pressure leak as follows: 7.1. Install a hand pump installed with a
pressure gauge of the specified value to the
6.1. Install an adaptor with a piece of clear tube brake piston port.
to the brake piston port. Special Tool: Pressure Gauge (0-40 Bar)
6.2. Make sure you keep the tube vertical during (Qty.: 1)
the test. Use tape to attach the tube to the 7.2. Fill the hand pump with the correct
side of the machine. Hydraulic Fluid.
6.3. Fill the tube until approximately three 7.3. Use the hand pump to generate a pressure
quarters full with the correct Hydraulic Fluid. in the brake piston housing. Do not exceed
6.4. Use a suitable pen to mark the level line of the specified value.
the brake fluid on the tube. Pressure: 69bar (1,000.0psi)
6.5. After approximately 30 minutes, check if 7.4. If the pressure falls off rapidly, or if no
the level has dropped below the original pressure reading can be obtained, the
marked line. If it has, check the brake piston piston seal is severely damaged. Install a
seal for slight nicks, cuts or generally for new seal.
wear.
7.5. Repeat the 7.1 to step 7.4 at port 4.
6.6. Repeat the step 6.1 to step 6.5 at port 4.
24 - 52 9813/9400-1 24 - 52
24 - Brake System
03 - Service Brake
39 - Piston
Figure 540. 1. Low Pressure Leaks- Seal damage, or scoring to

seal component surfaces, caused by a build-up
of metal particles.
2. High Pressure Leaks- Mechanical leakage past
X a badly damaged or perished seal.
The low pressure leak test should be performed

first. Low pressure leaks are difficult to find using a
high pressure test, seals and other components can
distort and form a seal under pressure.
The following procedures explain how to check for

E low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.
F
The procedures are the same for the front and rear
axle. Refer to the applicable illustration.
E Port 4
F Brake piston port
X Brake fluid level line 2. Make sure that the axle is cold.
8. Put the brake system back to the original 3. Disconnect the brake piston feed pipe (or hose,
condition as follows: as applicable) at port 1.
8.1. Connect all the brake pipes and bleed 4. Plug all the open ports and hoses to prevent
the brake system. Refer to brakes- service contamination.
brake. Refer to (PIL 24-03).
5. Fill brake piston housing with the correct fluid
For twin axle brake systems, do this procedure on through port 1.
the other axle, if applicable.
6. Test for a Low Pressure Leak:
(For: 512-26 [T4F])
Special Tools
Hand Pump Pressure 892/00223 1
Test
Bar)

machine rolling.
WARNING Do not use the machine with any part
of its brake system disconnected or inoperative.
When the test has been completed, make sure all
brake system components are installed and the
system is operating correctly.
Brake Piston Seal Leakage

The most common reason for internal piston seal
leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service
periods.

axle or hub:
24 - 53 9813/9400-1 24 - 53
24 - Brake System
03 - Service Brake
39 - Piston
Figure 541. Front Axle Figure 542. Rear Axle
A B
A C
A Piston port 1
B Clear tube
C Piston port 2
X Level marking on tube
6.1. Install an adaptor installed with a piece of
clear tube to the brake piston port 1. The
tube must be kept vertical during the test,
use tape to attach the tube to the side of the
machine.
6.2. Fill the tube until approximately three
quarters full with JCB Light Hydraulic Fluid.
6.3. Using a suitable pen, mark the level line of
the brake fluid X on the tube.
6.4. After approximately 30 minutes, check if
the level has dropped below the original
marked line. If it has, check the brake piston
seal for slight nicks, cuts or generally for
wear.
6.5. Repeat the steps above for port 2.
7. Test for a high pressure leak:
24 - 54 9813/9400-1 24 - 54
24 - Brake System
03 - Service Brake
39 - Piston
Figure 543. Disassemble and Assemble
Refer to driveline- front axle, refer to (PIL 27-20).
D Hand pump
A Port 1
7.1. Install a hand pump D with the specified
pressure gauge to brake piston port 1.
Special Tool: Hand Pump Pressure Test
(Qty.: 1)
Special Tool: Pressure Gauge (0-40 Bar)
(Qty.: 1)
7.2. The hand pump must be filled with the
correct fluid. Make sure you do not exceed
the specified pressure.
Pressure: 69bar (1,000.0psi)
7.3. Use the hand pump to generate a pressure
in the brake piston housing.
7.4. If the pressure falls off rapidly, or if no
pressure reading can be obtained, the
piston seal is severely damaged and needs
replacing with a new one.
7.5. Repeat the steps above for port 2.
8. Re-instate the brake system.
8.1. Reconnect all brake pipes and bleed the
brake system. Refer to (PIL 24-03).
24 - 55 9813/9400-1 24 - 55
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit Check (Leaks)

Check (Leaks) ............................................... 24-56 Refer to (PIL 24-03-46).
24 - 56 9813/9400-1 24 - 56
24 - Brake System
03 - Service Brake
Remove and Install
(For: 506-23 [T4F], 509-23 [T4F]) 4. Disconnect and install a plug on the master
cylinder output pipe. Install a plug on the cylinder
Servo unit- Single axle brakes port.
5. Disconnect and install a plug on the cylinder
Remove output hose. Install a plug on the cylinder port.
1. Make the machine safe. Refer to (PIL 01-03). 6. Loosen the securing bolts (x3) and slide the
servo unit out of its mounting bracket.
Refer to (PIL 01-03). 7. Make sure you carefully keep the washers (if
installed).
3. Disconnect the servo vacuum hose.
Figure 544.
D A B
D D
D
E
G F
A Servo vacuum hose B Master cylinder output pipe

C Cylinder output hose D Bolts (x3)
E Bracket F Washers
G Servo unit
24 - 57 9813/9400-1 24 - 57
24 - Brake System
03 - Service Brake
Install
steps.
1.1. Check the brake fluid level. Refer to (PIL
24-00).
1.2. Make sure to install the washers, if installed.
1.3. Bleed the brake system. Refer to (PIL
24-03).
24 - 58 9813/9400-1 24 - 58
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump Introduction

Introduction .................................................... 24-59 The service brake system requires vacuum
Check (Leaks) ............................................... 24-60 assistance to operate.
On machines with standard hydraulic service brakes
the vacuum assistance is provided by a vacuum
pump mounted on the engine.
24 - 59 9813/9400-1 24 - 59
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Check (Leaks) 7.1. Make sure that the mercury (Hg) level stays
above the specified value after 60 seconds.
(For: 506-23 [T4F], 509-23 [T4F])
7.2. Check that the vacuum is sufficient for 3 or 4
The procedure explains how to determine if the brake pedal operations. The vacuum must decay
servo vacuum system is functioning correctly. slowly with each pedal operation.
The following test equipment is used to carry out this 8. The brake vacuum pump and brake servo unit
test: are non-serviceable parts. If they are suspected
as being faulty, install new parts.
• Vacuum gauge (range up to 1 bar).
Figure 545. Typical Vacuum Pump Installation
• T-adaptor.
• Vacuum hose- 2 lengths x 75 mm (3 inch) long.
• Clips- worm drive.
Brake Vacuum Test (if applicable) A

2. Open the engine compartment cover. Refer to
(PIL 06-06). A
3. Disconnect the brake vacuum line at the brake
vacuum pump and connect a vacuum gauge
directly to the pump.
3.1. The location of the vacuum pump may
differ depending on the specification of your
machine.
4. Run the engine at 1500 RPM (Revolutions Per
Minute) and note the reading on the vacuum
gauge:
4.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
B
4.2. If there is little or no vacuum, renew the
vacuum pump.
5. Remove the vacuum gauge from the pump port
and connect it again into the brake vacuum line
using a T-adaptor.
6. Run the engine at 1500 RPM and note the
reading on the vacuum gauge:
6.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5. A Brake vacuum line
B T-adaptor
6.2. If there is little or no vacuum, check the
vacuum hose connections for leaks.
6.3. Check the security of the clips and then do
step 7.
7. Switch OFF the engine and monitor the vacuum
gauge reading:
24 - 60 9813/9400-1 24 - 60
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Remove and Install
(For: 506-23 [T4F], 509-23 [T4F], JCB Tier 7. Disconnect the oil feed hose.
4F Engine 4 Cyl) 8. Install a cap on the open ends of the hoses to
prevent the ingress of dirt. Tie the hoses out of
If the brake performance is poor and the brake servo
the way.
vacuum is suspected, do the brake vacuum test
before you install a new servo exhauster unit. Refer 9. Remove the screws and carefully take out the
to brakes- service brake. Refer to (PIL 24-03). servo exhauster unit from the engine. Discard the
gasket.
Remove
Install
1. Make the machine safe. Refer to (PIL 01-03)
2. Follow the general health and safety procedures. The servo exhauster unit is a non-serviceable part. If
Refer to (PIL 01-03). it is suspected as being faulty it must be renewed as
a complete assembly.
3. Disconnect the battery. Refer to (PIL 33-03).
The special adaptor is installed with an oil feed
4. Open the engine compartment cover. Refer to restrictor orifice (3 mm diameter). Check to make
(PIL 06-06). sure that the orifice is not blocked before installing
the servo exhauster unit.
5. Access to the servo exhauster unit is limited. If
necessary remove the machine cooling pack to 1. The installation procedure is the opposite of the
gain sufficient access. Refer to (PIL 21-03). removal procedure. Additionally do the following
steps.
6. Remove the clip and release the brake vacuum
hose from the pipe stub.
24 - 61 9813/9400-1 24 - 61
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Figure 546.
A
B
A Vacuum hose B Pipe stub

C Oil feed hose D Screw
E Gasket F Adaptor
G Gear
1.1. Make sure that the servo exhauster unit

flange and the engine mating face is clean.
Install a new gasket.
1.2. Carefully align the gear so that the gear
teeth engages with the drive gear in the
engine.
1.3. Tighten the screws to the specified torque
value.
1.4. On completion, test the brakes.

Item Nm
D 47
24 - 62 9813/9400-1 24 - 62
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-63 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-64 harness.
Figure 547.
3 2 1 3 2 1
24 - 63 9813/9400-1 24 - 63
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 549.
Brake Light Switch- Proximity Type
Figure 548.
D
E F
F
C
B
D Brake light switch
E Metal vane
F Switch faces
1. This type of switch is not adjustable.
2. If a switch failure is suspected, check all
associated wing and connectors for damage.
3. Make sure the vane moves between the switch
faces when the brake pedal is pressed.
4. If the switch does not work, it must be renewed.

Item Nm
A Proximity sensor C 20
B Brake lever
C Locknut
1. Set the ignition switch to the on position, do not
start the engine.
2. Adjust the proximity sensor to the correct
clearance between the sensor face and the edge
of the brake lever.
Length/Dimension/Distance: 2–3mm
3. Tighten the locknut to the correct torque.
4. Press the brake pedal and check that the sensor
operates (brake light illuminates) when the brake
pedal has travelled the correct distance. Check
that the sensor remains on throughout the rest of
the travel.
5. Check that the brake lights illuminate when the
brake pedal is pressed.
24 - 64 9813/9400-1 24 - 64
24 - Brake System
03 - Service Brake
50 - Light Switch
Remove and Install
Remove 4. Disconnect the electrical connector from the

panel harness.
5. Hold the switch and remove the screw.
Refer to (PIL 01-03). 6. Remove the switch from the bracket.
3. Press the brake pedal.
Figure 550.
A Electrical connector B Bracket

C Screw D Switch
24 - 65 9813/9400-1 24 - 65
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 66 9813/9400-1 24 - 66
24 - Brake System
03 - Service Brake
57 - Pressure Sensor
57 - Pressure Sensor Component Identification

Diagram ......................................................... 24-68
(For: 506-23 [T4F], 509-23 [T4F])
Check (Operation) ......................................... 24-72 The Footbrake Pressure Transducer is located on
Remove and Install ....................................... 24-73 the brake servo.
Figure 551.
2
2 Footbrake Pressure Transducer
24 - 67 9813/9400-1 24 - 67
24 - Brake System
03 - Service Brake
Diagram
For: 512-26 [T4F] ...................... Page 24-68 Figure 552.

For: 506-23 [T4F], 509-23 [T4F]
................................................... Page 24-69
(For: 512-26 [T4F])

2 3
The Footbrake Pressure Transducer is connected to
the Chassis harness. 1 4
1 4
2 3
Table 218. Harness Connector C018

Connectors Pins Pins Pins Pins Details
C018 1 2 3 4
C003 1 - Chassis Earth
Point Refer to
(PIL 33-00-90)
i016 38 - 63 Refer to (PIL
33-00-50)
P002 18 - Fusebox B, Re-
fer to (PIL 33-09)
P069 - 9 Transmission
ECU (Electron-
ic Control Unit)
0711 Connector
A
24 - 68 9813/9400-1 24 - 68
24 - Brake System
03 - Service Brake
Figure 553. (For: 506-23 [T4F], 509-23 [T4F])
- 1 Wires and Connectors

A The Footbrake Pressure Transducer is connected to
+ 2
the Chassis harness.
3
4
Figure 554.
C
ECU
B
2 3
1 4
V
3
12
4
5.0
4.5 1 4
0.9 2 3
0.5
0 X
0 20 250
A Fuse
B Transmission 0711 ECU
C Pressure Transducer
3 Pin 3- Switch output- brake pedal operated
4 Pin 4- proportional output- brake pedal pressure
V Volts
X Pressure (bar)
Machines with Gearpump Parallel Hydraulic System

C027 1 2 3 4
Point - Refer to
(PIL 33-00-90)
33-00-50)
P002 18 - Fusebox B- Re-
fer to (PIL 33-09)
ECU 0711 Con-
nector A
24 - 69 9813/9400-1 24 - 69
24 - Brake System
03 - Service Brake
Machines with Electro Servo Hydraulic System (excluding 526-56)

C018 1 2 3 4
Point - Refer to
(PIL 33-00-90)
33-00-50)
fer to (PIL 33-09)
ECU 0711 Con-
nector A
526-56 Machines
C011 1 2 3 4
Point - Refer to
(PIL 33-00-90)
33-00-50)
fer to (PIL 33-09)
P74A - 9 Transmission
ECU 0711 Con-
nector A
24 - 70 9813/9400-1 24 - 70
24 - Brake System
03 - Service Brake
Schematic Diagram
Figure 555.
- 1
A
+ 2
4
C
ECU
V
3
12
4
5.0
4.5
0.9
0.5
0 X
0 20 250
A Fuse
B Transmission 0711 ECU
C Pressure Transducer
3 Pin 3- Switch output- brake pedal operated
4 Pin 4- Proportional output- brake pedal pressure
V Volts
X Pressure (bar)
24 - 71 9813/9400-1 24 - 71
24 - Brake System
03 - Service Brake
Check (Operation)
Special Tools
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
tools shown.
Test Procedures
1. Use the applicable Servicemaster diagnostics
tool to identify faults. Ensure that the applicable
control interface operates correctly. Rectify as
required. Refer to (PIL 33-57).
Special Tool: Servicemaster Electronic Test Kit /
2. Test the applicable wires and connectors for
continuity, shorts to battery and shorts to earth.
Rectify as required.
24 - 72 9813/9400-1 24 - 72
24 - Brake System
03 - Service Brake
Remove and Install
For: 512-26 [T4F] ...................... Page 24-73 ground. Put blocks on all wheels to prevent the
For: 506-23 [T4F], 509-23 [T4F] machine rolling.
................................................... Page 24-74
(For: 512-26 [T4F])

Figure 556.
1 Footbrake Pressure Transducer
Removal Install
1. Park the machine and make it safe. Obey the 1. Replacement is the opposite of the removal
care and safety procedures. Refer to (PIL 01-03). procedure.
2. Vent the hydraulic system pressure. Refer to (PIL 2. During the replacement procedure do this work
30-00-00). also:
3. Vent the braking system pressure. Refer to (PIL 2.1. Tighten the transducer to the specified
30-00-00). torque.
4. Remove the transducer from the circuit. Torque: 19N·m
2.2. Make sure that any O-ring seals are
renewed.
24 - 73 9813/9400-1 24 - 73
24 - Brake System
03 - Service Brake
(For: 506-23 [T4F], 509-23 [T4F])

machine rolling.
Figure 557.
2
1 Brake servo
3 Sensor
Removal
1. Park the machine and make it safe. Obey the
care and safety procedures. Refer to (PIL 01-03).
2. Vent the hydraulic system pressure. Refer to (PIL
30-00-00).
3. Get access to the brake servo
4. Disconnect the chassis harness electrical
connector from the sensor electrical connector.
5. Remove the transducer from the servo unit.
Install
1. Replacement is the opposite of the removal
procedure.
2. During the replacement procedure do this work
also:
2.1. Tighten the transducer to the specified
torque.
Torque: 19N·m
2.2. Replace any O Ring Seals.
2.3. Check the brake fluid level. Top up if
necessary.
2.4. Bleed the brake system. Refer to (PIL.
24 - 74 9813/9400-1 24 - 74
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-77

24-18-03 Switch ............................................................................................................................. 24-92
24-18-06 Cable .............................................................................................................................. 24-93
24-18-15 Pad ............................................................................................................................... 24-103
24-18-18 Caliper .......................................................................................................................... 24-104
24-18-21 Disc .............................................................................................................................. 24-111
24-18-48 Actuator ........................................................................................................................ 24-121
24 - 75 9813/9400-1 24 - 75
Notes:
24 - 76 9813/9400-1 24 - 76
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-77 The park brake also called the hand brake is a
Technical Data ............................................... 24-78 latching brake usually used to keep the vehicle
Component Identification ............................... 24-78 stationary. It is also used to prevent a vehicle from
Operation ....................................................... 24-79 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Check (Condition) .......................................... 24-80
Check (Operation) ......................................... 24-81 The park brake usually consists of a cable directly
Adjust ............................................................ 24-83 connected to the brake mechanism on one end, and
Disassemble and Assemble .......................... 24-87 to a hand-operated lever, on the floor at the side of
the driver.
24 - 77 9813/9400-1 24 - 77
24 - Brake System
18 - Park Brake
00 - General

For: PS764, PS766 ................... Page 24-78
For: PS750 MK4 ....................... Page 24-78 (For: HM560 Variable Transmission)
Figure 558.
(For: PS764, PS766)
Table 222. Park Brake Multi-
pack Brakes (If Installed)
Description Acceptable Tolerances
(mm)
Friction pack assembly 37.1 to 39.6
thickness
(For: PS750 MK4)

Description Acceptable Tolerances
Disc minimum thickness 8.9mm
Pad minimum thickness 1mm
1 Capscrews
2 Park brake cable
3 Rear case
4 Brake actuator housing
5 Plug
6 Collar
7 O-ring
8 Special clevis pin
9 Brake actuator
24 - 78 9813/9400-1 24 - 78
24 - Brake System
18 - Park Brake
00 - General
Figure 559. Operation

For: PS750 MK4 ....................... Page 24-79
For: PS764, PS766 ................... Page 24-79
................................................... Page 24-80
(For: PS750 MK4)

The park brake is Independent of the service brakes.
It operates on the drive to the front axle by means of
a disc mounted on the gearbox output shaft.
When the operator moves the park brake lever to the

vertical position, the cable pulls the caliper reaction
lever and pressure is applied to the caliper mounted
brake pads to hold the brake disc.
1 Reaction pins
2 Brake multi-pack plates Figure 560.
B
C
D
A Gearbox output shaft

B Brake pads
C Caliper reaction lever
D Brake disc
The lever has a simple system for adjustment of the

cable when necessary.
An electrical switch senses if the park brake lever

is set to the brake on or brake off position. The
switch controls operator warnings and transmission
interlocks.
(For: PS764, PS766)
Internal park brake

The park brake is Independent of the service brakes.
It operates on the drive to the front axle via an oil
immersed, multi-plate brake pack housed inside the
gearbox. The brake assembly is mounted on the
gearbox layshaft.
When the operator moves the park brake lever to the

vertical position, the cable causes the brake plates
to be pressed together.
24 - 79 9813/9400-1 24 - 79
24 - Brake System
18 - Park Brake
00 - General
The lever has a simple system for adjustment of the Check (Condition)
cable when necessary.
For: HM560 Variable Transmission, PS764,
Figure 561. PS766 ....................................... Page 24-80
For: PS750 MK4 ....................... Page 24-81
(For: HM560 Variable Transmission,

A PS764, PS766)
Before inspecting the brake components carefully
remove all traces of sealing compound from
component mating faces. Use a suitable degreaser,
clean the brake components including the brake
housing in the gearbox rear case.
Multi-Plate Pack
1. Carefully inspect the friction plates and counter
plates. If any of the plates show signs of damage
A Multi-plate brake pack or distortion, renew the complete plate pack.
An electrical switch senses if the park brake lever Figure 562.

is set to the brake on or brake off position. The
switch controls operator warnings and transmission
interlocks.
1

The park brake is independent of the service brakes. 2
It operates on the drive to the rear axle via an oil
immersed, multiplate brake pack housed inside the
gearbox. The brake assembly is mounted on the
gearbox layshaft. When the operator moves the park
brake lever to the vertical position, the cable causes 3
the brake plates to be pressed together.
The park brake lever has a simple system for

adjustment of the cable when necessary. An
electrical switch senses if the park brake lever is
set to the brake on or brake off position. The 1 Thrust plate
switch controls operator warnings and transmission 2 Counter plates
interlocks. 3 Friction plates
2. Assemble the friction and counter plates
(including the thrust plate) on a suitable datum
table. Measure the overall thickness of the
assembled friction pack. The thickness X must
be between the recommended tolerances, refer
to Technical Data.
Figure 563.
X Friction pack assembly thickness

2.1. If the friction pack is outside these limits,
the complete friction pack assembly must
be renewed.
24 - 80 9813/9400-1 24 - 80
24 - Brake System
18 - Park Brake
00 - General
Note: The friction pack may be outside the maximum Check (Operation)
thickness value if the plates are distorted, typically
after the brake has performed an emergency stop. For: PS764, PS766 ................... Page 24-81
(For: PS750 MK4) ................................................... Page 24-82
WARNING Oil on the brake disc will reduce
brake effectiveness. Keep oil away from the (For: PS764, PS766)
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the WARNING! Before testing the park brake make
solvent manufacturer's safety instructions. If the sure the area around the machine is clear of
pads are oily, install with the new pads. people.
1. Park the machine and make it safe.

1. Follow the brake pad removal instructions. refer
to (PIL 24-03). 2. Follow the care and safety procedures. Refer to
(PIL 01-03).
2. Make sure that the minimum thickness of the
friction material on either pad is 1mm (0.04 in), 3. Apply the park brake fully.
but it is recommended to install new pads as it
may not be possible to adjust pads worn to this 4. Start the engine and raise the attachments to the
limit. appropriate travelling position.
3. Check the condition of the disc surface. Install a 5. Select the fourth gear.
new disc if the surface is badly warped, pitted or
worn. 6. Push down hard on foot brake pedal.
4. Make sure the actuator is adjusted correctly. 7. Select forward drive on the left hand column
switch.
WARNING! If the machine starts to move during

the park brake test, immediately apply the foot
brake and reduce the engine speed.
8. Test the park brake as follows:

8.1. Move the park brake lever slowly forward
until the warning light is just extinguished.
8.2. Slowly release the foot brake pedal.
8.3. If the machine has not moved, use the
accelerator pedal to gradually increase the
engine speed to 1500 RPM (Revolutions
Per Minute) The machine should not move.
8.4. Do not do this test for more than the
specified time.
Duration: 20s
8.5. Reduce the engine speed to idle and select
neutral on the left hand column switch.
8.6. Return the park brake lever to the fully on
position from its partially applied position.
8.7. Lower the attachments and stop the engine.
8.8. If the machine moved during this test, adjust
the park brake and repeat the test. Refer to
brakes- park brake, refer to (PIL 24-18).
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
24 - 81 9813/9400-1 24 - 81
24 - Brake System
18 - Park Brake
00 - General
If you have any queries concerning this test 3. Start the engine and raise the attachments to the
procedure or park brake adjustment, consult your appropriate travelling position.
local JCB distributor.
4. Select snail mode by pressing and holding the
Figure 564. gear downshift button. Make sure the snail
mode symbol is displayed. (Snail mode restricts
D D the transmission to hydrostatic mode only and
enables the varispeed control). Refer to the
operators handbook.
5. Set the varispeed control to the specified
12
P
9 3
percentage. (The percentage is displayed on the

10 15
RPM x 100
20
5
0 25
B dashboard).
Percentage: 15%
6. Set the hand throttle control to the give the
535 530 correct engine speed. The correct engine speed
is 1500 RPM.
7. Push the drive pedal down gradually until full
C pedal travel is reached.
8. The machine must not move. If the machine
moves at any time during the test, stop the test.
9. Do not do this test for more than the specified
time.
A Duration: 10s
10. When the test has finished, set the hand throttle
A Park brake lever
to idle speed and allow the engine to idle for the
B Left hand column switch
specified time allow the oil to be cooled.
C Foot brake pedal
D Warning light Duration: 2min
11. Turn off the engine.
WARNING Before testing the park brake make 12. If the machine moved during this test, adjust the
sure the area around the machine is clear of park brake and repeat the test. Refer to brakes-
people. park brake, refer to (PIL 24-18).
WARNING If the machine starts to move during 13. When testing is finally completed, Lower the
the park brake test, immediately apply the foot attachments and stop the engine.
brake and reduce the engine speed.
If you have any queries concerning this test
WARNING Do not use a machine with a faulty procedure or park brake adjustment, consult your
park brake. local JCB distributor.
WARNING Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes
may adversely affect the performance of the park
brake.
Notice: To prevent oil overheating and machine
damage, make sure that the test does not take
longer than the specified time. Make sure you
allow sufficient time between tests for the oil to
cool.
1. Park the machine on firm level ground and make

it safe. Refer to (PIL 01-03).
2. Apply the park brake fully.
24 - 82 9813/9400-1 24 - 82
24 - Brake System
18 - Park Brake
00 - General
Adjust
For: PS750 MK4 ....................... Page 24-83 Figure 565.

For: HM560 Variable Transmission A
................................................... Page 24-83
For: PS764, PS766 ................... Page 24-84
(For: PS750 MK4)

WARNING The park brake must not be used to
slow the machine from travelling speed, except
in an emergency, otherwise the efficiency of the
brake will be reduced. Whenever the park brake
has been used in an emergency the brake pack
must be renewed. B
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and
engine being started. Block all four wheels. A Handle grip
B Pin
Notice: Over adjustment or failure to disengage
the park brake properly will cause excessive wear
of the park brake mechanism. (For: HM560 Variable Transmission)
WARNING The park brake must not be used to
Before you try to adjust the park brake after an slow the machine from travelling speed, except
emergency stop, remove and install new brake in an emergency, otherwise the efficiency of the
friction components. Install other new components if brake will be reduced. Whenever the park brake
necessary. has been used in an emergency the brake pack
must be renewed.
The park brake must be engaged fully when the Notice: Over adjustment or failure to disengage
lever is vertical. The park brake indicator light should the park brake properly will cause excessive wear
illuminate when the brake is engaged with the of the park brake mechanism.
forward and reverse lever away from neutral (starter
switch at IGN).
1. Park the machine and make it safe, Refer to (PIL
Do the park brake adjustment as follows: 01-03).
2. Disengage the park brake and set it on the off
1. Disengage the park brake (lever horizontal).
position, (lever horizontal).
2. Pull and turn the handle grip clockwise, half a
3. Rotate the handle grip clockwise, until the clevis
turn.
is in its lowest position (set the park brake lever
3. Test the park brake. Refer to brakes- park brake, in the vertical on position to check this and then
refer to (PIL 24-18). set the lever back to the off position).
4. If the brake fails the test, repeat steps 1, 2 and 3. 4. Adjust the nuts to take up the slack so that the
pads are almost touching the disc.
5. If no more adjustment is possible and the pin is
at the end of its travel, then adjust the cable at 5. Test the park brake. Refer to brakes- park brake,
the calliper. Refer to brakes- service brake, refer refer to (PIL 24-18).
to (PIL 24-18).
24 - 83 9813/9400-1 24 - 83
24 - Brake System
18 - Park Brake
00 - General
Figure 566. Dual Tech Variable Transmission
A
D
A Cab (front) B Clevis

C Park brake lever (off position) D Park brake lever (on position)
E Cable F Oil immersed park brake assembly
(For: PS764, PS766) has been used in an emergency the brake pack
must be renewed.
Consumables
During normal operation little or no adjustment of
JCB Multi-Gasket 4102/1212 0.05L the brake cable at the lever is required. In the
event of poor brake performance it is likely that
WARNING Before working on the brake system, components have failed or, after extended service,
make sure that the machine is on solid level friction material is worn away. Remove, inspect and
ground. Put blocks on all wheels to prevent the renew components if necessary.
machine rolling.
Notice: Over adjustment or failure to disengage Adjustment at the park brake lever should only
the park brake properly will cause excessive wear be required after renewal of the cable, brake
of the park brake mechanism. components or extended service.
WARNING Do not use a machine with a faulty
park brake.
Lever Adjustment
WARNING The park brake must not be used to The parking brake should be fully engaged when
slow the machine from travelling speed, except the lever is vertical. The parking brake indicator light
in an emergency, otherwise the efficiency of the should illuminate when the brake is engaged with the
brake will be reduced. Whenever the park brake forward and reverse lever away from neutral (starter
switch at IGN).
24 - 84 9813/9400-1 24 - 84
24 - Brake System
18 - Park Brake
00 - General
1. Make the machine safe. Refer to (PIL 01-03). damage to the brake components and excessive
overheating of the brake assembly.
2. Follow the health and safety procedures. Refer
to (PIL 01-03). 7.1. Remove the 5 screws and 2 bolts 1. Using a
flat blade screwdriver located in the housing
3. Disengage the parking bake (lever horizontal). cut out, lever off the cover plate.
4. Turn the hand grip half a turn clockwise. 7.2. Use the cover plate as a wear indicator.
Use a bolt 2 to install the plate at right
Figure 567. angles to the housing as shown. Pull the
plate down when tightening the bolt to take
up the clearance in the bolt hole.
Figure 569.
D G
A Screws H D
B Bolts 1
C Housing cut out D Cover plate
D Cover plate G Clevis pin
H Bolt 2
Figure 568.
7.3. Fully apply the park brake (lever vertical). If
the brake is within service limits, the clevis
pin hexagon must not be visible above the
cover plate. Renew the friction pack if any
of the clevis pin hexagon is visible.
8. If the friction pack components are distorted
E (typically after performing an emergency stop)
the clevis pin may not be visible in the check
F described. If the park brake performance is
poor it may be due to distorted components.
E Hand grip Disassemble and inspect the park brake
F Pin assembly as follows.
5. Test the park brake. Refer to (PIL 24-18). 8.1. Disengage the park brake (lever horizontal).
6. If the brake fails the test, do 3 and 4 again. If there 8.2. Make sure that the brake is fully released.
is no more adjustment and if the pin is at the end
of its travel, remove, inspect and renew the park 8.3. Remove the cover plate and feel the edge
brake components as necessary. of the brake pack plates.
7. After adjusting the park brake lever, do

the following steps to confirm correct brake
operation. Incorrect adjustment can result
24 - 85 9813/9400-1 24 - 85
24 - Brake System
18 - Park Brake
00 - General
Figure 570.
8.4. When the brake is released free play

between the plates should be easily
detectable. If the plates are not free, do not
operate the machine. Disassemble, inspect
and renew the park brake components as
required.
8.5. If the brake pack is serviceable, clean off
all traces of old sealant from the cover
plate and brake housing. Make sure that no
sealant enters the gearbox. Apply a bead of
multi-gasket to the brake housing.
Consumable: JCB Multi-Gasket
8.6. Install the cover plate.
value.

Item Description Nm
A Screws 16
B Bolts 1 56
24 - 86 9813/9400-1 24 - 86
24 - Brake System
18 - Park Brake
00 - General
(For: PS764, PS766)

Consumables
JCB Multi-Gasket 4102/1212 0.05L
24 - 87 9813/9400-1 24 - 87
24 - Brake System
18 - Park Brake
00 - General
Disassemble
Figure 571.
D
E
X
A
A Bolt (x2) B Screw (x5)

C Cover plate D Cover
E Needle roller thrust bearing. F Reaction pins
G Thrust plate H Friction plate
J Counter plate X Location1 and Location 2 for bolt removal
24 - 88 9813/9400-1 24 - 88
24 - Brake System
18 - Park Brake
00 - General
1. Position the output yoke as shown. Refer to 5.3. Friction plates.

Figure 572.
5.4. Counter plates.
Figure 572.
6. If the brake assembly is being removed before
you disassemble the gearbox, then remove the
reaction pins. Refer to Figure 571.
7. If the brake actuator is to be disassembled, or the
cable is to replaced, then remove the park brake
cable as follows: Refer to Figure 573.
Figure 573.
M
K
K Output yoke
2. Remove the cover plate as follows: Refer to
Figure 571.
2.1. Remove only two bolts from location1 and
location 2.
2.2. Remove the screws.
2.3. Before the cover plate is removed, place a
container below to collect the gearbox oil.
2.4. Remove the cover plate with a flat bladed
screwdriver.
3. Remove the remaining bolts (x4) and carefully N
remove the cover, keeping it parallel to the
mating face of the gearbox. Refer to Figure 571.
4. Be aware that the needle roller thrust bearing and
the reaction pins may come away with the cover. L Brake cable
Refer to Figure 571. M Circlip
N Clevis pin
5. Remove the following: Refer to Figure 571.
7.1. Remove the clevis pin.
5.1. Needle roller thrust bearing. 7.2. Remove the circlip and then remove the
5.2. Thrust plate cable from the cover.
24 - 89 9813/9400-1 24 - 89
24 - Brake System
18 - Park Brake
00 - General
Assemble
Figure 574.
G
D
E
A X
C
Z
A Bolt (x2) B Screw (x5)

E Needle roller thrust bearing. F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover
24 - 90 9813/9400-1 24 - 90
24 - Brake System
18 - Park Brake
00 - General
1. Inspect the brake pack. 5. Apply a bead of sealant to the mating face on the
gearbox case. Refer to Figure 574.
2. Assemble the reaction pins and then install the
friction pack in the gearbox case. Refer to Figure Consumable: JCB Multi-Gasket
574. 6. Attach the cover with the bolts (x4). Refer to
2.1. Note that a counter plate is installed first Figure 574.
followed by a friction plate and so on. 6.1. Note that 2 bolts at location 1 and location
2.2. Install the thrust plate last. 2 are not installed at this stage.
3. If removed during disassembly install the park 7. Tighten the bolts to the correct torque value.
brake cable as follows: Refer to Figure 575. Refer to Figure 574.
Figure 575. 8. Apply a bead of sealant to the mating face on the

cover. Refer to Figure 574.
L R Consumable: JCB Multi-Gasket
M 9. Attach the cover plate with screws (x5) and the

bolts (x2). Refer to Figure 574.
10. Tighten the screws and bolts to the correct torque
value. Refer to Figure 574.
It is essential that the park brake cable is adjusted

Q correctly when the gearbox is installed into the
machine. Incorrect adjustment of the cable can
result in damage to the brake components and
excessive overheating of the brake assembly. See
the applicable machine Service Manual for the cable
adjustment procedure.

Item Nm
A 56
B 16
N N 9
L Brake cable
M Circlip
N Clevis pin
P Brake actuator
Q O-ring
R Collar
3.1. Put the cable into the housing and connect
the fork end to the brake actuator with clevis
pin.
3.2. Never replace the clevis pin with a normal
bolt or screw.
3.3. Make sure that the O-ring is not damaged
and correctly installed on the collar.
3.4. Locate the collar inside the brake housing
and secure with the circlip.
4. Make sure that the needle roller thrust bearing is
correctly installed on the actuator assembly.
24 - 91 9813/9400-1 24 - 91
24 - Brake System
18 - Park Brake
03 - Switch
03 - Switch Install
Remove and Install removal procedure.
2. When installing do the following steps also:
Remove
2.1. To align the switch correctly, engage the
1. Park the machine and make it safe. Follow all switch location dowel with the hole in the
safety precautions. Please see (PIL 01-03). mounting bracket.
2. Put chocks on both sides of the wheels to prevent

the machine rolling. Release the park brake.
3. Remove the rubber gaiter.
switch connector.
5. Hold the switch and remove the screw.
Figure 576.
B G D
F
C
A Rubber gaiter
B Switch
D Switch connector
E Screw
F Dowel
G Mounting bracket
24 - 92 9813/9400-1 24 - 92
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-93 For: PS750 Mk4, PS750 MK4
................................................... Page 24-93
For: PS764, PS766 ................... Page 24-94
(For: PS750 Mk4, PS750 MK4)

If the adjustment of the park brake lever is not
sufficient, then adjust the cable at the calliper.
If it is not possible to adjust at the lever or at the

calliper, then change the brake pads.
Make sure that you install a new cable if the cable is

worn or damaged.

2. Follow the care and safety procedures. Refer to
(PIL 01-03).
4. Turn the hand grip anti-clockwise to centre the
pin in its slot.
5. Release the two locknuts and adjust the cable
length as required.
6. If you install a new cable, make sure to put the
threaded section of the cable with approximately
four threads visible below the bottom adjusting
nut.
7. Make sure there is enough freedom of movement
of the operating lever to ensure a positive brake
application. The lever must return to the rest
position when the park brake is released.
8. Make sure that the clearance between the brake
pad and the brake disc is within the specified
range.
Length/Dimension/Distance: 0.5–0.75mm
9. Test the park brake. Refer to brakes- park brake,
Make final adjustments at the park brake lever if

the brake fails the test. Refer to operator station-
controls, refer to (PIL 09-27).
24 - 93 9813/9400-1 24 - 93
24 - Brake System
18 - Park Brake
06 - Cable
Figure 577.
C
A Hand grip
B Pin
C Locknuts
Figure 578.
D
D Operating lever
(For: PS764, PS766) The park brake should be fully engaged when
the lever is vertical. The park brake indicator light
During normal operation little or no adjustment of should illuminate when the brake is engaged with the
the brake cable at the lever is required. In the forward and reverse lever away from neutral (starter
event of poor brake performance it is likely that switch at IGN).
components have failed or, after extended service,
friction material is worn away. Dismantle, inspect and 1. Before attempting to adjust the park brake
install components as required. after an emergency stop remove and inspect
24 - 94 9813/9400-1 24 - 94
24 - Brake System
18 - Park Brake
06 - Cable
the brake friction components. Install new 5. Test the park brake. If the brake fails the test
components if necessary. repeat steps 3 and 4. Refer to (PIL 24-18). If there
is no more adjustment and the pin is at the end
2. Make the machine safe. Refer to (PIL 01-03). of its travel, dismantle, inspect and renew park
brake components as required.
3. Disengage the park bake (lever horizontal)
4. Turn the hand grip clockwise, half a turn.
Figure 579.
A Screws (x5) B Bolts (x2)

C Housing cut out D Cover plate
Figure 580. 6. After adjusting the park brake lever makes sure
you carry out the following steps to make sure
that the park brake operates correctly. Incorrect
adjustment can result damage to the brake
components and excessive overheating of the
brake assembly.
E Hand grip
F Pin
24 - 95 9813/9400-1 24 - 95
24 - Brake System
18 - Park Brake
06 - Cable
Figure 581.
H J
G Clevis pin hexagon H Bolt

J Cover plate
6.1. Remove (x5) screws and (x2) bolts. Using a Figure 582.
flat blade screwdriver located in the housing
cut out, lever off the cover plate.
6.2. Use the cover plate as a wear indicator.
Use a bolt to fit the plate at right angles
to the housing as shown. Pull the plate
down when tightening the bolt to take up the
clearance in the bolt hole.
6.3. Fully apply the park brake (lever vertical). If
the brake is within service limits the clevis
pin hexagon must not be visible above the
cover plate. Renew the friction pack if any
of the clevis pin hexagon is visible.
6.4. If the friction pack components are distorted
(typically after performing an emergency
stop) the clevis pin may not be visible
in the check described. If the park brake
performance is poor it may be due
to distorted components. Dismantle and
inspect the park brake assembly.
8. If the plates are not free make sure that you do
not operate the machine, dismantle, inspect and
Make sure that the brake is fully released.
renew park brake components as required.
Remove the cover plate and feel the edge of the
brake pack plates. When the brake is released 9. If the brake pack is serviceable, clean off all
free play between the plates should be easily traces of old sealant from the cover plate and
detectable. brake housing. Make sure that no sealant enters
24 - 96 9813/9400-1 24 - 96
24 - Brake System
18 - Park Brake
06 - Cable
the gearbox. Apply a bead of JCB Multigasket to

the brake housing.
10. Install the cover plate. Tighten the bolts to the
correct torque.

Item Nm
A 16
B 56
24 - 97 9813/9400-1 24 - 97
24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
For: PS750 Mk4, PS750 MK4 Remove

................................................... Page 24-98
For: PS764, PS766 ................. Page 24-100 1. Make the machine safe. Obey all care and safety
procedures Refer to (PIL 01-03).
(For: PS750 Mk4, PS750 MK4) 2. Release the park brake lever (lever horizontal).
Consumables
Strength)
Figure 583.
A
A Clevis pin B Actuating lever

C Locknut 1 D Bracket
3. Remove the clevis pin from the park brake 9. Remove the lever fixing bolts.
caliper.
10. Remove the lever assembly together with the
4. Make sure you note which of the three holes on cable.
the actuating lever is used.
11. Measure and record the dimension between the
5. Remove the clip or loosen the locknut 1 as sleeve and the locknut.
applicable.
12. Remove both the buffer bracket fixing bolts.
6. Disconnect the cable from the bracket ad note
the cable routing located underside the cab. 13. Remove the cable nipple from the clevis and then
remove the cable sideways from the lever.
7. Remove the gaiter fixings and pull up the gaiter.
14. Disengage the cable nipple from the clevis.
8. Disconnect the park brake switch electrical
connector. 15. Remove the buffer assembly from the cable.
24 - 98 9813/9400-1 24 - 98
24 - Brake System
18 - Park Brake
06 - Cable
Figure 584.
K
K
N L
M
P
Install
Table 227. Installation is opposite of the removal procedure and
Item Description additionally do the steps below.
E Park brake lever (hori-
1. Make sure you correctly route the cable.
zontal)
F Electrical connector 2. Make sure that the locknut is screwed fully down.
G Lever fixing bolts
3. Adjust the sleeve to allow cable location to the
H Clevis lever assembly.
J Buffer assembly
K Bracket fixing bolts 4. Apply threadlocker to the buffer bracket fixing
bolts.
L Sleeve
M Locknut 2 Consumable: JCB Threadlocker and Sealer
(Medium Strength)
N Dimension between the
sleeve and locknut 2 5. Make sure that the buffer bracket assembly is
P Cable located correctly.
24 - 99 9813/9400-1 24 - 99
24 - Brake System
18 - Park Brake
06 - Cable
7. Adjust the sleeve and the locknut 2 until you get Figure 585.
the dimension measured between the sleeve and G
the locknut at the time of removal. A
8. If a new cable is installed make sure that the F

dimension between the sleeve and the locknut
will be of the specified value.
Dimension: 15mm Y
9. Tighten the locknut 2.

D
10. Make sure that the cable clevis is is connected at
the correct hole in the caliper actuating lever.
11. Make sure that the actuating lever is not being B
pulled by the cable when the park brake lever is
in the off (horizontal) position.
12. If necessary adjust sleeve until the actuating
lever is allowed to return fully to its off position.
C E
13. Adjust the cable. Refer to (PIL 24-18-06).
A Cable
Table 228. Torque Values B Bolts (x2)
C Screws (x5)
Item Description Nm D Cover plate
K Bracket fixing bolts 3 E Clevis screw
F Circlip
(For: PS764, PS766) G Cable assembly
Y O-ring
Consumables
Description Part No. Size 3. Clean off all dirt from the gearbox brake housing.
JCB Multi-Gasket 4102/1212 0.05L Make sure there is no dirt or debris trapped in the
housing at the cable entry.
and Sealer (Medium 4101/0251 0.05L 4. Remove the screws and the bolts securing the
Strength) cover plate. Remove the cover plate.
Park Brake Maintenance 5. Remove the clevis screw and the circlip. Remove
the cable assembly from the housing.
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels 6. Working at the park brake lever, remove the
to prevent the machine rolling. Stop the engine and gaiter fixings and pull up the gaiter (not shown).
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the 7. Disconnect the park brake switch electrical
machine could run over you. connector.
Internal park brake cable 8. Remove the lever fixing bolts and then remove
the lever assembly together with the cable.
Remove 9. Measure and record the dimension between the
sleeve and the locknut.
1. Make the machine safe. Obey all care and safety
procedures. Refer to (PIL 01-03). 10. Remove the two buffer bracket fixing bolts.
2. Release the park brake lever (lever horizontal). 11. Remove the cable sideways from the lever,
disengaging the cable nipple from the clevis
screw.
12. Remove the buffer assembly from the cable.
24 - 100 9813/9400-1 24 - 100

24 - Brake System
18 - Park Brake
06 - Cable
Figure 586.
H
J
N
S P
X Q
H Brake lever (Lever horizontal) J Electrical connector

K Lever fixing bolts L Clevis
M Buffer assembly N Buffer bracket fixing bolts
P Sleeve Q Locknut
R Cable X Dimension between the sleeve and the locknut
Install 5. Make sure that the buffer bracket assembly is

located correctly.
Installation is the opposite of the removal procedure.
During the installation procedure do these below 6. Tighten the buffer bracket fixing bolts to the
steps also. correct torque value.
1. Make sure you correctly route the cable. 7. Adjust the sleeve and the locknut until you get
the dimension measured between the sleeve and
2. Make sure that the locknut is screwed fully down. the locknut at the time of removal.
3. Adjust the sleeve to allow cable location to the 8. Tighten the locknut.
lever assembly.
9. Make sure that the O-ring is not damaged and
4. Apply JCB threadlocker to the buffer bracket install it properly.
fixing bolts.
10. After you connect both ends of the cable set the
Consumable: JCB Threadlocker and Sealer park brake lever to the off (horizontal) position.
(Medium Strength)
24 - 101 9813/9400-1 24 - 101

24 - Brake System
18 - Park Brake
06 - Cable
11. Feel the edge of the brake pack plates. When the Table 229. Torque Values
brake is released free play between the plates
Item Nm
should be easily detectable.
B 56
Figure 587. C 16
E 9
N 3
12. If necessary adjust sleeve until the plates are

free.
13. Clean off all traces of old sealant from the cover
plate and brake housing. Make sure that no
sealant enters the gearbox.
14. Apply a bead of JCB Multigasket to the brake
housing.
Figure 588.
T JCB Multigasket
15. Install the cover plate and secure it with the bolts.
24 - 102 9813/9400-1 24 - 102

24 - Brake System
18 - Park Brake
15 - Pad
15 - Pad
Check (Condition)

WARNING Oil on the brake disc will reduce
brake effectiveness. Keep oil away from the
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the
solvent manufacturer's safety instructions. If the
pads are oily, install with the new pads.
1. Follow the brake pad removal instructions. refer

to (PIL 24-03).
2. Make sure that the minimum thickness of the
friction material on either pad is 1mm (0.04 in),
but it is recommended to install new pads as it
may not be possible to adjust pads worn to this
limit.
3. Check the condition of the disc surface. Install a
new disc if the surface is badly warped, pitted or
worn.
4. Install a new park brake cable if it is worn or
damaged.
24 - 103 9813/9400-1 24 - 103

24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Component Identification

Check (Condition) ........................................ 24-105
Figure 589.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
Table 230. Item Description

Q Bearing ring
Item Description
R Housing
A Carrier side pad
S Shaft seal
B Lever side pad
C Screw
D Washer1
E Washer2
F Lever
G Spring
H Rotor
J Ball spacer
K Ball bearings
L Mounting bushes
M Dust seals
N O-rings
P Rotor Seal
24 - 104 9813/9400-1 24 - 104

24 - Brake System
18 - Park Brake
18 - Caliper
Check (Condition)

Refer to Component Identification, (PIL 24-18-18).
1. Clean and dry all parts.

2. Check that all the parts are free from excessive
wear, damage or corrosion. Light scores or stains
should be removed. Renew corroded or deeply
scored parts.
3. Check rotor for damage or distortion.
4. Install new if necessary. Make sure to change
both the brake pads if the park brake has been
used in an emergency.
5. Check the ball pockets in housing for signs of
scoring, pitting, damage or corrosion.
6. Install new housing if damaged. Check that the
spring is not broken or distorted.
7. Check the condition of the disc surface.
8. Install new disc if badly warped, pitted or worn.
Refer to brakes- park brake, refer to (PIL 24-18).
24 - 105 9813/9400-1 24 - 105

24 - Brake System
18 - Park Brake
18 - Caliper
Remove and Install
(For: PS750 Mk4, PS750 MK4) 2. Release the park brake lever (horizontal).
Safety Critical Installation 3. Remove the pin and disconnect the clevis joint,
This is a safety critical installation. Do not attempt note which of the three holes on the lever is used.
to do this procedure unless you are skilled and 4. Remove the clip and disconnect the cable from
competent to do so. the bracket.
Installation and mounting of the park brake caliper
requires tightening of the mounting bolts to a specific 5. Support the caliper and remove the two mounting
torque figure. Do not attempt to do this job unless you bolts and hardened washers.
have the correct tools available. 6. Lift the caliper clear of the brake disc.
Remove 7. Do not remove transmission mounting bracket,
unless it is necessary to be replaced.
Figure 590.
A B C D
E
B
A Clip B Mounting bolts

C Clevis joint D Pin
E Operating lever F Transmission mounting bracket
24 - 106 9813/9400-1 24 - 106

24 - Brake System
18 - Park Brake
18 - Caliper
Install
Installation is the opposite of the removal procedure
but additionally do the below steps.
1. Locate the caliper on the brake disc.

2. Install new mounting bolts with hardened
washers.
3. Tighten the mounting bolts to the correct torque
value.
4. Attach the cable to the mounting bracket and
secure in place with the clip.
5. Install the clevis joint and the pin into the relevant
hole in the operating lever.
6. Make sure there is enough space for the
movement of the operating lever, to make sure
that positive brake application, and that the lever
returns to the rest position when the park brake
is released.
7. Adjust the park brake cable. Do not remove the
he clevis to adjust the cable.

Item Description Nm
B Mounting bolts 255
24 - 107 9813/9400-1 24 - 107

24 - Brake System
18 - Park Brake
18 - Caliper
(For: PS750 Mk4, PS750 MK4) 7. Push out the rotor the remove the ball spacer and
the ball bearings.
Safety Critical Installation
This is a safety critical installation. Do not attempt 8. Make sure you keep the ball bearings properly in
to do this procedure unless you are skilled and a container.
competent to do so. 9. Push out the mounting bushes and then remove
Installation and mounting of the park brake caliper the dust seals.
requires tightening of the mounting bolts to a specific
torque figure. Do not attempt to do this job unless you 10. Remove the O-rings.
have the correct tools available. 11. Remove the rotor seal and then the bearing ring.
Disassembly 12. Note that the rotor seal may be located on the
rotor shaft or may have been left in the calliper
1. Remove the caliper and the brake pads. Refer to housing.
remove and install (PIL 24-18-18).
13. It is not necessary to replace the shaft seal
2. Hold the lever against the tension of the spring. unless it is excessively worn or damaged.
3. Remove the screw and both the washer 1, 13.1. If removal is necessary, use a suitable
washer 2. spacer block and a bench press to push
the seal out from inside the housing.
4. Note the position of the lever with respect to the
splines of the rotor shaft. 13.2. Clean out any remains of the seal after
removal.
5. Mark the end of the shaft and lever to assist in
assembly. Before assembly make sure all parts are clean
and serviceable. Refer to park brake caliper-check
6. Remove the lever and the spring. condition (PIL 24-18-18).
24 - 108 9813/9400-1 24 - 108

24 - Brake System
18 - Park Brake
18 - Caliper
Figure 591.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
1. If removed, Install a new shaft seal. Use a

Table 232. suitable spacer block and bench press to push
the seal into the housing.
Item Description
A Carrier side pad 2. Apply silicon grease on the shaft, the outer
B Lever side pad diameter and ball pockets of rotor and the ball
pockets of housing.
C Screw
D Washer 1 3. Install the three ball bearings into the pockets in
E Washer 2 the housing. Install the ball spacer.
F Lever 4. Apply silicon grease on the bearing ring and
G Spring install the ring to the inner diameter on rotor seal.
H Rotor
5. Assemble the rotor seal to the rotor.
J Ball spacer
K Ball bearings 6. Move the rotor through the casting and seat the
L Mounting bushes ball pockets against the bearings.
M Dust seals 7. Position the spring over the shaft of rotor.
N O-rings
8. Put the large diameter end of the spring into hole
P Rotor Seal
in the face of the housing. Refer to Figure 592.
Q Bearing ring
R Housing
S Shaft seal
Assembly
Before assembly make sure all parts are clean and
serviceable.
24 - 109 9813/9400-1 24 - 109

24 - Brake System
18 - Park Brake
18 - Caliper
Figure 592.
T U
T Spring hole
U Lever outside edge
9. Locate the small diameter end of spring around
the outside edge of lever. Refer to Figure 592.
10. Install the lever and align the lever to the mark
made at the time of disassembly.
11. Hold the lever against the tension of the spring
and install the washer 1 and washer 2.
12. Install the screw and tighten the screw to the
13. Install the brake pads.
14. Apply silicon grease to the dust seals and the
bushes.
15. Install the dust seals to the housing and put
mounting bushes.
16. Make sure that the dust seals locate in their
location grooves on the bushes and housing.
17. Lubricate and install new O-rings. Wipe off any
excess grease.
18. Before you install the caliper, make sure that the
lever rotates smoothly and that the lever side
pad returns to the off position when the lever is
released.
19. Install the brake caliper.
20. Install and adjust the park brake cable.
Table 233. Torque table

Item Torque value
Screw 13–16N·m
24 - 110 9813/9400-1 24 - 110

24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................. 24-111 A disc brake is a wheel brake that slows the rotation
Check (Condition) ........................................ 24-112 of the wheel by the friction caused by pushing brake
Remove and Install ..................................... 24-113 pads against a brake disc with a set of calipers.
24 - 111 9813/9400-1 24 - 111

24 - Brake System
18 - Park Brake
21 - Disc
Check (Condition)

1. Inspect the thickness of the park brake disc.
Renew the disc if it is below the minimum
thickness. Refer to (PIL 24-18-00).
2. Inspect the condition of the disc. If the disc is
deeply pitted or scored, replace it with a new one.
24 - 112 9813/9400-1 24 - 112

24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
(For: PS750 MK4) 7. Do not use a steel hammer, damage can occur
to the output shaft bearing.
Special Tools
Description Part No. Qty. 8. If necessary remove the oil seal. Do not damage
Flange Spanner 992/04800 1 the seal housing.
Remove Install
1. If installed remove the park brake caliper. 1. Make sure that the oil seal interface on the brake
disc is clean and free from wear or damage.
2. Bend back the stake nut locking ring.
2. If necessary install a new oil seal. Lubricate the
3. Clean the brake disc and the gearbox around the lips of the seal.
brake disc. Make sure no contamination enters
the gearbox when the brake disc is removed. 3. Install the brake disc onto the output shaft.
4. Hold the brake disc with the service tool and 4. Install the washer.
remove the output shaft stake nut. Discard the 5. Hold the brake disc with the service tool.
stake nut.
Special Tool: Flange Spanner (Qty.: 1) 6. Install a new stake nut.
5. Remove the washer. 7. Progressively tighten the nut to the correct torque
value.
6. Lift off the brake disc. If necessary use a soft
faced mallet to remove the brake disc. 8. Stake the nut to the shaft with a square ended
staking tool.
24 - 113 9813/9400-1 24 - 113

24 - Brake System
18 - Park Brake
21 - Disc
Figure 593.
E
D
C
B
A Brake disc B Stake nut

C Washer D Output shaft
E Oil seal F Bearings
G Oil seal interface H Stake nut locking ring

Item Nm
B 300
24 - 114 9813/9400-1 24 - 114

24 - Brake System
18 - Park Brake
21 - Disc
(For: PS764, PS766) A separate disassembly procedure is given for each

sub-assembly.
The internal park brake consists of a wet multi plate
friction pack and a mechanical actuator assembly.
24 - 115 9813/9400-1 24 - 115

24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the multi-plate brake pack
Figure 594.
D
E
X
A
A Bolt B Screw (x5)

E Needle roller thrust bearing F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt removal
24 - 116 9813/9400-1 24 - 116

24 - Brake System
18 - Park Brake
21 - Disc
1. From inside the cab, disengage the park brake 4. From underneath the machine, remove the two
(lever horizontal). Rotate the park brake lever to bolts and five screws that attach the cover plate.
fully slacken the cable.
5. Before the cover plate is removed, place a
2. Remove the rear propshaft. container below to collect the gearbox oil.
3. Position the output yoke. Refer to Figure 595. 6. Use a flat bladed screwdriver at the cover cutout
to remove the cover plate.
Figure 595.
7. Remove the remaining four bolts and carefully
remove the cover but make sure you keep it
square to the mating face on the gearbox. The
park brake cable is still attached at this stage.
8. If the cover does not come free then one or more
reaction pins will have remained in the cover.
9. Use a pair of long nosed pliers to push the pins
back into the gearbox case. Make sure that the
surface of the pin is not damaged.
10. Remove the needle roller thrust bearing, thrust
plate, friction plates and the counter plates.
11. If the brake actuator is to be disassembled, or the
K cable to be replaced then do the following steps.
K Output yoke (Shown in position required)
11.1. Remove the park brake cable.
Figure 596.
L Brake cable M Circlip

N Clevis screw pin
11.2. Remove the clevis screw pin. 11.3. Remove the cable from the housing.
24 - 117 9813/9400-1 24 - 117

24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the brake actuator Inspection

Refer to park brake actuator (PIL 24-18-48). Refer to (PIL 24-18-00).
For inspection refer to park brake, check(condition) Assemble the brake actuator
(PIL 24-18-00).
Refer to park brake actuator (PIL 24-18-48).
Assemble the multi-plate brake pack
Figure 597.
G
D
E
A X
C
Z
24 - 118 9813/9400-1 24 - 118

24 - Brake System
18 - Park Brake
21 - Disc
A Bolts B Screws (x5)

E Needle roller thrust bearing F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover
1. From underneath the machine, assemble the 2.1. Feed the cable into the housing and
reaction pins followed by the friction pack into the connect the fork end to the brake actuator
gearbox case. with the screw. Tighten to the correct torque.
1.1. Note that a counter plate is installed first, 2.2. The screw is a special clevis pin. Make sure
then a friction plate and so on. Install the that only the special screw clevis pin used.
thrust plate at last. Make sure that a normal bolt or screw is not
used.
2. If the park brake cable is removed then install the
park brake cable.
Figure 598.
L R
L Brake cable M Circlip

N Clevis screw pin P Brake actuator
Q O-ring R Collar
2.3. Make sure that the O-ring is not damaged 4. Before you install the cover, apply bead of JCB
and correctly installed on the collar. Locate Multigasket sealant to the mating face on the
the collar inside the brake housing and keep gearbox case.
with circlip.
5. Install the cover and four bolts. Tighten the bolts
3. Make sure that the needle roller thrust bearing is to the correct torque value.
correctly located on the brake actuator assembly,
if necessary apply grease to keep the bearing. 5.1. Do not install the two cover plate bolts at
this stage.
24 - 119 9813/9400-1 24 - 119

24 - Brake System
18 - Park Brake
21 - Disc
5.2. Carefully feed the park brake cable up into

the cab, through the opening in the cab
floor.
6. From inside the cab, connect the park brake
cable to the park brake lever and adjust the lever.
7. From under the machine, view the brake friction
pack through the housing aperture. Check the
operation. Play in the paltes will be easily felt
when the brake is off
8. Before you install the cover plate, apply a bead
of JCB Multigasket sealant to the mating face on
the cover.
8.1. Install all the five screws and remaining two
bolts.
8.2. Tighten the screws and bolts to the correct
toque value.
9. If any brake components have been replaced it
must be assumed that the gearbox oil will be
contaminated. Change the gearbox oil and filter.
Refer to clean, (PIL 27-06-00).
A small quantity of gearbox oil will be transferred from

the sump to fill the brake cavity when the engine is
started. Check the gearbox oil level and top up if
necessary. Refer to the operators manual.

Item Nm
A 56
B 16
N 9
24 - 120 9813/9400-1 24 - 120

24 - Brake System
18 - Park Brake
48 - Actuator
48 - Actuator Check (Condition)

Check (Condition) ........................................ 24-121
(For: PS764, PS766)
Before you check the brake components use a
suitable degreaser to clean the brake components.
Check the following components for signs of

excessive wear or damage:
• Ball bearings and their tapered locating slots.

• Needle roller thrust bearing and the
corresponding bearing surfaces.
Note: Some discolouration of the needle rollers is

acceptable providing the surface of the rollers is
otherwise undamaged.
Figure 599.
4
1 Tapered locating slots
2 Ball bearings
3 Tapered locating slots
4 Needle roller thrust bearing
• Make sure that the park brake cable is smooth
and free in operation. Check the cable outer
for signs of damage. Replace the cable if it is
damaged or hard to operate.
24 - 121 9813/9400-1 24 - 121

24 - Brake System
18 - Park Brake
48 - Actuator
(For: PS764, PS766) 2. Remove the washer 1 and washer 2.

3. Remove the spring 1 and spring 2.
Disassembly
4. Remove the brake actuator plate then the ball
1. Carefully remove the screw. bearings.
1.1. Be careful the screw is under tension from
spring 1 and spring 2.
Figure 600.
Item Description
Table 236. F Actuator plate
Item Description G Ball bearings (x5)
A Screw H Brake actuator cover
B Spring 1
C Spring 2 Assembly
D Washer 1 1. Locate the ball bearings in their slots in the cover.
E Washer 2
24 - 122 9813/9400-1 24 - 122

24 - Brake System
18 - Park Brake
48 - Actuator
2. Install the actuator plate then the springs.

3. Install the washers.
4. Compress the springs and install the screw.
4.1. Tighten the screw to the correct torque
value.

Item Description Nm
A Screw 16
24 - 123 9813/9400-1 24 - 123

24 - Brake System
36 - Trailer Brake
36 - Trailer Brake
Contents Page No.
24-36-00 General ......................................................................................................................... 24-125
24 - 124 9813/9400-1 24 - 124

24 - Brake System
36 - Trailer Brake
00 - General
00 - General
Operation

The TBV (Trailer Brake Valve) is mounted in
the chassis. It provides a proportional braking
pressure to a trailer brake circuit connected to the
ISO (International Organization for Standardization)
connector on the rear of the machine.
The TBV is supplied with oil from the charge

priority valve. When the service brake is applied,
a pilot signal to the TBV operates it and delivers
a maximum pressure up to the specified value at
the ISO coupling. The specified pressure is 150bar
(2,173.9psi)
Releasing the service brake releases the trailer

brake.
24 - 125 9813/9400-1 24 - 125

Notes:
24 - 126 9813/9400-1 24 - 126

Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-00-03 Manual Steer Mode System .......................................................................................... 25-23
25-00-06 Auto Steer Mode System ............................................................................................... 25-29
25-01 Pump
25-01-00 General ........................................................................................................................... 25-41
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-43
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-51
25-09 Mode Valve
25-09-03 Manual Mode Valve ....................................................................................................... 25-59
25-09-06 Auto Mode Valve ............................................................................................................ 25-67
25-12 Column
25-12-00 General ........................................................................................................................... 25-69
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-73
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-79
25-33 Link Arm
25-33-00 General ........................................................................................................................... 25-97
9813/9400-1
2017-10-02
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
LS Load Sense
9813/9400-1
2017-10-02
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3

25-00-03 Manual Steer Mode System .......................................................................................... 25-23
25-00-06 Auto Steer Mode System ............................................................................................... 25-29
25 - 1 9813/9400-1 25 - 1
Notes:
25 - 2 9813/9400-1 25 - 2
00 - General
Introduction ...................................................... 25-3 Your machine may be installed with either manual
Health and Safety ........................................... 25-4 or auto steer mode systems depending on the
Technical Data ................................................. 25-4 specification of the machine.
Operation ....................................................... 25-10 Manual Steer Mode System
Diagram ......................................................... 25-12 In a manual steer system, there are three steering
Fault-Finding .................................................. 25-15 modes available:
Check (Leaks) ............................................... 25-18
Check (Pressure) .......................................... 25-19 1. 2WS (Two Wheel Steer) (front axle only)- only
the front wheels are steered.
Adjust ............................................................ 25-20
Bleed ............................................................. 25-21 2. 4WS (Four Wheel Steer) both axles are steered,
giving a smaller turning circle
3. Crab steer- allows the machine to be driven
diagonally
Auto Steer Mode System

In an auto steer system, there are three steering
modes available:
1. 2WS (front axle only)- only the front wheels are

steered.
2. 4WS both axles are steered, giving a smaller
turning circle
3. Crab steer- allows the machine to be driven
diagonally
The operation of the steer mode switch, solenoids

and proximity switches is controlled by an ECU
(Electronic Control Unit).
On some machines a separate Steer Mode Control

ECU is used - refer to (PIL 33-45-18).
Other machines the steer modes are controlled by

either the hydraulic control ECU or the transmission
control ECU. For details of the ECU operation refer
to (PIL 33-45).
25 - 3 9813/9400-1 25 - 3
00 - General

Engine/Steering Failure For: 506-23 [T4F], 509-23 [T4F]
..................................................... Page 25-4
If the engine or steering fails, stop the machine as For: 512-26 [T4F] ........................ Page 25-4
quickly as possible. Do not operate the machine until
the fault has been corrected.
(For: 506-23 [T4F], 509-23 [T4F])
Make the machine safe before getting beneath it. Table 238.
Make sure that any attachments on the machine are Model Rexroth Bosch Eaton 160cc
correctly attached. Engage the park brake, remove LAGC 160
the ignition key, disconnect the battery. If the machine Volumetric 160 cc/rev 160 cc/rev
has wheels use blocks to prevent unintentional displacement
movement. gerotor 1:
Fluid Under Pressure Volumetric - -
Fine jets of fluid at high pressure can penetrate the displacement
skin. Keep face and hands well clear of fluid under gerotor 2:
pressure and wear personal protective equipment. Relief Valve Op- 195–200bar 175bar
Hold a piece of cardboard close to suspected erating Pres- (2,826.1– (2,536.2psi)
leaks and then examine the cardboard for signs of sure (at 1500 2,898.5psi)
fluid. If fluid penetrates your skin, get medical help RPM (Rev-
immediately. olutions Per
Minute))
Hydraulic Pressure
Shock valve op- 250bar 235bar
Hydraulic fluid at system pressure can injure you. erating pres- (3,623.2psi) (3,405.8psi)
Before connecting or removing any hydraulic hose, sure- if installed
service line has been vented before connecting or (For: 512-26 [T4F])
removing hoses. Make sure the engine cannot be
started while the hoses are open. Table 239.
WARNING! When getting access for maintenance Model Eaton SXB

work, make sure no-one is in a position to be caught Volumetric displacement 125 cc/rev
and/or crushed by the wheels when the steering gerotor 1:
wheel is turned. Volumetric displacement 285 cc/rev
gerotor 2:
Relief valve operating 175–182bar (2,536.2–
pressure (at 1500 RPM) 2,637.7psi)
Shock valve operating 235–242bar (3,405.8–
pressure- if installed 3,507.2psi)
25 - 4 9813/9400-1 25 - 4
00 - General

..................................................... Page 25-5
For: 506-23 [T4F], 509-23 [T4F]
..................................................... Page 25-7
Figure 601. Dual Tech Variable Transmission- Steering System

A
B C
F
D E
H J
G
K L
N
S P
333/D7602-4
Q
A Steer valve B Port T

C Port L D Port P
E Port R F Port LS
G Steer mode valve H Port R2
J Port F2 K Port R1
L Port F1 M From DLS port on control valve port
N From D port on control valve port P Front steering ram
Q Yellow line R Return to tank
S Rear steering ram
25 - 5 9813/9400-1 25 - 5
00 - General
Figure 602. Auto Steer Mode Figure 603. Auto Steer Mode System- Sensors
System- Auto Steer Valve
A
A A C
B
A
A Rear steer sensor
B Front steer sensor
C Front axle
A Auto steer valve D Rear axle
B Steer mode switch
25 - 6 9813/9400-1 25 - 6
00 - General
(For: 506-23 [T4F], 509-23 [T4F])
Manual Steer Mode System
Figure 604.
B
A
A Steer mode selection lever B Steer mode selection unit

C Steer mode unit cable D Steer mode valve
25 - 7 9813/9400-1 25 - 7
00 - General
Auto Steer Mode System
Figure 605.
A Steer mode switch B Front steer proximity switch

C Rear steer proximity switch
Figure 606. Auto Steer Mode Valve
C B
D A
1
25 - 8 9813/9400-1 25 - 8
00 - General
1 Located under the LH centre of the chassis
25 - 9 9813/9400-1 25 - 9
00 - General
Operation
The main components of the steering system are the steer unit, which in turn directs the flow to the steer
priority valve (PIL 25-03) , the load sensing steer rams on the axles.
unit (PIL 25-06), the steer mode control valve (PIL
25-09) (if installed) and the double acting steer rams When the steering lock is achieved, the pressure
or power track rods as applicable (PIL 25-18 and or signal in the load sense line ceases. The priority
19). valve then directs the oil from the hydraulic pump
into the main hydraulic system for operation of the
When the you turn the steering wheel, a pressure hydraulic services.
signal (demand) is generated in the load sense line
from the steer unit to the priority valve. The priority The maximum steering system pressure is set by a
valve then directs oil from the hydraulic pump to the relief valve housed inside the steer unit.
Figure 607. Machine with Power Track Rods
A,B
D
E
C
25 - 10 9813/9400-1 25 - 10
00 - General
Figure 608. Machine with Steer Rams
F
D
A, B
F
C
Table 240.
Item Description
A Hydraulic pump
B Priority valve
C Steer unit
D Control valve
E Power track rods
F Steer rams
25 - 11 9813/9400-1 25 - 11
00 - General
Diagram Figure 609.

C
(For: 512-26 [T4F])
Gear Pump Machines

D E
These diagrams are for illustration purposes, a
typical hydraulic circuit is shown. For specific details
of the circuit refer to the applicable hydraulic
schematic, refer to hydraulic system, general,
schematic circuit, (PIL 30-00-50).
Machines with Steer Rams

The diagram shows the complete steer circuit. There
are different steer modes. Refer to steering system-
steer mode system, refer to (PIL 25-00).
B
B1 B2
A1
A Hydraulic pump
A1 Priority valve
B Steer unit
B1 Relief valve
B2 Non-return valve
C Steer mode control valve
D Steer rams- front axle
E Steer rams- rear axle
T Hydraulic tank
Machines with Power Track Rods

25 - 12 9813/9400-1 25 - 12
00 - General
Figure 610. Variflow Machines

C
D E A dual gerotor unit is fitted to the steer unit of 550-80

machines.
B2
B
B1
A1
A
A Hydraulic pump
A1 Priority valve
B Steer unit
B1 Steering system relief valve
B2 Shock valves
C Steer mode control valve
D Power track rod- front axle
E Power track rod- rear axle
F Hydraulic tank
X Steering pressure test point
25 - 13 9813/9400-1 25 - 13
00 - General
Figure 611.
E F
C2
C
C1
M LS D
DLS
0.8
B
8 BAR
B1
X
X1
T
LIFT
A Hydraulic pump
B Control valve block- priority inlet section
B1 Priority valve
C Steer unit
C1 Steering system relief valve
C2 Shock valves
D Steer mode control valve
E Power track rod- front axle
F Power track rod- rear axle
G Hydraulic tank
X Pump output pressure test point
X1 Load sense pressure test point
25 - 14 9813/9400-1 25 - 14
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 241. Page 25-15
Steering wheel turns on its own. Table 242. Page 25-15
Machine will not turn when the steering wheel turned. Table 243. Page 25-15
Steering 'drifts' out of phase during operation. Table 244. Page 25-16
Steering fails to respond to selected mode (solenoid operated mode valve Table 245. Page 25-16
only).
Table 241. Steering wheel difficult to turn

Cause Remedy
Tyres not inflated to correct pressure. Inflate tyres to correct pressure.
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00 ).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 30-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. Check if the priority valve is sticking (contamination)
rectify as required. Check the load sense line from
the steer unit to the priority valve for signs of leaking
or poor connection. Refer to (PIL 25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Refer
to the Steer Mode Valve topic. Check if solenoids
operating, replace solenoids as required. Refer to
(PIL 25-00).
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00).
Table 242. Steering wheel turns on its own.

Cause Remedy
Dirt in the steer control unit (causing sleeves to stick Clean and inspect unit. Refer to (PIL 25-06).
open).
Steer control valve centring springs damaged, Check steer unit. Refer to (PIL 25-06).
broken or missing.
Steer control valve- position of rotor to shaft slot Correct as required. Refer to (PIL 25-06).
incorrect.
Table 243. Machine will not turn when the steering wheel turned.
Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
required. Refer to (PIL 30-00)
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 25-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
25 - 15 9813/9400-1 25 - 15
00 - General
Cause Remedy
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. – Check if the priority valve is sticking
(contamination) rectify as required. Check the load
sense line from the steer unit to the priority valve for
signs of leaking or poor connection. Refer to (PIL
25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Check if
solenoids operating, replace solenoids as required.
Refer to (PIL 25-00)
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00)
Steer column splined shaft not fully engaged in steer Check shaft engagement. Refer to (PIL 25-12)
valve.
Power track rod/Steer Ram failure. Check power track rod/Steer Ram for signs of
damage, leaks etc. Refer to (PIL 30-15).
Table 244. Steering 'drifts' out of phase during operation.

Cause Remedy
(1) Does steering go out of phase in less than four YES = go to (2), NO = Ensure system is rephased
hours of continuous use? after four hours of continuous use (see Operator's
Handbook).
(2) Does steering go out of phase by a small amount YES = go to 3, NO = go to 4.
and drift no further when changing steer modes?
(3) Ensure operator changes steer mode at low YES = done, NO = Ensure power track-rod piston
engine speed and observes 5 second delay between is centralised and wheel tracking is correct. Adjust
modes (see Operator's Handbook), is it OK now? alignment of steer proximity switches to optimise
accuracy.
(4) Bleed steering system to remove air. Is it OK YES = done, NO = go to 5.
now?
(5) Possible leakage through anti-cavitation valve (if YES = done, NO = go to 6.
fitted). Replace Steer Unit. Refer to (PIL 25-06).
(6) Check both front and rear power track rods YES = done, NO = go to 7.
for internal leakage. Check the seal installation is
correct, check the seal damage, scoring or bore
ovality. Re-seal or renew faulty unit(s). Refer to (PIL
30-15). Is it OK now?
(7) Strip steer mode valve and inspect spool for YES = done, NO = go to 8.
scoring or damage. Renew valve if required. Refer to
(PIL 25-06). Is it OK now?
(8) Check for contamination in the hydraulic system. YES = Filter the hydraulic system. Refer to (PIL
30-00), NO = It is likely that one of the preceding
tests was not conclusive. Go to (1).
Table 245. Steering fails to respond to selected mode (solenoid operated mode valve only).
Cause Remedy
Electrical failure. (The steer mode ECU will generate Check relevant electrical connectors, if problem still
a blink code for some fault conditions). Refer to (PIL persists, do a wiring continuity check on relevant
57-90). circuits.
Selector switch faulty. Check selector switch, replace as required.
Proximity switches not operating correctly. Check operation of proximity switches, adjust or
replace switches as required. Refer to (PIL 25-15).
Steer mode relay not operating correctly. Renew relay. Refer to (PIL 33-09).
25 - 16 9813/9400-1 25 - 16
00 - General
Cause Remedy
Steer mode valve not operating correctly. – Check if spools sticking, rectify as required. Refer
to (PIL 25-06). Check if solenoids operating in
accordance with the mode selected. Refer to (PIL
25-06).
Leaks in the relevant hoses or component Check hoses and connections for leaks.
connections.
ECU failure. The ECU is normally a reliable component and
failure is unlikely. Before renewing the ECU make
sure that all relevant electrical connections and
components are functioning correctly. (Make sure
you do not connect a test meter directly to the pins
on the ECU).
25 - 17 9813/9400-1 25 - 17
00 - General
Check (Leaks) 4. Select the machine in 2WS mode and then close
the ball valves. Measure the length of one side of
the track rod and record the value.
Internal hydraulic leakage check 5. Drive the machine, in a circle, in one direction,
several times. Stop the machine and again
If hydraulic leaks at the steer mode valve or power
measure the track rod length. Compare the
track rods, the steering system will go progressively
measurements.
out of phase, the more the steering is operated the
further the front and rear wheels will drift out of phase. 5.1. If the track rod has moved then it can
be assumed that there is internal leakage
Some drifting out of phase is normal over time and across the piston seals in the power track
the system must be routinely re-phased. Refer to rod. This may be due to defective or
(PIL 25-00). incorrectly installed seals, or a defective
cylinder bore. Disassemble and inspect the
If the system goes out of phase over short periods
power track rod.
of time it is probable that there is hydraulic leakage.
External leakage is obvious and may occur at 5.2. If the track rod has not moved it can be
track rod seals, relevant hoses, pipes and adaptors. assumed there is internal leakage at the
Internal leakage can occur across power track rod steer mode valve.
piston seals or within the steer mode valve.
To check the internal leakage follow the below steps.
• 4WS (Four Wheel Steer) mode faults: Both

front and rear track rods and the steer mode
valve must be checked individually for possible
leakage.
• 2WS (Two Wheel Steer) mode faults: It is
possible to identify fault, if internal leakage is
at the rear power track rod, or steer mode
valve without first removing and dismantling
components. Follow the steps below.
2. Disconnect the hydraulic hoses from the rear
power track rod and Install isolating ball valves
at each port on the track rod and then reconnect
the hoses.
3. Open the ball valves. Start the engine and bleed
the system. Refer to (PIL 25-00).
Figure 612.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 18 9813/9400-1 25 - 18
00 - General
Check (Pressure) 6. Set the steering to neutral (do not turn

the steering wheel), and start the engine.
Special Tools Gradually increase the engine speed to 1000
Description Part No. Qty. RPM (Revolutions Per Minute) and check the
Pressure Gauge (0-400 892/00279 1 maximum pressure gauge reading, it should be
Bar) within the specified limit.
Pressure Gauge (0-70 892/00346 1 Pressure: 5.9–8.7bar (85.5–126.1psi)
Bar)
6.1. If the pressure is more than the specified
The steer circuit pressure is integrated with operation limit then clean the priority valve. Refer to
of the hydraulic pump and the main hydraulic system (PIL 25-03).
pressures. Refer to (PIL 30-00-00) 6.2. If after cleaning the valve the pressure is
more than the specified limit then check
Gear pump machines the steering pump section flow rate and
pressure.
Hydraulic pressure tests 6.3. If the hydraulic pump flow and pressure
tests are satisfactory, then the priority valve
Standby pressure must be replaced with a new one. Refer to
1. Make the machine safe. Refer to (PIL 01-03). (PIL 25-03).
2. Turn the steering wheel to the left and to the right Steering pressure
several times to discharge the system pressure.
3. Disconnect hose 1 and install a pressure test
2. Turn the steering wheel to the left and to the right
gauge into the valve port.
3. Connect a pressure gauge to the test point
4. Put the open end of hose 1 into a clean container located on the priority valve.
in order to collect any oil drainage.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
Figure 613. 1)
G H Figure 614.
E K J F F
D K
F Priority valve
D Hose 2 K Test point
E LS (Load Sense) port adaptor
F Priority valve 4. Run the engine at 1500 RPM and turn the
G Hose 1 steering wheel to full lock.
H Hose 3
5. Hold the wheel on full lock and check the gauge
J Socket head screws
reading. This should be equal to the relief valve
K Test point
operating pressure. Refer to (PIL 25-00).
5. Disconnect hose 2 from load sensing port
6. If necessary, remove the plug on the hydraulic
adaptor and put a plug on the hose opening. Do
steer unit and adjust the pressure setting.
not cap the LS port adaptor.
25 - 19 9813/9400-1 25 - 19
00 - General
7. Use an Allen key to adjust the valve screw until Adjust

the correct pressure is shown on the gauge.
8. You can get access to the pressure adjusting To change the steer mode:
screw through a cut-out at the base of the
steering column after you remove the panels. 1. Stop the machine. Select the neutral position on
the forward/reverse lever.
Figure 615.
2. Turn the steering wheel until all the wheels are
pointing in the straight ahead position.
3. Use the steer mode selector lever to select the
steer mode required.
L Figure 616.
A
M
L Pressure adjusting screw B

M Plug
9. It may be necessary to remove the hydraulic C
steer unit if access is restricted.
D
10. Install the plug.
A Steer mode selector lever

B 4-wheel steer
C 2-wheel steer
D Crab steer
To align the wheels:
1. Stop the machine. Select the neutral position on

the forward/reverse lever.
2. Use the steer mode selector lever to select 4-
wheel steer.
3. Turn the steering wheel until the rear wheels are
4. Use the steer mode selector lever to select 2-
wheel steer.
5. Turn the steering wheel until the front wheels are
6. All wheels are now pointing straight ahead, select
the steer mode required and continue in the
normal manner.
25 - 20 9813/9400-1 25 - 20
00 - General
Bleed Machines with manual steer mode valve

(optional)
Machines with auto steer mode valve Whenever any hydraulic steering component is
disconnected or removed the system must be bled
Whenever any hydraulic steering component is as follows:
disconnected or removed the system must be bled
as follows: This procedure must be carried out in the correct
order that is laid down. You must not change the
With the engine running, the following procedure order of selections and operations.
must be carried out in the correct order that is laid
down. You must not change the order of selections 1. Start the engine.
and operations.
2. Select 2WS.
1. Select 2WS (Two Wheel Steer).
2.1. Turn the steering wheel to left, until front
1.1. Turn the steering wheel to left, until both the wheels are fully locked to the left.
front wheels are fully locked to the left. 2.2. Turn the steering wheel to right, until front
1.2. Turn the steering wheel to right, until both wheels are fully locked to the right.
the front wheels are fully locked to the right. 2.3. Turn the steering wheel to left until front
2. Select 4WS (Four Wheel Steer). wheels are in the straight ahead position.
2.1. Turn the steering wheel to left, until the front 3. Select 4WS.
wheels are fully locked to the left. 3.1. Turn the steering wheel to left, until front
3. Select 2WS. wheels are fully locked to the left.
3.2. Turn the steering wheel to right until front
3.1. Turn the steering wheel to full right lock. wheels are in the straight ahead position.
3.2. Turn the steering wheel to full left lock.
4. Select 2WS.
3.3. Turn the steering wheel to full right lock.
4. Select 4WS.
4.1. Turn the steering wheel to left, until the front 4.3. Turn the steering wheel to full right lock.
wheels are fully locked to the left.
4.4. Turn the steering wheel to left until front
5. Select 2WS. wheels are in the straight ahead position.
5.1. Turn the steering wheel to full right lock. 5. Select 4WS.
5.2. Turn the steering wheel to full left lock. 5.1. Turn the steering wheel to left, until the front
5.3. Turn the steering wheel to full right lock. wheels are fully locked to the left.
6. Select 4WS. 5.2. Turn the steering wheel to right until front
wheels are in the straight ahead position.
6.1. Turn the steering wheel to left, until front
wheels are fully locked to the left. 6. Select 2WS.
7. Select 2WS. 6.1. Turn the steering wheel to full right lock.
6.4. Turn the steering wheel to left until front
7.3. Turn the steering wheel to full right lock. wheels are in the straight ahead position.
8. Select 4WS. 7. Select 4WS.
8.1. Turn the steering wheel to left, until the front 7.1. Turn the steering wheel to left, until front
and rear wheels are fully locked. wheels are fully locked to the left.
9. Stop the engine and fill up the hydraulic tank as 7.2. Turn the steering wheel to right until front
necessary. wheels are in the straight ahead position
25 - 21 9813/9400-1 25 - 21
00 - General
8. Select 2WS.
8.4. Turn steering wheel to left until front wheels
are in the straight ahead position.
9. Select 4WS.
9.1. Turn the steering wheel to left, until the front
and rear wheels are fully locked.
10. Stop the engine and fill up the hydraulic tank as
necessary.
25 - 22 9813/9400-1 25 - 22
03 - Manual Steer Mode System
Operation
Manual Steer Mode System Figure 617. Right turn shown
Machines with power track rods

A
2-wheel steer selected
With the spool of the steer mode control valve in the

2-wheel steer position there is a hydraulic connection
between the steer unit and the front power track L R
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track
rod is blocked by the spool assembly and the axle is
held in the straight ahead position by the locked-up
hydraulic oil in the track rod ram.
When the steering wheel is turned, the steering

system only operates the front power track rod. P
If the steering wheel is turned to the left, the oil flow B
E
is reversed and the machine will turn in the opposite T
direction.
D
V
Table 246.
Item Description
A Front power track rod
B Steer unit
C Rear axle power track rod
D Steer mode control valve port
E Steer mode control valve port
L Left side
P Steer mode control valve port
R Right side
T Steer mode control valve port
V Steer mode control valve
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 23 9813/9400-1 25 - 23
4-wheel steer selected Figure 618. Right turn shown
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection A
between the steer unit and the front and rear axle
power track rods. Steer mode control valve ports
are internally connected. When the steering wheel is
turned to the right, oil is fed to the rear power track rod
and the displaced oil is fed to the front power track L R
rod through the valve spool. The front power track
rod turns the wheels in the opposite direction to the
rear wheels and displaced oil returns to tank.
If the steering wheel is turned to the left, the oil flow

is reversed and the machine will turn in the opposite
direction. P
E
B
D T
Table 247.
Item Description
B Steer unit
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
Crab steer selected axle power track rods. Steer mode valve ports are
internally connected. When the steering wheel is
With the spool of the steer mode valve in the turned to the right, oil is fed to the rear power track
crab steer position there is a hydraulic connection rod and the displaced oil is fed to the front power
between the steer unit and the front and rear
25 - 24 9813/9400-1 25 - 24
track rod through the valve spool. The front power Figure 619. Right turn shown
track rod turns the wheels in the same direction as
the rear wheels, causing the machine to crab to the
right. Displaced oil returns to tank. A

is reversed and the machine will crab in the opposite
direction.
L R
P
B
E
D V T
Table 248.
Item Description
B Steer unit
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 25 9813/9400-1 25 - 25
Machines with steer rams Figure 620.
2-wheel steer selected
With the spool of the steer mode control valve in the

2-wheel steer position there is a hydraulic connection
between the steer unit and the front steer rams. Steer
mode control valve ports are internally connected.
The oil feed to the rear axle steer rams is blocked by
the spool assembly and the axle is held in the straight L R
ahead position by the locked-up hydraulic oil in the F G
rams.
When the steering wheel is turned, only the front axle

rams are operated by the steering unit.
If the steering wheel is turned to the left, the oil flow P

direction. B
E
D T
H J
Table 249.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 26 9813/9400-1 25 - 26
4-wheel steer selected Figure 621.
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection
steer rams. Steer mode control valve ports are
internally connected. When the steering wheel is
turned to the right, oil is fed to the rear rams and
the displaced oil is fed to the front rams through the
spool assembly. The front rams turn the wheels in the L
opposite direction to the rear wheels and displaced F R
G
oil returns to tank.

direction. P
E T
B
D
H J
Table 250.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
25 - 27 9813/9400-1 25 - 27
Crab steer selected Figure 622.
With the spool of the steer mode valve in the

crab steer position there is a hydraulic connection
steer rams. Steer mode valve ports are internally
connected. When the steering wheel is turned to the
right, oil is fed to the rear rams through the spool
assembly. The front rams turn the wheels in the same
direction as the rear wheels, causing the machine to L R
crab to the right. Displaced oil returns to tank. F G

direction.
P
B
E
T
D
V
H J
Table 251.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 28 9813/9400-1 25 - 28
06 - Auto Steer Mode System
Operation
Auto Steer Mode System Figure 623.
There are 3 steering modes available:
• 2WS (Two Wheel Steer) (front axle only)

• 4WS (Four Wheel Steer) F
• Crab steer
In the 2WS mode, only the front wheels are steered.

In 4WS mode, both the axles are steered, giving a
smaller turning circle. The crab steer mode allows the
machine to be driven diagonally. L R
The system is prevented from changing mode until

all the wheels are in the straight ahead position. This
is detected by proximity sensors on the front and E.C.U.
rear axles. If the system is set in 4WS and 2WS

is selected, the system will stay in 4WS until the
rear wheels are turned to the straight ahead position.
The rear wheels are then hydraulically locked in the
straight ahead position.
S
The operation of the steer mode switch, solenoids
V
and proximity switches is controlled by the hydraulic
control ECU (Electronic Control Unit) and the
transmission control ECU. Refer to steering system-
general, refer to (PIL 25-00). T
Hydraulic Operation and Schematics A
Machines with power track rods

Operation- 2-wheel steer selected
The illustrations shown are for the purpose of circuit

explanation only. Actual installations may not be as
shown.
With the spools of steer mode control valve in B

the 2WS position (solenoid energised), there is a
hydraulic connection between the steer unit and the
front power track rod. The oil feed to the rear axle A Solenoid Energised
power track rod is blocked by the spool assembly and B Rear power track rod
the axle is held in the straight ahead position by the F Front power track rod
locked-up hydraulic oil in the track rod ram. L Left
R Right
When the steering wheel is turned, the steering unit S Steer unit
operates only the front power track rod. V Control valve
If the steering wheel is turned to the left, the oil flow Operation- 4-wheel steer selected
direction. The illustrations shown are for the purpose of circuit
shown.
25 - 29 9813/9400-1 25 - 29
With the spools of steer mode valve in the 4WS S Steer unit
position (solenoid 1 and solenoid 2 energised), there T Tank
is a hydraulic connection between the steer unit and V Steer mode valve
the front and rear axle power track rods. When the
steering wheel is turned (right turn shown), oil is fed Operation- Crab Steer Selected
to the rear power track rod and the displaced oil is fed
to the front power track rod via the valve spools. The The illustrations shown are for the purpose of circuit
front power track rod turns the wheels in the opposite explanation only. Actual installations may not be as
direction to the rear wheels and displaced oil returns shown.
to tank.
With the spools of steer mode valve in the crab
If the steering wheel is turned to the left, the oil flow steer position (solenoid 1 and solenoid 2 energised),
is reversed and the machine will turn in the opposite there is a hydraulic connection between the steer unit
direction. and the front and rear power track rods. When the
steering wheel is turned (right turn shown), oil is fed
Figure 624. to the rear power track rod and the displaced oil is fed
to the front power track rod via the valve spools. The
front power track rod turns the wheels in the same
direction as the rear wheels, causing the machine to
F crab to the right. Displaced oil returns to tank.

direction.
L R
E.C.U.
S
C
D T
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
R Right
25 - 30 9813/9400-1 25 - 30
Figure 625. R Right

S Steer unit
V Steer mode valve
F Schematics
The steer mode valve spools have mechanical

detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer mode
suddenly.
L R
E.C.U.
C
D
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
25 - 31 9813/9400-1 25 - 31
2- wheel steer
Figure 626.
R2 C B F2
F1
R1 D A
S
R2 F2
R L
B A FR
R1 F1
D C
R Oil flow direction- right

turn
Table 252. 2- wheel steer
L Oil flow direction- left
Steer Mode 2WS turn
Ports internally connect- F2 - F1 V Steer mode valve
(1)
ed FR Front axle
Ports internally blocked R1 - R2
(1) Refer to component location for variation of valve
Solenoids energised A orientation.
Key
S Steer unit
25 - 32 9813/9400-1 25 - 32
4- wheel steer
Figure 627.
R2 F2
C B
D A F1
R1
V
S
R2 F2
R L
B A FR
R1 F1
D C
S Steer unit
Table 253. 4- wheel steer
turn
Steer Mode 4WS L Oil flow direction- left
Ports internally connect- F1 - R2 turn
ed F2 - R1 V Steer mode valve
(1)
Ports internally blocked - FR Front axle

Solenoids energised B, D (1) Refer to component location for variation of valve
Key orientation.
25 - 33 9813/9400-1 25 - 33
Crab steer
Figure 628.
R2 F2
C B
D A F1
R1
V
S
R2 F2
R L
B A FR
R1 F1
D C
Machines With Steer Rams

Table 254. crab steer
Steer Mode Crab Steer
Ports internally connect- F1 - R1 The illustrations shown are for the purpose of circuit
ed explanation only. Actual installations may not be as
F2 - R2
shown.
Ports internally blocked -
Solenoids energised B, C With the spools of the steer mode control valve in
Key the 2WS position, there is a hydraulic connection
between the steer unit and the front steer ram 1 and
S Steer unit
front steer ram 2. The oil feed to the rear axle steer
R Oil flow direction- right ram 1 and the rear axle steer ram 2 is blocked by the
turn spool assembly and the axle is held in the straight
L Oil flow direction- left ahead position by the locked-up hydraulic oil in the
turn rams.
V Steer mode valve
(1)
When the steering wheel is turned, only the front axle

FR Front axle rams (or front power track rod) are operated by the
(1) Refer to component location for variation of valve steering unit.
orientation.
25 - 34 9813/9400-1 25 - 34
If the steering wheel is turned to the left, the oil flow With the spools of the steer mode valve in the 4WS
is reversed and the machine will turn in the opposite position, there is a hydraulic connection between the
direction. steer unit and the front and rear axle steer rams.
When the steering wheel is turned (right turn shown),
Figure 629. oil is fed to the rear rams and the displaced oil is fed
to the front rams via the spool assembly. The front
rams turn the wheels in the opposite direction to the
rear wheels and displaced oil returns to tank.

direction.
Figure 630.
L R
F1 F2
S
R
V L
F1 F2
H
S
V
T
F3 F4
F1 Front steer ram 1

F3 Rear steer ram 1
F4 Rear steer ram 2
L Left
R Right
S Steering unit
T Tank
F3 F4
The illustrations shown are for the purpose of circuit F3 Rear steer ram 1
explanation only. Actual installations may not be as F4 Rear steer ram 2
shown. L Left
R Right
25 - 35 9813/9400-1 25 - 35
S Steer unit Figure 631.

T Tank
V Steer mode valve
Operation- Crab Steer Selected

The illustrations shown are for the purpose of circuit
shown.
With the spools of steer mode valve in the crab steer R

position there is a hydraulic connection between the F1 L F2
steer unit and the front and rear axle steer rams.
When the steering wheel is turned (right turn shown),
oil is fed to the rear rams and the displaced oil is fed
to the front rams via the spool assembly. The front
rams turn the wheels in the same direction as the
rear wheels, causing the machine to crab to the right.
Displaced oil returns to tank.
If the steering wheel is turned to the left, the oil flow S

direction. V
F3 F4
F3 Rear steer ram 1
F4 Rear steer ram 2
L left
R Right
S Steering unit
T Tank
V Steer mode valve
Schematics
The steer mode valve spools have mechanical
detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer
mode suddenly. Faulty electrical connections to the
solenoid coils (energising the coil) could cause the
steer mode to change suddenly with no operator
input.
25 - 36 9813/9400-1 25 - 36
2- wheel steer
Figure 632.
F1 R1
A D
B C
F2 R2
C
F1 D
R1
A
FR B
S
F2 R2
R L
S Steer unit
Table 255.
turn
Steer Mode 2WS L Oil flow direction- left
Ports internally connect- F2 - F1 turn
ed V Steer mode valve
Ports internally blocked R1, R2 FR Front axle
Solenoids energised A
Key
25 - 37 9813/9400-1 25 - 37
4- wheel steer
Figure 633.
F1 A D R1
F2 B C R2
C D
F1 R1
A B
FR
S
F2 R2
R L
Key
S Steer unit
Table 256.
Steer Mode 4WS turn
Ports internally connect- F1 - R2 L Oil flow direction- left
ed F2 - R1 turn
Ports internally blocked - V Steer mode valve
Solenoids energised B, D FR Front axle
25 - 38 9813/9400-1 25 - 38
Crab steer
Figure 634.
V
F1 R1
A D
B C R2
F2
C
F1 D
R1
A B
FR
S
F2 R2
R L
V Steer mode valve

Table 257. FR Front axle
Steer Mode Crab Steer
Ports internally connect- F1 - R1
ed F2 - R2
Ports internally blocked -
Solenoids energised B, C
Key
S Steer unit
turn
L Oil flow direction- left
turn
25 - 39 9813/9400-1 25 - 39
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-41
25 - 40 9813/9400-1 25 - 40
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 41 9813/9400-1 25 - 41
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-43
25 - 42 9813/9400-1 25 - 42
03 - Priority Valve
00 - General
00 - General Component Identification

Operation ....................................................... 25-45
Gear pump machines
Clean ............................................................. 25-47 The priority valve is mounted on the side of the gear
Remove and Install ....................................... 25-48 pump.
Figure 635.
LS P EF
EF
LS
EF Return line
P Pressure port
LS Load sense
Variable flow machines

The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
Electro servo (Agri Xtra) machines

Figure 636.
A Control valve block priority inlet section
Electro servo (Agri excluding Extra)

machines
The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
25 - 43 9813/9400-1 25 - 43
03 - Priority Valve
00 - General
Figure 637.
A Control valve block priority inlet section
25 - 44 9813/9400-1 25 - 44
03 - Priority Valve
00 - General
Operation
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 638. Gear pump type valve shown
LS P EF
LS
A
B
P EF
orifice 2, onto the end of the priority valve spool. This

creates a large pressure difference across the spool,
Table 258. causing it to move up against the force of the spring.
Item Description This allows the full pump flow to be directed through
port (EF) back to the tank or join with the main flow
A Pump outlet
to the control valve.
B Orifice 1
C Priority valve spool Turning
D Orifice 2
E Steering unit When the steering wheel is turned, a pressure signal
is generated in the load sense line from the steering
P Pressure line
unit.
LS Load sense line
EF Port Pressure is then applied to the spring end of
the priority valve spool. This reduces the pressure
When the steering is not being operated, flow to the difference across the spool, causing it to move down
steering circuit is dead ended by the closed centre under spring force. This allows some of the pump
steering unit, and no pressure signal (demand) is outlet flow to be directed through the pressure port
generated in the load sense line. Pressure from the to the steering unit, which in turn directs the flow to
pump outlet is directed through the orifice 1 and the corresponding steer rams to turn the wheels.
25 - 45 9813/9400-1 25 - 45
03 - Priority Valve
00 - General
Figure 639. Gear pump type valve shown
LS P EF
LS
A
B
P EF
Table 259.
Item Description
A Pump outlet
B Orifice 1
C Priority valve spool
D Orifice 2
E Steering unit
P Pressure line
LS Load sense line
EF Port
The excess flow goes through the port (EF) back to

the tank or joins with the main flow to the control.
When the steering reaches the required position,

the pressure signal in the load sense line from
the steering unit ceases and restore the pressure
difference across the spool. The spool moves back
up and allow the pump full flow to be directed through
port (EF) back to the tank or joins with the main flow
to the control valve.
The maximum steering system pressure is set by a

relief valve located inside the steering unit.
25 - 46 9813/9400-1 25 - 46
03 - Priority Valve
00 - General
Clean 10. Reconnect the hose to the LS port, and bleed the
LS line as described below.
The priority valve spool and spring may be removed 10.1. Start the engine.
for cleaning with the pump in the machine. 10.2. Loosen the connection on the valve, then
turn and hold the steering wheel fully in
1. Make the machine safe. Refer to (PIL 01-03). either direction.
2. Follow the general health and safety procedure. 10.3. When bubble free oil seeps from the joint,
Refer to (PIL 01-03). tighten the connection.
3. Discharge the hydraulic pressure. Refer to (PIL Table 260.
30-00).
Item Description
4. Turn the steering wheel to the left and to the right B 100–105N·m
several times to discharge system pressure.
C 75–81N·m
5. Disconnect the hose from the LS (Load Sense)
port. Blank off the hose to prevent loss of fluid.
6. Remove the adaptor and extract the priority valve
spring.
6.1. Remove the blanking plug and extract the
priority valve spool. Make sure that the bore
of the valve is not damaged.
7. Clean these components paying particular
attention to the orifices at each end of the spool.
Dry off and lubricate with clean hydraulic fluid.
Figure 640.
B D C
A Hose
B Adaptor
C Blanking plug
D Priority valve
8. Install the priority valve spool and make sure that
the spring seat end of the spool faces towards
the LS port.
9. Install the blanking plug and tighten it to the
25 - 47 9813/9400-1 25 - 47
03 - Priority Valve
00 - General
Remove and Install
(For: 506-23 [T4F], 509-23 [T4F], Agri- 2. Remove the plunger and the washer.
Xtra) 3. Remove the spring.
Consumables
4. Carefully remove the spool from the valve body.
JCB High Strength 4102/0551 0.05L 5. Use an allen key to remove the screw 2 and then
Threadlocker remove the filter.
32 6. When you remove the retaining screw hold the
4002/1025 20L spool carefully to prevent damage.
4002/1024 200L
7. Remove the spring, ball and the screw 1.
Electro servo control valve- Steer 8. When you remove O-rings and seals, use a
priority valve rounded tool so that will not cause any damage
to the seal grooves. Discard all O-rings and back-
Remove up rings. Do not use worn or damaged items.
1. Remove the end cap and discard the O-ring.
Figure 641.
B
D
E
G
H
K
C M
F
J
L
Item Description
Table 261. J Washer
K Plunger
Item Description
L O-ring
A Valve block
M End cap
B Screw 1
C Ball Install
D Spring
E Spool 1. Lubricate the parts with hydraulic fluid before you
F Filter assemble them.
G Screw 2 Consumable: JCB Hydraulic Fluid HP 32
H Spring
25 - 48 9813/9400-1 25 - 48
03 - Priority Valve
00 - General
2. Apply sealant to the screws and tighten the

screw1 into the housing.
3. Install the ball and the spring into the housing.
4. Put the filter into the spool assembly.
5. Apply sealant to the screw 2 and tighten onto the
spool.
6. Put the spring, washer and plunger into the valve
block.
7. Replace the o-ring with new one.
8. Install the end cap into the valve housing.

Item Description Nm
B Screw 1 10
G Screw 2 10
M End cap 100
25 - 49 9813/9400-1 25 - 49
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-51
25 - 50 9813/9400-1 25 - 50
00 - General
Introduction .................................................... 25-51 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-52 fluid flow in the steering system.
Operation ....................................................... 25-54
25 - 51 9813/9400-1 25 - 51
00 - General
For: 506-23 [T4F], 509-23 [T4F]

................................................... Page 25-52
For: 512-26 [T4F] ...................... Page 25-53
(For: 506-23 [T4F], 509-23 [T4F])
Figure 642.
D E
C C
A
B
G D
G K J F
J
F E
Item Description
Table 263. D Left feed/ return port
Item Description E Right feed/ return port
A Hydraulic steer unit F Valve inlet
B Shock Valves (if in- G Return line
stalled) H Steer valve
C Check valve
25 - 52 9813/9400-1 25 - 52
00 - General
Item Description
J Load sense port
K Steering system relief
valve
(For: 512-26 [T4F])
Figure 643.
L R
A B
C C
T D
E
L
LS
P F
R
J
K H
T LS P
A Shock valve B Shock valve

C Anti cavitation valves D Gerotor (power steering only)
E Logic valve F Gerotor (power and manual steering)
G Integral steer control valve H Inlet check valve
J Manual steer check valve K Steering system relief valve
L Left feed/ return port R Right feed/ return port
P Valve inlet port T Valve return port
LS Load sense port
25 - 53 9813/9400-1 25 - 53
00 - General
Operation
(For: 512-26 [T4F])

Refer to Steer/unit valve, general, diagram (PIL
25-06-00).
Integral valves and oil displacement gerotors are

installed in the hydraulic steering unit to control the
flow of oil to the axle mounted power track rods.
When the steering wheel is turned, the spool of the

control valve moves and allows oil pressure from the
machine hydraulic pump to flow to the gerotors. The
gerotors rotate as the steering wheel is turned and
oil is displaced to and from the power track rods.
When there is no hydraulic pressure from the

machine, the hydraulic pump (engine stopped) and
the spool of the logic valve moves due to the force
from its actuating spring. The valve isolates the
(power steering only) gerotor from the power track
rods.
When the steering is turned, only the smaller

displacement (power and manual steering) gerotor
displaces the oil to and from the power track rods.
Since the reduced displacement requires less torque
at the steering wheel, it is possible to operate the
steering when the engine is stopped.
25 - 54 9813/9400-1 25 - 54
00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F] 6. Get access to the steer unit. Remove the front
................................................... Page 25-55 panel from the cab.
For: 512-26 [T4F] ...................... Page 25-56 Refer to: PIL 06-06-12.
(For: 506-23 [T4F], 509-23 [T4F]) 7. Put a label on the hoses to help installation.
8. Disconnect the hydraulic hoses from the steering
Remove unit.
1. Make the machine safe. Refer to (PIL 01-03). 9. Plug all the open ports and hoses to prevent
contamination.
2. Follow all the general health and safety
procedure. Refer to (PIL 01-03). 10. Mark the orientation of steering unit to the splined
shaft.
30-00). 11. Remove the bolts from inside the cab. At the
same time, get an assistant to support the
4. Turn the steering wheel to the left and to the right steering unit from under the machine.
12. Remove the steering unit.
5. Make sure that the steering wheel is in the
Figure 644.
C
B
B Steering unit C Bolts (x 4)

D Splined shaft
Install 1.2. Make sure that the hoses are connected in

the correct positions.
1.3. If the hydraulic adaptors are removed make
sure that they are tightened to the correct
steps.
torque value.
25 - 55 9813/9400-1 25 - 55
00 - General
Figure 645.
E Hydraulic adaptor 1 F Hydraulic adaptor 2
1.4. The steering unit is spring loaded to the 2. Follow the general health and safety procedures.
neutral position. Make sure that the steering Refer to (PIL 01-03).
wheel is in the straight ahead position when
you connect the splined shaft. 3. Turn the steering wheel to the left and to the right
several times to vent system pressure. When
1.5. Before you drive the machine, bleed the you have done this, make sure that the steering
system. Refer to (PIL 25-00). wheel is in the straight ahead position.
1.6. If a new steering unit is installed then
4. Disconnect the five hydraulic hoses at the
the system relief valve must be tested for
steering unit.
correct pressure setting.
1.7. Check the hydraulic oil level and top up as 5. Put a label on each hydraulic hose to help
required. Refer to (PIL 30-00). installation.
Table 264. Torque Values 6. Disconnect the hydraulic hoses.
Item Nm 7. Plug all the open ports and hoses to prevent

C 45 contamination.
E 48 8. Mark the orientation of the steering unit to the
F 14 splined shaft.
9. Remove the four bolts from inside the cab. At
(For: 512-26 [T4F]) the same time get an assistant to support the
steering unit beneath the machine.
Remove
10. Remove the steering unit.
25 - 56 9813/9400-1 25 - 56
00 - General
Figure 646.
D
C
B E
A-E Hoses F Steering unit

G Bolts H Splined shaft
Table 265. Hose Colour Code Bands 1.3. The steering unit is spring loaded to the
neutral position (i.e. straight ahead). Make
item Band Colour Port
sure the steering wheel is in the straight
A White P ahead position when you re-connect the
B Blue T splined shaft.
C Yellow L 1.4. Before you drive the machine, bleed the
D Green / Yellow R steering system. Refer to (PIL 25-00).
E Grey LS
Install Item Description Nm
G Bolts 45
steps.
value.
1.2. Make sure that the hoses are installed
correctly. The hoses have colour
identification bands. Refer to Table 265.
25 - 57 9813/9400-1 25 - 57
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-03 Manual Mode Valve ....................................................................................................... 25-59

25-09-06 Auto Mode Valve ............................................................................................................ 25-67
25 - 58 9813/9400-1 25 - 58
09 - Mode Valve
03 - Manual Mode Valve
03 - Manual Mode Valve Remove and Install

(For: 506-23 [T4F], 509-23 [T4F])
Remove
30-00).
5. Turn the steering wheel to the left and to the right
several times to discharge the system pressure
fully.
6. Make sure that the steering wheel is in the
8. Disconnect the hydraulic hoses from the steer
mode valve.
contamination.
10. Remove the nuts and bolts that secure the steer
mode valve to the chassis.
11. Remove the steer mode selector control handle
located inside the cab.
12. Before you remove the steer mode valve
assembly from the machine, observe the routing
of the operating cable.
13. Remove the nuts securing the steer mode
selector unit to the cab.
14. The steer mode selector unit, operating cable
and valve can now be removed from the machine
as a complete assembly.
15. Make sure to collect the two washers to the rear
of the valve block which may fall out when screws
are removed.
16. Retain the spacer plate.
25 - 59 9813/9400-1 25 - 59
09 - Mode Valve
Figure 647.
A C
A B
A
A Hoses B Bolts
C Steer mode valve
25 - 60 9813/9400-1 25 - 60
09 - Mode Valve
Figure 648.
D Steer mode selector control handle
25 - 61 9813/9400-1 25 - 61
09 - Mode Valve
Figure 649.
E E
E Nuts F Steer mode selector unit
Figure 650.
G A B
H C
A Spacer plates B Bolts

C Steer mode valve G Chassis side plate
H Washer
25 - 62 9813/9400-1 25 - 62
09 - Mode Valve
Install
steps.
1.1. Make sure that the hoses are installed in the
correct position.
1.2. Bleed the steering system. Refer to (PIL
25-00).
1.3. Install the two washers between the valve
block, spacer and the chassis side plate.
1.4. Check the hydraulic oil level and top up as
25 - 63 9813/9400-1 25 - 63
09 - Mode Valve
(For: 506-23 [T4F], 509-23 [T4F]) travel away from the valve) until they disengage
the operating cable thread.
Consumables
Description Part No. Size 4. Remove the locknut 2 and disconnect the
JCB Threadlocker 4101/0250 0.01L operating cable from valve adaptor.
and Sealer (Medium 4101/0251 0.05L 5. Remove the screws 2 from the end cap 2.
Strength)
6. Remove the locknut 3. Rotate the locknut 3 and
Disassemble the end cap 2 counterclockwise (so that the parts
travel away from the valve) until they disengage
1. Remove the steer mode valve assembly from the the operating cable thread.
machine. Refer to (PIL 25-09).
7. Disengage the operating cable from the steer
2. Remove the screws 1 from the end cap 1. mode selector.
3. Remove the locknut 1. Rotate the locknut 1 and
the end cap 1 counterclockwise (so that the parts
Figure 651.
H K
E
A
C D
A Screws 1 B End cap 1

C Locknut 1 D Locknut2
E Operating cable F Adaptor
G Screws 2 H End cap 2
25 - 64 9813/9400-1 25 - 64
09 - Mode Valve
J Locknut 3 K Steer mode selector
25 - 65 9813/9400-1 25 - 65
09 - Mode Valve
Assemble
the disassembly procedure. Additionally do the
following steps.
Figure 652.
F
D
10 mm
D Locknut 2 F Adaptor
1.1. Before you connect the operating cable to

the valve, set the locknut 2 as shown in the
figure. Refer to Figure 652. In this position,
the locknut can be used as a guide as to
how far to wind the operating cable into the
valve adaptor.
2. Apply the specified sealant to the screws 1 and
the screws 2.
(Medium Strength)
25 - 66 9813/9400-1 25 - 66
09 - Mode Valve
06 - Auto Mode Valve
06 - Auto Mode Valve 3. Check the solenoid coil resistance which should
measure a few ohms (if you are not sure about
the value compare with a known good solenoid).
Check (Operation)
3.1. Replace the solenoid, if the reading
indicates a short circuit (zero ohms) or open
Machines may be installed with different types of circuit (infinite resistance). If a reading is
steer mode solenoid valve. somewhere between the zero and infinite,
then reverse the two instrument probes and
The solenoids operate according to the selected repeat for a valid check.
steer mode.
The electrical connectors at the steer mode valve
Figure 653. solenoids are identical. Before you remove any of the
connectors, make sure you label them A, B, C or D
as applicable. If you think that the connectors have
A D been made to the wrong solenoids see the electrical
connection data for wire number identification.
C
B
A Solenoid1
B Solenoid2
C Solenoid3
D Solenoid4
Table 267.
Mode Solenoid(s) energised
2 Wheel Steer A
4 Wheel Steer B, C
Crab Steer B, D
Operation (energisation) of a solenoid can be easily

identified by placing a steel object (e.g. screwdriver
blade) close to the outer case. magnetic attraction
of the steel object towards the solenoid indicates
energisation.
If a solenoid is not energising do the following

checks:
1. Check the appropriate fuse. If it has blown, make

sure the wiring is not damaged and then renew
the fuse. Check that all steer mode solenoid
combinations function correctly.
2. If the fuse is ok then, remove the electrical
connector from the malfunctioning solenoid(s)
and check that the 12V supply is available across
the connector pins. If not, check the supply
circuit.
25 - 67 9813/9400-1 25 - 67
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-69
25 - 68 9813/9400-1 25 - 68
12 - Column
00 - General
00 - General Figure 654.

X Y
Remove and Install
There are two types of steering column. Type X is

tilt adjustable and type Y is tilt and height adjustable.
The removal and installation procedures are the
same for both types.
Remove
3. Remove the steering wheel and steering column
surround. Refer to (PIL 09-36).
4. Remove the column switches. Refer to (PIL
33-27). H H
5. The electrical connector 1 and electrical
connector 2 are the same. Record the position of D E
the connectors.
6. Disconnect the electrical connector 1 and the
electrical connector 2.
7. Align the marks on the steering shaft and the C
steering column.
8. Remove the clips and the pins.
9. Hold the steering column assembly and remove
the lever lock (if installed).
10. Lift the column assembly away from the cab. A B
A Electrical connector 1
B Electrical connector 2
C Lever lock
D Steering shaft
E Steering column
F Clips
G Pins
H Steering shaft splines
25 - 69 9813/9400-1 25 - 69
12 - Column
00 - General
Install
steps.
1.1. Align the marks on the steering shaft and
the steering column put during removal.
1.2. Engage the steering shaft splines with the
steer valve internal spline.
1.3. Put the electrical connector 1 and the
electrical connector 2 in the correct
positions.
25 - 70 9813/9400-1 25 - 70
15 - Proximity Switch
Contents Page No.
25-15-00 General ........................................................................................................................... 25-73
25 - 71 9813/9400-1 25 - 71
Notes:
25 - 72 9813/9400-1 25 - 72
00 - General
Introduction .................................................... 25-73 These are installed on machines with auto steer
Adjust ............................................................ 25-74 mode system or manual (indicated) mode system.
25 - 73 9813/9400-1 25 - 73
00 - General
Adjust
For: 512-26 [T4F] ...................... Page 25-74 The proximity switch is the same for both the front
For: 506-23 [T4F], 509-23 [T4F], 512-26 and rear axles.
[T4F] .......................................... Page 25-74
The proximity switch is not adjustable. The switch
senses the position of the power track rod via a
(For: 512-26 [T4F]) magnet located centrally on the power track rod
Raised Equipment piston head.
Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Figure 655.
A
C
E D
A Proximity switch B Electrical connector

C Electrical schematic D Signal
E Feed F Earth
If necessary the proximity switch operation can be (For: 506-23 [T4F], 509-23 [T4F], 512-26
tested using a suitable multi-meter or test light at the [T4F])
electrical connector. When you connect a test device
refer to the electrical schematic. If the proximity switch is defective, replace it. Refer
to steering system- proximity switch, refer to (PIL
If the proximity switch is defective, replace it. Refer 25-15).
to Remove and install, (PIL 25-15-00).
25 - 74 9813/9400-1 25 - 74
00 - General
For electrical operation and testing, refer to electrical Figure 657.

system- electronic diagnostic, refer to (PIL 33-57).
A
The proximity switch setting procedure is the same
for both the front and rear axles.
1. Align the wheels in the straight ahead position.

2. Check the alignment as shown in the figure. Set
the steering so that the dimension X is of the B
specified value.
Length/Dimension/Distance: 129mm Y
Figure 656.
D
D C
A Target disc
B Proximity switch
C Bracket
D Bolts
Y Distance between the sensor tip and the end of
the target disc
5. If the dimension is not correct, adjust the switch
as follows:
5.1. Loosen the bolts.
X Wheel alignment dimension 5.2. Move the bracket up or down to make
dimension Y correct.
3. Remove the proximity switch cover.
5.3. Tighten the bolts.
4. Measure the dimension Y between the sensor tip
and the edge of the target disc and make sure 5.4. Repeat the step 4 again.
that it is to the specified value.
25 - 75 9813/9400-1 25 - 75
00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], 512-26 Remove

[T4F] .......................................... Page 25-76
For: 512-26 [T4F] ...................... Page 25-77 1. Make the machine safe. Follow all the general
safety procedures. Refer to (PIL 01-03).
(For: 506-23 [T4F], 509-23 [T4F], 512-26 2. Disconnect the harness electrical connector from
[T4F]) the switch electrical connector.
Working Under the Machine 3. Remove the proximity switch cover.
Make sure that any attachments on the machine are 4. Remove the bolt and nut that secure the
correctly attached. Engage the park brake, remove proximity switch to the support bracket.
the ignition key, disconnect the battery. If the machine 5. Remove the proximity switch from the support
has wheels use blocks to prevent unintentional bracket.
movement.
The following procedure applies to each of the steer

proximity switches on the front and rear axles.
Figure 658.
C B
A Proximity switch B Nut

C Support bracket D Proximity switch electrical connector
25 - 76 9813/9400-1 25 - 76
00 - General
Install
During the installation procedure do this below step
also.
1. Make sure to set the proximity switch air gap.
(For: 512-26 [T4F])

If the proximity switch is defective replace it. Refer
to track rod, remove and install (550-80), (PIL
25-18-00).
25 - 77 9813/9400-1 25 - 77
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-79
25 - 78 9813/9400-1 25 - 78
00 - General

Check (Condition) .......................................... 25-79
Check Energiser Seals
Disassemble and Assemble .......................... 25-89 If there is difficulty in steering the machine and
routine fault finding indicates power track rod
leakage, it is possible that the rectangular section
piston head seal on the power track rod piston head
is installed incorrectly i.e. twisted.
Check the front and rear power track rods as follows:
1. Disassemble the ram. Refer to Steering System-

Track Rod. Refer to (PIL 25-18).
2. Remove the piston seal and check to see if
the energiser seal has been installed twisted or
rolled.
3. Inspect the cylinder bore and piston rod for
scoring, nicks and burrs.
Figure 659.
A
B
A Piston seal
B Energiser seal
4. Assemble the ram with new seals. Make sure that
the energiser seal is not twisted or rolled. Check
the white installation marks.
Figure 660.
B
B Energiser seal
5. To prevent damage to the seals, clamp the
cylinder in a vertical position and lower the piston
rod assembly into the cylinder during installation.
25 - 79 9813/9400-1 25 - 79
00 - General
6. Install new wiper seals (not shown).

7. Install the power track rod assembly again.
8. Check the tracking. Refer to Driveline - Front
Wheel. Refer to (PIL 27-29).
9. Check for correct operation and steer phasing.
10. Check the hydraulic oil level and top up as
Figure 661.
25 - 80 9813/9400-1 25 - 80
00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], 512-26 10.3. Remove the mounting screw 1.
[T4F], Front, Rear ..................... Page 25-81
10.4. Remove the pipe assembly.
For: 512-26 [T4F], Front ............ Page 25-83
10.5. Remove the adaptor 2.
(For: 506-23 [T4F], 509-23 [T4F], 512-26 10.6. Plug all the open ports and hoses to
[T4F], Front, Rear) prevent contamination.
11. At this point, if the power track rod is to be
Remove dismantled, loosen the track rod link arms while
the track rod is still securely clamped. Refer to
steering system, Arm. Refer to (PIL 25-33).
2. Follow the general health and safety procedures
12. Remove the screw and the pin at each end
for the hydraulic system. Refer to (PIL 30-00).
of the axle and separate the link arms from
3. Discharge the hydraulic pressure. Refer to (PIL their mounting points. Discard the two web seals
30-00). seated in the eye of each link arm.
4. Turn the steering wheel to the left and to the right 13. Make alignment marks on the cylinder flange,
several times to discharge the system pressure. the end cover of the power track rod and on the
Make sure that the steering wheel is in the housing flange of the axle.
14. Remove the mounting screws 2 (x4).
5. Before you start work, clean the area around the
15. If you work on the front axle, do the following
axle and the power track rod.
steps:
6. Raise the front or the rear wheels from the
15.1. Use suitable jacks to support both ends
ground with suitable lifting equipment.
of the axle and then remove the mounting
7. Block the chassis. nuts from both ends. Leave the bolts in
position.
8. Remove the front left or the rear right wheel as
15.2. Lower the jack at the left end so that there
applicable.
is sufficient room for removal of the power
9. If you work on the front axle, do the following track rod.
steps: 15.3. Use a soft-faced hammer to gently tap the
closed end of the track rod cylinder to the
9.1. Put a label on the hoses to help installation.
left and out of its mounting.
9.2. Disconnect hose 1 and hose 2 and then
remove the adaptor 1. 16. If you work on the rear axle, do the following
steps:
contamination. 16.1. Use a suitable jack to raise the left end of
the axle so as to swivel the right end down
10. If you work on the rear axle, do the following to make room for removal of the power
steps: track rod.
10.1. Put a label on the hoses to help 16.2. Use a soft-faced hammer to gently tap the
installation. closed end of the track rod cylinder to the
right and out of its mounting.
10.2. Disconnect the pipe assembly from the
power track rod at the end point 1 and the
end point 2.
25 - 81 9813/9400-1 25 - 81
00 - General
Figure 662.
B
A
P
L
K N
F
E
H
D
M
A Hose 1 B Hose 2
C Adaptor 1 D Pipe assembly
E End point 1 F End point 2
G Mounting screw 1 H Adaptor 2
J Screw K Pin
L Link arm M Mounting screw 2
N Nuts P Bolt
25 - 82 9813/9400-1 25 - 82
00 - General
Install Figure 663.

removal procedure. Additionally do the following A
steps.
1.1. Apply grease and install the two new web
seals in each link arm eye. Make sure that
they are installed correctly and fully seated.
1.2. Apply grease to the machined external P
shoulders of the power track rod. Install by
tapping with a soft-faced hammer on the
mounting flange.
1.3. Take care to align the marks made during
removal. A Proximity switch
1.4. Check the steer proximity switch setting. P Screws 2
2. Loosen the check nuts on the joints of the link
1.5. Before you drive the machine, bleed the arms. Remove the nuts. Refer to Figure 664.
steering system. Refer to (PIL 25-00).
Figure 664.
Item Description Nm
G Mounting screw 56
H Adaptor 2 56
J Screw 56 E
F
M Mounting screw 166
N Mounting nut 600 G
D
P Bolts 600
(For: 512-26 [T4F], Front)

Consumables
Description Part No. Size D Check nuts 1
JCB Activator 4104/0251 0.2L E Joints
F Link arms
4104/0253 1L
G Swivels
and Sealer (Medium 4101/0251 0.05L 3. If the joint rotates, hold it with a hex wrench
Strength) inserted in the seat provided.
4. Replace the self locking nuts once in every five
Remove disassemblies.
1. Remove the proximity switch. Refer to Figure 5. Disconnect the tapered pins of the joints from
663. the steering swivels with a puller. Refer to Figure
665.
25 - 83 9813/9400-1 25 - 83
00 - General

K
E
G
E Joints J Check screws

G Swivels K Steering cylinder
6. Disconnect the left and right link arms from the 9. Remove the steering cylinder using a plastic
power track rod. Refer to Figure 666. hammer. Refer to Figure 668.
H K
H Power track rod K Steering cylinder
7. If necessary, heat the threads portion of the Install

power track rod to the specified temperature with
a heat gun. 1. Check the condition of the axle unit’s O-rings.
Temperature: 100°C (211.9°F) Apply grease on the piston seats with Tecnolube
Seal 101 and install cylinder using a plastic
8. Loosen and remove the check screws of the hammer. Refer to Figure 669.
steering cylinder. Refer to Figure 667.
Figure 669.
K Steering cylinder
25 - 84 9813/9400-1 25 - 84
00 - General
2. Lock the steering cylinder with the check screws Figure 672.
coated with JCB sealant and tighten to the
specified torque value. Refer to Figure 670.
(Medium Strength)
Figure 670. E
F
J K
G
D
D Check nuts 1
E Joints
F Link arms
G Swivels
6. If necessary, install the proximity switch for
J Check screws checking the piston centring. Tighten the screws
K Steering cylinder 2 to the specified torque value. Refer to Figure
673.
3. Apply JCB sealant to the threaded portion of the
steering bars and connect the bars by tightening Figure 673.
the ends in the piston rod to the specified torque
value. Refer to Figure 671. A
Torque: 450N·m
(Medium Strength)
Figure 671.
H P
A Proximity switch
P Screws 2
7. Attach the Dana tool T10 onto the wheel hubs
and lock tools.
8. Check that tools are perfectly flat and parallel to
each other using a level 1. Refer to Figure 674.
H Power track rod
4. Accurately remove the grease from the threads
using an activator before applying the thread
locking compound.
Consumable: JCB Activator
5. Install the pins in the steering cases and lock into
position with the check nuts 1 tightened to the
specified torque value. Refer to Figure 672.
25 - 85 9813/9400-1 25 - 85
00 - General
Figure 674. 11. Check the dimension of the piston rod on either
of the two sides and note down the dimension
to check the subsequent adjustments. Refer to
Figure 677.
Figure 677.
B
B Level 1
9. Connect the proximity switch to a test device.
Refer to steering system- proximity switch, refer
to (PIL 25-15). Refer to Figure 675.
C Dimension of the piston rod
Figure 675.
12. Lay the level 2 on two upper studs and line
them up. Attach the Dana tool T10 to the two
A horizontal studs. Hold them in position with two
nuts, level them, and finally lock into position.
Figure 678.
A Proximity switch
10. Centre by slowly moving the piston rod first
in one direction, then in the opposite one and
position the piston rod in the middle point of
the stroke, which is determined by the control
device signalling lamp turning on and switching
off. Refer to Figure 676. L Level 2
Figure 676. 13. Make sure that the Dana tool T10 perfectly mate
with the hub wheel mount facing.
14. Without moving the piston rod, check front and
rear distance between the edges of the Dana tool
T10. The maximum allowed difference must be
of the specified value.
Length/Dimension/Distance: 1–1.5mm
15. If necessary, adjust the parallelism after
loosening the check nuts 2 of the ball pins. Refer
to Figure 679.
25 - 86 9813/9400-1 25 - 86
00 - General

N N
M M
M Check nuts 2 M Check nuts 2

N Ball pins N Ball pins
16. Hold the joints tight and rotate the ball pins until 19. Adjust the steering angle lock stops:
the Dana tools T10 become parallel to each
other. Refer to Figure 680. 19.1. Perform the same operations on both
sides and loosen the nut of one of the
Figure 680. adjusting screws on cylinder side. Refer to
Figure 682.
N Figure 682.
N Ball pins
17. Loosen the nuts by a few turns. Half a turn of the
pin will reduce the front distance by about 3 mm
and increase the rear one by about 3 mm. 19.2. Adjust the protrusion of the screw 3 and
18. Once the toe-in has been adjusted, tighten the lock into position with nut 2 tightened to
check nuts 2 to the specified torque value. Refer the specified torque value. Refer to Figure
to Figure 681. 683.
25 - 87 9813/9400-1 25 - 87
00 - General

1 a b c d e f
2
T Q S
R Q
Q Nut 2
1 Steering angle (in degrees)
S Screw 4
a Steering angle (1) = 43° / Distance (B) =
T Axle arm stop
58.5mm
b Steering angle (1) = 45° / Distance (B) = 19.5. The screw 3 and the screw 4 must touch
53.5mm the respective axle arm stops at the same
c Steering angle (1) = 35° / Distance (B) = time.
51.6mm
d Steering angle (1) = 55° / Distance (B) = Table 269. Torque Values
23.8mm
e Steering angle (1) = 40° / Distance (B) = Item Description Nm
36.6mm D Check nuts 1 370
f Steering angle (1) = 50° / Distance (B) = J Check screws 190
38.2mm M Check nuts 2 346
2 Distance
B Distance P Screws 2 6
Q Nut 2 Q Nut 2 148
R Screw 3
19.3. Turn the steering until the adjusted screw 3
touches the axle arm stop. Refer to Figure
684.
Figure 684.
R
Q
Q Nut 2
R Screw 3
19.4. As you hold the adjusted screw 3 in
position against the arm stop, adjust the
screw 4 opposite, on link arm side, until it
touches the axle arm stop. Refer to Figure
685.
25 - 88 9813/9400-1 25 - 88
00 - General
For: 506-23 [T4F], 509-23 [T4F], 512-26 2. Remove the steering link arm 1 and the steering
[T4F] .......................................... Page 25-89 link arm 2. Refer to steering system- track rod,
For: 512-26 [T4F] ...................... Page 25-91 refer to (PIL 25-18).
3. Remove the end cap and then pull the piston rod
(For: 506-23 [T4F], 509-23 [T4F], 512-26 assembly from the cylinder.
[T4F])
4. Do not allow the piston rod to come into contact
Consumables with the cylinder bore. The cylinder bore may be
Description Part No. Size damaged by careless dismantling.
Cleaner/Degreaser 4104/1557 0.4L
- General purpose 5. Position the piston rod assembly on the bench in
solvent based parts place of the ram cylinder.
cleaner
6. Remove and discard the wear rings and the seal/
JCB Multi-Gasket 4102/1212 0.05L energising ring.
Use the alphabetical sequence shown on the 7. The piston head cannot be removed from the
illustration as a guide to disassembly. Refer to Figure rod, if there is damage to the rod or piston head,
686. replace the complete assembly.
Disassemble 8. Carefully inspect the bore of the cylinder and the

piston rod outer diameter for scoring, nicks and
1. Fix the ram assembly on a locally manufactured burrs. If damaged, install a new component.
strip/ rebuild bench.
25 - 89 9813/9400-1 25 - 89
00 - General
Figure 686.
AA
K C
E
G
J H L
A
D
F J
CC
B
BB
K
A Screw B End cap

C Cylinder D Piston head
E Wear ring 1 F Wear ring 2
G Seal H Energising seal
J Piston rod seals K Wiper rings
L Cover seal AA Steering link arm 1
BB Steering ring arm 2 CC Piston sleeve
25 - 90 9813/9400-1 25 - 90
00 - General

F G E
H
E Wear ring 1
F Wear ring 2
G Seal
Figure 688. H Energising seal
8. Apply grease to the piston seal and to the
surfaces of the piston rod.
9. Install the piston rod assembly.
10. Clamp the cylinder vertically.
11. Lower the piston rod assembly from the top.
Make sure its orientation is correct so that the
piston sleeve is nearest to the closed end of the
cylinder. Refer to Figure 688.
12. Make sure that the piston rod does not touch the
cylinder bore.
13. Engage the new piston head wear rings and
Assemble seals carefully into the cylinder.
1. Make sure all threads are free of grease, 14. If the piston head wear rings or the seals
hydraulic oil and sealant with the degreaser. are damaged during this stage, they must be
replaced.
purpose solvent based parts cleaner 15. When operating in conditions which are
consistently below freezing, it is recommended
2. Allow the degreaser to dry for 15 minutes and that the track rod is operated slowly to its full
then apply the sealant. extent in both directions before you start normal
Consumable: JCB Multi-Gasket working.
3. Make sure that the lubricants used during 16. Check the energiser seals. Refer to Front Track
assembly do not come into contact with the JCB Rod - Check Condition (PIL 25-18).
multi-gasket.
(For: 512-26 [T4F])
4. Install the piston rod seals and the wiper rings
correctly into the closed end of cylinder and into
the cover along with the cover seal. Disassemble
5. Make sure that the energiser ring is not twisted. 1. Before you disassemble the unit, drain the oil in
the cylinder chambers completely.
6. If the installation is not correct, it may lead to
leakage of the hydraulic fluid between the two 2. Using a screwdriver, remove the snap ring of the
sides of the power track rod and will cause cylinder head. Refer to Figure 690.
steering problems.
7. Make sure that three white marks are visible on
the outside diameter arrowed before install the
seal.Refer to Figure 689.
25 - 91 9813/9400-1 25 - 91
00 - General
B
C
A
D
A Snap ring C Cylinder

B Cylinder head D Stop ring
3. Lightly tap the cylinder head with a plastic 6. Using a plastic hammer, hit the piston rod so that
hammer so as to push it inside the cylinder. Refer it strikes against the head. Refer to Figure 693.
to Figure 691.
Figure 693.
Figure 691.
E
B C
C
B Cylinder head
B Cylinder head C Cylinder
C Cylinder E Piston rod
4. Insert the cylinder head so it is flush with the 7. Continue until the head is ejected from the
cylinder. cylinder.
5. Using a punch, force the stop ring located inside 8. Take the cylinder unit apart by extracting the
the cylinder and extract ring using a screwdriver. head first, followed by the piston rod. Refer to
Refer to Figure 692. Figure 694.
25 - 92 9813/9400-1 25 - 92
00 - General
E B
G F
B Cylinder head B Cylinder head

C Cylinder F Seal ring
E Piston rod G Scraper ring
9. Note down the direction of installation of the 3. Install the seal 1 on the outside of the cylinder
piston rod. The sealing ring whose seal ring is head. Refer to Figure 697.
oriented towards cylinder head.
Figure 697.
10. Remove all the seals, the anti-extrusion rings and
the scraper rings from the head, the cylinder and H
the piston rod. B
11. All seals must be replaced at each disassembly.

Do not damage the seal seats and the piston
beds.
Assemble
1. Apply grease and install the piston rod seal ring
and the scraper ring into the cylinder. Refer to
Figure 695.
Figure 695. B Cylinder head
H Seal 1
4. To ease installation, put grease on the outer
F G surface of the piston. Do not roll the seal 1.
5. Prepare piston rod by installing it with the guide
ring, magnetic ring, O-ring and the seal 2. Refer
to Figure 698.
F Seal ring
G Scraper ring
2. Apply grease and install the piston rod seal ring
and the scraper ring into the cylinder head. Refer
to Figure 696.
25 - 93 9813/9400-1 25 - 93
00 - General
K
M J
E
L
E Piston rod E Piston rod

J Guide ring
K Magnetic ring 9. Remove the Dana tool T11, and attach it to the
L O-ring opposite side of the piston rod. Refer to Figure
M Seal 2 701.
6. To ease installation, lubricate with grease. Figure 701.
7. Attach the Dana tool T11 to the piston rod on

the non-head side and the centre rod into the
cylinder so as to install it into the piston. Refer to
Figure 699.
Figure 699.
E Piston rod
C 10. Put grease on the seals of the cylinder head
and install the head onto the piston rod. Using a
E plastic hammer, install the head into the cylinder.
C Cylinder Figure 702.
E Piston rod
8. Install the piston rod into the cylinder by the B C
specified length using a plastic hammer. Refer to
Figure 700.
B Cylinder head
C Cylinder
11. Insert the head so that it is flush with the cylinder.
25 - 94 9813/9400-1 25 - 94
00 - General
12. Insert the stop ring and make sure that it sets in 15. Make sure that the snap ring seats perfectly in
the seat of cylinder. Refer to Figure 703. its seat.
Figure 703. 16. If necessary, force it into the seat with a punch
and hammer.
D C
C Cylinder
D Stop ring
13. Using two screwdrivers or levers, force the head
until it is seated against the stop ring. Refer to
Figure 704.
Figure 704.
D Stop ring
14. Install the snap ring of the cylinder head. Refer
to Figure 705.
Figure 705.
A Snap ring
B Cylinder head
25 - 95 9813/9400-1 25 - 95
33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ........................................................................................................................... 25-97
25 - 96 9813/9400-1 25 - 96
33 - Link Arm
00 - General
00 - General
Remove and Install

Strength)
Remove
If you have to dismantle the power track rod or
replace the link arms, do the following steps:
Remove
1. Fix the assembly on a locally made strip/rebuild 2. Use two suitable open ended spanners at point1
bench. Refer to Figure 706. and point2 and turn against each other until one
ball joint unscrews as shown. Refer to Figure
707.
3. For this explanation, assume the ball joint at
point1 is now loose, do as follows:
25 - 97 9813/9400-1 25 - 97
33 - Link Arm
00 - General
Figure 707.
A
B
A Point1 B Point2
25 - 98 9813/9400-1 25 - 98
33 - Link Arm
00 - General
C Point3 D Point4
3.1. Unscrew the ball joint until you can fit an Install
open ended spanner on the rod at point3.
Turn the ball joint towards the spanner to If the you have to dismantle the power track rod
secure it and to prevent damage to the rod. ram, carry out the procedure before you remove and
install the link arms. Refer to (PIL 30-15).
3.2. The piston rod operates at full length. Any
damage to the surface will cause fluid leaks. 1. The installation procedure is the opposite of the
Make sure you do not damage it or attempt removal procedure.
to grip the rod diameter with pipe grips etc.
3.3. Hold the spanner at point3 and remove the 2. When you install, also do the following steps:
ball joint at point4 by moving it against the 2.1. Install the target disc (where applicable).
spanner at point3.
2.2. Apply threadlocker and sealer on the first
4. Remove the target disc where applicable. three threads of the inner ball joint where it
screws into the end of the track rod.
5. If you replace the inner or outer ball joints, make
sure you install a replacement link arm assembly. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Figure 708.
2.3. If the link arms have been renewed, make
sure you check the wheel alignment.
2.4. Bring the wheels to straight ahead position.
J 2.5. Measure the distance1 and distance2

between the outer edges of the wheel hub
as shown.
2.6. Make sure that the difference between
the distance1 and the distance2 is of the
specified value for correct alignment.
E F G H 2.7. To adjust the wheel alignment, remove
the lock nuts. Turn the threaded adjusters
equally to get the correct alignment. Tighten
E Lock nut the lock nuts.
F Threaded adjuster 2.8. Check the target disc and proximity switch
G Spanner flat on ball joint setting (where applicable). Refer to steering
H Spanner flat on the rod system- track rod, refer to (PIL 25-18).
J Target disc
25 - 99 9813/9400-1 25 - 99
33 - Link Arm
00 - General
Figure 709.
X Distance1 Y Distance2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 100 9813/9400-1 25 - 100

27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-05 Hybrid Gearbox
27-05-00 General ............................................................................................................................. 27-7
27-05-07 Clutch - 2WD/4WD ......................................................................................................... 27-41
27-05-11 Clutch - Forward (Input) ................................................................................................. 27-45
27-05-15 Solenoid Control Valve ................................................................................................... 27-52
27-05-18 Pressure Relief Valve ..................................................................................................... 27-54
27-05-19 Control Valve .................................................................................................................. 27-55
27-05-21 Pressure Maintenance Valve (PMV) .............................................................................. 27-59
27-05-23 Motor .............................................................................................................................. 27-60
27-05-24 Oil Pump ........................................................................................................................ 27-66
27-05-27 Speed Sensor ................................................................................................................ 27-70
27-05-30 Oil Pressure Sensor ....................................................................................................... 27-72
27-05-33 Oil Temperature Sensor ................................................................................................. 27-76
27-05-39 Filter ............................................................................................................................... 27-80
27-05-40 Suction Strainer .............................................................................................................. 27-82
27-05-42 Dipstick ........................................................................................................................... 27-84
27-05-45 Piston Ring Seal ............................................................................................................ 27-85
27-05-47 Oil Seal .......................................................................................................................... 27-87
27-05-62 Clutch - Pump ................................................................................................................ 27-89
27-05-63 Clutch - Motor ................................................................................................................ 27-95
27-05-65 Clutch - Front (Output) ................................................................................................. 27-102
27-05-81 Mount ........................................................................................................................... 27-109
27-05-90 Front Case ................................................................................................................... 27-110
27-05-91 Rear Case .................................................................................................................... 27-112
27-05-93 Hose ............................................................................................................................. 27-114
27-05-95 Coupling Yoke .............................................................................................................. 27-116
27-06 Semi-Automatic Gearbox
27-06-00 General ......................................................................................................................... 27-121
27-06-06 Clutch - Reverse .......................................................................................................... 27-191
27-06-07 Clutch - 2WD/4WD ....................................................................................................... 27-195
27-06-08 Clutch - Layshaft .......................................................................................................... 27-224
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-243
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-256
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-264
27-06-15 Solenoid Control Valve ................................................................................................. 27-279
27-06-18 Pressure Relief Valve ................................................................................................... 27-284
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-285
27-06-24 Oil Pump ...................................................................................................................... 27-287
27-06-27 Speed Sensor .............................................................................................................. 27-289
9813/9400-1
2017-11-01
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-300
27-06-33 Oil Temperature Sensor ............................................................................................... 27-304
27-06-39 Filter ............................................................................................................................. 27-312
27-06-40 Suction Strainer ............................................................................................................ 27-314
27-06-45 Piston Ring Seal .......................................................................................................... 27-316
27-06-47 Oil Seal ........................................................................................................................ 27-318
27-06-52 Driveshaft ..................................................................................................................... 27-320
27-06-54 Main Shaft .................................................................................................................... 27-323
27-06-56 Layshaft ........................................................................................................................ 27-326
27-06-57 Input Shaft .................................................................................................................... 27-327
27-06-58 Output Shaft ................................................................................................................. 27-328
27-06-81 Mount ........................................................................................................................... 27-338
27-06-85 Oil Feed Pipe ............................................................................................................... 27-339
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-340
27-06-90 Front Case ................................................................................................................... 27-341
27-06-91 Rear Case .................................................................................................................... 27-351
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-353
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-357
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-383
27-14-06 Control Valve ................................................................................................................ 27-391
27-14-09 Relief Valve .................................................................................................................. 27-393
27-27 Hub
27-27-00 General ......................................................................................................................... 27-397
27-27-03 Upper Trunnion ............................................................................................................ 27-406
27-27-60 Swivel ........................................................................................................................... 27-408
27-27-66 Wheel Stud ................................................................................................................... 27-416
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-419
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-423
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-427
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-435
9813/9400-1
2017-11-01
Acronyms Glossary
2WD Two Wheel Drive

LSP Load Sense Pump
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PMV Pressure Maintenance Valve
PRV Pressure Relief Valve
PTFE Polytetrafluoroethylene
PTO Power Take-Off
RAS Rear Axle Stabilization
RWD Rear Wheel Drive
9813/9400-1
2017-11-01
Notes:
9813/9400-1
2017-11-01
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/9400-1 27 - 1
Notes:
27 - 2 9813/9400-1 27 - 2
27 - Driveline
00 - Driveline
00 - General

Health and Safety ........................................... 27-3 Working Under the Machine
Technical Data ................................................. 27-4 Make the machine safe before getting beneath it.
Operation ......................................................... 27-5 Make sure that any attachments on the machine are
movement.
WARNING! A raised and badly supported machine
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine
when working under it. Disconnect the battery, to
prevent the machine being started while you are
beneath it.
WARNING! Before disconnecting any propshaft,
make sure you block both sides of all wheels to
prevent machine movement. The park brake will
become ineffective or may only operate on 2 wheels
(depending on machine specification).
WARNING! If a 4 wheel drive machine is to be
raised and the engine/transmission run, make sure
all four wheels are raised off the ground. Make sure
the machine is correctly supported by the correct
axle stands. If only one pair of wheels is raised, the
machine could move and fall off the stands.
WARNING! Under no circumstances must the
engine be run with the transmission in gear and only
one driving wheel jacked clear of the ground, since
the wheel on the ground will move the machine.
27 - 3 9813/9400-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
For details of PS754, PS764 and PS766 For details of DTVT (HM560 Variable Transmission)
transmission Refer to: PIL 27-06-00. Refer to: PIL 27-05-00.
Table 271.
Machine Transmission Front Axle Rear Axle Front Differen- Rear Differen-
Options tial (Option)
(1)
tial
506-23
PS754 SD70 Pad SD55 Trunnion LSD or Maxtrac Maxtrac
PS764 mount mount
PS766
DTVT
509-23
PS754 SD70 Pad SD55 Trunnion LSD or Maxtrac Maxtrac
PS764 mount mount
PS766
DTVT
512-26
PS764 Dana 213 Pad Dana 223 Trun- LSD or Maxtrac Standard
PS766 mount nion mount
(1) If the LSD differential option is not installed, a JCB Maxtrac differential (for SD70 axles) or a standard Dana
differential (for 213 axles) is installed.
27 - 4 9813/9400-1 27 - 4
27 - Driveline
00 - Driveline
00 - General
Operation
The transversely mounted engine drives a The bevel gearbox and the gearbox share the same
permanently engaged 90° bevel gearbox. A torque lubricating oil. The transmission has dedicated oil
converter is mounted on the output end of the bevel filtering and cooling systems.
gearbox. The output from the torque converter drives
an electro hydraulically controlled gearbox (526-56 Drive is taken from the bevel gearbox to the main
machines have the option of a Manually Controlled hydraulic pump via a short splined tube.
gearbox). Drive from the gearbox is transmitted to the
steer drive front axle and to the steer drive rear axle The engine has a vibration damper bolted to the
via the propshafts. flywheel.
Figure 710.
A Engine B Bevel gearbox

C Output end of the bevel gearbox D Electro hydraulically controlled gearbox
E Steer drive front axle F Steer drive rear axle
G Propshafts J Hydraulic pump
K Flywheel
27 - 5 9813/9400-1 27 - 5
27 - Driveline
05 - Hybrid Gearbox
05 - Hybrid Gearbox
Contents Page No.
27-05-00 General ............................................................................................................................. 27-7

27-05-07 Clutch - 2WD/4WD ......................................................................................................... 27-41
27-05-11 Clutch - Forward (Input) ................................................................................................. 27-45
27-05-15 Solenoid Control Valve ................................................................................................... 27-52
27-05-18 Pressure Relief Valve ..................................................................................................... 27-54
27-05-19 Control Valve .................................................................................................................. 27-55
27-05-21 Pressure Maintenance Valve (PMV) .............................................................................. 27-59
27-05-23 Motor .............................................................................................................................. 27-60
27-05-24 Oil Pump ........................................................................................................................ 27-66
27-05-27 Speed Sensor ................................................................................................................ 27-70
27-05-30 Oil Pressure Sensor ....................................................................................................... 27-72
27-05-33 Oil Temperature Sensor ................................................................................................. 27-76
27-05-39 Filter ............................................................................................................................... 27-80
27-05-40 Suction Strainer .............................................................................................................. 27-82
27-05-42 Dipstick ........................................................................................................................... 27-84
27-05-45 Piston Ring Seal ............................................................................................................ 27-85
27-05-47 Oil Seal .......................................................................................................................... 27-87
27-05-62 Clutch - Pump ................................................................................................................ 27-89
27-05-63 Clutch - Motor ................................................................................................................ 27-95
27-05-65 Clutch - Front (Output) ................................................................................................. 27-102
27-05-81 Mount ........................................................................................................................... 27-109
27-05-90 Front Case ................................................................................................................... 27-110
27-05-91 Rear Case .................................................................................................................... 27-112
27-05-93 Hose ............................................................................................................................. 27-114
27-05-95 Coupling Yoke .............................................................................................................. 27-116
27 - 6 9813/9400-1 27 - 6
27 - Driveline
05 - Hybrid Gearbox
00 - General
Introduction ...................................................... 27-7 The JCB Dual Tech Variable Transmission is an
Technical Data ................................................. 27-8 innovative transmission designed to provide the
Component Identification ............................... 27-10 driver with the benefits of hydrostatic or mechanical
Operation ....................................................... 27-16 constant mesh gearboxes when certain criteria is
met.
Diagram ......................................................... 27-23
Fault-Finding .................................................. 27-29 To achieve this, the transmission can be considered
Drain and Fill ................................................. 27-30 to have two drive independent operating modes,
Check (Level) ................................................ 27-31 depending on the road speed of the machine. These
modes are independent of driver control and they are
Check (Pressure) .......................................... 27-31 not normally distinguishable in operation. Hydrostatic
Remove and Install ....................................... 27-32 drive is not engaged above the transition speed and
Disassemble and Assemble .......................... 27-34 the mechanical gearbox is not driving the machine
below this speed.
For road speeds up to the transition speed the

transmission operates in hydrostatic mode for
forward and reverse. The hydrostatic pump is
controlled by a swashplate to provide a constantly
variable ratio drive system giving excellent stop/start
and low speed controllability and efficient operation
up to the transition speed. Thus no fluid flywheel or
torque converter is required.
The transmission electronic control system allows

the mode to change smoothly from hydrostatic drive
to drive through the constant mesh gearbox at
speeds above the transition speed whilst maintaining
continuous operation. This means that the machine
can operate at higher speeds with 3 ratios using the
more "high speed efficient" mechanical gearbox.
Clutches
The clutches used in this transmission
are hydraulically actuated mechanical devices
consisting of wet a multiplate clutch operated
by a hydraulic piston. The clutch is operated
by the transmission control valve block which is
itself controlled by the TCM (Transmission Control
Module). Depending on the application, clutches
may be either engaged by hydraulic pressure or
disengaged.
The 4WD (Four Wheel Drive) clutch is spring applied

and is released by hydraulic pressure.
Moving a Disabled Machine

To move a disabled machine, make sure you refer
to the instructions in the correct operators manual
before you attempt to move the machine.
27 - 7 9813/9400-1 27 - 7
27 - Driveline
05 - Hybrid Gearbox
00 - General
Technical Data
Table 272. Refer to driveline, hybrid gearbox, general, check

(pressure), (PIL 27-05-00).
Designation Dual Tech Variable
Transmission
Description Dual hydrostatic and
mechanical transmis-
sion. The transmission
switches between hydro-
static and mechanical
constant mesh torque
transmission when re-
quired.
Weight (dry) 500kg
Clutch solenoid current 0.85A
draw
Table 273. Transmission Clutch Pressures

Test Point Description Speed Mode Engine RPM Temp °C Specified
Pressure
H1 Hydrostatic 0–19km/h Power 2350 RPM 55–60°C 12–14.5bar
clutch (0.0–11.8mph) (Revolutions (130.9– (173.9–
M2 Powershift 16–23km/ Per Minute) 139.9°F) 210.1psi)
clutch h (9.9–
14.3mph)
M3 Powershift 23–32km/
clutch h (14.3–
19.9mph)
M4 Powershift 32–40km/
clutch h (19.9–
24.9mph)
4WD 4WD (Four 16–23km/
Wheel Drive) h (9.9–
Clutch 14.3mph)
Table 274. Hydrostatic Pressures

Test Point Description Speed Mode Engine Gear Temp °C Specified
RPM Selected Pressures
R Pump/motor 0km/h Power 2350 RPM Neutral 55–60°C 3bar
case drain (0.0mph) (130.9– (43.5psi)
MH Pump ser- 0km/h Neutral 139.9°F) 25bar
vice pres- (0.0mph) (362.3psi)
sure Minimum
MH
(2)
Pump max- Transmis- 1 470–485bar
imum pres- sion stall (6,811.6–
sure 7,029.0psi)
MH Hydrostat- 8–19km/ 1 Delta-P
ic transmis- h (5.0– = 70bar
sion 11.8mph) (1,014.5psi)
(1)
M1 Motor dis- 8–19km/ 1

placement h (5.0–
11.8mph)
(1) Delta P = MH-M1
(2) This measurement is carried out with the propshafts installed and the machine held in a stalled condition.
27 - 8 9813/9400-1 27 - 8
27 - Driveline
05 - Hybrid Gearbox
00 - General
Table 275. Transmission Supply and Lubrication Pressures

Test Point Description Speed Mode Engine Gear Temp °C Specified
RPM Selected Pressure
TF Transmis- 0km/h Power 2350 RPM Neutral 55–60°C 12–14.5bar
sion pump (0.0mph) (130.9– (173.9–
supply 139.9°F) 210.1psi)
TL Transmis- 0km/h TBA
sion lube (0.0mph)
BBL Bevel box 0–19km/ TBA
lube h (0.0–
11.8mph)
YST Charge 0km/h 27–30bar
pressure (0.0mph) (391.3–
434.8psi)
Table 276. DTVT Pressure Test Results

Test point Description Test Result
(1)
H1 Hydrostatic
clutch
M2 Powershift
clutch
M3 Powershift
clutch
M4 Powershift
clutch
4WD 4WD Clutch
- - -
R Pump/motor
case drain
MH Pump service
pressure
MH Pump maxi-
mum pressure
MH Hydrostatic
transmission
M1 Motor displace-
ment
- - -
TF Transmission
pump supply
TL Transmission
lube
BBL Bevel box lube
YST Charge pres-
sure
(1) Make sure the oil is at the correct temperature.
27 - 9 9813/9400-1 27 - 9
27 - Driveline
05 - Hybrid Gearbox
00 - General

D
E B A
S
L
G
K
H J T
A Bevel gearbox bell housing B Control valve block

D Mounting bracket E Priming tube- Hydrostatic system
F Hydrostatic filter G Hydrostatic motor
H Oil cooler manifold connections J Sensor
K Serial number plate L Park brake mechanism
S Solenoid T Hydraulic oil port (return to tank)
27 - 10 9813/9400-1 27 - 10
27 - Driveline
05 - Hybrid Gearbox
00 - General
C D
A
G S
D B
A Bevel gearbox bell housing B Control valve block

C Hydrostatic pump D Mounting bracket
G Hydrostatic motor L Park brake mechanism
R Hydrostatic filter mounting block S Solenoids
27 - 11 9813/9400-1 27 - 11
27 - Driveline
05 - Hybrid Gearbox
00 - General

E R
D B E
F
M
H Q
P
B Control valve block D Mounting bracket

E Priming tube- Hydrostatic system F Hydrostatic filter
G Hydrostatic motor H Oil cooler manifold connections
L Parkbrake mechanism M 4WD (Four Wheel Drive) Output flange (To front
axle)
N Gearbox oil filter (Mechanical) P Drive output flange to rear axle
Q Mounting flange for service hydraulic pump R Hydrostatic filter mounting block
(Pump not installed)
27 - 12 9813/9400-1 27 - 12
27 - 13
640
650
400 550
410 10 470
460
390 90
300 720 30
270
360 150
140
450
150 520
370 340 70 530 670
380 140
500
330 130 560 710
660 50 510
350 100
150140 480
320 110 160
630 60
620 310 490
610 600
260 170
690 160
680
9813/9400-1
120
40
700 310
180
290 280 220
190 80
100 230
240 210
20 200
170 590 260

270
580 440 540
570
430 420 280
250
432-M0200-7
27 - 13
00 - General
05 - Hybrid Gearbox
27 - Driveline
27 - Driveline
05 - Hybrid Gearbox
00 - General
Table 277.
Item Quantity Description
10 1 Casing-Front-Machining
20 1 Casing - Rear Machining
30 1 G.A. Clutch - Input DTVT
40 1 G.A. Clutch - Output Front DTVT
50 1 G.A. Clutch - Layshaft - DTVT
60 1 G.A. Clutch - Pump DTVT
70 1 G.A. Shaft - Motor DTVT
80 1 G.A. 4Wd Clutch - DTVT
90 1 Spacer Kit
100 4 Dowel
110 1 W.A. Pipe - Layshaft Clutch
120 1 W.A. Pipe - Layshaft Lube
130 1 W.A. Pipe - Bevel Lube
140 8 Copper Washer M12
150 4 Bolt - Banjo M12
160 11 Taper Plug - 1/8 BSP
170 15 Set Screw M10 X 30 G8.8
180 1 Plate Carrier - 4Wd Output
190 1 Needle Roller Brg
200 3 Seal Ring
210 1 Cover - 4Wd
220 1 O Ring
230 1 Bearing-Ball
240 1 Circlip - Internal 80Mm
250 2 Seal - Triple Lip
260 12 Bolt M10 X 100 G8.8
270 2 Coupling Yoke - 1480 DTVT
280 2 Setscrew
290 1 Washer-M16-DTVT
300 1 Stake Nut M30 X 2
310 3 Plug-Relief Valve
320 3 Bonded Washer - 1/2" BSP
330 1 Ga Bevel Pinion & Carrier
340 1 Kit-Bevel Pinion & Gear-DTVT
350 1 Spacer Kit
360 1 Nut - Stake - M42 X 1.5
370 1 Shim Kit (Bevel Gearbox)
380 6 Verbus Ripp Bolt M10X1.5 25L
390 1 Ga Parkbrake - Ausco
400 2 Bolt M10 X 70 G8.8
410 5 Set Screw M10 X 40 G8.8
420 1 Suction Strainer
430 3 Set Screw M8 X 16 Encaps. G8
440 1 Gasket - Suction Strainer
450 1 DTVT Speed Sensor
460 1 Mtg Bracket M10 For Dt04
470 1 Tab Anti Rotation DTVT
27 - 14 9813/9400-1 27 - 14
27 - Driveline
05 - Hybrid Gearbox
00 - General
Item Quantity Description

480 1 Ga Valve Block DTVT
490 1 Gasket - Valve Block
500 14 Cap Screw M8 X 50 G12.9
510 1 Temp Sender
520 1 Switch - Oil Pressure
530 1 Bonded Washer 1/4"BSP
540 1 Washer
550 1 W.A. Bracket - DTVT Harness
560 2 Elbow Adaptor M/M
570 1 G.A. Oil Pump - DTVT
580 4 Cap Screw M6 X 40 G12.9
590 1 Filter Adaptor
600 1 Adaptor-Hose
610 1 Bonded Washer 10Mm
620 1 Adaptor G3/4A-G3/4A
630 1 Bonded Washer
640 1 Adaptor Male/Male
650 1 Bonded Washer
660 1 O Ring Seal
670 1 Adaptor 90 M/F Swivel
680 4 Washer-Copper Sealing
690 2 Bolt - Banjo 1/4 BSP
700 0 Locking Sealant A/R
710 2 Pressure Test Point M10X1
720 1 Pressure Test Point 1/4" BSP
27 - 15 9813/9400-1 27 - 15
27 - Driveline
05 - Hybrid Gearbox
00 - General
Operation
Figure 715.
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
A Front axle B Hydrostatic drive pump

C Engine D Hydraulic services pump
E Rear axle F Hydrostatic drive motor
G Drive output to front axle H Drive output to rear axle
J Clutch/gear M4 K Clutch/gear M3
L Gear M Layshaft gear
N H1 Hydrostatic drive motor disconnect clutch P Hydrostatic drive motor pinion gear
Q 4WD (Four Wheel Drive) output clutch R Hydrostatic pump drive gear
S Gear T Gear
U Clutch/gear M2 V Sensor
W Bevel gear X Front differential
Y Rear differential Z Propeller shaft
1 Park brake 2 Wheels
Operation gearbox output sensor shifts the transmission into

mechanical only mode. The transmission will shift to
The engine transmits power through the bevel a mechanical gear to match the engine speed and
gearbox to the gearbox input shaft. the road speed. The transition from hydrostatic drive
to mechanical drive has been calibrated to be as
A transmission electronic control unit senses the smooth and seamless as possible.
speed of the engine and inputs from the operator
controls of the transmission. The solenoid control valves used to control
the oil flow to the clutches are controlled
When the transmission is engaged, initially it will shift by the transmission electronic control unit. The
into Hydrostatic speed (H1) until the transition road transmission electronic control unit uses a PWM
speed is reached. Refer to the operators manual. (Pulse Width Modulation) signal to progressively
energise or de-energise the clutch solenoids
At this point the transmission electronic control unit depending on the road speed and speed of the
which is calculating the machines speed from the
27 - 16 9813/9400-1 27 - 16
27 - Driveline
05 - Hybrid Gearbox
00 - General
engine. The operator can also limit the highest gear from the hydrostatic motor to the transmission output
selected by the transmission ECU to allow for precise shaft. If required, the 4WD clutch can be engaged
operational requirements. (not shown- see 4WD). The machine can be driven
in hydrostatic mode up to the transition speed.
Clutch H1
Above the transition speed the transmission
Refer to Figure 716. electronic control unit disconnects the drive from the
hydrostatic motor to allow the mechanical clutches to
The engine drives the hydrostatic pump via two drive the geartrain.
constant mesh gears. The oil flows through a
hydraulic pipe to drive the hydrostatic motor and When the vehicle speed drops below the transition
returns via the other pipe. When starting to drive, speed, the electronically controlled mechanical gear
the H1 clutch is engaged which transfers the drive train clutches will be de-energised and the H1 clutch
will re-engage to drive the transmission.
Figure 716. Clutch H1
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch M2 the 4WD clutch can be engaged (not shown- see

4WD).
Mechanical clutch M2 is engaged when the speed of 4WD is automatically engaged when the machine is
the machine is above the transition speed and will set in Auto mode. When the machine is in auto mode,
drive the transmission until a higher gear is selected. if 4WD is switched on, it is engaged for H1, M2, M3
and M4.
M2 is disengaged and the drive flows through the M3
engaged clutch gear to the output shaft. If required,
27 - 17 9813/9400-1 27 - 17
27 - Driveline
05 - Hybrid Gearbox
00 - General
Figure 717. Clutch M2
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch M3 Hydrostatic drive is disengaged and the drive flows

through the engaged clutch gear to the output shaft.
Refer to Figure 718. If required, the 4WD clutch can be engaged (not
shown- see 4WD). In auto mode, the 4WD clutch is
Mechanical clutch M3 is engaged when the speed of disconnected.
the machine is above a preset speed and will drive
the transmission until a higher gear is selected.
27 - 18 9813/9400-1 27 - 18
27 - Driveline
05 - Hybrid Gearbox
00 - General
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch M4 drive the transmission until the machine slows and a

lower gear or hydrostatic drive is required.
M3 is disengaged and the drive flows through the
Mechanical clutch M4 is engaged when the speed engaged clutch gear M4 to the output shaft. If
of the machine is above a preset speed the and will required, the 4WD clutch can be engaged (not
shown- see 4WD).
27 - 19 9813/9400-1 27 - 19
27 - Driveline
05 - Hybrid Gearbox
00 - General
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch 4X4 If required, the 4WD clutch can be engaged in all

gears.
27 - 20 9813/9400-1 27 - 20
27 - Driveline
05 - Hybrid Gearbox
00 - General
Figure 720. Clutch 4X4
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Parkbrake the layshaft and 2 constant mesh gears. 4WD is

disengaged and the park brake operates via the rear
Refer to Figure 721. axle.
All gears are deselected and the gearbox is in H1 clutch is engaged to prevent the transmission
neutral. The Park brake is engaged by the park brake from rolling backwards or forwards when the park
lever via a cable. The output shaft is locked via brake is applied.
27 - 21 9813/9400-1 27 - 21
27 - Driveline
05 - Hybrid Gearbox
00 - General
Figure 721. Park brake
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
27 - 22 9813/9400-1 27 - 22
27 - Driveline
05 - Hybrid Gearbox
00 - General
Diagram
Figure 722. Dual Tech Variable Transmission, Hydraulic Schematic (TLG4330-D)................Page 27-25
27 - 23 9813/9400-1 27 - 23
Notes:
27 - 24 9813/9400-1 27 - 24
27 - Driveline
05 - Hybrid Gearbox
00 - General
Page 27-26 Figure 722. Dual Tech Variable Transmission,

Hydraulic Schematic (TLG4330-D) Page 27-27
6
5
2
13
3 12
8 9 10
14
11
15
16
18
TLG4330-D
17
27 - 25 9813/9400-1 27 - 25
27 - Driveline
05 - Hybrid Gearbox
00 - General
Figure 722. (Part 1 of 2) Page Page
27-26 27-27
Page 27-27
16
18
17
27 - 26 9813/9400-1 27 - 26
27 - Driveline
05 - Hybrid Gearbox
00 - General
27-26 27-27
6
5
13
12
8 9 10
Page 27-26
14
11
15
16
TLG4330-D
27 - 27 9813/9400-1 27 - 27
27 - Driveline
05 - Hybrid Gearbox
00 - General
1 Control piston direction control 2 Cut off valve

3 High pressure valves 4 Dual Tech Variable Transmission Pump
(Case full)
5 Clutch supply pressure 14bar (202.9psi) 6 Clutch feeds
7 Charge pump 8 Pump drain (pump clutch)
9 Valve drain 10 Gearbox lubrication (maximum) pressure
3bar (43.5psi)
11 Oil filter 12 PMV (Pressure Maintenance Valve) Drain-
Bevel box
13 Valve block assembly 14 Bevel box lubrication
15 Transmission 16 Tank
17 Flushing valve 18 Dual Tech Variable Transmission Motor
(Case empty)
PT2 Pump drain PMT Pump drain to motor
R Air bleed MA HP Service line
MB HP Service line X1 Control pressure
X2 Control pressure S Suction
Fa Boost pressure inlet Fb Boost pressure outlet
Yst Pilot pressure MT2 Motor drain
M1 Pilot pressure A HP Service line
B HP Service Line
27 - 28 9813/9400-1 27 - 28
27 - Driveline
05 - Hybrid Gearbox
00 - General
Fault-Finding
Fault
Fault Finding Table 278. Page 27-29
Table 278. Fault Finding

Cause Remedy
Any suspected Dual Tech Variable Transmission Refer to JCB Service for assistance
faults
27 - 29 9813/9400-1 27 - 29
27 - Driveline
05 - Hybrid Gearbox
00 - General
Drain and Fill 3. Remove the access panel to gain access to the
underside of the gearbox. Refer to (PIL 06-06).
CAUTION Oil will gush from the hole when the
drain plug is removed. Keep to one side when you 4. Pace a suitable container below the gearbox
remove the plug. strainer.
5. Remove the gearbox strainer and gasket. Refer
Gearbox- Hydrostatic Drive System to (PIL 27-05-40).
The hydrostatic drive system is supplied from the 6. Drain the oil in to a suitable container for at least
machine main hydraulic oil system and this oil supply the specified time.
is separate from the mechanical part of transmission Duration: 6min
system.
7. Install the gearbox strainer. Refer to (PIL
To remove either the hydrostatic pump or motor you 27-05-40).
will need to drain the machine hydraulic system.
8. If necessary, install a new gearbox (mechanical)
Refer to hydraulic system, tank, (PIL 30-03-00). oil filter. Refer to (PIL 27-39).
Refill Refill
The hydrostatic pump system is installed with a 1. Get access to the gearbox dipstick/filler tube in
priming pipe located on the machine. When the the engine compartment. Refer to (PIL 06-06).
hydrostatic drive system is installed carry out the 2. Clean and remove the dipstick.
following: This procedure assumes the hydraulic
oil tank has already been drained and all safety 3. Fill the gearbox with the correct specification
procedures have been carried out. and quantity of oil to the maximum mark on the
dipstick. Refer to (PIL 75-00).
1. Make sure that all pipes and hoses are correctly
installed. 4. Make sure you do not overfill the gearbox.
2. Fill the machine hydraulic system (this will part 5. Install the dipstick.
fill the hydrostatic system). Make allowance for
the lift arm being raised. Refer to machine, 6. Operate the machine though all the gears for the
description, service point locations, refer to (PIL specified time.
01-09-15) and also (PIL 30-03-00). Duration: 1min
3. Clean the area around the priming tube cap to 7. Recheck the oil level and top up if required.
prevent the ingress of debris. Remove the cap.
8. Check for leaks.
4. Prime the hydrostatic system using the priming
tube. Refer to (PIL 06-06-10). 9. Install all access covers.
5. Make sure you use the same grade of hydraulic
fluid as the main hydraulic system. Refer to (PIL
75-00-00).
6. Install the cap and tighten to the correct torque.
7. Reconnect the battery and start the machine and
run for the specified time.
Duration: 60s
8. Recheck the hydraulic oil level
Gearbox- Mechanical Drive System

Drain
1. Make sure the gearbox is hot.
27 - 30 9813/9400-1 27 - 30
27 - Driveline
05 - Hybrid Gearbox
00 - General
Check (Level) Check (Pressure)

Special Tools
1. Make the machine safe with the boom lowered. Description Part No. Qty.
2. Start the engine and operate at low idle for few Digital Hydraulic 998/11051 1
minutes. This allows the oil to fill the filter, pump, Pressure Test Kit
torque converter, oil cooler and hoses.
WARNING Fine jets of fluid at high pressure can
Duration: 4min penetrate the skin. Keep face and hands well
3. Stop the engine. clear of pressurised fluid and wear protective
glasses. If fluid penetrates your skin, get medical
4. Remove the ignition key. help immediately.
WARNING Before disconnecting any propshaft,
5. Open the engine compartment cover.
make sure you block both sides of all wheels
6. Before you complete a check of the oil level, to prevent machine movement. The park brake
you must wait as shown on the instructional will become ineffective or may only operate on 2
label. The instructional label shows the time in wheels (depending on machine specification).
seconds.
To help with fault identification, record the test results
7. Check the gearbox oil level on the dipstick. The on a check list. The check list will help the engineer to
oil level must be between the end of the dipstick identify the cause of a gearbox fault and if needed it
and maximum mark on the dipstick. can be sent to JCB Technical Service by email. Refer
to technical data, PIL (27-05-00).
8. If necessary add oil through the dipstick tube.
1. Park the machine on a firm level surface.
3. Make sure the lift arm maintenance safety strut
is installed. Refer to PIL (06-69).
4. Remove the machine belly guard. Refer to PIL
(06-06-30).
5. The MH measurement is taken with the propeller
shafts installed and the machine in a stalled
condition by using a suitable method.
6. Remove the front and rear propeller shafts from
the machine. Refer to PIL (27-47 and 27-48).
6.1. Pressure tests must not be carried (except
the MH measurement) out unless the front
and rear propeller shafts are removed.
7. Remove the transmission control valve block
access plate. Refer to PIL (06-06-10).
8. Connect the test equipment as required to
complete the check list. Refer to control valve,
component identification PIL (27-05-19) and
hybrid gearbox, component identification PIL
(27-05-00).
(Qty.: 1)
9. When all testing is completed, install the
transmission control valve block access plate.
Refer to PIL (06-06-10).
27 - 31 9813/9400-1 27 - 31
27 - Driveline
05 - Hybrid Gearbox
00 - General
10. Install the front and rear propeller shafts to the Remove and Install
machine. Refer to PIL (27-47 and 27-48).
11. Install the machine belly guard. Refer to PIL Lifting Equipment
(06-06-30). You can be injured if you use incorrect or faulty lifting
12. Remove the maintenance safety strut and lower be lifted then choose lifting equipment that is strong
the lift arm. Refer to (PIL 01-03). enough and suitable for the job. Make sure that lifting
13. Send the test results to JCB Technical Service equipment is in good condition and complies with all
for review. local regulations.
CAUTION! You can be injured if you use incorrect or
faulty lifting equipment. You must identify the weight
of the item to be lifted then choose lifting equipment
that is strong enough and suitable for the job. Make
sure that lifting equipment is in good condition and
complies with all local regulations.
Remove
2. Remove any attachments that may be installed.
4. Remove the transmission compartment access
covers. Refer to (PIL 06-06-10).
30-00-00).
6. Discharge the brake pressure. Refer to (PIL
24-03-00).
7. Open the engine compartment cover. Refer to
(PIL 06-06).
8. Remove the undershield. Refer to (PIL 06-06).
9. To drain the hydrostatic drive, drain the hydraulic
oil tank. Refer to (PIL 30-03).
10. Drain the gearbox mechanical transmission oil.
11. Remove the engine. Refer to (PIL 15-00).
12. Use a suitable method to support the gearbox
from underneath the machine.
13. Disconnect the propeller shafts. Refer to (PIL
27-47).
14. Disconnect all the hydraulic pipes, breather
pipe and electrical connections to the gearbox
including the following.
14.1. Hose from the valve block to the pump.
14.2. Hoses to the trailer brake valve.
14.3. Oil cooler hoses.
14.4. Gearbox mechanical system filling pipe.
Refer to (PIL 06-06-10) for identification.
27 - 32 9813/9400-1 27 - 32
27 - Driveline
05 - Hybrid Gearbox
00 - General
14.5. Solenoid and sensor connections.

15. Remove the oil cooler hoses.
A
A
A Gearbox mounting locations
16. Remove the gearbox mounts.
17. Manoeuvre the gearbox from the machine.
Install
steps.
1.1. Tighten all fastening and connections to the
correct torque value. Refer to (PIL 72-00).
1.2. Make sure all hoses, pipes and electrical
wiring are routed correctly.
1.3. Fill the hydraulic system. Make sure that
you allow space in the tank for oil to be
returned from the lift arm when it is lowered.
1.4. Bleed the hydrostatic drive system of the
gearbox. Refer to (PIL 27-05-00).
1.5. Refill the gearbox mechanical system with
the correct oil. Refer to (PIL 27-05-00).
1.6. Check the hydraulic oil level and top up if
1.7. Inspect the hydraulic system for leaks.
27 - 33 9813/9400-1 27 - 33
27 - Driveline
05 - Hybrid Gearbox
00 - General
Before following some of the procedures, remove table lists all the service procedures for the gearbox.
the gearbox from its machine installation. Refer to For some procedures it is necessary to do other
the correct machine service documentation. The procedures first, these are shown in the table.
Table 279. Service Procedures List

Step Procedure Name Notes
1 Remove the oil cooler pipework. -
Seal the apertures to prevent the
ingress of debris.
2 Remove the oil filter housing mani- -
fold. Refer to (PIL 30-30-00).
3 Remove the hydrostatic motor and -
pump flexible hoses. Refer to (PIL
27-05-93).
4 Remove the hydrostatic motor and -
pump. Refer to (PIL 27-05-23) and
(PIL 30-13-00).
5 Remove speed sensor to allow the -
transmission to fit in the cradle.
Make sure the transmission is cor-
rectly retained in the cradle. Refer
to (PIL 27-05-27).
6 Remove the parking brake assem- -
bly. Refer to (PIL 24-18-00 ).
7 Remove 4WD (Four Wheel Dri- -
ve) cover and clutch. Refer to
(25-05-07).
8 Remove the plate carrier (4WD
output). Refer to (27-05-07). Slack- A
en the setscrew (A) inside plate

carrier shaft (C) and remove the
shaft and setscrew together. Make
sure you discard this bolt and in-
stall a new one, (the needle roller
bearing (B) will have to be re-
moved and renewed to renew this
setscrew). (For bearing installation
use tool 332/M5883).
9 Remove union. -
27 - 34 9813/9400-1 27 - 34
27 - Driveline
05 - Hybrid Gearbox
00 - General

10 Invert the stand and remove the -
shaft output housing bolts and
small valve block. Watch for the
small "O" Rings.
11 Remove the transmission oil pump.
13 Before further disassembly, mea-

D
sure the motor shaft end float.
Install the push/pull plate 332/
M5714, (and screws 1315/0707Z x
2, 1315/0407Z x 1. 0.01–0.11mm
Install the special tool and measure

the motor shaft end float. Push
down using the specified force and
zero DTI. Then turn torque wrench
around and measure deflection.
The specified force is 38N·m
14 Reposition and use the same tools

to measure the layshaft end float.
27 - 35 9813/9400-1 27 - 35
27 - Driveline
05 - Hybrid Gearbox
00 - General

15 Repositions and use the same
tools to measure the output shaft
end float. The output shaft bearing
is preloaded and deflection should
be zero.
16 Measure the pump clutch shaft end

float
17 Using the special tool, lock off the

bevel pinion gear. Measure bevel
gear backlash. The tool is installed
the opposite side of the transmis-
sion case.
18 Remove output shaft yolk RWD -

(Rear Wheel Drive).
19 Remove bevel gear carrier and
shim. Refer to PIL (27-12).
20 Remove input shaft stake nut and

components. Special tools are re-
quired. Make sure you de-stake
the nut or the shaft will be dam-
aged. Refer to PIL (27-12). Use
tool 332/M6571 and 459/M0155
(and setscrews 1314/0411Z).
27 - 36 9813/9400-1 27 - 36
27 - Driveline
05 - Hybrid Gearbox
00 - General
27 - 37 9813/9400-1 27 - 37
27 - Driveline
05 - Hybrid Gearbox
00 - General
21 Invert the transmission

22 Using the correct lifting equipment,
remove bolts and separate the
gear box housing. Bearing races
are not an interference fit and may
drop out during this procedure.
23 Remove the geartrain components:
24 Remove the pump clutch (1).
1
25 Remove the pump shaft (2) and 1

races. 2
26 Remove the remaining geartrain

components together using the
special lifting bracket (3).
27 - 38 9813/9400-1 27 - 38
27 - Driveline
05 - Hybrid Gearbox
00 - General

27 Install the geartrain on the special
tool and make secure. Remove
the lifting bracket and the compo-
nents can then be removed side-
ways using the slots in the tool be-
fore removing the remaining com-
ponent vertically. Make sure that
no components fall off the tool dur-
ing this procedure. Use tool 332/
M5604 (and bolts 1315/0712Z,
1315/0307Z and 1370/0201Z).
28 Strip gearbox components as re- -

quired:
29 Motor shaft and race. Refer to PIL -
(27-05-57).
30 Pump shaft and race. Refer to PIL -
(27-05-67).
31 Clutch, 4WD Refer to (PIL -
27-05-07).
32 Clutch forward input. Refer to (PIL -
27-05-11).
33 Remove the transmission case
components as required.
34 The installation procedure is the -

opposite of the removal procedure.
Additionally do the following steps:
35a Make sure that all o-rings, seals -
and sealing washers are renewed
and lubricated with clean new
transmission oil.
35b Make sure the transmission and -
its components are kept clean and
free of debris.
35c Make sure that all lubrication paths -
are clean and free of debris
27 - 39 9813/9400-1 27 - 39
27 - Driveline
05 - Hybrid Gearbox
00 - General

35d Make sure that all components are -
inspected.
35e Make sure you check all endfloats -
measurements during assembly.
The endfloats are not adjustable
and components or the transmis-
sion will require replacement if the
endfloats are incorrect. Refer to
JCB service for advice.
27 - 40 9813/9400-1 27 - 40
27 - Driveline
05 - Hybrid Gearbox
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Component Identification

Check (Condition) .......................................... 27-42
Check (Operation) ......................................... 27-42
Adjust ............................................................ 27-43
Figure 724. Clutch- 4WD

E B A J
D F M
C S
P N K
A Clutch Drum M/C B Piston Housing

C Shaft- 4WD (Four Wheel Drive) Output D Seal Ring
E Master- O Ring F Master- O Ring
G Sleeve- Oil Feed- 4WD Shaft H Friction Plate- 4WD
J Counter Plate K Pressure Plate
L Disc Spring M Circlip 1
N Actuating Sleeve 4WD Clutch P Disc Spring
Q Steel Ring R Piston 4WD Clutch
S Shim Plate
27 - 41 9813/9400-1 27 - 41
27 - Driveline
05 - Hybrid Gearbox
Do a visual check of the friction and counter plates Check the clutch pack operates smoothly by carrying
and gears: out an operation check using an airline. Apply the
specified pressure for the specified time and make
Counter plates sure there are no leaks. 10s at 3bar (43.5psi)
1. Light scoring or polishing is permissible, plates

that are not flat, worn or heavily marked or scored
must be replaced with a new one.
Friction plates
1. The lubrication slots should be clearly visible,
plates that are not flat, have friction material
damage or scoring must be replaced with a new
one.
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings.
The piston consists of a small check valve. Visually

check the piston to make sure that the ball is in
place and that the seat is free from contamination.
If necessary clean the valve by blowing through with
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat.
Gears
1. Check the gear teeth for wear, cracking or
damage.
27 - 42 9813/9400-1 27 - 42
27 - Driveline
05 - Hybrid Gearbox
Refer to driveline, hydrostatic gearbox, clutch The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
2WD/4WD, disassemble and assemble. (PIL (Four Wheel Drive) clutch, reverse clutch, mainshaft
27-05-07). clutch and forward / input clutch are all part of the
mainshaft assembly.
1. Install a single shim plate if required to achieve
the specified dimension. Refer to the mainshaft remove and install procedure.
Length/Dimension/Distance: 0.75–1.5mm Refer to (PIL 27-06-54).
Figure 725.
A
A Specified dimension
27 - 43 9813/9400-1 27 - 43
27 - Driveline
05 - Hybrid Gearbox
Disassemble and Assemble 9. Make sure the clutch has the bolt, washer and
coupling yolk installed before doing the following:
CAUTION The spring (or springs) apply
considerable force. Make sure you take care to 9.1. Check the clutch pack operates smoothly
avoid damage or injury. by carrying out an operation check using an
airline. Apply the specified pressure for 10
seconds and make sure there are no leaks.
Refer to driveline, hydrostatic gearbox, clutch
2WD/4WD, (PIL 27-05-07). Pressure: 3bar (43.5psi)
Make a note of the fitted orientation of all the

components to assist in installation.
Discard all o-rings and seals.
1. Remove bolt, washer and coupling yolk (If not

already removed).
2. Remove the oil feed sleeve.
3. Remove the piston housing.
4. Remove the circlip and remove the clutch
pressure, friction and counter plates in their
installed order.
5. Different clutches may have different
specification plates depending on the
application. Make sure that the plates are not
mixed up with plates from other clutches. You
may not be able to distinguish the difference if
the plates have been used.
Assemble
Assembly is the reverse of dismantle, however carry
out the following:
1. Make sure all components are clean.

2. Install new seals and o-rings
3. Make sure all seals and o-rings are lubricated but
do not lubricate anything with grease. Make sure
you use transmission oil only, unless otherwise
stated in the procedure. Refer to (PIL 75).
4. Lightly lubricate all bearings and components
with the correct oil. Make sure you use
transmission oil only unless otherwise stated in
the procedure. Refer to (PIL 75).
5. Take care not to damage seals or o-rings during
assembly.
6. Install the first friction plate up against the clutch
drum.
7. On assembly of the splines, the friction plate
groove pattern is to be aligned.
8. Make sure the clutch plates have the correct
free movement and adjust if required. Refer to
driveline, hydrostatic gearbox, clutch 2WD/4WD,
adjust, (PIL 27-05-07).
27 - 44 9813/9400-1 27 - 44
27 - Driveline
05 - Hybrid Gearbox
11 - Clutch - Forward (Input)
11 - Clutch - Forward (Input) Component Identification

Check (Condition) .......................................... 27-47
Check (Operation) ......................................... 27-47
Adjust ............................................................ 27-48
Figure 726. Clutch- Input (Input Shaft With M3 Clutch)

J G P E F
Q
U A H
B C D
N R Y
V L
X K
T
M
W,X
459-m6574-1
A Gear 42T and plate carrier B Bearing- taper roller

C Gear 35T- input D Input shaft
E Plate- counter, clutch F Plate- friction, clutch
G Circlip- internal H Circlip- external
J Washer- spring retainer K Compression spring
L Oil baffle plate M Piston- clutch
N Circlip- external P Plate- pressure, clutch
Q O-ring R O-ring
S Seal ring T Spacer kit
U Bearing- deep groove ball V Disc spring
W Plate- pressure, clutch X Plate- shim, clutch
27 - 45 9813/9400-1 27 - 45
27 - Driveline
05 - Hybrid Gearbox
Y Bearing- taper roller
27 - 46 9813/9400-1 27 - 46
27 - Driveline
05 - Hybrid Gearbox
Carry out a visual inspection of the friction and Check the clutch pack operates smoothly by carrying
counter plates: out an operation check using an airline. Apply the

must be replaced with a new set.
Friction plates
1. The cross hatching should be clearly visible,
set.
2. DO NOT mix old and new plates, if a plate is
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
cracking. If in doubt install a new disc spring.
27 - 47 9813/9400-1 27 - 47
27 - Driveline
05 - Hybrid Gearbox
Clutch Pack Endfloat Adjustment The layshaft clutch, 2WD / 4WD clutch, reverse
clutch, mainshaft clutch and forward / input clutch are
1. Use a DTI (Dial Test Indicator) as shown, all part of the mainshaft assembly.
measure the end float of the pressure (end) plate,
which should be within the specified tolerances. Refer to the mainshaft remove and install procedure.
Figure 727. For Illustration Purposes
2. If necessary, install a shim between the retaining

circlip and pressure (end) plate to correct end
float inaccuracies. Make sure the pressure plate
is installed with the flattest face against the
circlip.
3. Install the required pressure plate with either
the shim or counter plate installed between the
circlip and pressure plate as required to obtain
the correct endfloat. Refer to Table 280.
Table 280. Clutch Pack Adjustment

Item Size
Pressure plate 6
6.5
Plate- shim, clutch Sized as supplied
Plate- counter, clutch Sized as supplied
27 - 48 9813/9400-1 27 - 48
27 - Driveline
05 - Hybrid Gearbox

considerable force. Make sure you take care to
avoid damage or injury.
Figure 728. Clutch- Input (Input Shaft With M3 Clutch)

J G P E F
Q
U A H
B C D
N R Y
V L
X K
T
M
W,X
459-m6574-1
A Gear 42T and plate carrier B Bearing 1- taper roller

C Gear 35T- input D Input shaft
E Plate- counter, clutch F Plate- friction, clutch
G Circlip 2- internal H Circlip- external
J Washer- spring retainer K Compression spring
L Oil baffle plate M Piston- clutch
N Circlip 1- external P Plate- pressure, clutch
Q O-ring R O-ring 1
S Seal ring 1 T Spacer kit
U Bearing 2- deep groove ball V Disc spring
W Plate- pressure, clutch X Plate- shim, clutch
Y Bearing 3- taper roller
27 - 49 9813/9400-1 27 - 49
27 - Driveline
05 - Hybrid Gearbox
Refer to driveline, hydrostatic gearbox, clutch Figure 729. For illustration only
forward (input), component identification. Refer to:
PIL 27-05-11. 11 11
Make a note of the fitted orientation of all the 12
1. Starting at the left hand side of the illustration.

13
2. Remove the seal rings 1 Y 13A

3. Remove the taper bearing 1 using the correct
tool.
4. Remove the circlip 1.
5. Remove the 42T gear and plate carrier from the
shaft together with the ball bearings 2.
6. Remove the circlip 2 and remove the pressure
plate, clutch friction and counter plates in their
installed order.
specification plates depending on the 11 Circlip
application. Make sure that the plates are not 12 Spring retaining plate
mixed up with plates from other clutches. You 13A Oil baffle plate
may not be able to distinguish the difference if Y Cut away tube
the plates have been used. 9. Remove the washer, spring, and oil baffle
8. Position the clutch assembly in a press. Use a together.
cutaway tube to compress the piston spring then 10. Remove the o-ring 1 from the shaft.
remove the circlip.
11. Remove the 35T input gear
12. Remove the taper bearing 3 using the correct tool
13. Remove the clutch piston assembly from the
shaft
14. Remove and discard the piston and shaft O-
rings.
Assemble
out the following:

you use transmission oil only unless otherwise
stated in the procedure.
Refer to: PIL 75.
the procedure.
27 - 50 9813/9400-1 27 - 50
27 - Driveline
05 - Hybrid Gearbox
Refer to: PIL 75.

assembly.
6. Make sure the clutch pack pressure plate is
installed with the flattest face against the circlip
2. Refer to X. Refer to Figure 728.
adjust,
8. Check the clutch pack operates smoothly by
carrying out an operation check using an airline.
Apply the specified pressure for 10 seconds and
make sure there are no leaks.
9. Carry out a pressure check.
27 - 51 9813/9400-1 27 - 51
27 - Driveline
05 - Hybrid Gearbox
15 - Solenoid Control Valve
15 - Solenoid Control Valve Introduction

Introduction .................................................... 27-52 The solenoid control valves provides the switching
Check (Condition) .......................................... 27-53 for forward drive and reverse drive to select the
direction of travel.
On some transmission systems the solenoid control

valves are also used for gear selection and 2WD
(Two Wheel Drive) / 4WD (Four Wheel Drive)
selection.
27 - 52 9813/9400-1 27 - 52
27 - Driveline
05 - Hybrid Gearbox
Check (Condition)
If damage to any component or distortion of the

spool is evident the complete valve assembly must
be renewed. Great care should be taken when
dismantling and assembling the valve to avoid the
following:
• Contamination
• Damage to spools
• Damage to seal grooves
Any of the above may result in possible problems

with the operation of the valve.
27 - 53 9813/9400-1 27 - 53
27 - Driveline
05 - Hybrid Gearbox
18 - Pressure Relief Valve
Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due
to a fault in the system.
The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.
27 - 54 9813/9400-1 27 - 54
27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
19 - Control Valve Component Identification

Figure 730. Valve Block

F J
C M
H L
K
B D E
A
N
G
O
V R Q
U T S
P
A Oil pressure switch B Test point- H1

C Test point- Trans feed D Test point- 4WD (Four Wheel Drive)
E Test point- M3 F Test point- Tans lube
G Test point- M2 H Inlet elbow
J Breather (Hose not installed) K Test point- M4
L Outlet elbow M Cap screw (X14)
N Valve- PRV (Pressure Relief Valve) O Banjo bolt
P Valve- PMV (Pressure Maintenance Valve) Q Temperature sender
R Solenoid valve- proportional M4 S Solenoid valve- proportional M2
T Solenoid valve- proportional M3 U Solenoid valve- on/off valve 4WD
V Solenoid valve- proportional H1
27 - 55 9813/9400-1 27 - 55
27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
Remove and Install
Remove hoses and the pressure test points are remotely

located.
Before you start the removal procedure, pressure
wash all dirt and debris from the external case of the 4. Mark for correct replacement, remove the hoses
gearbox. Make sure that the electrical and hydraulic from the pressure points, plug the hoses and cap
connections are protected from any chemicals used the adaptors to prevent ingress of dirt.
in the wash equipment. 5. When you remove the cap screws, slacken
progressively and in a logical opposing sequence
1. Disconnect the wiring connectors from each of
to prevent distortion of the aluminium valve block.
the solenoid valves.
6. Remove and discard the gasket between the
2. Disconnect the hydraulic hose, plug the hose and
valve block and the gearbox case.
cap the adaptor.
7. Lift and remove the valve block.
3. The illustration shows self seal pressure test
points positioned on the valve, on some 8. Prevent ingress of debris in to the mating face on
machines they may be replaced with microbore the transmission.
Figure 731.
G C
B D
F E
A
A Solenoid valve connections (x5) B Hydraulic hose connections (x2)

C Cap screws (x14) D Banjo bolt
E Oil pressure sender F Temperature sender
G Pressure test points (x7)
27 - 56 9813/9400-1 27 - 56
27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
Install
Installation is the opposite of the removal procedure
with the following precautions.
1. Make sure that all surfaces and components are

clean and free of debris.
2. Position the new gasket on the case.
3. Position the valve block using a capscrew as a
guide.
4. Install the fixing screws into the remaining
positions.
5. Tighten in an opposing pattern from the
centre outwards to prevent the valve becoming
distorted.
6. Reconnect the hydraulic hoses to the pressure
test points (if required) in the correct positions as
marked on the removal.
27 - 57 9813/9400-1 27 - 57
27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
Valve Block
The valve block is a single block type, The illustration
is intended as a guide to identify the components.
Be sure to note the location of all components when

you disassemble. Although some components may
appear to be identical, they are not interchangeable.
Make sure that components are assembled in their
original positions.
Great care should be taken when you disassemble

and assemble a valve to avoid the following:
• Contamination
• Damage to spools
• Damage to seal grooves

with the operation of the valve.
Disassemble
1. Remove the valve block from the machine. Refer
to remove and install, (PIL 27-05-19).
2. Place the valve block on a suitable surface that
will not damage the valve.
3. Using the correct tools, remove the desired
components.
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. When you assemble, also do the following steps:
2.1. Make sure that the components are
thoroughly clean before assembly.
2.2. Renew any seals or gaskets. Make sure
that the seals are not trapped or damaged.
2.3. Lubricate parts with the correct JCB
hydraulic fluid before assembling. Make
sure that all the parts move freely.
27 - 58 9813/9400-1 27 - 58
27 - Driveline
05 - Hybrid Gearbox
21 - Pressure Maintenance Valve (PMV)
21 - Pressure Maintenance Valve

(PMV)
Introduction
Refer to driveline, hydrostatic gearbox, general, (PIL

27-05-00).
27 - 59 9813/9400-1 27 - 59
27 - Driveline
05 - Hybrid Gearbox
23 - Motor
23 - Motor Introduction
Introduction .................................................... 27-60 The axial piston variable motor converts hydrostatic
Component Identification ............................... 27-61 flow into mechanical rotation.
Operation ....................................................... 27-61
Fault-Finding .................................................. 27-63 The hydraulic flow to the motor can be reversed to
depending on the direction of travel required.
Bleed ............................................................. 27-64
27 - 60 9813/9400-1 27 - 60
27 - Driveline
05 - Hybrid Gearbox
23 - Motor

Figure 732. Layout of the Axial Piston Unit The A6VM is a variable motor with axial piston rotary
group of bent-axis design, for hydrostatic drives in
open and closed circuits. For axial piston units with
bent axis design, the pistons are arranged askew to
the drive shaft. The pistons rest directly on the drive
B
shaft where they generate torque depending on the
A pressure and swivel angle. The specific torque and
displacement can be changed by adjusting the bent
axis.
Open Circuits (If Installed)

In an open circuit, the hydraulic fluid flows from
the reservoir to the hydraulic pump from where
G it is transported to the hydraulic motor. From the
C hydraulic motor, the hydraulic fluid flows directly back
to the reservoir. The output direction of rotation of the
F hydraulic motor can be changed, e.g. by a directional
E D valve.
A Drive shaft Closed Circuit (If Installed)

B Control piston
C Stroke piston In the closed circuit, the hydraulic fluid flows from
D Port plate the hydraulic pump to the hydraulic motor and
E Lens plate from there directly back to the hydraulic pump. The
F Cylinder output direction of rotation of the hydraulic motor is
G Piston changed, e.g. by reversing the flow direction in the
hydraulic pump.
Figure 733.
B
G
C
F
E D
A Drive shaft
B Control piston
C Stroke piston
D Port plate
E Lens plate
F Cylinder
G Piston
27 - 61 9813/9400-1 27 - 61
27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Motor Function
A hydraulic motor converts hydrostatic energy into
mechanical energy. Hydraulic fluid is directed via the
port plate and the lens plate to the cylinder bores.
The pistons in the cylinder bores execute a stroke
that is converted into rotary movement by the piston
on the drive shaft flange. During this process, the
pistons move the cylinder and generate an output
torque at the drive shaft. The output torque increases
with the pressure difference between the high- and
low-pressure sides and increasing displacement.
The output speed is proportional to the inward flow
and inversely proportional to the displacement of the
hydraulic motor.
Control
The swivel angle of the bent-axis rotary group is
steplessly variable. With two-point control (HZ, EZ),
the swivel angle can be switched from maximum
to minimum angle. Control of the swivel angle of
the bent-axis rotary group changes the piston stroke
and therefore the displacement. The swivel angle
is controlled hydraulically by the stroke piston. The
cylinder,including the piston and lens plate, is then
swiveled. The lens plate is mounted for easy motion
in a guideway. Increasing the swivel angle results
in an increase in the displacement and specific
torque; decreasing the swivel angle results in a
corresponding decrease of these values. The output
speed is dependent on the input flow and the
displacement of the hydraulic motor.
27 - 62 9813/9400-1 27 - 62
27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Fault-Finding
Fault
Motor Operation Is Noisy Under Load Table 281. Page 27-63
Motor Operation Is Noisy Without Load Table 282. Page 27-63
Motor Does Not Revolve Table 283. Page 27-63
Motor Sluggish Under Load Table 284. Page 27-63
Motor Revolves Irregularly Table 285. Page 27-63
Hydraulic Leak at Motor Table 286. Page 27-63
Table 281. Motor Operation Is Noisy Under Load

Cause Remedy
Excessive internal leaks. Replace the cylinder block and valving assembly.
Table 282. Motor Operation Is Noisy Without Load

Cause Remedy
Worn bearing support. Replace the motor bearing support.
Vibration- mountings and / or hydraulic piping has Torque tighten motor mountings and hydraulic piping.
become loose.
Table 283. Motor Does Not Revolve

Cause Remedy
No hydraulic fluid flow to the motor. Check the pump drive for correct operation and
pump outlet pressure.
The hydraulic circuit does not reach working Check the circuit for leaks.
pressure.
Brake remains engaged. Check the brake pilot circuit.
Table 284. Motor Sluggish Under Load

Cause Remedy
Low pump flow to the motor. Check the pump drive speed.
The hydraulic circuit does not reach working Check the circuit for leaks.
pressure.
Faulty replenishing (charge pressure) circuit. Check the replenishing circuit.
Table 285. Motor Revolves Irregularly

Cause Remedy
Irregular pump flow. Check the pump flow.
Table 286. Hydraulic Leak at Motor

Cause Remedy
Hydraulic pressure within the motor housing is too Check the drain circuit and filter for blockages.
high.
Deterioration / damage to seals. Replace seals.
Incorrect assembly of motor unit. Check the tightness of all bleed screws, mounting
screws and hydraulic fittings. Torque tighten where
required.
27 - 63 9813/9400-1 27 - 63
27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Bleed Remove and Install

Refer to Driveline, Hybrid Gearbox, General, Drain be removed or handled using a suitable lifting
and Fill, (PIL 27-05-00). method and device.
Refer to driveline, hydrostatic gearbox, motor,

remove and install, (PIL 27-05-23).
Removal
2. Vent the hydraulic system, refer to the machines
operator manual. Also refer to (PIL 30-00-00).
3. Isolate the machines battery, refer to (PIL
33-03-03).
4. Make the pump is cool enough to work on.
5. If required on your machine, seal the connection
to the tank to prevent loss of fluid.
6. Label and remove the hydraulic and electrical
connections. Use suitable containers to collect
the displaced fluid.
7. This component is heavy, make sure you
attach suitable lifting equipment and remove
the pump retaining bolts. Refer to hydraulic
system, hydrostatic pump, general, introduction,
technical data (PIL 30-13-00).
8. Empty the pump of fluid over a suitable container
and place the pump on a suitable surface.
9. Plug all openings to prevent the ingress of debris.
10. The pump may subsequently be moved by use
of a suitable eyebolt in the shaft.
Installation
Installation is the reverse of removal. In addition carry
out the following procedures:
1. Make sure the hydraulic fluid level is correct

when installation is complete.
2. Make sure all connections are correct according
to the labels made during removal.
3. Bleed the pump. Refer to hydraulic system,
general, bleed, (PIL 30-00-00).
27 - 64 9813/9400-1 27 - 64
27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Refer to JCB Service for advice.
27 - 65 9813/9400-1 27 - 65
27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump
24 - Oil Pump Introduction

Introduction .................................................... 27-66 The oil pump supplies the mechanical gearbox
Component Identification ............................... 27-67 components of the transmission.
Check (Condition) .......................................... 27-67
Remove and Install ....................................... 27-68 It is not part of the hydrostatic drive system of the
transmission.
27 - 66 9813/9400-1 27 - 66
27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump

Figure 734. Dual Tech Vari-
able Transmission Oil Pump
Check (Condition)
C D A pump which is damaged or worn can cause
B damage to the gearbox.
1. Remove the pump from the transmission. Refer

A to Driveline, Oil Pump, Remove and Install, (PIL
27-24).
2. Remove the pump assembly screws.
3. Separate the pump body.
4. Carefully check for any signs of wear or damage
on the gear teeth, white metal bearing and gear
mating faces. If any signs of wear or damage is
visible then you must replace the pump with a
new one.
C
E
F
A Transmission oil pump
B Hydrostatic pump mounting flange
C Dual Tech Variable Transmission
D Hydrostatic motor mounting flange
E Hydrostatic pump
F Hydrostatic motor
27 - 67 9813/9400-1 27 - 67
27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump

A
C
B Remove
B
CAUTION! This component is heavy. It must only
method and device.
1. Remove the hydrostatic pump assembly. Refer

to Hydraulic System, Hydrostatic Pump, General,
Remove and Install, (PIL 30-13-00).
2. Remove the securing screws.
3. Use the jacking screw hole to remove the pump
from the transmission case.
B 4. Check the condition of the pump. Refer to

Driveline, Hydrostatic Gearbox, Oil Pump, Check
B (Condition), (PIL 27-24-00).
E
E D
A Oil pump body (front)
B Securing screw
C Jacking screw hole
D Oil pump body (rear)
E Oil pump assembly screw
5. Renew any gaskets or seals (if installed).
6. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.

Item Nm
E 4
27 - 68 9813/9400-1 27 - 68
27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump
Figure 736. 6. Torque all bolts progressively in a criss-cross

A sequence, to the specified amount until the final
C torque is reached.
B 6.1. Specified torque per tightening sequence
B
Torque: 5N·m
6.2. Specified torque final torque to attain
Torque: 9.5–16.2N·m
7. Make sure the pump is free to rotate when it has
been installed.
8. Install the hydrostatic drive pump. Refer to
Hydraulic System, Hydrostatic Pump, General,
Remove and Install, (PIL 30-13-00).
B
B
E
E D
A Oil pump body (front)
B Securing screw (X4)
C Jacking screw hole (X1)
D Oil pump body (rear)
E Oil pump assembly screw
Install
1. If the existing pump is to be installed,
check the condition of the pump. Refer to
Driveline, Hydrostatic Gearbox, Oil Pump, Check
(Condition), (PIL 27-24-00).
2. Lubricate the pump with the correct clean oil.
3. Make sure the pump is free to rotate before
installation. Do not install it if it is not free to rotate.
4. Install the pump over the input shaft. Make sure
that the bolt holes are aligned.
5. Install the bolts and finger tighten.
27 - 69 9813/9400-1 27 - 69
27 - Driveline
05 - Hybrid Gearbox
27 - Speed Sensor
27 - Speed Sensor Technical Data

Technical Data ............................................... 27-70 Table 288.
Type Magnetic gear tooth
Remove and Install ....................................... 27-71 sensor
Air gap 1.03–2.03mm
Output frequency 0–5Hz
27 - 70 9813/9400-1 27 - 70
27 - Driveline
05 - Hybrid Gearbox
27 - Speed Sensor
Component Identification Remove and Install

Figure 737. Dual Tech Variable Trans-
mission- Transmission Speed Sensor
Remove
B
3. Refer to driveline, hydrostatic gearbox,
component identification, (PIL 27-05-27).
4. Disconnect the electrical connector to the wiring
harness.
5. Remove the sensor retaining screw from the
transmission end of the sensor.
6. Withdraw the sensor from the transmission.
7. Make sure no debris can enter the transmission.
Install
Installation is the reverse of removal. Also carry out
the following steps:
1. Install a new o-ring seal if the sensor is to be re-

installed.
2. Tighten the sensor fastener to the specified
torque.
Torque: 11.3N·m
B
A
A Dual Tech Variable Transmission

B Dual Tech Variable Transmission speed sensor
27 - 71 9813/9400-1 27 - 71
27 - Driveline
05 - Hybrid Gearbox
30 - Oil Pressure Sensor
30 - Oil Pressure Sensor Introduction

Introduction .................................................... 27-72 This sensor detects the fluid pressure inside the
Technical Data ............................................... 27-73 gearbox. This is used for diagnostic purposes
Component Identification ............................... 27-73 to check the transmission fluid is at the correct
Remove and Install ....................................... 27-74 pressure.
27 - 72 9813/9400-1 27 - 72
27 - Driveline
05 - Hybrid Gearbox
Table 289. Figure 738. Oil Pressure Switch

Switch contact closing 2.76 ± 0.69 (40.0 ± 10.0)
set pressure
(1)
Contacts Normally closed

Size of sensor body 24mm
(across flats)
(1) Falling pressure at the specified temperature.
20°C (68.0°F) B A
A Pin 1 (+ve)
B Pin 2 (-ve)
27 - 73 9813/9400-1 27 - 73
27 - Driveline
05 - Hybrid Gearbox
Remove and Install
Remove 2. Unscrew the pressure sensor and remove the

sealing washer.
1. Clean off all debris, dirt and grit from around the
pressure sensor. Do not allow particles of grit to
fall into the valve block.
Figure 739.
A Pressure sensor B Sealing washer
27 - 74 9813/9400-1 27 - 74
27 - Driveline
05 - Hybrid Gearbox
C Valve block
Install
steps:
2. The oil pressure sensor is a non-serviceable
component. If it is faulty or damaged, it must be
renewed.
4. Tighten the pressure sensor to the correct torque
value.

Item Nm
A 16
27 - 75 9813/9400-1 27 - 75
27 - Driveline
05 - Hybrid Gearbox
33 - Oil Temperature Sensor
33 - Oil Temperature Sensor Introduction

Introduction .................................................... 27-76 This sensor determines the fluid temperature inside
Technical Data ............................................... 27-77 the gearbox. This is used for diagnostic purposes
Component Identification ............................... 27-78 to check the transmission fluid is at the correct
Remove and Install ....................................... 27-79 temperature.
27 - 76 9813/9400-1 27 - 76
27 - Driveline
05 - Hybrid Gearbox
Technical Data
Table 291.
Thread size 9/16-18 UNF
Table 292. Resistance vs Temperature

Temperature Resistance (Ohms)
-40°C (-39.9°F) 842.7Ω
-30°C (-22.0°F) 882.2Ω
-20°C (-4.0°F) 921.6Ω
-10°C (14.0°F) 960.9Ω
0°C (32.0°F) 1,000Ω
10°C (50.0°F) 1,039Ω
20°C (68.0°F) 1,077.9Ω
30°C (86.0°F) 116.9Ω
40°C (103.9°F) 1,155.4Ω
50°C (121.9°F) 1,194Ω
60°C (139.9°F) 1,232.4Ω
70°C (157.9°F) 1,270.7Ω
80°C (175.9°F) 1,308.9Ω
90°C (193.9°F) 1,347Ω
100°C (211.9°F) 1,385Ω
110°C (229.8°F) 1,422.9Ω
120°C (247.8°F) 1,460.6Ω
27 - 77 9813/9400-1 27 - 77
27 - Driveline
05 - Hybrid Gearbox
Figure 740. Dual Tech Variable Transmission- Temperature Sensor
A B
1 2
A Pin 1 B Pin 2
C Temperature sensor D Valve block
27 - 78 9813/9400-1 27 - 78
27 - Driveline
05 - Hybrid Gearbox
Remove and Install
Remove
Refer to driveline, hydrostatic gearbox, oil
temperature sensor, component identification, (PIL
27-05-33).
temperature sensor. Do not allow particles of grit
to fall into the gearbox
2. Unscrew the temperature sensor and remove the
sealing washer.
Install
Replacement is the opposite of the removal
procedure. During the replacement procedure do the
following work:
1. The oil temperature sensor is a non serviceable

component. If it is faulty or damaged, it must be
renewed.
3. Tighten the temperature sensor to the specified
torque value.
Torque: 16N·m
27 - 79 9813/9400-1 27 - 79
27 - Driveline
05 - Hybrid Gearbox
39 - Filter
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 9813/9400-1 27 - 80
27 - Driveline
05 - Hybrid Gearbox
39 - Filter
Special Tools
Oil Filter Removal Tool 892/00292 1
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20L
4000/2603 200L
For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).
Remove
1. Clean the area around the filter. Do not allow
particles of grit to fall into the gearbox. A
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.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
Consumable: JCB Transmission Fluid EP SAE
30
2. Screw the filter on until it just contacts the filter
head.
3. Turn the filter at least another 3/4 of a turn.
27 - 81 9813/9400-1 27 - 81
27 - Driveline
05 - Hybrid 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 9813/9400-1 27 - 82
27 - Driveline
05 - Hybrid Gearbox

Item Nm
Consumables
Description Part No. Size B 12
Strength)
Remove
1. Clean the area around the strainer. Do not allow
particles of grit to fall into the gearbox.
2. Place a container, of suitable size beneath the
suction strainer. Remove the bolts. Remove the
strainer and the gasket. Allow the oil to drain into
the container. Be aware that the oil may be hot.
Refer to Gearbox, Drain and Fill (PIL 27-06).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 742.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
threads of the bolts. Tighten the bolts to the
(Medium Strength)
27 - 83 9813/9400-1 27 - 83
27 - Driveline
05 - Hybrid Gearbox
42 - Dipstick
42 - Dipstick
Figure 743. Dual Tech Variable Transmission- Dipstick

C
A
B
A Engine B Dual Tech Variable Transmission

C Dipstick and dipstick tube
27 - 84 9813/9400-1 27 - 84
27 - Driveline
05 - Hybrid Gearbox
45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................... 27-85 A piston ring is a split ring that fits into a groove on
Remove and Install ....................................... 27-86 the outer diameter of a piston
27 - 85 9813/9400-1 27 - 85
27 - Driveline
05 - Hybrid Gearbox
Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Assemble procedure (PIL 27-06).
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 744.
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 745.
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 - 86 9813/9400-1 27 - 86
27 - Driveline
05 - Hybrid Gearbox
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................... 27-87 Oil seals close spaces between components in
Remove and Install ....................................... 27-88 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 - 87 9813/9400-1 27 - 87
27 - Driveline
05 - Hybrid Gearbox
47 - Oil Seal

1. Make sure that the oil seal interface on the yoke
Remove is clean and free from wear or damage.
1. Bend back the stake nut locking ring. 2. Install a new oil seal. Locate the seal in the
position shown, the seal does not locate to the
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
3. Lubricate the lips of the oil seal.
3. Remove the oil seal. Do not damage the seal
housing. 4. Install the yoke, refer to Gearbox, Yoke- Remove
and Install (27-06-95).
Figure 746.
5. Install a NEW stake nut. Tighten to the correct
torque value.
6. Stake the nut to the shaft using a square ended
staking tool, as shown.

Item Nm
B 400
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
27 - 88 9813/9400-1 27 - 88
27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
62 - Clutch - Pump Component Identification

Check (Condition) .......................................... 27-92
Adjust ............................................................ 27-92
Figure 747. Clutch- Pump (Pump Shaft With M4 Clutch) (459/M7618-1)
Y
F
Q
G
A
N
W D
T
L
C
E
V
S B
M
K
U, Z H
P, X J
27 - 89 9813/9400-1 27 - 89
27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Item Description
M O-Ring
Table 295.
N G.A. Piston- Clutch
Item Description
P Plate-Pressure-Clutch
A Gear- 44T & Plate Carri-
Q Circlip 150mm- Internal
er
R Bearing- Needle Thrust
B Bearing-Taper Roller
Assy S Seal Ring 50mm
C Washer- Thrust T Washer- Bevelled-
Thrust
D Gear 39T- Pump Drive
Shaft U Washer- Thrust
E Pump Drive Shaft V Compression Spring
F Plate-Counter-Clutch W Washer- Spring Retainer
G Plate-Friction-Clutch X Plate-Pressure-Clutch
H Oil Baffle Plate Y Plate-Shim-Clutch
J Circlip- External Z Washer- Thrust
K Bearing- Needle Roller
L O-Ring
Figure 748.
20
40
50
130
110
60
80
120 140
240
230
150
70 200
210
90
190
160
180
100
170
180
160
30
250
20
10
459-M7618-1
27 - 90 9813/9400-1 27 - 90
27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Table 296.
10 Gear- 44T & Plate Carri-
er
20 Bearing-Taper Roller
Assy
30 Washer- Thrust
40 Gear 39T- Pump Drive
Shaft- HMH
50 W.A. Pump Drive Shaft-
HMH
60 Plate-Counter-Clutch
70 Plate-Friction-Clutch
80 Oil Baffle Plate
90 Circlip- External
100 Bearing- Needle Roller
110 O-Ring
120 O-Ring
130 G.A. Piston- Clutch
140 Plate-Pressure-Clutch A/
R 6mm
150 Circlip 150mm- Internal
160 Bearing- Needle Thrust
170 Seal Ring 50mm
180 Washer- Bevelled-
Thrust
190 Washer- Thrust
200 Compression Spring
210 Washer- Spring Retainer
R 6.5mm
240 Plate-Shim-Clutch A/R
250 Washer- Thrust A/R
3.53mm
27 - 91 9813/9400-1 27 - 91
27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Check (Condition) Adjust
Do a visual check of the friction and counter plates Refer to driveline- hydrostatic gearbox, refer to (PIL
and gears: 27-05-62).
Counter plates If required, install a pressure plate of the specified

value along with a shim or counter plate. Install the
1. Light scoring or polishing is permissible, plates shim or counter plate between the circlip and the
that are not flat, worn or heavily marked or scored pressure plate.6–6.5mm
Make sure that the free movement on the clutch plate
is between the specified value. 1.9–2.5mm
Friction plates
one.

Gears
damage.
27 - 92 9813/9400-1 27 - 92
27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Remove and Install Disassemble and Assemble

Special Tools
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD Description Part No. Qty.
(Four Wheel Drive) clutch, reverse clutch, mainshaft Spring Compressor 892/00916 1
clutch and forward / input clutch are all part of the Tool
mainshaft assembly.
Refer to the mainshaft remove and install procedure.
Refer to driveline, hydrostatic gearbox, clutch pump,

component identification (PIL 27-05-62).
Make a note of the orientation of all the components

to assist in installation.
Discard all O-rings and seals.
1. Remove the taper roller bearing using the correct

tool from both the sides.
2. Remove the 39T gear from the pump drive shaft.
3. Remove the thrust washer 1.
4. Remove the needle thrust bearing and the
bevelled thrust washer.
shaft together with the needle roller bearing.
6. Remove the clutch pack retaining circlip.
7. If installed, remove the thrust washers 2.
8. Remove the clutch friction and counter plates in
their installed order.
8.1. Different clutches may have different
application. Make sure that the plates
are not mixed up with plates from other
clutches. You may not be able to distinguish
the difference if the plates have been used.
10. Position the clutch assembly in a press. Use a
cutaway tube to compress the piston spring then
remove the external circlip.
27 - 93 9813/9400-1 27 - 93
27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Figure 749. For illustration only transmission oil only unless otherwise stated in
11 11
5. Take care not to damage seals or O-rings during
12 assembly.
6. Make sure that the 44T gear and plate carrier can
rotate freely on the assembly.
13 6.1. Make sure that the thrust washer is of the
thickest size.
Y 13A Length/Dimension/Distance: 3.7mm
6.2. If the 44T gear and plate carrier does
not rotate freely, install the thinner thrust
washer.
6.3. Recheck for free rotation.
installed with the flattest face against the circlip.
8. Make sure that the clutch plates have the correct
11 Circlip driveline- hydrostatic gearbox- clutch pump, refer
12 Spring retaining plate to (PIL 27-05-62).
13A Oil baffle plate
Y Cut away tube 9. Check the clutch pack operates smoothly by
10.1. If no press is available, use the spring Apply the specified pressure for 10 seconds and
compressor tool. Position the feet of the make sure there are no leaks.
tool underneath the circlip. Install the C- Pressure: 3bar (43.5psi)
plate over the spring retaining plate, use
the two bolts to relieve spring tension and 10. Carry out a pressure check. Refer to (PIL
remove the circlip. 27-05-62).
Special Tool: Spring Compressor Tool
(Qty.: 1)
11. Remove the spring retainer washer, spring, and
oil baffle together.
12. Remove the shaft O-rings from the shaft.
Assemble
The assembly procedure is the opposite of the
disassembly procedure. When you assemble, do the
following steps also:

2. Install new seals and O-rings
3. Make sure that all seals and O-rings are
lubricated but do not lubricate anything with
grease. Make sure you use transmission oil only
unless otherwise stated in the procedure. Refer
to (PIL 75).
4. Lightly lubricate all the bearings and components
27 - 94 9813/9400-1 27 - 94
27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
63 - Clutch - Motor Component Identification

Check (Condition) .......................................... 27-98
Check (Operation) ......................................... 27-98
Adjust ............................................................ 27-99
Figure 750. Clutch- Motor (Layshaft With H1 Clutch) (459/M5179-2)
Y,Z
K A
B Q
U L
R
C H,X E D
N
G
T
J
S
V F
M
W
Item Description
Table 297. G Bearing- Needle Thrust
Item Description H Washer- Thrust
A Gear- 48T & Plate Carri- J Circlip- External
er K Plate-Counter (2.5mm)
B Clutch Housing Layshaft L Plate-Friction-Clutch
C Bearing-Taper Roller M Circlip 150mm- Internal
Assy
N O-Ring
D Bearing-Taper Roller
P Seal Ring- Dia 35
Assy
Q Bearing- Needle Roller
E Layshaft
R O-Ring
F Washer- Bevelled-
Thrust S Compression Spring
27 - 95 9813/9400-1 27 - 95
27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
Item Description Item Description

T Oil Baffle Plate X Washer- Thrust
U Washer- Spring Retainer Y Plate-Pressure-Clutch
V Piston- Clutch Z Plate-Pressure-Clutch
W Plate-Shim-Clutch
Figure 751. Clutch- Motor (459/M5179-2)
40
50
140 10
80
70
60
160 130
60 100
70 110
80
90
210
190
200
280
270
240
170
220
20
250
30
150
459-M5179-2
70 Bearing- Needle Thrust

Table 298. 80 Washer- Thrust
10 Gear- 48T & Plate Carri- 90 Circlip- External
er 100 Plate-Counter (2.5mm)
20 Wa.Clutch Housing 110 Plate-Friction-Clutch
Layshaft HMH 130 Circlip 150mm- Internal
30 Bearing-Taper Roller 140 O-Ring
Assy 150 Seal Ring- Dia 35
40 Bearing-Taper Roller 160 Bearing- Needle Roller
Assy
170 O-Ring
50 Layshaft- HMH
190 Compression Spring
60 Washer- Bevelled-
Thrust 200 Oil Baffle Plate
27 - 96 9813/9400-1 27 - 96
27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
210 Washer- Spring Retainer

220 G.A. Piston- Clutch
240 Plate-Shim-Clutch
250 Washer- Thrust A/R
3.53mm
270 Plate-Pressure-Clutch
280 Plate-Pressure-Clutch
27 - 97 9813/9400-1 27 - 97
27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor

Friction plates
one.

Gears
damage.
27 - 98 9813/9400-1 27 - 98
27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
1. Use a DTI as shown, measure the end float of all part of the mainshaft assembly.
the pressure (end) plate, which should be within
the specified tolerances. Refer to the mainshaft remove and install procedure.

circlip.

Item Size
Pressure plate 6
6.5
27 - 99 9813/9400-1 27 - 99
27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
Disassemble and Assemble Figure 753. For illustration only
Special Tools 11 11
Bearing Press 892/00179 1 12

avoid damage or injury. 13
Refer to driveline, hydrostatic gearbox, clutch

Y 13A
2WD/4WD, component identification. Refer to: PIL
27-05-07.

Discard all o-rings and seals. Always install new

ones.
1. Remove the taper bearing using the correct tool.

2. Remove the thrust washer.
3. Remove the 53T gear and plate carrier from the 11 Circlip
shaft together with the needle roller bearing. 12 Spring retaining plate
13A Oil baffle plate
4. Remove the needle thrust washer and washer Y Cut away tube
from the shaft (if not inside the 53T gear hub).
8. Remove the washer, spring, and oil baffle
5. Remove the clutch pack retaining circlip and together.
remove the clutch friction and counter plates in
their installed order. 9. Remove the shaft o-rings from the shaft (X3).
6. Different clutches may have different 10. Remove the taper bearing using the correct tool
application. Make sure that the plates are not 11. Remove the 47T output gear from the shaft using
mixed up with plates from other clutches. You moderate force to overcome the clutch piston
may not be able to distinguish the difference if seal rings. The clutch piston assembly will remain
the plates have been used. on the shaft.
7. Position the clutch assembly in a press. Use a 12. Remove the clutch piston assembly from the
cutaway tube to compress the piston spring then shaft
remove the circlip.
13. Remove and discard the piston and shaft O-
Special Tool: Bearing Press (Qty.: 1) rings.
Assemble
out the following:

stated in the procedure.
Refer to: PIL 75.
27 - 100 9813/9400-1 27 - 100

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor

the procedure.
Refer to: PIL 75.
assembly.
Refer to H.
rotate freely on assembly.
7.1. If the thrust washer 1 is renewed, make sure
it is the thickest size.
washer.
adjust,
10. Carry out a pressure check.
27 - 101 9813/9400-1 27 - 101

27 - Driveline
05 - Hybrid Gearbox
65 - Clutch - Front (Output)
65 - Clutch - Front (Output) Component Identification

Check (Condition) ........................................ 27-105
Check (Operation) ....................................... 27-105
Adjust .......................................................... 27-106
Figure 754. Clutch- Output Front (Output Shaft With M2 Clutch) (459/M5180-2)
D E F G H J
K
C
L
M
A
B
B
P
W
N
V S
R
U T O
A Shaft- output B O-rings

C Bearing- taper roller assembly D Gear- 47T, output
E Compression spring F Washer- spring retainer
G Plate- pressure clutch H Circlip 150mm internal
27 - 102 9813/9400-1 27 - 102

27 - Driveline
05 - Hybrid Gearbox
J Washer- thrust K Bearing- needle thrust

L Washer- thrust M Bearing- taper roller
N Bearing- needle roller O Gear- 53 T and plate carrier
P Washer- bevilled thrust R Plate-shim, clutch
S Circlip- external T Plate- friction, clutch
U Plate- counter, clutch V Piston/clutch assembly
W Oil baffle plate
Figure 755. Clutch- Output Front (Output Shaft With M2 Clutch) (459/M5180-2)
30
10
60
230
70
140
50
160 170
250
90 240
100 150
260
200 210
220 110 80
120
190
130
40
270
20
220
459-M5180-2
Item Description
Table 300. 90 Washer- Spring Retainer
Item Description 100 Circlip- External
10 Gear- 53T & Plate Carri- 110 Compression Spring
er 120 Oil Baffle Plate
20 Bearing-Taper Roller 130 G.A. Piston- Clutch
Assy 140 Bearing- Needle Roller
30 Bearing-Taper Roller 150 Plate-Counter-Clutch
40 Gear 47T- Output 160 Plate-Friction-Clutch
50 Shaft- Output HMH 170 Plate-Pressure-Clutch A/
60 Washer- Bevelled- R 6mm
Thrust 190 O-Ring
70 Bearing- Needle Thrust 200 O-Ring
80 Washer- Thrust
27 - 103 9813/9400-1 27 - 103

27 - Driveline
05 - Hybrid Gearbox
Item Description
210 O Ring
220 O Ring
230 Washer- Thrust
240 Circlip 150mm- Internal
R 6.5mm
260 Plate-Shim-Clutch
270 Washer- Thrust
27 - 104 9813/9400-1 27 - 104

27 - Driveline
05 - Hybrid Gearbox

Friction plates
one.

Gears
damage.
27 - 105 9813/9400-1 27 - 105

27 - Driveline
05 - Hybrid Gearbox
1. Use a DTI as shown, measure the end float of all part of the mainshaft assembly.
the pressure (end) plate, which should be within
the specified tolerances. Refer to the mainshaft remove and install procedure.

circlip.

Item Size
Pressure plate 6
6.5
27 - 106 9813/9400-1 27 - 106

27 - Driveline
05 - Hybrid Gearbox
Disassemble and Assemble Figure 757. For illustration only
Special Tools 11 11
Bearing Press 892/00179 1 12

avoid damage or injury. 13
Refer to driveline, hydrostatic gearbox, clutch front

Y 13A
(output), component identification Refer to: PIL
27-05-65.

1. Remove the taper bearing using the correct tool.

2. Remove the thrust washer.
shaft together with the needle roller bearing. 11 Circlip
12 Spring retaining plate
4. Remove the needle thrust washer and washer 13A Oil baffle plate
from the shaft (if not inside the 53T gear hub). Y Cut away tube
5. Remove the clutch pack retaining circlip and 8. Remove the washer, spring, and oil baffle
remove the clutch friction and counter plates in together.
their installed order.
9. Remove the shaft o-rings from the shaft (X3).
specification plates depending on the 10. Remove the taper bearing using the correct tool
application. Make sure that the plates are not
mixed up with plates from other clutches. You 11. Remove the 47T output gear from the shaft using
may not be able to distinguish the difference if moderate force to overcome the clutch piston
the plates have been used. seal rings. The clutch piston assembly will remain
on the shaft.
7. Position the clutch assembly in a press. Use a
cutaway tube to compress the piston spring then 12. Remove the clutch piston assembly from the
remove the circlip. shaft
Special Tool: Bearing Press (Qty.: 1) 13. Remove and discard the piston and shaft o-rings.
Assemble
out the following:

stated in the procedure. Refer to (PIL 75).
27 - 107 9813/9400-1 27 - 107

27 - Driveline
05 - Hybrid Gearbox

assembly.
Refer to H.
rotate freely on assembly.
7.1. If the thrust washer 1 is renewed, make sure
it is the thickest size.
washer.
free movement and adjust if required. Refer
to driveline, hydrostatic gearbox, clutch front
(output), adjust,
27 - 108 9813/9400-1 27 - 108

27 - Driveline
05 - Hybrid Gearbox
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
27 - 109 9813/9400-1 27 - 109

27 - Driveline
05 - Hybrid Gearbox
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-110
Check (Condition) ........................................ 27-111
- General purpose
solvent based parts
cleaner
1. Carefully remove all traces of gasket or gasket

compound from the front and rear case mating
faces. When removing gasket compound use a
gasket removal product such as Loctite Chisel.
Take care not to damage the mating faces. Clean
the faces with a fine carborundum paper. Use
a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris
2. Clean the inside of the cases using a suitable
degreasing agent.
27 - 110 9813/9400-1 27 - 110

27 - Driveline
05 - Hybrid Gearbox
90 - Front Case
Check (Condition)
Consumables
Strength)
1. If the gearbox cases are to be renewed, be

sure to install blanking plugs and adaptors as
required. Inspect the original cases and identify
the blanking plug and adaptor positions. Transfer
the plugs and adaptors to the new cases. Apply
JCB Threadlocker and Sealer to the threads
before installation.
(Medium Strength)
27 - 111 9813/9400-1 27 - 111

27 - Driveline
05 - Hybrid Gearbox
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-112 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-113
27 - 112 9813/9400-1 27 - 112

27 - Driveline
05 - Hybrid Gearbox
91 - Rear Case
Refer to Front Case - Check Condition (PIL The front and rear case are separated at the same
27-06-90). time. Refer to the removal procedure of the front
case. Refer to (PIL 27-05-90).
27 - 113 9813/9400-1 27 - 113

27 - Driveline
05 - Hybrid Gearbox
93 - Hose
93 - Hose Introduction
Introduction .................................................. 27-114 Refer to hydraulic system, hose, general, (PIL
Remove and Install ..................................... 27-115 30-93-00).
27 - 114 9813/9400-1 27 - 114

27 - Driveline
05 - Hybrid Gearbox
93 - Hose
Remove and Install Figure 758. Hydrostatic Hoses
CAUTION Make sure the hose is restrained A

sufficiently during this procedure. If the
hose clamps are released without sufficiently
restraining the hose, personal injury may occur
due to hose whip. E
B
Removal
1. This procedure assumes the transmission is F
already removed from the machine. Refer to
2. Make sure the transmission is correctly
restrained on a suitable work bench.
3. Label the hoses and ports to make sure they are
installed correctly later.
4. Make sure the areas around the hose and the D
hose itself are clean and free of debris. C
5. Position a suitable oil container and remove A Hose 1
clamp 1 on hose 1. B Hose 2
C Clamp 1 (left)
6. Using an assistant hold hose 1 very firmly whilst D Clamp 2 (right)
removing clamp 2. E Clamp 3 (left)
F Clamp 4 (right)
7. Carefully allow the hose to relax to its uninstalled
shape. Install
8. Plug the hose and ports. 1. Install hose 2 on to the pump body and tighten
9. Remove the clamps from the pump end of the the two clamps loosely to just allow the hose to
hose. be positioned.
10. Plug the hose and ports and store the hose 2. Install clamp 4 loosely on the motor and move
correctly. the hose so that the hose flange is engaged with
the clamp and the hose will stay in position. Make
11. Repeat steps 5 to 10 for hose 2 and clamps 3 sure the hose cannot become detached from the
and 4. clamp.
3. Install clamp 3 loosely.
4. Make sure the hose is seated correctly and
tighten clamp 4 and clamp 3 on the motor
sequentially to the correct torque.
Torque: 80N·m
5. Make sure the other end of hose 2 is seated
correctly and tighten the clamps on the pump
body to the correct torque.
Torque: 80N·m
6. Repeat steps 1 to 5 for hose 1 and clamps 1 and
2.
27 - 115 9813/9400-1 27 - 115

27 - Driveline
05 - Hybrid Gearbox
95 - Coupling Yoke
95 - Coupling Yoke Introduction

Introduction .................................................. 27-116 The drive yoke is an important component of a
Remove and Install ..................................... 27-117 driveshaft assembly. The drive yoke assembly allows
a driveshaft or PTO (Power Take-Off) to flex or slip
with their given application. The drive yoke is also
essential for allowing u-joints to rotate properly with
the driveshaft.
27 - 116 9813/9400-1 27 - 116

27 - Driveline
05 - Hybrid Gearbox
95 - Coupling Yoke
Special Tools
Drive Coupling 892/00812 1
Spanner
Remove
2. Clean the area around the yoke. Do not allow
3. Use service tool 892/00812 to hold the yoke and
at the same time undo the nut. The nut is very
tight, the help of an assistant will be required.
Discard the nut.
Special Tool: Drive Coupling Spanner (Qty.: 1)
4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
the seal housing.
A Yoke
B Stake nut
C Oil seal
E Washer
F Locking ring
Install
is clean and free from wear or damage.
2. If necessary install a new oil seal. Locate the seal
in the position shown, the seal does not locate to
the back of the housing.
4. Install the yoke.
5. Install the stepped washer the correct way
around with the plan face facing the stake nut as
shown.
27 - 117 9813/9400-1 27 - 117

27 - Driveline
05 - Hybrid Gearbox
95 - Coupling Yoke

torque value.

Item Nm
B 400
27 - 118 9813/9400-1 27 - 118

27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ......................................................................................................................... 27-121

27-06-06 Clutch - Reverse .......................................................................................................... 27-191
27-06-07 Clutch - 2WD/4WD ....................................................................................................... 27-195
27-06-08 Clutch - Layshaft .......................................................................................................... 27-224
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-243
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-256
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-264
27-06-15 Solenoid Control Valve ................................................................................................. 27-279
27-06-18 Pressure Relief Valve ................................................................................................... 27-284
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-285
27-06-24 Oil Pump ...................................................................................................................... 27-287
27-06-27 Speed Sensor .............................................................................................................. 27-289
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-300
27-06-33 Oil Temperature Sensor ............................................................................................... 27-304
27-06-39 Filter ............................................................................................................................. 27-312
27-06-45 Piston Ring Seal .......................................................................................................... 27-316
27-06-47 Oil Seal ........................................................................................................................ 27-318
27-06-52 Driveshaft ..................................................................................................................... 27-320
27-06-54 Main Shaft .................................................................................................................... 27-323
27-06-56 Layshaft ........................................................................................................................ 27-326
27-06-57 Input Shaft .................................................................................................................... 27-327
27-06-58 Output Shaft ................................................................................................................. 27-328
27-06-81 Mount ........................................................................................................................... 27-338
27-06-85 Oil Feed Pipe ............................................................................................................... 27-339
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-340
27-06-90 Front Case ................................................................................................................... 27-341
27-06-91 Rear Case .................................................................................................................... 27-351
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-353
27 - 119 9813/9400-1 27 - 119

Notes:
27 - 120 9813/9400-1 27 - 120

27 - Driveline
00 - General
Introduction .................................................. 27-121 Semi-automatic gearboxes are a hybrid form of
Technical Data ............................................. 27-122 transmission where an integrated control system
Component Identification ............................. 27-130 handles manipulation of the clutch automatically,
Operation ..................................................... 27-143 but the driver can still take manual control of gear
selection.
Fault-Finding ................................................ 27-162
Drain and Fill ............................................... 27-169 Many of these transmissions allow the driver to fully
Clean ........................................................... 27-170 delegate gear shifting choice to the control system,
Check (Condition) ........................................ 27-170 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
Check (Level) .............................................. 27-171 torque converter instead of a straight friction clutch
Check (Pressure) ........................................ 27-172 to manage the connection between the transmission
Remove and Install ..................................... 27-185 gearing and the engine.
A typical JCB semi-automatic transmission is called
Powershift, it has an (A) on the gearshift to signify
Automatic. In this mode the machine will gear change
automatically according to road speed. The following
types exist:
• PS700
• PS750
• PS764
• PS766
Not all types of transmission are available on all

types of machine. Check the operators manual
or transmission identification label for the type of
transmission installed on your machine.
27 - 121 9813/9400-1 27 - 121

27 - Driveline
00 - General
Technical Data
For: PS750 MK4 ..................... Page 27-122

For: PS764 .............................. Page 27-124
For: PS766 .............................. Page 27-127
(For: PS750 MK4)

Table 303. PS 750 4- Speed 2/4 Wheel Drive
Designation PS 750 MkIV Powershift - ECU Control
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. ECU (Electron-
ic Control Unit) controlled gear selection. Permanent 4 wheel drive or selectable
2/4 wheel drive variants.
Weight (dry) 2/4 wheel drive 215kg
Permanent 4 wheel drive TBA
Clutch solenoid current draw 1.36A maximum (at 20°C (68.0°F))
Gearbox 'Limp Modes' (Powershift Mode Possible Reason

Electronic Control) Only 1st, 2nd and 3rd If the ECU does not de-
gears available. tect any input from the
When applicable, the gearbox ECU provides speed sensor it will pre-
restricted or modified gearbox operation if faults are vent selection of any
detected by the ECU. Typical 'limp mode' forms of gear above 3rd.
operation are shown here. Fault codes may also be
Limp Mode 4 (Repeating Error reading transmis-
displayed on the instrument panel. For fault codes
beeps until ECU power sion speed
refer to (PIL 33-57-90).
is reset)
On power up, the ECU will normally sound 3 beeps. Machine holds a gear If the ECU detects and
These beeps can be masked by other audible error with the speed
warnings on start up. sensor while operating,
it prevents autoshifting.
Table 304. Gearbox 'Limp
Modes' (Powershift Electronic Control). Stall Speed Combinations
Mode Possible Reason
The tests carried out at the factory record the correct
Limp Mode 1 (2 beeps Internal 'setup data'
engine r.p.m. (stall speed) when under maximum
at power up). ECU fault.
load from the transmission and hydraulic systems.
Machine autoshifts at If on power up the ECU
different road speeds detects an internal fault The figures relate to tests conducted at an ambient
than normal. with its 'set up' data, it temperature of 25°C (77.0°F) and barometric
will revert to use of a de- pressure of 1bar (14.5psi)at sea level. The changes
fault set of values. in ambient temperature, pressure and humidity and
Limp Mode 2 (1 beep at Error with ECU applica- fuel grade will affect engine power and hence the stall
power up). tion software. figures.
Machine remains in neu- If on power up, the ECU For example, at 10,000 ft the power reduction of a
tral at all times. detects an internal fault naturally aspirated engine could be 29% and for a
with its 'core operating turbo engine 8%.
software' it will prevent
operation of the gear- The figures apply to `bedded-in' engines, i.e. engines
box. that have done a minimum of 250 working hours.
Limp Mode 3 (Machine Error reading transmis- Therefore they should not be used for pre-delivery
will not autoshift). sion speed. inspection (PDI) checks.
All figures are recorded with the transmission oil

at 60°C (139.9°F) and the hydraulic oil at 55°C
(130.9°F). Figures achieved should be within +/- 100
27 - 122 9813/9400-1 27 - 122

27 - Driveline
00 - General
RPM (Revolutions Per Minute) from the figures given

in the table.
Table 305. Stall Speed Combinations

Engine Build Code SL SH
Engine Power 55kW 4 Speed PS750 (4 Speed 81kW 4 Speed PS750/PS764
SS700)
(1)
Model 531-70 5AA, 535-95 5AB, 541-70 531-70 5A(T)A, 535-95 5AB(TD),
5AD, 533-105 5AH, 540-140 536-60 5A(T)C, 541-70 5A(T)D,
5AL, 535-125 5AN, 535-140 5AP, 540-170 5AF, 550-140 5AG,
536-70 5AR, 526-56 5AS 533-105 5AH, 540-140 5AL,
550-1705AM, 535-125 5AN,
535-140 5AP, 536-70 5AR(TE),
526-56 5AS
Hydraulic System:
Gearpump
Variflow
Engine Stall Speeds RPM
Torque Converter Only
Hydraulics (MRV (Main Relief
Valve)) Only
Combined Converter + MRV
(2)
Combined Converter + LSRV

(Load Sense Relief Valve)
LSP (Load Sense Pump) Variflow
LSP Electro Servo
(1) 526-56 Machines only
(2) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service
operated until the relief valve is lifted.
Gearbox Specifications
Table 306. Oil Pressures
Pressure
Converter pressure (in neutral)
Converter In at 50°C (121.9°F) 1000 RPM 1.5–4bar (21.7–58.0psi)
2000 RPM 5–7bar (72.5–101.4psi)
Converter Out at 50°C (121.9°F) 1000 RPM TBA
2000 RPM TBA
Converter inlet relief pressure 6.5bar (94.2psi)
(max.)
Lubrication pressure (in neutral)
Oil at 50°C (121.9°F) 1000 RPM 0.14–0.28bar (2.0–4.1psi)
2000 RPM 0.28–0.55bar (4.1–8.0psi)
Main Line Pressure (in neutral)
Oil at 50°C (121.9°F) 1000 RPM 11–13bar (159.4–188.4psi)
2000 RPM 12–14.5bar (173.9–210.1psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7bar (10.1psi).
27 - 123 9813/9400-1 27 - 123

27 - Driveline
00 - General
Flow Rates (in Flow Rate

neutral)
Table 307. Oil Flow Rates
Pump oil flow at 1000 RPM 11–15
Flow Rates (in Flow Rate 50°C (121.9°F)
neutral) 2000 RPM 22.5–29.5
Cooler oil 1000 RPM 8–13
flow at 50°C For new gearboxes (i.e. under 100 hours service),
(121.9°F) or gearboxes that have been fully serviced, the
2000 RPM 19–25 pressures will be slightly higher than those shown
(approximately 0.7–1bar (10.1–14.5psi)).
(For: PS764)
Table 308. PS 764 4- Speed 2/4 Wheel Drive
Designation PS 764 Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. ECU controlled
gear selection.
Weight (dry) Permanent 4 wheel drive 242kg
Clutch ratio solenoid types 3 way, 2 position, normally closed, with integral pro-
portional solenoid.
Clutch ratio solenoid current draw 0.85A for clutch pressure of 12bar (173.9psi)
Clutch ratio solenoid coil resistance 7.25Ω (at 20°C (68.0°F))
Clutch 4WD (Four Wheel Drive) solenoid type 3 way, 2 position, normally closed, with integral on/off
solenoid and suppression diode.
Clutch 4WD solenoid current draw 1.68A at 12V at 20°C (68.0°F)
Torque converter diameter 310mm
Torque converter identification W300
Torque multiplication at stall 2.02:1

Modes' (Powershift Electronic Control).
Table 309. Gear ratios
Gear (Forward) Ratio Limp Mode 1 (2 beeps Internal 'setup data'
1st 6.17:1 at power up). ECU fault.
2nd 3.32:1 Machine autoshifts at If on power up the ECU
3rd 1.86:1 different road speeds detects an internal fault
4th 1.00:1 than normal. with its 'set up' data, it
will revert to use of a de-
fault set of values.
Gearbox 'Limp Modes' (Powershift
Electronic Control) Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software.
When applicable, the gearbox ECU provides Machine remains in neu- If on power up, the ECU
restricted or modified gearbox operation if faults are tral at all times. detects an internal fault
detected by the ECU. Typical 'limp mode' forms of with its 'core operating
operation are shown here. Fault codes may also be software' it will prevent
displayed on the instrument panel. For fault codes operation of the gear-
refer to (PIL 33-57-90). box.
Limp Mode 3 (Machine Error reading transmis-
On power up, the ECU will normally sound 3 beeps. will not autoshift). sion speed.
These beeps can be masked by other audible
warnings on start up. Only 1st, 2nd and 3rd If the ECU does not de-
gears available. tect any input from the
speed sensor it will pre-
vent selection of any
gear above 3rd.
27 - 124 9813/9400-1 27 - 124

27 - Driveline
00 - General
Mode Possible Reason pressure of 1bar (14.5psi)at sea level. The changes
Limp Mode 4 (Repeating Error reading transmis- in ambient temperature, pressure and humidity and
beeps until ECU power sion speed fuel grade will affect engine power and hence the stall
is reset) figures.
Machine holds a gear If the ECU detects and For example, at 10,000 ft the power reduction of a
error with the speed naturally aspirated engine could be 29% and for a
sensor while operating, turbo engine 8%.
it prevents autoshifting.
The figures apply to `bedded-in' engines, i.e. engines
Stall Speed Combinations that have done a minimum of 250 working hours.
Therefore they should not be used for pre-delivery
The tests carried out at the factory record the correct inspection (PDI) checks.
engine r.p.m. (stall speed) when under maximum
load from the transmission and hydraulic systems. All figures are recorded with the transmission oil
The figures relate to tests conducted at an ambient (130.9°F). Figures achieved should be within +/- 100
temperature of 25°C (77.0°F) and barometric RPM from the figures given in the table.

Engine Build Code SH
Engine Power 81kW 4 Speed PS750/PS764
Model 531-70 5A(T)A, 535-95 5AB(TD), 536-60 5A(T)C,
541-70 5A(T)D, 540-170 5AF, 550-140 5AG, 533-105
5AH, 540-140 5AL, 550-1705AM, 535-125 5AN,
535-140 5AP, 536-70 5AR(TE), 526-56 5AS
Hydraulic System:
Gearpump
Variflow
Engine Stall Speeds RPM
Torque Converter Only
Hydraulics (MRV) Only
Combined Converter + MRV
(1)
Combined Converter + LSRV

LSP Variflow
LSP Electro Servo
(1) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service
operated until the relief valve is lifted.
27 - 125 9813/9400-1 27 - 125

27 - Driveline
00 - General
Engine Build SH DH
Code
Variflow
Engine Build SH DH
Code Engine Stall Speeds RPM
Engine Power 93kW 4 Speed 108kW 4 Speed Torque Convert-
PS764 PS764 er Only
Model 531-70 5A(T)A, 531-70 5A(T)A, Hydraulics
535-95 535-95 (MRV) Only
5AB(TD), 5AB(TD), Combined Con-
verter + MRV
(1)
536-60 5A(T)C, 536-60
541-70 5A(T)D, 5A(T)C, 541-70 Combined Con-
540-170 5AF, 5A(T)D, 536-70 verter + LSRV
550-140 5AG, 5AR(TE), LSP Variflow
540-140 5AL, 550-80
550-1705AM, 5AW(UW) LSP Electro
536-70 Servo
5AR(TE), (1) Combined stall tests on machines fitted with a
550-80 hydraulic gearpump are performed with the crowd
5AW(UW) service operated until the relief valve is lifted.
Hydraulic System:
Gearpump
Pressure
Converter pressure in neutral
Converter In at 50°C (121.9°F) 1000 RPM 1.4–2.2bar (20.3–31.9psi)
2000 RPM 5.8–6.9bar (84.1–100.0psi)
Converter In at 100°C (211.9°F) 1000 RPM 0.5–1.3bar (7.2–18.8psi)
2000 RPM 2.5–3.5bar (36.2–50.7psi)
Converter Out at 50°C (121.9°F) 1000 RPM 0.6–1.6bar (8.7–23.2psi)
2000 RPM 2.8–3.8bar (40.6–55.1psi)
Converter Out at 100°C (211.9°F) 1000 RPM 0.2–1bar (2.9–14.5psi)
2000 RPM 1–1.9bar (14.5–27.5psi)
Converter inlet relief pressure 7.1bar (102.9psi)
(max.)
2000 RPM 1.1–2.1bar (15.9–30.4psi)
2000 RPM 0.4–1.4bar (5.8–20.3psi)
Oil at 50°C (121.9°F) 1000 RPM 11–13bar (159.4–188.4psi)
2000 RPM 13–15.2bar (188.4–220.3psi)
2000 RPM 11.4–14.5bar (165.2–210.1psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7bar (10.1psi) and 4WD clutch pressure to be within 1.4bar (20.3psi)
27 - 126 9813/9400-1 27 - 126

27 - Driveline
00 - General

neutral)
Pump oil flow at 1000 RPM 11.5–15.6L/min
Flow Rates (in Flow Rate 100°C (211.9°F)
neutral) 2000 RPM 24–33L/min
Cooler oil 1000 RPM 8.5–11L/min
flow at 50°C For new gearboxes (i.e. under 100 hours service),
(121.9°F) or gearboxes that have been fully serviced, the
2000 RPM 17–25.1L/min pressures will be slightly higher than those shown
Cooler oil 1000 RPM 6.2–9.5L/min (approximately 0.7–1bar (10.1–14.5psi)).
flow at 100°C
(211.9°F)
2000 RPM 15–19.5L/min
(For: PS766)
Table 315. PS 766 6- Speed 4 Wheel Drive
Designation PS 766 Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft,
6 speed and 4 wheel drive clutch packs giving 6 forward and 4 reverse speeds.
Electronically controlled gear selection. Integral wet multi-plate park brake.
Weight (dry) Permanent 4 wheel drive 285kg
Clutch solenoid types 3 way, 2 position, normally closed, integral suppres-
sion diode
Coil resistance 7.5Ω maximum (at 20°C (68.0°F))
Torque converter diameter 310mm
Torque converter identification W300 Lock up torque converter (LUC)
Torque multiplication at stall 2.52:1

Modes' (Powershift Electronic Control).
Table 316. Gear ratios
Gear (Forward) Ratio Limp Mode 1 (2 beeps Internal 'setup data'
1st 8.17:1 at power up). ECU fault.
2nd 4.90:1 Machine autoshifts at If on power up the ECU
3rd 3.62:1 different road speeds detects an internal fault
4th 2.25:1 than normal. with its 'set up' data, it
will revert to use of a de-
5th 1.35:1
fault set of values.
6th 1.00:1
Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software.
Gearbox 'Limp Modes' (Powershift
Machine remains in neu- If on power up, the ECU
Electronic Control) tral at all times. detects an internal fault
with its 'core operating
When applicable, the gearbox ECU provides software' it will prevent
restricted or modified gearbox operation if faults are operation of the gear-
detected by the ECU. Typical 'limp mode' forms of box.
operation are shown here. Fault codes may also be
displayed on the instrument panel. For fault codes Limp Mode 3 (Machine Error reading transmis-
refer to (PIL 33-57-90). will not autoshift). sion speed.
Only 1st, 2nd and 3rd If the ECU does not de-
On power up, the ECU will normally sound 3 beeps. gears available. tect any input from the
These beeps can be masked by other audible speed sensor it will pre-
warnings on start up. vent selection of any
gear above 3rd.
27 - 127 9813/9400-1 27 - 127

27 - Driveline
00 - General
Mode Possible Reason Table 318. Stall Speed Combinations

Limp Mode 4 (Repeating Error reading transmis- Engine Build SH DH
beeps until ECU power sion speed Code
is reset) Engine Power 93kW 6 Speed 108kW 6 Speed
Machine holds a gear If the ECU detects and PS766 PS766
error with the speed Model 531-70 5A(T)A, 531-70 5A(T)A,
sensor while operating, 535-95 535-95
it prevents autoshifting. 5AB(TD), 5AB(TD),
536-60 536-60
Stall Speed Combinations 5A(T)C, 541-70 5A(T)C, 541-70
5A(T)D, 536-70 5A(T)D, 536-70
The tests carried out at the factory record the correct 5AR(TE) 5AR(TE)
engine r.p.m. (stall speed) when under maximum Hydraulic System:
load from the transmission and hydraulic systems.
Gearpump
The figures relate to tests conducted at an ambient Variflow
temperature of 25°C (77.0°F) and barometric Engine Stall Speeds RPM
pressure of 1bar (14.5psi)at sea level. The changes
in ambient temperature, pressure and humidity and Torque Convert-
fuel grade will affect engine power and hence the stall er Only
figures. Hydraulics
(MRV) Only
For example, at 10,000 ft the power reduction of a Combined Con-
naturally aspirated engine could be 29% and for a verter + MRV
(1)
turbo engine 8%.

Combined Con-
The figures apply to `bedded-in' engines, i.e. engines verter + LSRV
that have done a minimum of 250 working hours. LSP Variflow
Therefore they should not be used for pre-delivery LSP Electro
inspection (PDI) checks. Servo
(1) Combined stall tests on machines fitted with a
All figures are recorded with the transmission oil
hydraulic gearpump are performed with the crowd
service operated until the relief valve is lifted.
(130.9°F). Figures achieved should be within +/- 100
RPM from the figures given in the table.
Pressure
Converter pressure (in neutral)
Converter In at 50°C (121.9°F) 1000 RPM 2–4.95bar (29.0–71.7psi)
2000 RPM 4–6.8bar (58.0–98.6psi)
Converter Out at 50°C (121.9°F) 1000 RPM 0.6–2.25bar (8.7–32.6psi)
2000 RPM 1.25–2.5bar (18.1–36.2psi)
Lock up torque converter inlet relief valve pressure (Maximum) 8.5bar (123.2psi)
Oil at 50°C (121.9°F) 1000 RPM 0.25–1bar (3.6–14.5psi)
2000 RPM 0.5–1bar (7.2–14.5psi)
2000 RPM 12.4–17bar (179.7–246.4psi)
27 - 128 9813/9400-1 27 - 128

27 - Driveline
00 - General

neutral)
Cooler oil 1000 RPM 14L/min
flow at 50°C
(121.9°F)
2000 RPM 17L/min
Pump oil flow at 1000 RPM 16L/min
50°C (121.9°F)
2000 RPM 34L/min
For new gearboxes (i.e. under 100 hours service),

or gearboxes that have been fully serviced, the
pressures will be slightly higher than those shown
(approximately 0.7–1bar (10.1–14.5psi)).
27 - 129 9813/9400-1 27 - 129

27 - Driveline
00 - General
For: PS750 MK4 ..................... Page 27-130 Figure 760.

For: PS764, PS766 ................. Page 27-136
(For: PS750 MK4)
Unit Identification
details on the unit identification plate. In the case of
stamped on the gear, and the number of teeth.
A Identification plate
27 - 130 9813/9400-1 27 - 130

27 - Driveline
00 - General
Main Component Identification
Figure 761. External components
27 - 131 9813/9400-1 27 - 131

27 - Driveline
00 - General
Item Description
13 Oil pump
Table 321.
14 Park brake caliper
Item Description bracket
1 Front case with integral 15 Park brake disc and dri-
torque converter hous- ve shaft coupling
ing
16 Suction strainer
2 Rear case
17 Speed sensor 1
3 Torque converter relief
18 Road speed sensor (if
valve
installed)
4 Pressure maintenance
19 Oil transfer pipe
valve
20 Oil filler / dipstick port
5 Oil pressure switch
21 Oil filter
6 Oil outlet port- to oil
cooler 22 2/4 wheel drive solenoid
control valve (if installed)
7 Oil inlet port- from oil
cooler 23 Input (forward) clutch
solenoid control valves
8 Clutch shaft inspection
port- reverse clutch 24 Main shaft / layshaft
clutch solenoid control
valves
port- main shaft clutch
25 Reverse clutch solenoid
control valves
port- layshaft clutch
26 Oil drain plug
11 Input shaft
12 Yoke- drive shaft cou-
pling
27 - 132 9813/9400-1 27 - 132

27 - Driveline
00 - General
Figure 762. Internal component
19 2
1 18
11 10 4
17 3
12
13
4
7 4
6
12
4
9
6 5
16 15
7
10.5
4
14
8
Item Description
5 Yoke - drive shaft cou-
Table 322.
pling
Item Description 6 Oil seal
1 Rear case 7 Locking nut (stake nut)
2 Front case 8 Oil feed pipe
3 Gearbox oil pump 9 Park brake disc
4 Shim
27 - 133 9813/9400-1 27 - 133

27 - Driveline
00 - General

10 Park brake caliper 18 Input shaft clutch as-
bracket sembly
11 Park brake caliper 19 Reverse shaft clutch as-
12 Output shaft support sembly
bearings (1) Permanent 4 wheel drive variants have a one-
13 Spacer piece shaft in place of the 2/4 wheel drive clutch
14 2/4 wheel drive clutch
(1) assembly.
15 Layshaft clutch assem- The internal component drawing is not a true
bly sectional view. It is drawn to show the main
16 Main shaft clutch as- components as clearly as possible
sembly
17 Output shaft
27 - 134 9813/9400-1 27 - 134

27 - Driveline
00 - General
Figure 763. Test Point
1 4
Test point Description

4 Forward high ratio clutch
Table 323.
pressure
Test point Description 5 Forward low ratio clutch
1 Mainline pressure pressure
2 Main shaft clutch pres- 6 Reverse high ratio clutch
sure pressure
3 Converter inlet and con- 7 Reverse low ratio clutch
verter relief valve pres- pressure
sure
27 - 135 9813/9400-1 27 - 135

27 - Driveline
00 - General
Test point Description Clutch Control Solenoids

8 Layshaft clutch pressure
Figure 764.
9 2/4 wheel drive clutch
pressure
3022
3021
3033
3041
3029
3040
Table 324.
Gear Clutches engaged Solenoids energised Refer to
Figure 764.
1st gear forward Forward Low 3022
Layshaft 3029
2nd gear forward Forward high 3021
Layshaft 3029
3rd gear forward Forward low 3022
Mainshaft 3033
4th gear forward Forward high 3021
Mainshaft 3033
1st gear reverse Reverse Low 3041
Layshaft 3029
2nd gear reverse Reverse high 3040
Layshaft 3029
3rd gear reverse Reverse low 3041
Mainshaft 3033
4th gear reverse Reverse high 3040
Mainshaft 3033
(For: PS764, PS766) details on the unit identification plate. In the case of
Unit Identification stamped on the gear, and the number of teeth.

27 - 136 9813/9400-1 27 - 136

27 - Driveline
00 - General
Figure 765.
A Identification plate
27 - 137 9813/9400-1 27 - 137

27 - Driveline
00 - General
Main component identification
Figure 766.
H N
A
S J
B
C
D
R
Q
T
U
K L E
C
P
M V
Item Description
M Hose connection (to oil
Table 325.
cooler)
Item Description N Hose connection (from
A Torque converter oil cooler)
B Forward and input clutch P 6 speed assembly (if in-
C Reverse clutch stalled)
D Main shaft assembly Q Oil filter
E Layshaft assembly R Driveshaft (typically dri-
F 2 and 4 Wheel drive ves a hydraulic pump)
clutch S Gear drive to reverse
G Torque converter relief clutch
valve T Solenoid control valves
H Oil pressure mainte- U Transmission oil pres-
nance valve sure switch
J Transmission oil pump V Speed sensor
K Park brake actuator
L Park brake friction pack
27 - 138 9813/9400-1 27 - 138

27 - Driveline
00 - General
Sectional Drawing
Figure 767.
1 2
23
22 3
21 4
17
18
20
12
16
14
15
13
11 5
10
9 19
7 6
8
27 - 139 9813/9400-1 27 - 139

27 - Driveline
00 - General
Item Description
13 Bearing end float control
Table 326.
spacer
Item Description 14 Oil seal
1 Rear case 15 Transfer gear and shaft
2 Front case 16 Yoke - drive shaft cou-
3 Torque converter hous- pling
ing 17 Auxiliary device mount-
4 Gearbox oil pump ing interface
5 Yoke - drive shaft cou- 18 Auxiliary device drive
pling shaft
6 Oil seal 19 Layshaft and layshaft
7 4WD (Four Wheel Drive) clutch assembly
case 20 Main shaft and clutch
8 4WD clutch assembly assembly
9 Integral park brake as- 21 Input shaft and forward
sembly cover (if in- clutch assembly
stalled) 22 Reverse shaft and clutch
10 Park brake friction plate assembly
pack (if installed) 23 6 speed shaft and clutch
11 Park brake actuator (if assembly (if installed)
installed)
12 Transfer gear shaft sup- The drawing is not a true sectional view. It is drawn
port bearings to show the main components as clearly as possible.
Clutch Control Solenoids

PS764
Figure 768. PS764
A B C D
G F E
27 - 140 9813/9400-1 27 - 140

27 - Driveline
00 - General
Table 327.
Gear Clutches engaged Solenoids engaged Refer to Fig-
ure 768.
1st gear forward Forward low A
Layshaft E
2nd gear forward Forward high B
Layshaft E
3rd gear forward Forward low A
Mainshaft F
4th gear forward Forward high B
Mainshaft F
1st gear reverse Reverse low C
Layshaft E
2nd gear reverse Reverse high D
Layshaft E
3rd gear reverse Reverse low C
Mainshaft F
4th gear reverse Reverse High D
Mainshaft F
PS766
Figure 769. PS766
A B C D
G F E
Table 328.
ure 769.
1st gear forward 6 speed E
Layshaft F
2nd gear forward Forward low A
27 - 141 9813/9400-1 27 - 141

27 - Driveline
00 - General

ure 769.
Layshaft F
3rd gear forward Forward high B
Layshaft F
4th gear forward 6 speed E
Mainshaft G
5th gear forward Forward low A
Mainshaft G
6th gear forward Forward high B
Mainshaft G
1st gear reverse Reverse low C
Layshaft F
2nd gear reverse Reverse high D
Layshaft F
3rd gear reverse Reverse low C
Mainshaft G
4th gear reverse Reverse High D
Mainshaft G
27 - 142 9813/9400-1 27 - 142

27 - Driveline
00 - General
Operation
For: PS764 .............................. Page 27-143 A gearbox mounted ground speed sensor detects
For: PS766 .............................. Page 27-151 the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via
the machine control ECU and the CANbus. The ECU
(For: PS764) responds by preventing ratio selection if the machine
ground speed is not within pre-set values.
The gearbox system is controlled electronically.
Inputs from control devices are connected to various When the ratio up (plus) button is pressed the
ECU (Electronic Control Unit)s. The ECU’s energise transmission ECU selects the next (higher) gear
the applicable electrical devices depending on the ratio. When the ratio down (minus) button is pressed
machine status. The ECU’s are connected to the the transmission ECU selects the next (lower) gear
machine CAN (Controller Area Network)bus which ratio.
enables integrated control of all the main machine
systems.
Park brake on
For details of the ECUs installed on the machine refer
to (PIL 33-45). When the park brake is on, an electrical switch sends
a signal to the transmission ECU which sets the
transmission to neutral even if forward or reverse is
Start up selected. A warning sound will be audible.
Electrical interlocks prevent the engine being started,
unless the transmission is set to neutral. The Transmission dump
interlock is controlled by the ECU.
A transmission dump switch on the hydraulic control
lever sends a signal to the transmission ECU which
Direction Control de-selects the transmission drive when the switch is
operated.
A column switch controls the direction control,
forward, neutral or reverse. The switch is connected
to inputs on the ECU which in turn energise the Foot Brake Control
applicable gearbox control solenoids.
When the foot brake operates a pressure transducer
Joystick Direction Control mounted in the hydraulic brake line detects the
change in brake system pressure. Input from
Drive direction can also be controlled with the joystick the transducer is connected to the transmission
direction control switch. Inputs from the switch are ECU. The transmission ECU selects neutral even
connected to the transmission ECU via the joystick if Forward or Reverse is selected. The feature
powerbase ECU and the CANbus. There is a logic enables an increase in machine braking efficiency.
control for drive direction selection. Selection of An operator switch in the cab can be set to enable or
Forward or Reverse with the column switch disables disable the feature.
the joystick direction control switch. Both the joystick
and column switch must first be set to Neutral before 2/4 Wheel drive select
the joystick switch is enabled.
A cab mounted switch controls 2 or 4 wheel
Manual gear select drive selection. The switch provides an input to
the transmission ECU which in turn energises
A rotating barrel switch controls selection of the gear the applicable gearbox control solenoid. The
ratios (1,2,3 or 4). The switch is connected to inputs transmission automatically selects 4 wheel drive
on the ECU which energise the applicable gear box when the service brakes are applied.
control solenoids.
Transmission Oil Pressure and
Joystick Gear Selection Temperature
Gear ratio selection can be controlled with the Oil pressure and temperature sensors are connected
joystick ratio up (plus) and down (minus) buttons. to the machine instrumentation which displays the
Inputs from the buttons are connected to the pressure and temperature status. Warning displays
transmission ECU via the machine control ECU and and fault codes are activated if the oil pressure or
the CANbus. temperature is not within pre-set values.
27 - 143 9813/9400-1 27 - 143

27 - Driveline
00 - General
Limp Modes Figure 771. 2nd gear forward (4 wheel drive)
When necessary the transmission ECU will provide

alternative gear selection should faults occur. This
enables the machine to be moved (`limped') under its
own power. For limp mode details refer to Technical
Data (PIL 27-06).
U
Fault codes may also be displayed on the instrument
panel. For fault codes refer to (PIL 33-57-90).
Drive paths
Forward
Z
Figure 770. 1st gear forward (4 wheel drive) S
T Table 330.
Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us)
Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring -
applied) (S)
Z Figure 772. 3rd gear forward (4 wheel drive)
Table 329.
Clutches engaged Solenoids energised T
Forward low ratio (T) 3022 (Ts) Y
applied) (S)
Table 331.
Forward low ratio (T) 3022 (Ts)
Mainshaft (Y) 3033 (Ys)
applied) (S)
27 - 144 9813/9400-1 27 - 144

27 - Driveline
00 - General
Figure 773. 4th gear forward (4 wheel drive) Figure 775. 2nd gear reverse
S S

Clutches engaged Solenoids energised Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us) Reverse high ratio (V) 3040 (Vs)
Mainshaft (Y) 3033 (Ys) Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring - 2/4 wheel drive (spring -
applied) (S) applied) (S)
Reverse
Figure 776. 3rd gear reverse
Figure 774. 1st gear reverse
W
W
S
S
Table 335.
Table 333.
Clutches engaged Solenoids energised Reverse low ratio (W) 3041 (Ws)
Reverse low ratio (W) 3041 (Ws) Mainshaft (Y) 3033 (Ys)
Layshaft (Z) 3029 (Zs) 2/4 wheel drive (spring -
2/4 wheel drive (spring - applied) (S)
applied) (S)
27 - 145 9813/9400-1 27 - 145

27 - Driveline
00 - General
Figure 777. 4th gear reverse torque is transferred from the converter assembly to
the clutch/gear assemblies through the input shaft on
the forward clutch assembly.
V
The forward clutch assembly contains two
hydraulically operated clutches: one clutch gives a
forward low ratio drive and the other gives a forward
high ratio drive. The clutches are controlled by a
three position solenoid valve. When the applicable
solenoid is energised, pressurised oil is directed to
Y
either the forward low (solenoid 3022) or forward high
(solenoid 3021) clutch.
The reverse clutch assembly is also similar to the

forward clutch assembly. It contains two hydraulically
operated clutches: one clutch gives a reverse low
S ratio drive and the other gives a reverse high ratio
drive. The reverse clutches are controlled by a
either the reverse low (solenoid 3041) or reverse high
Table 336.
Clutches engaged Solenoids energised Both the mainshaft and the layshaft assemblies have
Reverse high ratio (V) 3040 (Vs) a single clutch each. Both clutches are controlled
by a three position solenoid valve. When energised,
Mainshaft (Y) 3033 (Ys) solenoid 3029 directs pressurised oil to the layshaft
2/4 wheel drive (spring - clutch and solenoid 3033 directs pressurised oil the
applied) (S) mainshaft clutch.
Hydraulic operation and schematics When a gear is selected through the control switch in
the cab, two clutches are always engaged. When you
The engine directly drives the oil pump through the select different pairs of clutches different gear ratios
torque converter. are engaged. The hydraulic control ECU electrically
controls the solenoids. All the clutches work on the
Oil from the pump is fed through an internal passage same principle.
via the filter to the PMV (Pressure Maintenance
Valve), which maintains pressure to the solenoid The 2/4 wheel drive unit also has a single clutch.
valves for clutch selection. Excess oil from the In normal operation the clutch is spring loaded and
maintenance valve flows back through the case to therefore engaged to give 4 wheel drive. When
the torque converter. A relief valve controls pressure 2 wheel drive is selected, solenoid valve 3002 is
in the converter and dumps oil from the converter line energised and directs pressurised oil to the 2/4 wheel
back to the sump. drive clutch.
Oil from the torque converter flows out of the gearbox In the schematic, the gearbox is shown with 2nd
to the external oil cooler and again comes back to gear forward engaged. 2nd gear forward requires
the converter. Oil then flows through internal oil ways the forward low clutch T and layshaft clutch Z to
providing lubrication for clutches and bearings before be engaged. When the gear selection switch is
it goes back to the gearbox sump. moved to 2nd gear forward, the electrical control
system energises solenoid valves 3022 and 3029.
The torque converter is a fluid coupling bolted to Pressurised oil is diverted to the back of pistons
a drive plate which in turn is bolted to the engine in both clutches to engage the drive. At the same
driven bevel gearbox. As the engine starts to rotate, time all other solenoids are de-energised, diverting
the converter gives smooth power take off and oil from the back of the other clutch pistons to the
gradually increases the torque transmitted. This gearbox sump. The 4 wheel drive clutch 3002 is also
energised to give 2 wheel drive.
27 - 146 9813/9400-1 27 - 146

27 - Driveline
00 - General
Figure 778.
H G
2 1 K X
2 3 3
3004 C
5 1 W V Q A
3021 J
3022 T U
1
3002
B
3041
Y
M
3040 z
L 6
3033
D
E S
3029
N F
P
Table 337.
Item Description
A Torque converter
B Forward clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive unit
G Torque converter relief valve
H Pressure maintenance valve
J Pump
L Park brake pack
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P 6-Speed clutch assembly (if installed)
S Gear drive to reverse unit clutch assembly
Q Oil filter
T Forward low ratio clutch
U Forward high ratio clutch
V Reverse high ratio clutch
W Reverse low ratio clutch
X 6 speed clutch (PS766 only)
Y Mainshaft clutch
Z Layshaft clutch
1 Solenoid port 1
27 - 147 9813/9400-1 27 - 147

27 - Driveline
00 - General
Item Description
2 Solenoid port 2
3 Solenoid port 3
5 Solenoid valve control block
6 External oil cooler
Forward and Reverse Clutch Operation is then transmitted from the input shaft to the gear
1. Clutch for gear 2 is disengaged and no drive is
The forward and reverser clutch assembly transfers transmitted to gear 2 plate carrier. The gear is also
drive from the input shaft to either gear 1 or gear 2 free to rotate on the input shaft assembly.
depending on which of the two clutches is engaged,
giving forward or reverse drive. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve.
When neither clutch is engaged, neutral is selected.
When neutral is selected both solenoids are
The clutches are of the wet, multi plate type. deactivated and the flow of pressurised oil to the
clutches is blocked. The gear springs 1 and 2 move
The clutch housings and input shaft are a one piece the pistons away from the clutch plates and oil from
assembly. The assembly is permanently driven by both pistons is vented to the sump.
the engine via the torque converter.
When either forward or reverse is selected, the
Clutch counter plates are also permanently driven solenoid control valve diverts pressurised oil via
via meshing teeth inside the clutch housings. Clutch cross drillings inside the input shaft to the appropriate
friction plates are meshed with the gear plate clutch piston in the unit. Pressure from the other
carriers. clutch is vented to the sump via the solenoid valve
spool. Oil is prevented from leaking by seals on the
In the diagram, clutch for gear 1 is engaged. pistons and ring seals on the input shaft.
The counter plates and friction plates are pressed

together by a hydraulically actuated piston. Drive
27 - 148 9813/9400-1 27 - 148

27 - Driveline
00 - General
Figure 779.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q
A Input shaft assembly B Gear 1 clutch

C Gear 1 piston D Piston external seal
E Gear 2 piston F Gear 2 clutch
G1 Gear 1 G2 Gear 2
H Input shaft ring seals J Gear 2 spring
K Gear 1 spring L Piston internal seal
M Clutch friction plates N Clutch counter plates
P Solenoid - gear 1 Q Solenoid - gear 2
R Solenoid control valve
27 - 149 9813/9400-1 27 - 149

27 - Driveline
00 - General
Mainshaft and Layshaft Clutch Operation The clutch is engaged and disengaged by
introducing or dumping pressurised oil behind the
The mainshaft and layshaft units incorporate one piston via a solenoid valve. The solenoid valve is
clutch and not two, as in the forward and reverse operated by a switch in the cab.
units. The operation of the single clutches is the
same as for one clutch in the forward or reverse units. When the switch is in the 4WD position, the solenoid
valve is de-energised. With the solenoid 1 de-
2 and 4 Wheel Drive Clutch Operation energised, the valve spool moves under the force of
the spring. The oil supply to the piston is blocked. At
the same time oil vents from the back of the piston to
4 Wheel Drive Operation the sump via ports 1 and 2.
This clutch is of the Spring-ON (4WD (Four Wheel Because there is no pressure behind the piston, the
Drive))/Pressure-OFF (2WD (Two Wheel Drive)) clutch friction/counter plates of the clutch pack are
type. forced together by the disc springs, thus driving the
output yoke.
Figure 780.
B C
A1
3 2
1
A2
A Solenoid control valve A1 Solenoid 1

A2 Solenoid 2 B Clutch pack
C Piston D Springs
E Output yoke
27 - 150 9813/9400-1 27 - 150

27 - Driveline
00 - General
2 Wheel Drive Operation and then the pressure plate against the force of the
springs, thus releasing the spring force on the clutch
When the switch is in the 2WD position, the solenoid friction/counter plates of the clutch pack.
valve is energised. The energised solenoid 1 causes
the valve spool to move and form a connection Because there is no spring force, the friction/counter
between ports 3 and 2. plates of the clutch pack now freely rotate on the
output shaft, thus disengaging drive to the front axle.
Pressurised oil is directed to the piston via ports
3 and 2. The piston moves the actuating sleeve
Figure 781.
B C
A1
A
3 2
1
A2

C Piston D Springs
E Output yoke F Actuating sleeve
G Pressure plate
(For: PS766) Start up

The gearbox system is controlled electronically. Electrical interlocks prevent the engine being started,
Inputs from control devices are connected to various unless the transmission is set to neutral. The
ECUs. The ECU’s energise the applicable electrical interlock is controlled by the ECU.
devices depending on the machine status. The
ECU’s are connected to the machine CANbus which Direction Control
enables integrated control of all the main machine
systems. A column switch controls the direction control,
forward, neutral or reverse. The switch is connected
For details of the ECUs installed on the machine refer to inputs on the ECU which in turn energise the
to (PIL 33-45). applicable gearbox control solenoids.
27 - 151 9813/9400-1 27 - 151

27 - Driveline
00 - General
Joystick Direction Control the gearbox. If the road speed is too high a single
double beep is sounded.
Drive direction can also be controlled with the joystick
direction control switch. Inputs from the switch are Pressing the kick down switch a second time causes
connected to the transmission ECU via the joystick the transmission ECU to select the previous gear. An
powerbase ECU and the CANbus. There is a logic indicator light will illuminate until the operator selects
control for drive direction selection. Selection of another gear position using the column switch.
Forward or Reverse with the column switch disables
the joystick direction control switch. Both the joystick Park brake on
and column switch must first be set to Neutral before
the joystick switch is enabled. When the park brake is on, an electrical switch sends
a signal to the transmission ECU which sets the
Manual gear select transmission to neutral even if forward or reverse is
selected. A warning sound will be audible.
When the machine is “Manual” transmission mode
(Transmission mode switch set to “Off”) the gears Transmission dump
can be selected manually. A rotating barrel switch
controls selection of the gear ratios (1,2,3 or 4). The A transmission dump switch on the hydraulic control
switch is connected to inputs on the ECU which lever de-selects the transmission drive when the
energise the applicable gear box control solenoids. switch is operated.
Joystick Gear Selection 2/4 Wheel drive select

Gear ratio selection can be controlled with the A cab mounted switch controls 2 or 4 wheel
joystick ratio up (plus) and down (minus) buttons. drive selection. The switch provides an input to
Inputs from the buttons are connected to the the transmission ECU which in turn energises
transmission ECU via the machine control ECU and the applicable gearbox control solenoid. The
the CANbus. transmission automatically selects 4 wheel drive
when the service brakes are applied.
A gearbox mounted ground speed sensor detects
the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via Foot Brake Control
the machine control ECU and the CANbus. The ECU
responds by preventing ratio selection if the machine When the foot brake operates a pressure transducer
ground speed is not within pre-set values. mounted in the hydraulic brake line detects the
change in brake system pressure. Input from
When the ratio up (plus) button is pressed the the transducer is connected to the transmission
transmission ECU selects the next (higher) gear ECU. The transmission ECU selects neutral even
ratio. When the ratio down (minus) button is pressed if Forward or Reverse is selected. The feature
the transmission ECU selects the next (lower) gear enables an increase in machine braking efficiency.
ratio. An operator switch in the cab can be set to enable or
disable the feature.
Automatic gear select
Transmission Oil Pressure and
An operator switch in the cab can be set to enable Temperature
‘Auto mode’. The gearbox will automatically up shift
and down shift. The transmission ECU programme Oil pressure and temperature sensors are connected
selects the most economical gear for a given road to the machine instrumentation which displays the
speed and engine load. To enable up shifts the pressure and temperature status. Warning displays
accelerator pedal must be pressed, this prevents up and fault codes are activated if the oil pressure or
shifting when coasting down hill for example, thus temperature is not within pre-set values.
ensuring maximum machine control.
Lock up torque converter option
Kickdown operation
The lock up torque converter operates automatically
The column switch incorporates a kickdown switch between preset parameters when F5 or F6 gears are
which enables the operator to down shift to the selected. When field mode is selected the lock up
next lowest gear, depending on which `mode' is torque converter can be disabled.
selected. The transmission ECU checks to see if the
machine road speed is suitable before down shifting
27 - 152 9813/9400-1 27 - 152

27 - Driveline
00 - General
Limp Modes Figure 783. 2nd gear forward (4 wheel drive)
When necessary the transmission ECU will provide

alternative gear selection should faults occur. This
enables the machine to be moved (`limped') under its
own power. For limp mode details refer to Technical
Data (PIL 27-06).
Fault codes may also be displayed on the instrument

panel. For fault codes refer to (PIL 33-57-90).
T
Drive paths
Forward
Figure 782. 1st gear forward (4 wheel drive)
Z
X
S
Table 339.
Z applied) (S)
S Figure 784. 3rd gear forward (4 wheel drive)
Table 338.
6 speed (X) 3004 (Xs)
Layshaft (Z) 3029 (Zs) U
applied) (S)
27 - 153 9813/9400-1 27 - 153

27 - Driveline
00 - General
Table 340. Figure 786. 5th gear forward (4 wheel drive)

applied) (S)
Figure 785. 4th gear forward (4 wheel drive)

T
X
Table 342.
Z Clutches engaged Solenoids energised
S 2/4 wheel drive (spring -
applied) (S)
Table 341. Figure 787. 6th gear forward (4 wheel drive)

6 speed (X) 3004 (Xs)
applied) (S)
27 - 154 9813/9400-1 27 - 154

27 - Driveline
00 - General
Table 343. Figure 789. 2nd gear reverse

applied) (S)
V
Reverse
Figure 788. 1st gear reverse
W Z
Table 345.
Z Clutches engaged Solenoids energised
Reverse high ratio (V) 3040 (Vs)
S Layshaft (Z) 3029 (Zs)
applied) (S)
Figure 790. 3rd gear reverse

Table 344.
Reverse low ratio (W) 3041 (Ws)
2/4 wheel drive (spring - W
applied) (S)
27 - 155 9813/9400-1 27 - 155

27 - Driveline
00 - General
Table 346. driven bevel gearbox. As the engine starts to rotate,

the converter gives smooth power take off and
gradually increases the torque transmitted. This
Reverse low ratio (W) 3041 (Ws) torque is transferred from the converter assembly to
Mainshaft (Y) 3033 (Ys) the clutch/gear assemblies through the input shaft on
2/4 wheel drive (spring - the forward clutch assembly.
applied) (S)
The forward clutch assembly contains two
Figure 791. 4th gear reverse hydraulically operated clutches: one clutch gives a
forward low ratio drive and the other gives a forward
high ratio drive. The clutches are controlled by a
either the forward low (solenoid 3022) or forward high
V
The reverse clutch assembly is also similar to the
forward clutch assembly. It contains two hydraulically
operated clutches: one clutch gives a reverse low
ratio drive and the other gives a reverse high ratio
drive. The reverse clutches are controlled by a
Y three position solenoid valve. When the applicable
either the reverse low (solenoid 3041) or reverse high
Both the mainshaft and the layshaft assemblies have

a single clutch each. Both clutches are controlled
S by a three position solenoid valve. When energised,
solenoid 3029 directs pressurised oil to the layshaft
clutch and solenoid 3033 directs pressurised oil the
mainshaft clutch.
Table 347.
On 6-speed gearboxes, the 6-speed clutch X is
Clutches engaged Solenoids energised controlled via solenoid valve 3004.
Reverse high ratio (V) 3040 (Vs)
When a gear is selected through the control switch
in the cab, two clutches are always engaged.
2/4 wheel drive (spring - When you select different pairs of clutches different
applied) (S) gear ratios are engaged. Relays electrically control
the solenoids. All the clutches work on the same
Hydraulic operation and schematics principle.
The engine directly drives the oil pump through the The 2/4 wheel drive unit also has a single clutch.
torque converter. In normal operation the clutch is spring loaded and
therefore engaged to give 4 wheel drive. When
Oil from the pump is fed through an internal passage 2 wheel drive is selected, solenoid valve 3002 is
via the filter to the PMV, which maintains pressure energised and directs pressurised oil to the 2/4 wheel
to the solenoid valves for clutch selection. Excess oil drive clutch.
from the maintenance valve flows back through the
case to the torque converter. A relief valve controls In the schematic, the gearbox is shown with 2nd
pressure in the converter and dumps oil from the gear forward engaged. 2nd gear forward requires
converter line back to the sump. the forward low clutch T and layshaft clutch Z to
be engaged. When the gear selection switch is
Oil from the torque converter flows out of the gearbox moved to 2nd gear forward, the electrical control
to the external oil cooler and again comes back to system energises solenoid valves 3022 and 3029.
the converter. Oil then flows through internal oil ways Pressurised oil is diverted to the back of pistons
providing lubrication for clutches and bearings before in both clutches to engage the drive. At the same
it goes back to the gearbox sump. time all other solenoids are de-energised, diverting
oil from the back of the other clutch pistons to the
The torque converter is a fluid coupling bolted to gearbox sump. 4 wheel drive clutch 3002 is also
a drive plate which in turn is bolted to the engine energised to give 2 wheel drive.
27 - 156 9813/9400-1 27 - 156

27 - Driveline
00 - General
Figure 792.
H G
2 1 K X
2 3 3
3004 C
5 1 W V Q A
3021 J
3022 T U
1
3002
B
3041
Y
M
3040 z
L 6
3033
D
E S
3029
N F
P
Table 348.
Item Description
A Torque converter
B Forward clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive unit
G Torque converter relief valve
H Pressure maintenance valve
J Pump
L Park brake pack
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P 6-Speed clutch assembly (if installed)
S Gear drive to reverse unit clutch assembly
Q Oil filter
T Forward low ratio clutch
U Forward high ratio clutch
V Reverse high ratio clutch
W Reverse low ratio clutch
X 6 speed clutch (PS766 only)
Y Mainshaft clutch
Z Layshaft clutch
1 Solenoid port 1
27 - 157 9813/9400-1 27 - 157

27 - Driveline
00 - General
Item Description
2 Solenoid port 2
3 Solenoid port 3
5 Solenoid valve control block
6 External oil cooler
Forward and Reverse Clutch Operation is then transmitted from the input shaft to the gear
1. Clutch for gear 2 is disengaged and no drive is
The forward and reverser clutch assembly transfers transmitted to gear 2 plate carrier. The gear is also
drive from the input shaft to either gear 1 or gear 2 free to rotate on the input shaft assembly.
depending on which of the two clutches is engaged,
giving forward or reverse drive. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve.
When neither clutch is engaged, neutral is selected.
When neutral is selected both solenoids are
The clutches are of the wet, multi plate type. deactivated and the flow of pressurised oil to the
clutches is blocked. The gear springs 1 and 2 move
The clutch housings and input shaft are a one piece the pistons away from the clutch plates and oil from
assembly. The assembly is permanently driven by both pistons is vented to the sump.
the engine via the torque converter.
When either forward or reverse is selected, the
Clutch counter plates are also permanently driven solenoid control valve diverts pressurised oil via
via meshing teeth inside the clutch housings. Clutch cross drillings inside the input shaft to the appropriate
friction plates are meshed with the gear plate clutch piston in the unit. Pressure from the other
carriers. clutch is vented to the sump via the solenoid valve
spool. Oil is prevented from leaking by seals on the
In the diagram, clutch for gear 1 is engaged. pistons and ring seals on the input shaft.
The counter plates and friction plates are pressed

together by a hydraulically actuated piston. Drive
27 - 158 9813/9400-1 27 - 158

27 - Driveline
00 - General
Figure 793.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q
A Input shaft assembly B Gear 1 clutch

C Gear 1 piston D Piston external seal
E Gear 2 piston F Gear 2 clutch
G1 Gear 1 G2 Gear 2
H Input shaft ring seals J Gear 2 spring
K Gear 1 spring L Piston internal seal
M Clutch friction plates N Clutch counter plates
P Solenoid - gear 1 Q Solenoid - gear 2
R Solenoid control valve
27 - 159 9813/9400-1 27 - 159

27 - Driveline
00 - General
Mainshaft and Layshaft Clutch Operation piston via a solenoid valve. The solenoid valve is
operated by a switch in the cab.
The mainshaft and layshaft units incorporate one
clutch and not two, as in the forward and reverse When the switch is in the 4WD position, the solenoid
units. The operation of the single clutches is the valve is de-energised. With the solenoid 1 de-
same as for one clutch in the forward or reverse units. energised, the valve spool moves under the force of
the spring. The oil supply to the piston is blocked. At
2 and 4 Wheel Drive Clutch Operation the same time oil vents from the back of the piston to
the sump via ports 1 and 2.
4 Wheel Drive Operation Because there is no pressure behind the piston, the
clutch friction/counter plates of the clutch pack are
This clutch is of the Spring-ON (4WD)/Pressure-OFF forced together by the disc springs, thus driving the
(2WD) type. output yoke.
The clutch is engaged and disengaged by
introducing or dumping pressurised oil behind the
Figure 794.
B C
A1
3 2
1
A2

C Piston D Springs
E Output yoke
27 - 160 9813/9400-1 27 - 160

27 - Driveline
00 - General
2 Wheel Drive Operation and then the pressure plate against the force of the
springs, thus releasing the spring force on the clutch
When the switch is in the 2WD position, the solenoid friction/counter plates of the clutch pack.
valve is energised. The energised solenoid 1 causes
the valve spool to move and form a connection Because there is no spring force, the friction/counter
between ports 3 and 2. plates of the clutch pack now freely rotate on the
output shaft, thus disengaging drive to the front axle.
Pressurised oil is directed to the piston via ports
3 and 2. The piston moves the actuating sleeve
Figure 795.
B C
A1
A
3 2
1
A2

C Piston D Springs
E Output yoke F Actuating sleeve
G Pressure plate
27 - 161 9813/9400-1 27 - 161

27 - Driveline
00 - General
Fault-Finding
Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 349. Page 27-162
overheating.
Machine does not drive in any gear. Table 350. Page 27-163
Some gears fail to engage or lack power. Table 351. Page 27-164
Gearbox oil overheating. Table 352. Page 27-164
Noisy operation. Table 353. Page 27-165
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 354. Page 27-165
Cannot engage 2WD (Spring ON clutch). Table 355. Page 27-165
Gearbox oil contaminated with water. Table 356. Page 27-166
Consequential Faults (Gearbox faults caused typically by water Table 357. Page 27-166
contamination and other factors related to the gearbox oil.)- Pressurisation
of gearbox casing. Dipstick blows out and oil escapes from dipstick tube.
contamination and other factors related to the gearbox oil.)- Clutch failure
due to friction lining separation.
contamination and other factors related to the gearbox oil.)- Badly worn or
noisy bearings.
Machine does not achieve maximum speed when travelling on the highway Table 360. Page 27-167
(Lock-up torque converter variants only).
Gear shifts fail to function normally- Sychroshuttle gearboxes only. Table 361. Page 27-167
Gear shifts fail to function normally or shifts occur at the incorrect road Table 362. Page 27-167
speed.
The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and Table 363. Page 27-167
6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th
gears fail to engage, check that the lower 3 gears function correctly before
investigating a possible Shiftmaster fault, refer to `Fault Table- Some gears
fail to engage or lack power').
Table 349. Machine drives but lacks power in all gears. Gearbox oil may also be overheating.
Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Pressure maintenance valve defective. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the pressure maintenance valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the torque converter relief valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
27 - 162 9813/9400-1 27 - 162

27 - Driveline
00 - General
Cause Remedy
Oil cooler lines restricted or blocked. Internal Carry out oil pressure and flow tests. Refer to
blockage within the oil cooler matrix due to driveline- semi-automatic gearbox, refer to (PIL
contamination. 27-06).
Clear the restriction. Inspect the hose routing
and install new the hoses or oil cooler matrix as
applicable.
Faulty torque converter. Carry out torque converter stall tests to confirm stall
speeds are within specification. Refer to driveline-
Torque converter, refer to (PIL 27-14).
Remove the gearbox and install new the torque
converter. Note that the torque converter assembly is
a non serviceable item.
Failure of oil pump assembly. Carry out the oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect the oil pump for
signs of damage or excessive wear. Install new oil
pump as applicable.
Gearbox internal leakage fault. Carry out oil pressure and flow tests. Refer to
27-06).
Remove and disassemble the gearbox. Inspect all
components for signs of damage or excessive wear.
In particular, check the seals and install new as
applicable.
Table 350. Machine does not drive in any gear.

Cause Remedy
Park brake switch or transmission dump switch Check the function of the park brake switch and
defective. transmission dump switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Gear selector column switch defective. Check the function of the gear selector column
switch.
Clutch solenoid wiring defective Inspect the condition of the associated electrical
Low mainline oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new oil pump as
applicable.
27 - 163 9813/9400-1 27 - 163

27 - Driveline
00 - General
Table 351. Some gears fail to engage or lack power.

Cause Remedy
Gear selector column switch defective. Check the function of the gear selector column
switch.
The relevant solenoid valve is not being energised. Inspect the condition of the associated electrical
Solenoid coil faulty. Check the solenoid for open or short circuits.
Measure the solenoid coil resistance. If required,
install new solenoid coil.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
automatic gearbox, refer to (PIL 27-06).
Check for clutch slippage. Carry out torque
converter stall tests to confirm stall speeds are within
specification. Refer to driveline- Torque converter,
Remove and disassemble the gearbox. Inspect
relevant clutch components for signs of damage or
excessive wear. Install new as applicable.
Table 352. Gearbox oil overheating.

Cause Remedy
Oil cooler heat exchanger matrix clogged with dirt Clean the oil cooler matrix. Refer to operators
particles or chaff. (Air blast coolers only. Some manual.
machines have liquid to liquid type coolers.)
gearbox. Refer to driveline- semi-automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or renew
Oil cooler hoses kinked or trapped. Clear the restriction. Inspect the hose routing and
reroute or renew the hoses as applicable.
Machine being operated incorrectly i.e. Incorrect gear Educate the operator.
ratio.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new the pump
as applicable.
27 - 164 9813/9400-1 27 - 164

27 - Driveline
00 - General
Table 353. Noisy operation.

Cause Remedy
gearbox. Refer to driveline- semi-automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
Low lubrication oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Gearbox components damaged or excessively worn. Remove and disassemble the gearbox. Inspect all
the components for signs of damage or excessive
wear. In particular, check shaft seals and bearings.
Install new as applicable.
Table 354. Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch).
Cause Remedy
4 wheel drive solenoid valve spool is sticking in Remove and inspect the solenoid valve cartridge.
the 2WD (Two Wheel Drive) drive position due to Clean the valve or renew as applicable.
contamination.
Solenoid coil permanently energised. Check the function of the 4WD selector switch.
Failure of clutch assembly Remove the 4WD clutch assembly. Inspect the clutch
Renew as applicable.
Table 355. Cannot engage 2WD (Spring ON clutch).

Cause Remedy
4WD selector switch defective. Check the condition of the 4WD selector switch.
4WD solenoid valve is not being energised. Inspect the condition of the associated electrical
Solenoid coil faulty. Check the solenoid for open or short circuits.
install a new solenoid coil.
4WD solenoid valve spool is sticking in the 4WD Remove and inspect the solenoid valve cartridge.
position due to contamination. Clean the valve or install new as applicable.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
Remove the 4WD clutch assembly. Inspect the clutch
Install new as applicable.
27 - 165 9813/9400-1 27 - 165

27 - Driveline
00 - General
Table 356. Gearbox oil contaminated with water.

Cause Remedy
Water ingress during filling or topping-up. Drain the oil and flush the gearbox. Refer to
27-06).
Missing or incorrect dipstick. Damaged filler tube. Install new parts as required. Drain the oil and flush
the gearbox.
Machine operated in deep water. Drain the oil and flush the gearbox. Refer to
27-06).
Gearbox oil cooler faulty, gearbox oil contaminated Remove and test the oil cooler. Refer to cooling
with engine coolant. (Liquid to liquid oil coolers only.) system- cooling pack, refer to (PIL 21-03-09).
Gearbox casings damaged. Inspect the gearbox casing. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Gearbox oil circuit pipework or hoses damaged. Inspect the pipework and hoses. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Table 357. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Pressurisation of gearbox casing. Dipstick blows out and oil escapes
from dipstick tube.
Cause Remedy
Water in the oil combined with heat from torque Replace or renew the dipstick.
converter causes steam. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Clutch failure due to friction lining separation.
Cause Remedy
Water ingress. Remove and dismantle gearbox. Inspect relevant
clutch components for signs of damage or excessive
wear. Install new as applicable.
Overheating transmission oil. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Badly worn or noisy bearings.
Cause Remedy
Water ingress. Remove and dismantle the gearbox. Inspect all
Install new components as applicable.
Insufficient lubrication. Drain the oil and flush the gearbox. Refer to
27-06).
Carry out oil pressure and flow tests. Refer to
27-06).
27 - 166 9813/9400-1 27 - 166

27 - Driveline
00 - General
Table 360. Machine does not achieve maximum speed when travelling on the highway (Lock-up torque
converter variants only).
Cause Remedy
Operator error. Educate the operator. Ensure operator fully
understands the characteristics of the lock up
function.
Lock up torque converter solenoid not being Inspect the condition of the associated electrical
energised. wiring, plugs and connectors for damage and check
Lock up torque converter solenoid coil faulty. Check the solenoid for open or short circuits.
renew the solenoid coil.
Engine or transmission speed sensor faulty. Use the applicable JCB Diagnostics software to
check the ECU (Electronic Control Unit) inputs
and outputs. Refer to electrical system- electronic
diagnostic, refer to (PIL 33-57).
wiring, plugs and connectors or damage and check
that the relevant fuses are intact. If required, install a
new speed sensor.
Faulty lock up torque converter. Remove the gearbox and renew the lock up torque
converter. Note that the torque converter assembly is
a non serviceable item.
Table 361. Gear shifts fail to function normally- Sychroshuttle gearboxes only.
Cause Remedy
Cable shift mechanism faulty Adjust or replace gear shift cables as necessary.
Table 362. Gear shifts fail to function normally or shifts occur at the incorrect road speed.
Cause Remedy
Gear selector column switch faulty Check the function of the gear selector column
switch. Also Inspect the condition of the associated
electrical wiring, plugs and connectors for damage
and make sure that the relevant fuses are intact.
Table 363. The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and 6th gears utilise
clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage, check that the lower 3
gears function correctly before investigating a possible Shiftmaster fault, refer to `Fault Table- Some
gears fail to engage or lack power').
Cause Remedy
Transmission speed sensor faulty. Check the function of the speed sensor.
If required, install a new speed sensor.
27 - 167 9813/9400-1 27 - 167

27 - Driveline
00 - General
Cause Remedy
Gearbox ECU defective. (In response to certain Use the ECU Diagnostics software to check the
faults the ECU will enter a `Limp Mode'. For a ECU inputs and outputs. Refer to electrical system-
detailed description of the Limp Modes, refer electronic diagnostic, refer to (PIL 33-57).
to `Service Procedures - Powershift Gearbox, Inspect the condition of the associated electrical
Electronic Control Unit'.) wiring, plugs and connectors for damage and check
Install new ECU. (The ECU is inherently reliable.
It is protected internally from electrical damage.
It is housed in a rugged case for protection from
mechanical damage and ingress of dirt and moisture.
Faults with associated systems are more likely to be
caused by wiring or other input and output device
failure. Before renewing the ECU make sure beyond
reasonable doubt that it is faulty.)
27 - 168 9813/9400-1 27 - 168

27 - Driveline
00 - General
Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30min
Transmission Oil and Filter
14. Allow the machine to cool then drain the
Refer to driveline, semi-automatic gearbox, Filter, transmission oil through the suction strainer
(PIL 27-06-39). aperture. Refer to (PIL 27-06-40).
15. Test the oil for contamination. If the oil is still
Transmission Oil Suction Strainer contaminated, repeat the flushing procedure
Refer to driveline, semi-automatic gearbox, Suction from step 3
Strainer, (PIL 27-06-40). 16. If the oil is clean:
Flushing the Transmission Oil 16.1. Replace the suction strainer. Refer to (PIL
27-06-40).
1. If the transmission oil has been contaminated
with water or incorrect oil types, the transmission 16.2. Install a new oil filter. Refer to (PIL
must be flushed to effectively remove the 27-06-39).
contaminated oil. 16.3. Fill the transmission with the correct grade
of fresh oil. Refer to (PIL 75-00)
16.4. Check the oil level and top up as required.
3. Drain the oil from the gearbox. Refer to (PIL Refer to (PIL 27-06-00).
27-06-40).
4. Remove the suction strainer. Refer to (PIL
27-06-40).
5. Clean the suction strainer and install. Refer to
(PIL 27-06-40).
6. Replace the oil filter. Note that the filter may be
remotely mounted on some installations. Refer to
(PIL 27-06-39).
7. Fill the transmission with the correct grade of
fresh oil. Refer to (PIL 75-00).
8. Check the oil level and top up as required. Refer
to (PIL 27-06-00).
9. Start the engine and run the machine until the
normal operating temperature is as specified.
Temperature: 50–100°C (121.9–211.9°F)
10. Stall the torque converter for the specified
duration. Refer to (PIL 27-14).
Duration: 5s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5min
12. Repeat step 10.
27 - 169 9813/9400-1 27 - 169

27 - Driveline
00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
solvent based parts Strength)
cleaner
Before assembling the gearbox, make sure that a
1. Carefully remove all traces of the gasket thorough inspection of all components is carried out.
or gasket compound from the following Remember that although a failed component may
components: be easy to identify, the cause of that failure may be
less easy to trace. It is also possible that a failed
1.1. Front and rear case mating faces component may have caused damage to other areas
1.2. Front case and torque converter housing of the gearbox.
mating faces
1. Cleaning: Refer to Semi-Automatic Gearbox -
1.3. Solenoid control valve manifold and case Clean, refer to (PIL 27-06).
mating faces
2. General Inspection:
1.4. 4WD case mating faces (if applicable)
1.5. Layshaft cover and rear case mating faces. 2.1. Carefully inspect all gears, bearings and
shafts for signs of excessive wear or
2. Clean the inside of the cases using a suitable damage. If wear or damage is evident, the
degreasing agent. components must be renewed.
Consumable: Cleaner/Degreaser - General 2.2. Make sure that all oil way cross drillings are
purpose solvent based parts cleaner clear and free from debris. Blocked oil ways
are a common cause of bearing failure. If
necessary use an air line to blow through
the oil ways.
3. Clutch Units:
3.1. If a clutch failure is suspected see the
relevant clutch dismantling and assembly
procedure, refer to (PIL 27-06).
4. Gearbox Oil Pump-Renew:
4.1. If tests have shown the pump performance
to be unacceptable, the pump must be
renewed as a complete unit.
4.2. Make sure that the pump mating face on the
gearbox front cover is clean and free from
surface damage.
5. Gearbox Oil Pump-Replace: If the existing pump
is to be re-installed proceed as follows:
5.1. Undo the security screw and separate
the pump body. Carefully inspect the gear
teeth, white metal bearing and gear/body
mating faces for signs of wear and damage,
(If either is evident, the pump must be
renewed).
5.2. Carefully remove and discard the oil seal.
Take care not to damage the seal housing.
5.3. Install a new seal. Install the seal the correct
way around. Push the seal flush with the
front of the housing.
27 - 170 9813/9400-1 27 - 170

27 - Driveline
00 - General
5.4. Re-assemble the pump. Check (Level)

Figure 796.
2. Start the engine and operate at low idle for the
specified time. This allows the oil to fill the filter,
pump, torque converter, oil cooler and hoses.
Duration: 4min
3. Stop the engine.
4. Remove the ignition key.
5. Gain access to the dipstick. Refer to (PIL 06-06).
A
B 6. Before you complete a check of the oil level, you
must wait as shown on the instructional label.
The instructional label shows the waiting time in
seconds.
7. Make sure that the area around the dipstick and
tube are clean and free of debris before removing
B the dipstick.
8. Check the gearbox oil level on the dipstick. The
C oil level must be between the end of the dipstick
and maximum mark on the dipstick.
A Security screw
B Oil seal 9. Clean the dipstick with a clean lint free cloth.
C Housing Make sure that no debris remain on the dipstick
or enters the transmission via the dipstick tube.
6. Cases:
10. If necessary add clean new oil through the
6.1. If the gearbox cases are to be renewed, be dipstick tube.
sure to install blanking plugs and adaptors
as required. Inspect the original cases Water Contamination
and identify the blanking plug and adaptor
positions. Transfer the plugs and adaptors Carefully inspect the gearbox oil for signs of water
to the new cases. Apply JCB Threadlocker contamination. Contaminated oil will contain water
and Sealer to the threads. Note that new droplets or be visibly emulsified.
plugs may be supplied with a sealant patch,
in which case sealant need not be applied. Water droplets may be visible on the dipstick or
Consumable: JCB Threadlocker and Sealer inside the filler tube. For oil analysis purposes, the
(Medium Strength) maximum permissible water content of the oil is
0.10%. If the gearbox oil has been contaminated
with water, faults or damage to the gearbox may
be apparent as a result. Before trying to remedy,
thoroughly investigate and rectify the cause of the
water contamination.
27 - 171 9813/9400-1 27 - 171

27 - Driveline
00 - General
Check (Pressure)
Special Tools Before you start any of the transmission pressure/

Description Part No. Qty. flow test, make sure that the oil level is correct and
Flowmeter 892/00229 1 at normal operating temperature (not less than 50°C
(121.9°F)).
Bar) Do the these test procedures:
To help with fault identification, record the test results • Pump flow test
on a check list. The check list will help the engineer to • Mainline pressure test
identify the cause of a gearbox fault and if needed it • Converter in pressure
can be sent to JCB Technical Service by email. Refer • Converter relief (safety) valve pressure
to Figure 803. • Converter out pressure and oil cooler flow rate
• Lubrication pressure
Make sure you follow all safety procedures before • Clutches- Isolating a suspect clutch
working on the machine. Refer to (PIL 01-03). • Clutches- Individual clutch leakage test
27 - 172 9813/9400-1 27 - 172

27 - Driveline
00 - General
Figure 797. Test points
A D
H
Item Description
F Reverse high ratio clutch
Table 364. Test points
pressure
Item Description G Reverse low ratio clutch
A Mainline pressure pressure
B Mainshaft clutch pres- H Layshaft clutch pressure
sure J 2/4 wheel drive clutch
C Converter inlet and con- pressure
(1)
verter relief valve pres-

sure (1) Machines with selectable 2/4 wheel drive option.
D Forward high ratio clutch
pressure
E Forward low ratio clutch
pressure
27 - 173 9813/9400-1 27 - 173

27 - Driveline
00 - General
Mainline pressure 2.1. A low reading can be caused by either

a faulty pressure maintenance valve or a
1. Stop the engine, connect a pressure gauge of the worn pump. Refer to Figure 798.
specified limit to the mainline pressure test point.
2.2. A high or low reading may indicate a
faulty pressure maintenance valve. Refer to
Pressure: 0–20bar (0.0–289.9psi) Figure 798.
2. Start engine and run at 1000 RPM (Revolutions 3. Do the 2 again with engine running at 2000 RPM
Per Minute). With the transmission in neutral the note the gauge readings. Refer to Figure 798.
pressure gauge will show the main line pressure.
Refer to Figure 798. 4. Stop engine and remove the test gauge. Refer to
Figure 798.
27 - 174 9813/9400-1 27 - 174

27 - Driveline
00 - General
Figure 798. Pump flow test
A
L
X Y Z
P
Q
N
27 - 175 9813/9400-1 27 - 175

27 - Driveline
00 - General
Special Tool: Flowmeter (Qty.: 1)
Table 365. 4. Start engine and run at 1000 RPM. With the
transmission in neutral the flowmeter will show
Item Description
the pump flow. Refer to Figure 798.
A Mainline pressure test
point 4.1. A low reading indicates a worn pump or
K Transmission oil filter blocked suction strainer. Refer to Figure
L Flowmeter 798.
M Male adapter 5. Again do step 4 and note gauge readings with
N Female adapter engine running at 2000 RPM. Refer to Figure
P Banjo bolt 798.
Q Fitting adapter 6. Stop engine and remove test adapters. Remove
R Pressure test adapter the gearbox adapter and install the filter. Refer to
Figure 798.
Pump flow (machines with direct mount
oil filter) Converter in pressure
1. Stop the engine. Clean the area around the Note that the converter in pressure is affected by
transmission oil filter. Refer to Figure 798. the transmission oil temperature, cooler circuit back
pressure and torque converter relief valve operation.
2. Remove the filter and the adapter installed to the Before carrying out tests check the operation of the
gearbox. Refer to Figure 798. relief valve.
3. Install one of the three alternative pump flow 1. Stop the engine, connect a pressure gauge of the
test adapters in place of the oil filter. The choice specified limit to the converter inlet and converter
of adapter is best determined by the ease of relief valve pressure test point. Refer to Figure
installation and/or accessibility. Refer to Figure 799.
798.
Pressure: 0–20bar (0.0–289.9psi)
3.1. Note that adapter type 'z' is installed as Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
standard on machines with a remote oil
filter. Refer to Figure 798. 2. Start engine and run at 1000 RPM. With the
transmission in neutral the pressure gauge will
3.2. Type 'x': Install the female adapter in the show the converter in pressure. Refer to Figure
gearbox case. Install the male adapter in 799.
the female adapter. Install the pressure test
adapter over the female and male adapter. 2.1. A low reading could indicate a worn pump,
Install the oil filter to clamp the pressure test a worn pump would also be evident during
adapter in place.Refer to Figure 798. a pump flow test. Refer to Figure 799.
3.3. Type 'y': With the component parts 2.2. A high pressure together with low flow could
assembled, install and secure with banjo be caused by a blocked oil cooler. Refer to
bolt screwed into the gearbox and tightened Figure 799.
to the correct torque value. Refer to Figure 2.3. Low pressure could be caused by a faulty
798. pump or internal leakage. Refer to Figure
3.4. Type 'z': With the component parts 799.
assembled, install and secure with fitting
adapter screwed into the gearbox, and 3. Stop the engine and remove the pressure test
tightened to the correct torque value. Refer gauge. Refer to Figure 799.
to Figure 798.
3.5. Connect the flowmeter to the flow and
return adapters (shown with arrows). Refer
to Figure 798.
27 - 176 9813/9400-1 27 - 176

27 - Driveline
00 - General
Figure 799. Converter in, converter relief valve pressure tests

S
C Converter inlet and converter relief valve S Load valve

pressure test point
27 - 177 9813/9400-1 27 - 177

27 - Driveline
00 - General
Converter relief (safety valve) pressure does not indicate a fault. If necessary reset the
load valve and perform the test again, carefully
The purpose of the torque converter relief valve is watch the pressure gauge. Refer to Figure 799.
to protect the torque converter from excessive oil
pressure. Excessive oil pressure can be generated 6. If the converter relief valve opens at a pressure
when the transmission oil temperature is below 50°C higher than specified then the valve is faulty.
(121.9°F) and/or the engine is run at over 2000 RPM. Refer to Figure 799.
7. A low opening pressure indicates a leaking pump
In this event the relief valve opens and returns
to casing seal or a faulty converter relief valve.
oil directly to the transmission sump, bypassing
the torque converter, cooler and clutch lubrication
circuits, protecting against damage due to excessive 8. Stop engine, remove test gauges and the load
pressure. valve. Refer to Figure 799.
For this reason it is essential that the transmission oil 9. Install hoses to their original position. Refer to
should be more than 50°C (121.9°F) and the engine Figure 799.
should run between idle and 1000 RPM when you
test the relief valve. Bypassing the converter relief valve
1. Connect a pressure gauge of the specified limit
During some powershift pressure and oil flow tests
to the converter inlet and converter relief valve
it is advisable to temporarily bypass the converter
pressure test point. Refer to Figure 799.
relief valve. If the relief valve opens at the time of the
Pressure: 0–20bar (0.0–289.9psi) following tests it will cause false results.
• Converter out pressure/Oil cooler flow rate
2. Install a load valve into the converter out line. • Converter in pressure
Make sure the load valve is fully open before • Lubrication pressure
starting the test. Refer to Figure 799. • Torque converter stall test
3. Do not allow the pressure to exceed more than Before you bypass the torque converter relief valve
the specified value, or else it can damage the make sure that the mainline pressure is correct and
converter seals. Refer to Figure 799. that the transmission oil filter is fitted.
To temporarily bypass the relief valve (prevent the
4. Start the engine and run at 1000 RPM. With the valve from opening) proceed as follows:
transmission in neutral, slowly screw down the
load valve and monitor the gauge reading which 1. Stop the engine and remove the relief valve.
should increase to the converter relief (safety) Refer to Figure 800.
valve pressure setting. Refer to Figure 799.
2. Carefully remove the spring. Refer to Figure 800.
5. The gauge pressure will fall, once the valve has
opened. This is normal relief valve operation and 3. Obtain a suitable plug, drill and tap the centre
then install a locking bolt. Refer to Figure 800.
27 - 178 9813/9400-1 27 - 178

27 - Driveline
00 - General
Figure 800. Bypass the converter relief valve
U
T
T Spring U Locking bolt

V Spool
4. Install the plug assembly to the relief valve 2. Do not run the engine at more than 2000 RPM
housing and tighten the bolt to hold the spool on for more than the specified time. Refer to Figure
its seat. Refer to Figure 800. 800.
5. Do not damage the spool and its seat. Refer to Duration: 1min
Figure 800.
When the check is complete make sure to remove
The torque converter can be damaged when the the plug assembly and install the spring and cover/
converter relief valve is bypassed. To prevent the plug.
torque converter from damage follow the below
steps. Converter out pressure and oil cooler
flow rate
1. Before you start the engine make sure that
the transmission oil temperature is above the Note that the converter out pressure and oil cooler
specified value. Refer to Figure 800. flow rate are affected by the torque converter relief
Temperature: 50°C (121.9°F) valve operation. Before you carry out the test check
the operation of the relief valve.
27 - 179 9813/9400-1 27 - 179

27 - Driveline
00 - General
1. Stop the engine. Connect a pressure gauge cooler flow rate. Make sure that the readings are
of the specified limit and flowmeter into the correct. Refer to Figure 801.
converter out line. Refer to Figure 801.
4.1. A high pressure together with low flow could
Pressure: 0–20bar (0.0–289.9psi) be caused by a blocked oil cooler. Low
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) pressure could be caused by a faulty pump
Special Tool: Flowmeter (Qty.: 1) or internal leakage. Refer to Figure 801.
2. The flowmeter may cause back pressure, so 5. Do the steps 3 and 4 with engine running at 2000
bypass the torque converter relief valve or else RPM and note gauge readings. Refer to Figure
it may open and cause false readings. Refer to 801.
Figure 801.
6. Stop the engine. Remove test gauges and install
3. Run the engine at 1000 RPM with transmission hoses to original position. Refer to Figure 801.
in neutral. Refer to Figure 801.
7. Make sure you remove the torque converter
4. The pressure gauge indicates the converter out relief valve by-pass assembly and install the
pressure and the flowmeter indicates the oil relief valve (ball, spring and cover/plug). Refer to
Figure 801.
Figure 801. Converter out, Lubrication pressure tests
W
L
AA
L Flowmeter W Pressure gauge

AA Pressure gauge connected to the return line
from the oil cooler
27 - 180 9813/9400-1 27 - 180

27 - Driveline
00 - General
Lubrication pressure park brake on. Therefore, so that we can

complete the test, move the park brake lever
Note that the lubrication pressure is affected by fractionally forward until the warning light is just
the torque converter relief valve operation and back extinguished; hold the lever in this position for the
pressure in the oil cooler circuit. Before you carry out duration of the test.
the test check the operation of the relief valve.
4. Do not move the lever too far forward, otherwise
1. Stop the engine, connect a suitable pressure the park brake will not be fully operational.
gauge into the return line from the oil cooler to Alternatively, disconnect the switch at the park
the transmission. Refer to Figure 801. brake.
2. Start the engine and run at 1000 rev/min. 5. Start engine and run at 1000 RPM, engage1st
With the transmission in neutral the pressure gear forward. Record the pressure reading.
gauge will indicate the lubrication pressure which Repeat the test for all gears in forward drive and
should be correct. Refer to Figure 801. record the pressure readings. Refer to Refer to
Table 366.
3. Do step 2 and note gauge readings with engine
running at 2000 RPM. If the pressure is high the 5.1. Readings should not vary between clutches
oil cooler may be blocked. Refer to Figure 801. by more than the specified value.
4. Stop the engine and remove the pressure gauge.
5.2. In the table of examples shown, we can
Isolate a suspect clutch see that pressure is low when 2nd and 4th
gear forward is selected, indicating clutch
1. Stop the engine. Connect a pressure gauge of leakage. Refer to Table 366.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 802. high clutch is used for selection of both 2nd
Pressure: 0–20bar (0.0–289.9psi) and 4th gear forward.
5.4. We know from the table that the mainshaft
2. Make sure that both sides of all four wheels are and layshaft clutches are working normally
chocked. Apply the foot brake and park brake. (1st and 3rd gear selection show normal
operating pressure). So we can assume
3. When fully engaged, the park brake electrically that the forward high clutch is leaking.
disconnects the transmission drive, this prevents
the machine from being driven with the 6. If necessary, do the above test again using
reverse clutch ratios.
Table 366.
Gear select Ratio clutch Mainshaft or layshaft Value (Examples Only)
clutch
1st Forward low Layshaft 9.65bar (139.9psi)
2nd Forward high Layshaft 8.62bar (124.9psi)
3rd Forward low Mainshaft 9.65bar (139.9psi)
4th Forward high Mainshaft 8.62bar (124.9psi)
27 - 181 9813/9400-1 27 - 181

27 - Driveline
00 - General
Figure 802.
A D
AB
A Mainline pressure (test point) D Forward high ratio clutch pressure (test point)
AB Layshaft clutch solenoid (3029)
Before you carry out individual clutch leakage tests, 4. Make sure that both sides of all four wheels are
we can confirm that the forward high clutch is leaking: chocked. Apply the foot brake and park brake.
Individual clutch leakage test 5. When fully engaged, the park brake electrically
In the following procedures the forward high clutch disconnects the transmission drive, this prevents
is tested, therefore in step 2 a pressure gauge is the machine from being driven with the
connected to the forward high clutch test point. park brake on. Therefore, so that we can
complete the test, move the park brake lever
When you test the other suspect clutches, connect fractionally forward until the warning light is just
a gauge to the relevant suspect clutch test point. extinguished; hold the lever in this position for the
Because the forward high clutch is suspect, a gear duration of the test. Refer to Figure 802.
must be selected that will use the forward high clutch, 6. Do not move the lever too far forward, otherwise
in this instance 2nd gear forward. the park brake will not be fully operational.
Alternatively, disconnect the switch at the park
1. Stop the engine. Connect a pressure gauge of
brake. Refer to Figure 802.
the specified to the mainline pressure test point.
Refer to Figure 802. 7. Start engine and run at 1000 RPM, select 2nd
Pressure: 0–20bar (0.0–289.9psi) gear forward. Note the pressure readings on both
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) gauges, which should not vary more than the
specified value. If the difference on the gauges is
2. Connect a pressure gauge of the specified vale greater than the specified value do the following.
to the forward high ratio clutch test point. Refer Refer to Figure 802.
to Figure 802.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 802.
3. Remove the electrical connector from the
layshaft clutch solenoid. This will ensure that only 7.2. Start the engine and run at 1000 RPM,
the forward high clutch is energised when 2nd select 2nd gear forward. If the difference on
gear forward is selected. Refer to Figure 802. the gauges is still greater than the specified
27 - 182 9813/9400-1 27 - 182

27 - Driveline
00 - General
value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 802. readings are different than the value
mentioned in step 7 then calibrate the
gauges and again do the check. Refer to
Figure 802.
27 - 183 9813/9400-1 27 - 183

27 - Driveline
00 - General
Figure 803. Transmission Technical Data Checklist
27 - 184 9813/9400-1 27 - 184

27 - Driveline
00 - General
Remove and Install
Remove 7. Carefully remove the gearbox from the torque

converter, keep the assemblies square to each
1. Because of the configuration of the engine and other.
transmission mounting system, the powershift
gearbox should be removed from the machine Figure 804.
together with the engine, bevel gearbox, torque
converter and hydraulic pump as a full assembly.
Refer to Engine- General. Refer to (PIL 15-00).
2. Support the engine and transmission assembly
on a suitable frame. Remove the engine lifting
beam.
3. Make sure that the engine is safely supported
when the transmission components are
removed.
5. Disconnect the following external oil hoses and
pipes, typically as follows.
5.1. Oil cooler hose 1 and hose 2.
5.2. Bevel gearbox drain pipe.
5.3. Remote oil filter pipes (if installed). x
6. Support the gearbox with suitable lifting gear and

remove the bolts that connect the gearbox to the X Hole
torque converter housing.
27 - 185 9813/9400-1 27 - 185

27 - Driveline
00 - General
Figure 805.
E C F
B D
A Frame B Cooler hose 1

C Cooler hose 2 D Drain pipe
E Oil filter pipes F Bolts
27 - 186 9813/9400-1 27 - 186

27 - Driveline
00 - General
Install
steps.
1.1. Before you install the powershift gearbox,
make sure that the pressure test points are
installed at the clutch pressure test points.
Refer to driveline- semi-automatic gearbox.
1.2. Make sure you align the gearbox square to
the torque converter housing.
1.3. Insert the torque converter drive shaft in to
the opening of the pump, make sure that
the drive shaft engages correctly with the
pump. Take care not to damage the oil seal.
1.4. Do not use the housing bolts or any other
device to pull the assemblies together.
1.5. Make sure you install any cable tie locators
retained by the bolts.
27 - 187 9813/9400-1 27 - 187

27 - Driveline
00 - General
For: PS750 MK4 ..................... Page 27-188 the correct machine service documentation. The
For: PS764, PS766 ................. Page 27-189 table lists all the service procedures for the gearbox.
For some procedures it is necessary to do other
procedures first, these are shown in the table.
(For: PS750 MK4)
Before following some of the procedures, remove
the gearbox from its machine installation. Refer to
Table 367. Service Procedures List

Serial No. Procedure Name Do these procedures first
1 Oil Filter - Removal and Replace- -
ment. Refer to (PIL 27-06-39).
2 Suction Strainer - Removal and -
Replacement. Refer to (PIL
27-06-40).
3 4 Wheel Drive Yoke and Oil Seal - -
Removal and Replacement. Refer
to (PIL 27-06-95).
4 Brake Disc - Removal and Re- -
placement Refer to (24-18-21).
5 Solenoid Control Valves - Re- -
moval and Replacement. Refer to
(27-06).
6 Torque Converter Relief Valve - -
Removal and Replacement. Refer
to (27-14).
7 Pressure Maintenance Valve - Re- -
(27-06-21).
8 Speed Sensors - Removal and Re- -
placement.
9 Oil Pressure Switch - Removal and -
Replacement. Refer to (27-06-30).
10 Oil Pump - Removal, Inspec- -
tion and Replacement. Refer to
(27-06-24).
11 Clutches - Removal. Refer to 1, 2, 3, 5, 8, 9, 10
(1)
(27-06).
12 Clutches - Replacement. Refer to -
(27-06).
13 Output Shaft and Bearing - Re- 11
(27-06-58).
14 Input Clutch, Forward and Revers- 11
er Clutch - Disassemble. Refer to
(27-06).
15 Input Clutch, Forward and Revers- -
er Clutch - Assemble. Refer to
(27-06).
16 Layshaft Clutch - Disassemble. 11
Refer to (27-06-08).
17 Layshaft Clutch - Assemble. Refer -
to (27-06-08).
27 - 188 9813/9400-1 27 - 188

27 - Driveline
00 - General
Serial No. Procedure Name Do these procedures first

18 Main shaft Clutch - Disassemble. 11
Refer to (27-06-54).
19 Main shaft Clutch - Assemble. Re- -
fer to (27-06-54).
20 2 and 4 Wheel Drive Clutch (4WD 11
Pressure ON) - Disassemble. Re-
fer to (27-06-07).
21 2 and 4 Wheel Drive Clutch (4WD -
Pressure ON) - Assemble. Refer to
(27-06-07).
21 2 and 4 Wheel Drive Clutch S1 11
(4WD Spring ON) - Disassemble.
Refer to (27-06-07).
23 2 and 4 Wheel Drive Clutch S1 -
(4WD Spring ON) - Assemble. Re-
fer to (27-06-07).
24 2 And 4 Wheel Drive Clutch (4WD 11
Spring ON) - Pressure Testing. Re-
fer to (27-06-07).
25 PTFE Piston Ring Seals. Refer to 11
(27-06-45).
(1) The components depicted in the procedures 5, 8, and 9 are to be removed to prevent component damage
during the disassembly of the gearbox.
(For: PS764, PS766) Figure 806.

Special Tools
Gearbox Assembly 892/01082 1
Cradle
Note: The Disassembly and Assembly procedures

given below illustrate and describe the 6x4 gearbox.
Procedures for the 4x4 version of the gearbox
are identical in most respects. Where there are
differences, procedures are identified under the
heading 4x4 Gearbox.
With the gearbox removed from the machine, place

suitable wooden blocks to securely support the
assembly. If the gearbox is installed with an integral
park brake the brake assembly must be removed B
A
before you disassemble the gearbox. Refer to (PIL
27-06). A Layshaft cover
B Bolt 1
Gearboxes compatible with a lock up torque
converter are installed with a control valve and 1.1. Remove the bolts.
interconnecting pipe. These components must be 1.2. Remove the cover.
removed before dismantling the gearbox.
1.3. Note: Unless the cases are to be replaced,
Disassemble or the gearbox oil has been contaminated it
is not necessary to remove the cover.
1. If installed, remove the layshaft cover. Refer to
Figure 806. 2. Separate the front and rear case and remove the
clutch shafts.
3. Do not attempt to disassemble the gearbox
further until it is safely positioned in a suitable
work cradle.
27 - 189 9813/9400-1 27 - 189

27 - Driveline
00 - General
4. Separate the front case and remove the clutch

shaft assemblies. Refer to (PIL 27-06).
5. Remove the transfer gear.
Install
1. Use suitable lifting equipment and put the rear
case of the gearbox in a work cradle.
Special Tool: Gearbox Assembly Cradle (Qty.: 1)
1.1. Clamp the gearbox at the three clamping
points on the rear case.
2. Do not attempt to assemble the gearbox further
until it is safely positioned in a suitable work
cradle.
3. Install the transfer gear.
4. Install the clutch shaft assemblies and the front
case. Refer to (PIL 27-06)
5. If applicable, install the layshaft cover as follows:
Figure 807.
B
A
A Layshaft cover
B Bolt 1
5.1. Make sure that the case mating faces are
clean and not damaged.
5.2. Apply a thin bead of sealant to the rear case
and install the layshaft cover.
5.3. Install the bolts 1.
5.4. Tighten the bolts 1 to the correct torque
value.

Item Description Nm
B Bolt 56
27 - 190 9813/9400-1 27 - 190

27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse Introduction

Introduction .................................................. 27-191 A clutch is a mechanical device that engages and
Check (Condition) ........................................ 27-192 disengages drive, from driving shaft to driven shaft.
Check (Pressure) ........................................ 27-192
Remove and Install ..................................... 27-193 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.
A combination of clutches is often used within the

gearbox to allow different gears to be engaged.
27 - 191 9813/9400-1 27 - 191

27 - Driveline
Check (Condition) Check (Pressure)

Special Tools
Carry out a visual inspection of the friction and Description Part No. Qty.
counter plates: Hand Pump Pressure 892/00223 1
Test
Counter plates Pressure Test Adaptor 993/59300 1
that are not flat, worn or heavily marked or scored 1. Assemble the 2 and 4 wheel drive clutch. Refer to
must be replaced with a new set. the relevant Clutch- Disassemble and Assemble
procedure (PIL 27-06).
Friction plates 2. Check the clutch pack end float and adjust
as required. Refer to the relevant Clutch -
1. The cross hatching should be clearly visible, Disassemble and Assemble procedure (PIL
plates that are not flat, have friction material 27-06).
set. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
2. DO NOT mix old and new plates, if a plate is and 4 wheel drive clutch shaft as shown. Hold the
damaged or worn install a complete new set. adaptor in position with clamp.
3. Needle roller bearings should slide into position Special Tool: Pressure Test Adaptor (Qty.: 1)
the cage has been distorted install new bearings. 4. Use the hand pump (892/00223) to pressurise
the clutch assembly until the gear can be turned
4. Take care when handling disc springs to avoid by hand. Note the pressure gauge reading. Do
marking or damage, which could result in stress not exceed the given value.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5. If the pressure gauge reading is between
the given values, then the clutch is operating
correctly and can be installed in the gearbox.
Pressure: 8.6–9.3bar (124.6–134.8psi)
6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
27 - 192 9813/9400-1 27 - 192

27 - Driveline
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, mainshaft
clutch and forward / input clutch are all part of the
mainshaft assembly.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 193 9813/9400-1 27 - 193

27 - Driveline

For: PS750 MK4 ..................... Page 27-194
For: PS764, PS766 ................. Page 27-194
(For: PS750 MK4)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).
(For: PS764, PS766)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).
27 - 194 9813/9400-1 27 - 194

27 - Driveline
07 - Clutch - 2WD/4WD Introduction

Component Identification ............................. 27-196 disengages drive, from driving shaft to driven shaft.
Check (Condition) ........................................ 27-202
Check (Pressure) ........................................ 27-202 Each gear on the gearbox has an associated clutch
Disassemble and Assemble ........................ 27-207 When the solenoid is engaged fluid is applied to the
shaft.

27 - 195 9813/9400-1 27 - 195

27 - Driveline
For: PS750 MK4, PS764, PS766

................................................. Page 27-196
For: PS750 MK4, PS764, PS766
................................................. Page 27-197
For: PS764, PS766 ................. Page 27-199
(For: PS750 MK4, PS764, PS766)
Figure 809. Pressure ON

G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A
A Bearing 1 B Piston ring seal

C Bearing 2 D Thrust washer 1
E 4WD (Four Wheel Drive)gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
27 - 196 9813/9400-1 27 - 196

27 - Driveline
U O-ring 2 (Shaft)
(For: PS750 MK4, PS764, PS766)
Figure 810. S1 Spring ON
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

C Bearing 2 D Thrust washer
E 4WD gear F Needle roller bearing
G Circlip 1 H1 Disc spring 1
H2 Disc spring 1 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
R Disc spring 2 S Piston
T Spring steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft Y Spacer
27 - 197 9813/9400-1 27 - 197

27 - Driveline
Figure 811. S2 Spring ON

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16
1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve
22 Clutch drum 23 Shaft
27 - 198 9813/9400-1 27 - 198

27 - Driveline
(For: PS764, PS766)
Figure 812. S1 - 4WD Spring ON
U
M
L
F
E
C
B
A
Q
G
S
H
P
T
N W
V
J1
J2
A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
27 - 199 9813/9400-1 27 - 199

27 - Driveline
R Piston S O-ring 1
T O-ring 2 U O-ring 3
V Capscrew W Reaction pin

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

27 - 200 9813/9400-1 27 - 200

27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 10 Pressure end plate
11 Shim(s) 12 Friction plates and counter plates
13 Bearing 2 14 Thrust washer 3
15 Piston housing 16 O-ring 1
17 O-ring 2 18 Piston
19 Spring steel ring 20 Disc spring 2
21 Actuating sleeve 22 Clutch drum
23 Shaft
27 - 201 9813/9400-1 27 - 201

27 - Driveline
Check (Condition) Check (Pressure)
Do a visual check of the friction and counter plates (For: PS750 MK4, PS764, PS766, Spring
and gears:
ON)
Counter plates Special Tools
1. Light scoring or polishing is permissible, plates Hand Pump Pressure 892/00223 1
that are not flat, worn or heavily marked or scored Test
Pressure Test Adaptor 993/59300 1
Friction plates 1. Assemble the 2 and 4 wheel drive clutch. Refer to
1. The lubrication slots should be clearly visible, the relevant Clutch- Disassemble and Assemble
plates that are not flat, have friction material procedure (PIL 27-06).
damage or scoring must be replaced with a new 2. Check the clutch pack end float and adjust
one. as required. Refer to the relevant Clutch -
2. Do not change individual plates, if a plate is Disassemble and Assemble procedure (PIL
damaged or worn install a complete new set. 27-06).
3. Needle roller bearings should slide into position 3. Use the service tool (993/59300), insert the
freely, do not bend or distort the cage to install. If adaptor into the oil gallery in the end of the 2
the cage has been distorted install new bearings. and 4 wheel drive clutch shaft as shown. Hold the
adaptor in position with clamp.
The piston consists of a small check valve. Visually Special Tool: Pressure Test Adaptor (Qty.: 1)
place and that the seat is free from contamination. 4. Use the hand pump (892/00223) to pressurise
If necessary clean the valve by blowing through with the clutch assembly until the gear can be turned
an air line. Do not use a wire rod (or screwdriver) as by hand. Note the pressure gauge reading. Do
it can damage the valve seat. not exceed the given value.
Gears Special Tool: Hand Pump Pressure Test (Qty.: 1)
1. Check the gear teeth for wear, cracking or 5. If the pressure gauge reading is between
damage. the given values, then the clutch is operating
correctly and can be installed in the gearbox.
Pressure: 8.6–9.3bar (124.6–134.8psi)
6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
27 - 202 9813/9400-1 27 - 202

27 - Driveline

For: PS764, PS766 ................. Page 27-203
For: PS750 MK4 ..................... Page 27-206
(For: PS764, PS766)

Special Tools
Spanner
Remove
1. Remove the 4WD clutch assembly as follows:
Figure 816.
B
D C
A Adaptor (Part of 993/59300) H

B Clamp (Part of 993/59300) E
A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 1 is installed)
D Nut
E Bolt 2
F Cover
G O-ring (If installed)
H Oil seal
J 4WD clutch and shaft assembly
1.1. Hold the output yoke with the tool.
27 - 203 9813/9400-1 27 - 203

27 - Driveline
Special Tool: Drive Coupling Spanner (Qty.: 1.1. Make sure that the inner bearing outer cup
1) is correctly installed in the front case.
1.2. Either remove the nut or the bolt1 along 1.2. Put the clutch and shaft assembly in the
with the thick washer. The nut or bolt is very housing.
tight and the help of a assistant would be
1.3. Make sure that the front and 4WD case
required.
mating faces are clean and not damaged.
1.3. Remove the yoke
1.4. If applicable install the O-ring to the front
1.4. Remove the bolts 2 (x8) and lift off the cover. case. The O-ring deforms to get positioned
in the recess.
1.5. Make sure to remove the bearing outer cup
from inside the cover. 1.5. For gearbox variants installed with an O-
ring apply a bead of Loctite 509 of the
1.6. If installed, remove the o-ring.
specified thickness to the front case at the
1.7. Remove the output shaft oil seal. Take care locations shown. Refer to Figure 818.
not to damage the seal housing. Dimension: 3mm
1.8. Lift the 4WD clutch and shaft assembly from
the housing. Figure 818.
1.9. Remove the inner bearing outer cup from

the case. P G
2. Remove the torque converter relief valve as
P
follows: Refer to Figure 817.
Figure 817.
K
L
M P
N
G O-ring
P Loctite 509
1.6. For gearbox variants not installed with O-
ring apply a bead of Loctite 509 of the
specified thickness on the front case at the
locations shown. Refer to Figure 819.
Dimension: 3mm
K Plug
L Sealing washer
M Spring
N Poppet
2.1. Remove the plug.
2.2. Remove the sealing washer and the spring.
2.3. Remove the poppet.
Install
1. Install the 4WD clutch assembly as follows: Refer
to Figure 820.
27 - 204 9813/9400-1 27 - 204

27 - Driveline

B
P
D C
P
A
H
P E
G
P
P Loctite509
J
1.7. Note that the bead is applied near the inner
or outer edge of the flange as applicable at
positions shown.
1.8. Make sure that the outer bearing outer cup
is correctly installed inside the cover.
1.9. Install the cover with the bolts 2 (x8).
1.10. Tighten the bolts 2 to the correct value.
A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 3 is installed)
D Nut
E Bolt 2
F Cover
G O-ring 3 (If installed)
H Oil seal
J 4WD clutch and shaft assembly
2. Measure the 4WD clutch shaft end float. as
follows:
2.1. The end float will be within limits provided
the components are installed correctly.
Rotate the shaft by hand, it should rotate
smoothly.
2.2. Install a bolt to the threaded hole in the end
of the shaft.
2.3. Pull up the bolt a to detect excessive end
float.
2.4. The end float must be within the range
specified.
Dimension: 0.01–0.16mm
3. Continue the installation of the 4WD clutch
assembly as follows:
27 - 205 9813/9400-1 27 - 205

27 - Driveline
3.1. Install a new oil seal. Make sure that the (For: PS750 MK4)
seal is positioned correctly in the housing.
3.2. Install the output yoke. The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
3.3. As applicable install either the thick washer clutch and forward / input clutch are all part of the
and bolt 1 or the stake nut. mainshaft assembly.
3.4. Hold the yoke with the tool.
Special Tool: Drive Coupling Spanner (Qty.: Refer to (PIL 27-06-54).
1)
3.5. Tighten the bolt or nut to the correct torque
value.
3.6. If the stake nut is installed, then stake the
nut with a square ended staking tool.
4. Install the torque converter relief valve as follows:
Figure 821.
K
L
M
N
K Plug
L Sealing washer
M Spring
N Poppet
4.1. Install the poppet and the spring.
4.2. Use a new sealing washer and install the
plug.
4.3. Tighten the plug to the correct torque value.

Item Description Nm
B Bolt 1 400
D Nut 300
E Bolt 2 56
K Plug 56
27 - 206 9813/9400-1 27 - 206

27 - Driveline
For: PS750 MK4, PS764, PS766, Pressure

ON ........................................... Page 27-207
For: PS750 MK4, S1, Spring ON
................................................. Page 27-211
For: PS750 MK4, S2, Spring ON
................................................. Page 27-214
For: PS764, PS766 ................. Page 27-217
(For: PS750 MK4, PS764, PS766, Pressure ON)

Special Tools
Test
27 - 207 9813/9400-1 27 - 207

27 - Driveline
Disassemble
Figure 822.
G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A

C Bearing 2 D Thrust washer 1
E 4WD gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
U O-ring 2 (Shaft)
1. Remove the bearing 1, only if it is required to be or damage on shaft grooves. If necessary

replaced. remove burrs with a fine grade abrasion
paper and oil.
2. Carefully remove the piston ring seal.
2.1. Note: If the piston ring seal is damaged
or excessively worn then check for burrs
27 - 208 9813/9400-1 27 - 208

27 - Driveline
3. With a puller or press, remove the 4WD gear and Figure 824.
splined hub, together with its bearing 2, needle
roller bearing and thrust washer 1.
4.1. Note the thrust washer 1 and thrust washer
2 are not interchangeable.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and shim (If
applicable).
7. Remove the friction plates and the counter
plates.
7.1. Keep them together in sets, do not mix the 12. Remove the piston.
plates with those from other clutches.
13. Remove and discard the piston O-ring 1.
8. Put the clutch assembly in a suitable press.
14. Remove and discard the shaft O-ring 2.
8.1. With a cut away tube compress the piston
spring and remove the circlip 2.
Assemble
Figure 823.
1. Install the new O-ring 1 onto the piston.
2. Install the new O-ring 2 onto the shaft.
3. Lubricate the piston with oil and press fully into
the bore of the clutch housing.
4. Install the oil baffle and piston spring. Make sure
that the spring is positioned properly in the piston.
5. Install the spring retaining plate.
6. Compress the spring with a cut away tube and
install the circlip 2.
7. Install one counter plate followed by one friction
plate.
9. Lift off the spring retaining plate. 7.1. Continue to install alternate counter and
friction plates, finishing with a friction plate.
10. Remove the spring and oil baffle.
8. Install the pressure end plate. Make sure the
11. Turn the assembly over and knock the clutch chamfered face of the pressure end plate faces
shaft on a piece of aluminium (or wood) to loosen the clutch pack.
the piston.
9. Make sure that the teeth are not aligned with the
11.1. If the piston does not loosen, then hand lubrication slots in the housing.
pump air down the shaft oil inlet hole.
10. Do not install the shim at this stage.
(Qty.: 1) 11. Install the friction and counter plate retaining
circlip 1.
12. With a DTI (Dial Test Indicator) measure the end
float of the pressure end plate. The value should
be within the specified range.
27 - 209 9813/9400-1 27 - 209

27 - Driveline
Figure 825. end plate, with either a shim or an extra counter

plate between the retaining circlip 1 and the
pressure end plate.
14. Use an air line to check the operation of the
clutch.
15. Install the thrust washer 2.
16. Carefully align the teeth of the clutch plates with
a thin rod (or screwdriver) and install the 4WD
gear and splined hub, needle roller bearings and
thrust washer 1.
17. Apply gearbox oil on the clutch end bearing 2 and
press the bearing onto the shaft to seat on the
13. If it is necessary to adjust the end float to bring it thrust washer 1.
within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure 18. Install the new piston ring seals.
27 - 210 9813/9400-1 27 - 210

27 - Driveline
(For: PS750 MK4, S1, Spring ON)
Disassemble
Figure 826.
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

C Bearing 2 D Thrust washer
E 4WD gear F Needle roller bearing
G Circlip 1 H1 Disc spring 1
H2 Disc spring 1 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
R Disc spring 2 S Piston
T Spring steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft Y Spacer
1. Remove the bearing 1 from the shaft only if it is 2. Carefully remove the piston ring seal.
to be replaced.
27 - 211 9813/9400-1 27 - 211

27 - Driveline
2.1. Note: If the piston ring seal is damaged 8. Install the clutch drum in the housing.
or excessively worn then check for burrs
or damage on shaft grooves. If necessary 9. Install the support washer and drum retaining
remove burrs with a fine grade abrasion circlip 2.
paper and oil.
10. Build up the clutch pack. Install one friction plate
3. With a suitable puller, remove the 4WD gear followed by one counter plate.
together with its bearing 2, thrust washer, and the
needle roller bearings (x2). 10.1. Continue to install alternate counter and
friction plates, finish with the pressure
CAUTION! The spring (or springs) apply plate.
considerable force. Make sure you take care to 11. Use the 4WD gear to align the clutch plate
avoid damage or injury. splines. Make sure that all the plates are
engaged with the gear shaft splines.
4. Use a suitable press and compress the disc
springs to remove the circlip 1. 12. Rotate the 4WD gear back and forth to create
maximum backlash then remove the gear taking
4.1. There is considerable force applied by the
care not to disturb the pack.
springs.
Weight/Force: 26,700N 13. Put the first two disc springs 1 with their convex
sides uppermost, onto the clutch pack. (There
5. Remove the disc springs 1 (x4), pressure end are four disc springs 1, which are identical). Put
plate and the shims. the other two disc springs 1, with their convex
sides down, onto the first two.
6. Remove the clutch pack friction plates and
counter plates. Figure 827.
6.1. Keep them together in sets, do not mix the
7. Remove the clutch drum retaining circlip 2 and
support washer.
8. Remove the clutch drum and the actuating
sleeve.
9. Remove the disc spring 2.
10. Remove the piston and its spring steel ring.
11. Remove and discard the piston O-ring 1 and O-
ring 2.
CAUTION! The spring (or springs) apply
12. If necessary, remove the piston housing. The
piston housing is a press fit on the shaft.
Assemble 14. Use a suitable press to compress the disc spring
and install the circlip 1.
1. Lubricate the shaft.
15. Use levers to remove free play.
2. Install the piston housing by pressing the shaft
squarely into the housing (make sure the housing
is securely supported).
3. Install the O-ring 1 and O-ring 2 onto the piston.
the bore of the housing.
5. Install the spring steel ring. Make sure that the
seal seats properly in its groove.
6. Put the disc spring 2 into the housing.
7. Put the actuating sleeve onto the disc spring.
27 - 212 9813/9400-1 27 - 212

27 - Driveline
Figure 828. 16.3. The shim can be a combination of a

single counter plate, shim (thinner than the
counter plate) or both counter plate and
shim.
16.4. Make sure that the clutch pack splines are
still aligned.
17. Install the two needle roller bearings into 4WD
gear.
18. Install the 4WD gear onto the shaft.
19. Install the thrust washer.
press the bearing onto the shaft to seat on the
16. Measure the gap between the pressure end plate thrust washer.
and the actuating sleeve.
21. Install the new piston ring seal.
16.1. The gap should be within the range
specified. 22. If required, install the new bearing 1 onto the
shaft.
23. Before pushing the outer cup of bearing 1 into the
16.2. If necessary, install a new shim to get the housing cover make sure you install the spacer.
correct gap.
24. Do an operational test of the clutch assembly.
27 - 213 9813/9400-1 27 - 213

27 - Driveline
(For: PS750 MK4, S2, Spring ON)
Disassemble
Figure 829.
8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 (x4) 10 Pressure end plate
27 - 214 9813/9400-1 27 - 214

27 - Driveline

23 Shaft
1. Carefully remove the piston ring seal from the Figure 830.
shaft. AA
1.1. If the piston ring seal is damaged or
excessively worn then check for burrs or
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
2. Use a suitable puller to remove the 4WD gear
with its related bearing 1, thrust washer 1, needle
roller bearing 1, and needle roller bearing 2. AB
AA Rounded profile
CAUTION! The spring (or springs) apply AB Flat profile
avoid damage or injury. 1.2. Install the needle roller bearings on the
4WD gear with the flat end profiles facing
3. Use a suitable press to compress the disc spring out (nearest the ends of the shaft).
1 and remove the circlip.
1.3. Use a suitable press to press the needle
3.1. There is considerable clamping force acting roller bearings into the 4WD gear.
on the springs.
2. Install the O-rings 1 and O-rings 2 onto the
Weight/Force: 26,700N piston.
4. Remove the disc spring 1 (x4), pressure end 3. Lubricate the piston with oil and press fully into
plate and shim(s). the bore of the piston housing.
5. Remove the clutch pack friction plates and 4. Install the spring steel ring onto the piston. Make
counter plates. sure that the seal seats firmly in its groove.
5.1. Keep them together in sets, do not mix the Figure 831.
7. Use a suitable press on the output end of the
shaft and push the clutch drum with its related
bearing 2, thrust washer 3, piston housing, and
actuating sleeve.
8. Remove the disc springs 2.
18 19
9. Remove the piston and its spring steel ring.
18 Piston
10. Remove and discard the piston O-ring 1 and O- 19 Spring steel ring
ring 2.
5. Use a suitable press to assemble the shaft to the
Assemble piston housing and clutch drum as follows:
1. Install the needle roller bearing 1 and needle 5.1. Place the thrust washer 3 on the press.
roller bearing 2 to the 4WD gear in the correct Arrange the press so that the shaft can
orientation. pass through the thrust washer a sufficient
distance during assembly.
1.1. One end of the bearing has a rounded 5.2. Put the piston housing and piston assembly
profile and the other end has a flat profile. centrally on the thrust washer.
5.3. Put the disc spring 2 in position.
27 - 215 9813/9400-1 27 - 215

27 - Driveline
Figure 832. 5.7. The shaft will approximately drop to

the specified distance when the splines
engage.
Distance: 3mm
5.8. Important: Make sure that the shaft and
clutch drum splines align and engage
correctly. If the splines are not aligned
the force from the press will damage the
components.
5.9. Put a suitable bushing at the top of the shaft
18 Piston and use the press to push the shaft fully
20 Disc spring 2 onto the piston housing and clutch drum.
Make sure that there are no splines visible.
5.4. Put the actuating sleeve over the clutch
drum and then put the clutch drum in the 6. Install the thrust washer 2. Make sure that the
piston housing. thrust washer 2 is positioned over the collar on
the shaft correctly.
Figure 833.
Figure 835.
AD
7 Thrust washer 2
23 Shaft
15 Piston housing AD Collar
20 Disc spring 2
21 Actuating sleeve 7. Build the clutch pack. Install one friction plate
22 Clutch drum followed by one counter plate.
5.5. Put the shaft on the clutch drum and piston 7.1. Continue to install alternate counter and
housing. friction plates.
Figure 834. 7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
Figure 836.
AC
22 Clutch drum
23 Shaft
AC Splines
5.6. Hold the clutch drum and carefully rotate the AE
shaft until the splines engage. 24 Cross hatching pattern
27 - 216 9813/9400-1 27 - 216

27 - Driveline
7.3. Install the shim or shims as applicable after 14. Measure the gap between the pressure end plate
you install the final counter plate. and actuating sleeve.
8. Install the pressure plate with its chamfer side 14.1. The gap should be within the specified
facing down. range.
9. Use the 4WD gear to align the clutch plate Distance: 0.75–1.5mm
splines. 14.2. If necessary install a new shim to achieve
the correct gap.
9.1. Make sure that all the plates are engaged
with the gear shaft splines. 14.3. The shim can be a combination of a
single counter plate, shim (thinner than the
9.2. Rotate the 4WD gear back and forth to counter plate) or both counter plate and
create maximum backlash then remove the shim.
gear taking care not to disturb the pack.
15. Make sure that the clutch pack splines are still
10. Place the first two disc springs 1 with their convex aligned and install the 4WD gear.
sides uppermost, onto the clutch pack. (There
are four disc springs 1, which are identical). 16. Install the thrust washer 1.
11. Place the other two disc springs 1, with their 17. Apply oil on the bearing 1 and press the bearing
convex sides down, onto the first two. onto the shaft to seat on the thrust washer 1.
Figure 837. 18. Install the thrust washer 2.
19. Apply oil on the bearing 2 and press the bearing
onto the shaft to seat on the thrust washer 2.
20. Install the new piston ring seal.
21. Do an operational test of the clutch assembly.
(For: PS764, PS766)

Special Tools
Test
Pressure Test Adaptor 993/59300 1
CAUTION! The spring (or springs) apply Adaptor Spanner 998/10738 1
avoid damage or injury. Consumables
12. Use a suitable press to compress the disc springs
1 and install the retaining circlip. JCB Threadlocker 4101/0250 0.01L
13. Use levers to remove the free play. Strength)
Figure 838. Gearboxes can be installed with one of three clutch

types 4WD (Four Wheel Drive) Spring ON.
Disassembly
1. Carefully remove the piston ring seal from the
shaft.
1.1. If the piston ring seal is damaged or
excessively worn then check for burrs or
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
2. Use a suitable puller or press to remove the 4WD
gear and splined hub together with its taper roller
27 - 217 9813/9400-1 27 - 217

27 - Driveline
bearing 1, needle roller bearing and the thrust 11.1. Match mark the piston and the clutch
washer 1. housing, to make sure that the piston is
assembled in the same orientation when
2.1. Remove the thick thrust washer. they are assembled again.
2.2. Note, the thick thrust washer and thrust
Figure 839.
washer1 are not interchangeable.
3. Use a suitable puller or press to remove the taper
roller bearing 2.
4. Use an adaptor spanner and a 1/2" square drive
socket to remove the locknut.
Special Tool: Adaptor Spanner (Qty.: 1)
5. Use the 4WD output yoke secured in a vice as
a holding fixture, to support the clutch assembly
and prevent it from rotation when torque is
applied.
6. Lift off the disc springs.
7. Turn the assembly over and remove the friction
and counter plates retaining circlip. 11.2. If the piston does not loosen, then hand
8. Remove the pressure end plate 1 and shims, if
installed. Special Tool: Hand Pump Pressure Test
(Qty.: 1)
plates. 12. Remove the piston.
9.1. Keep them together in sets, do not mix the 13. Remove and discard the O-ring 1 and O-ring 2
plates with those from other clutches. from the piston.
10. Remove the pressure end plate 2. 14. Remove and discard the O-ring 3 from the shaft.
11. Turn the assembly over and knock the clutch 15. If it is necessary to replace, remove the
shaft on a piece of aluminium (or wood) to loosen capscrews and the reaction pins.
the piston.
27 - 218 9813/9400-1 27 - 218

27 - Driveline
U
M
L
F
E
C
B
A
Q
G
S
H
P
T
N W
V
J1
J2
A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
R Piston S O-ring 1
T O-ring 2 U O-ring 3
27 - 219 9813/9400-1 27 - 219

27 - Driveline
V Capscrew W Reaction pin

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

27 - 220 9813/9400-1 27 - 220

27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 10 Pressure end plate
23 Shaft
27 - 221 9813/9400-1 27 - 221

27 - Driveline
Assembly the retaining circlip and the pressure end

plate2.
1. Assemble the reaction pins.
Figure 843.
1.1. If removed then install the reaction pins to
the piston. do the steps below to make sure
that the pins are correctly aligned.
1.2. Put the piston into the bore of the clutch
housing. Do not install any O-rings at this
stage.
1.3. Install each reaction pin in turn from the
opposite end of the housing and secure to
the piston with a capscrew.
1.4. Apply JCB Threadlocker and Sealer to the
threads of the capscrews before you install
them.
Consumable: JCB Threadlocker and Sealer 7. Install the thick thrust washer.
(Medium Strength)
8. Carefully use a thin rod (or screwdriver) to align
1.5. When all four reaction pins are installed, the teeth of the clutch plates.
tighten the capscrews to the specified
torque value. 8.1. Install the 4WD gear, splined hub and the
needle roller bearings.
Torque: 10–12N·m
1.6. Match mark the piston and the clutch 9. Install the thrust washer1.
housing to make sure that the piston is 9.1. Apply gearbox oil to the taper roller bearing
assembled in the same orientation. 2 and press the bearing onto the shaft to
1.7. Temporarily remove the piston from the seat on the thrust washer1.
clutch housing and assemble the clutch
pack. 10. Turn the assembly over and install a new O-ring
3 to the shaft.
2. Install the pressure end plate 2.
10.1. Install a new O-ring 1 and O-ring 2 to the
3. Install one counter plate followed by one friction piston.
plate. 10.2. Lubricate the piston with gearbox oil and
3.1. Continue to install alternate counter and press fully into the bore of the clutch
friction plates, finishing with a friction plate. housing (note the match marks made at
the time of disassembly).
4. Install the pressure end plate 1 but do not install
the shim at this stage. 11. Install the first two disc springs with their concave
sides uppermost (there are four disc springs,
4.1. Make sure that the chamfered face of the which are identical).
pressure end plate faces the clutch pack.
11.1. Place the other two disc springs with their
4.2. Make sure the teeth are not aligned with the concave sides down, on top of the first two
lubrication slots in the housing. as shown.
5. Install the friction and counter plates retaining 12. Use an adaptor spanner and a 1/2" square drive
circlip. socket to install the locknut and tighten the nut to
6. Use a DTI to measure the end float of the
pressure end plate. It should be within the Special Tool: Adaptor Spanner (Qty.: 1)
specified limit.
12.1. Note that the locknut is assembled dry
Dimension: 4–5mm with no thread lockers or sealant on the
threads.
6.1. If it is necessary to adjust the end float to
bring it within the specified limit mentioned 13. Use the 4WD output yoke secured in a vice as
in step6, Install a 6.0mm (0.23in) or 6.5mm a holding fixture, to support the clutch assembly
(0.25in) pressure end plate1 together with and prevent it from rotation when torque is
a shim or an extra counter plate, between applied.
27 - 222 9813/9400-1 27 - 222

27 - Driveline
14. Use the pressure test adaptor and clamp

assembly to check the operation of the clutch
assembly.
Special Tool: Pressure Test Adaptor (Qty.: 1)
14.1. Make sure that the clutch fully disengages
at the specified working pressure.
15. Apply gearbox oil to the taper roller bearing2 and
press the bearing onto the shaft.
16. Install the piston ring seal.

Item Description Nm
H Locknut 300
27 - 223 9813/9400-1 27 - 223

27 - Driveline
08 - Clutch - Layshaft
08 - Clutch - Layshaft Introduction

Check (Condition) ........................................ 27-230
Calibrate ...................................................... 27-231 Each gear on the gearbox has an associated clutch
shaft.

27 - 224 9813/9400-1 27 - 224

27 - Driveline
For: PS750 MK4 ..................... Page 27-226

For: PS764, PS766 ................. Page 27-228
27 - 225 9813/9400-1 27 - 225

27 - Driveline
(For: PS750 MK4)
Figure 844.
AA
D AB X
C
AC
P
Z L
J
R
Q B
N
K
H A
G
F
U S
W
V
T
A Piston ring seals B Taper roller bearing 1

C 4 wheel drive transfer gear D Taper roller bearing 2
E Piston housing F Spring retaining plate
27 - 226 9813/9400-1 27 - 226

27 - Driveline
G Spring H Oil baffle

J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
N Thrust washer 1 P Thrust bearing 1
Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
27 - 227 9813/9400-1 27 - 227

27 - Driveline
(For: PS764, PS766)
Figure 845.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
Item Description
Table 371.
C Circlip 1
Item Description D 4 wheel drive transfer
A Piston ring seals gear
B Taper roller bearing 1
27 - 228 9813/9400-1 27 - 228

27 - Driveline
Item Description
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
J1 Thin thrust washer 2
K Thrust bearing 2
L Thick thrust washer
M Taper roller bearing 2
N Friction and counter
plates retaining circlip
P Pressure end plate
Q Shim
R Friction plates
S Counter plates
T Circlip 2
U Spring retaining plate
V Spring
W Oil baffle
X Piston
Y O-ring 1
Z O-ring 2
27 - 229 9813/9400-1 27 - 229

27 - Driveline
Check (Condition)
Do a visual check of the friction and counter plates:
Counter plates
Friction plates
one.

27 - 230 9813/9400-1 27 - 230

27 - Driveline
Calibrate
.............................................. Page 27- Later clutch assemblies feature an additional thin

For: PS764, PS766 ................. Page 27-231 thrust washer. If any of the components listed below
are to be replaced, the end float of gear must be
measured and reset as required:
End float measurement
• Shaft assembly
1. Use a DTI (Dial Test Indicator) to measure the
• Gear and plate carrier assembly
end float of the pressure end plate.
• Thin thrust washers1
2. The end float should be within the specified limit. • Thin thrust washer2 and thin thrust washer3
• 4 wheel drive (WD) transfer gear or spacer as
Dimension: 1.9–2.5mm applicable
Figure 846. Measure the end float as follows:
1. Temporarily install thick thrust washer, thin

thrust washer3, thrust bearing2 and thin thrust
washer2.
2. Install the needle roller bearing.
A
3. Temporarily install the gear and plate carrier
assembly.
4. Install the thin thrust washer1 and thrust bearing1
followed by the remaining thrust washer1.
5. Temporarily install the 4WD transfer gear 4 onto
the layshaft spline. Make sure that the gear is
installed in the correct orientation.
5.1. 2 wheel drive machines have a spacer
installed instead of a gear.
6. Install the circlip1.
A DTI 7. Make sure that the 4 wheel drive gear (or spacer)
is fully seated against circlip1.
3. If the end float is more than the specified value
then install a 6.0mm (0.23in) or 6.5mm (0.25in) 8. Measure the end float of gear.
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip 9. The end float should be within the specified
and the pressure end plate. range.
clutch. 10. If the end float is to be adjusted select a suitable
thrust washer from the spacer kit and again
(For: PS764, PS766) assemble the components given in steps 1 to 6.
Special Tools Special Tool: Thrust Washer Kit (Qty.: 1)
Description Part No. Qty. 11. Measure the end float again and assemble the
Thrust Washer Kit 823/10420 1 clutch assembly.
End Float Setting - Plate Carrier and Gear 12. Make sure you install the correct thick thrust
washer on final assembly.
Note: The following procedure is only applicable to
clutch assemblies fitted with thin thrust washer3.
27 - 231 9813/9400-1 27 - 231

27 - Driveline
Figure 847.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
A Piston ring seals B Taper roller bearing1

C Circlip1 D 4 wheel drive transfer gear
E Gear and splined hub F Thin thrust washers1
G Thrust bearing1 H Needle roller bearings
J1 Thin thrust washer2 J2 Thin thrust washer3
K Thrust bearing2 L Thick thrust washer
M Taper roller bearing2 N Friction and counter plates retaining circlip
P Pressure end plate Q Shim
27 - 232 9813/9400-1 27 - 232

27 - Driveline
R Friction plates S Counter plates

T Circlip2 U Spring retaining plate
V Spring W Oil baffle
X Piston Y O-ring1
Z O-ring2
27 - 233 9813/9400-1 27 - 233

27 - Driveline
Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

clutch and forward / input clutch are all part of the
mainshaft assembly.

27 - 234 9813/9400-1 27 - 234

27 - Driveline
For: PS750 MK4 ..................... Page 27-236

For: PS764, PS766 ................. Page 27-239
27 - 235 9813/9400-1 27 - 235

27 - Driveline
(For: PS750 MK4)
Disassemble
Figure 848.
AA
D AB X
C
AC
P
Z L
J
R
Q B
N
K
H A
G
F
U S
W
V
T
27 - 236 9813/9400-1 27 - 236

27 - Driveline
C 4 wheel drive transfer gear D Taper roller bearing 2

E Piston housing F Spring retaining plate
G Spring H Oil baffle
J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
N Thrust washer 1 P Thrust bearing 1
Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
1. Carefully remove the piston ring seals. 11. Remove the thin thrust washer 2 and thrust
bearing 2.
1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 12. Remove the circlip 2 that retains the friction
grooves. If necessary remove burrs with a plates and counter plates.
fine grade abrasion paper and oil.
13. Remove the outer pressure end plate and shim
2. Remove the taper roller bearing 1 with a suitable (if installed).
puller and press.
2.1. This bearing would not normally be plates.
removed unless it was damaged. It is
permissible to use a standard bearing 14.1. Keep them together in sets, do not mix the
puller, although damage to the bearing cage plates with those from other clutches.
may be incurred which will require a new
bearing. 15. Remove the inner pressure end plate.
3. From the opposite side of the shaft, use a 16. Remove the piston.
suitable puller to remove the 4WD transfer gear 17. Remove and discard the O-ring 3 from the piston.
(if applicable) and the taper roller bearing 2.
3.1. The gear and bearing 1 are under pressure Assemble
from the spring, make sure you proceed
with caution. 1. Install the O-ring 3 onto the piston.
3.2. Make sure to remove the thrust washer 2. 2. Lubricate the piston with oil and press fully into
3.3. Make a record of the orientation of the gear
for ease during assembly. 3. Install the inner pressure end plate. Make sure
3.4. The 2 wheel drive machines have a spacer that the teeth are not aligned with the lubrication
installed instead of a gear. slots in the housing.
4. Lift off the piston housing complete with clutch 3.1. Note: The inner pressure end plate is 4 mm
pack. (0.157 in) thick and should not be confused
with the outer pressure end plate which is
5. Lift off the spring retaining plate. either 6 mm (0.23 in) or 6.5 mm (0.25 in)
thick.
6. Remove the spring and the oil baffle.
4. Install one friction plate followed by one counter
7. Remove and discard the O-ring 1 and O-ring 2 plate.
from the shaft.
4.1. Continue to install alternate friction and
8. Remove the circlip 1. counter plates, finishing with a friction plate.
9. Remove the gear and the splined hub together 5. Install the outer pressure plate.
with the thrust washer 1, thrust bearing 1, and
thin thrust washer 1. 5.1. Make sure that the flatter of the two faces is
installed outermost. It will face against the
10. Remove the two needle roller bearing retaining circlip 2 when this is installed.
assemblies.
27 - 237 9813/9400-1 27 - 237

27 - Driveline
5.2. Make sure that the teeth are not aligned with 17.1. Note: Always check that the oil baffle plate
the lubrication slots in the housing. and spring retaining plate are in the correct
order.
18. Carefully align the teeth of the clutch plates using
7. Install the friction and counter plates retaining a thin rod (or screwdriver).
circlip 2.
18.1. Wedge the plates together by inserting two
8. With a DTI (Dial Test Indicator) measure the end blunt tools (small rounded screwdrivers)
float of the pressure end plate. The value should through the bottom holes in the side of the
be within the specified range. clutch housing.
Figure 850.
Figure 849.
A A
A DTI
A Screwdrivers
9. If it is necessary to adjust the end float to bring
it within tolerance, there is a choice to install a 18.2. Position the clutch assembly onto the shaft
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure and splined hub.
end plate, with either a shim or an extra counter
plate between the retaining circlip 2 and pressure 19. Position the 4 wheel drive transfer gear onto the
end plate. shaft spline.
10. Install the thrust bearing 2 and thin thrust washer 19.1. Make sure that the gear is installed in the
2. correct position.
19.2. The 2 wheel drive machines have a spacer
11. Install the two needle roller bearings. installed instead of a gear.
12. Install the gear and splined hub. 20. Install the thrust washer 2 over the shaft.
13. Install the thin thrust washer 1, thrust bearing 1, 21. Apply gearbox oil onto the taper roller bearing
and thrust washer 1. 2 and install the bearing and the 4 wheel drive
14. Install the circlip 1. transfer gear into position with a bench press.
15. Install the spring and spring retainer. 21.1. When the taper roller bearing and the 4
wheel drive transfer gear have been fully
16. Install the new o-ring 1 and o-ring 2 onto the installed on the shaft, remove the two blunt
shaft. tools (small rounded screwdrivers) used to
wedge the clutch plates.
17. Install the oil baffle.
21.2. Rotate the gear to make sure that the
clutch has been correctly installed.
27 - 238 9813/9400-1 27 - 238

27 - Driveline
21.3. Use an air line to check the operation of 8. Remove the friction and counter plates retaining
the clutch. circlip.
22. Apply gearbox oil onto the taper roller bearing 1 9. Remove the pressure end plate and shim, if
and install the bearing onto the shaft. installed.
23. Install the new piston ring seals. 10. Remove the friction plates and the counter
plates.
(For: PS764, PS766) 10.1. Keep them together in sets, do not mix the
Special Tools plates with those from other clutches.
Test 11.1. With a cut away tube compress the piston
spring and then remove the circlip 2.
The illustration shows a main shaft assembly for a 6
speed gearbox. The main shaft assembly for 4 speed Figure 851.
gearboxes has some small differences. Procedures
are applicable for both 4 and 6 speed variants.
Disassembly
1. Carefully remove the piston ring seals.
then check for burrs or damage on the shaft
grooves. If necessary remove burrs with a
2. Remove the taper roller bearing 1 with a suitable
puller and press.
3. Remove the circlip 1 and remove the 4 wheel
drive(4WD) transfer gear.
12. Lift off the spring retaining plate.
3.1. Make a note in which orientation the gear is
installed for assembly. 13. Remove the spring and oil baffle.
3.2. The 2 wheel drive (2WD) machines have a 14. Turn the assembly over and knock the clutch
spacer installed instead of a gear. shaft on a piece of aluminium (or wood) to loosen
the piston.
4. Remove the gear and the splined hub together
with the thin thrust washer1 and thrust bearing1. 14.1. If the piston does not loosen, then hand
5. Remove the two needle roller bearing
assemblies.
(Qty.: 1)
5.1. 4-speed transmissions have only one
Figure 852.
needle roller bearing installed.
6. Remove the thin thrust washer 2, thrust bearing
2, thin thrust washer 3 (if installed) and thick
thrust washer 1.
7. Use a puller to remove the taper roller bearing 2.
7.1. It must be discarded and replaced.
7.2. This bearing would not normally be
removed unless it was damaged.
7.3. If a collet tool is not available, then it
is permissible to use a standard bearing
puller, although it can damage the bearing
cage which will require a new bearing.
27 - 239 9813/9400-1 27 - 239

27 - Driveline
15. Remove the piston. 17. Remove and discard the shaft O-ring 2.
16. Remove and discard the piston O-ring 1.
Figure 853.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
27 - 240 9813/9400-1 27 - 240

27 - Driveline
Figure 854.
Table 372.
Item Description
A Piston ring seals
C Circlip 1
D 4 wheel drive transfer
gear
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
K Thrust bearing 2 plate.
L Thick thrust washer
M Taper roller bearing 2 7.1. Continue to install alternate counter and
N Friction and counter
plates retaining circlip 8. Install the pressure end plate. Make sure that the
P Pressure end plate chamfered face of the pressure end plate faces
Q Shim the clutch pack.
R Friction plates 9. Make sure that the teeth are not aligned with the
S Counter plates lubrication slots in the housing.
T Circlip 2
10. A spring disc is not installed in this clutch pack.
U Spring retaining plate
V Spring 11. Do not install the shim at this stage.
W Oil baffle 12. Install the friction and counter plate retaining
X Piston circlip.
Y O-ring 1
Z O-ring 2
pressure end plate. The value should be within
the specified range.
Assembly
Figure 855.
2. Install the new O-ring 2 onto the shaft.
4. Install the oil baffle and piston spring. Make
sure that the spring is positioned correctly in the
piston.
14. If it is necessary to adjust the end float to

bring it within tolerance, there is a choice of
installing a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip
and the pressure end plate.
27 - 241 9813/9400-1 27 - 241

27 - Driveline
15. Use an airline to check the operation of the

clutch.
16. Install the thick thrust washer 1, thin thrust
washer 3, thrust bearing 2 and the thin thrust
washer 2.
17. Install the two needle roller bearing assemblies.
17.1. 4-speed transmissions have only one
needle roller bearing installed.
18. Carefully align the teeth of the clutch plates using
a thin rod (or screwdriver) and install the gear and
splined hub.
19. Install the thin thrust washer 1 and thrust bearing
1.
20. Install the 4 wheel drive transfer gear onto
the layshaft spline. Make sure that the gear is
installed in the correct orientation.
20.1. 2 wheel drive machines have a spacer
installed instead of a gear.
20.2. Install the circlip 1.
21. Apply gearbox oil on the taper roller bearing
1 and taper roller bearing 2 then push both
bearings onto the shaft.
22. Install new piston ring seals.
27 - 242 9813/9400-1 27 - 242

27 - Driveline
09 - Clutch - Main Shaft
09 - Clutch - Main Shaft Introduction

Check (Condition) ........................................ 27-248
Remove and Install ..................................... 27-248 Each gear on the gearbox has an associated clutch
shaft.

27 - 243 9813/9400-1 27 - 243

27 - Driveline
For: PS750 MK4 ..................... Page 27-244

For: PS764, PS766 ................. Page 27-246
(For: PS750 MK4)
Figure 856.
M
N
P J
K
L
Q
G
B
A
27 - 244 9813/9400-1 27 - 244

27 - Driveline
Item Description
H Counter plates
Table 373.
J Circlip 2
Item Description
K Spring retaining plate
A Piston ring seals
L Spring
M Oil baffle
C Taper roller bearing 2
N Piston
D Circlip 1
P O-ring 1 (Piston)
E Pressure plate
Q O-ring 2 (Shaft)
F Shim (if installed)
G Friction plates
27 - 245 9813/9400-1 27 - 245

27 - Driveline
(For: PS764, PS766)
Figure 857.
D
C
L
B M1
N
S
P
A Q
V R
T
M2
J
E
F
G
H

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
27 - 246 9813/9400-1 27 - 246

27 - Driveline
P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1
27 - 247 9813/9400-1 27 - 247

27 - Driveline
Do a visual check of the friction and counter plates: The layshaft clutch, 2WD / 4WD clutch, reverse
Counter plates all part of the mainshaft assembly.
1. Light scoring or polishing is permissible, plates Refer to the mainshaft remove and install procedure.
that are not flat, worn or heavily marked or scored Refer to (PIL 27-06-54).
Friction plates
one.

27 - 248 9813/9400-1 27 - 248

27 - Driveline
For: PS750 MK4 ..................... Page 27-249

For: PS764, PS766 ................. Page 27-252
(For: PS750 MK4)

Special Tools
Test
27 - 249 9813/9400-1 27 - 249

27 - Driveline
Disassemble
Figure 858.
M
N
P J
K
L
Q
G
B
A

C Taper roller bearing 2 D Circlip 1
E Pressure plate F Shim (if installed)
G Friction plates H Counter plates
J Circlip 2 K Spring retaining plate
L Spring M Oil baffle
27 - 250 9813/9400-1 27 - 250

27 - Driveline
N Piston P O-ring 1 (Piston)

Q O-ring 2 (Shaft)
1. Carefully remove the piston ring seals. 10.1. Note: If the piston does not loosen, then
hand pump air down the shaft oil inlet hole.
1.1. Note: If the piston ring seals are excessively
worn then check for burrs or damage on the Special Tool: Hand Pump Pressure Test
shaft grooves. If necessary remove burrs (Qty.: 1)
with a fine grade abrasion paper and oil. Figure 860.
2. Remove the taper roller bearing 1 with a suitable
puller and press.
2.1. Note: This bearing would not normally
be removed unless it was damaged. It
is permissible to use a standard bearing
puller, although damage to the bearing cage
may be incurred which will require a new
bearing.
3. Remove the taper roller bearing 2 from the
opposite of the shaft.
4. Remove the retaining circlip 1 of the friction and
counter plates.
5. Remove the pressure end plate and shim if
installed. 11. Remove the piston.
6. Remove the friction plates and counter plates. 12. Remove and discard the piston O-ring 1.
6.1. Keep them together in sets, do not mix the 13. Remove and discard the shaft O-ring 2.
Assemble
spring and then remove the circlip 2. 2. Install the new O-ring 2 onto the shaft.
Figure 859. 3. Lubricate the piston with oil and press fully into
that the spring is positioned properly in the piston.
plate.
7.1. Continue to install alternate counter and
8. Install the pressure end plate. Make sure that the
chamfered face of the pressure end plate faces
8. Lift off the spring retaining plate. the clutch pack.
9. Remove the spring and oil baffle. 9. Make sure the teeth are not aligned with the
10. Turn the assembly over and knock the clutch lubrication slots in the housing.
shaft on a piece of aluminium (or wood) to loosen 10. Do not install the shim at this stage.
the piston.
27 - 251 9813/9400-1 27 - 251

27 - Driveline
11. Install the friction and counter plate retaining 6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
circlip 1. end plate, with either a shim or an extra counter
12. With a DTI (Dial Test Indicator) measure the end pressure end plate.
float of the pressure end plate. The value should
be within the specified range. 14. Use an airline to check the operation of the
Length/Dimension/Distance: 1.9–2.5mm clutch.
Figure 861. 15. Apply gearbox oil to the taper roller bearings 1
and 2.
16. Install the bearings onto the shaft.
(For: PS764, PS766)

Special Tools
Test
The illustration shows a main shaft assembly for a 6

speed gearbox. The main shaft assembly for 4 speed
gearboxes has some small differences. Procedures
are applicable for both 4 and 6 speed variants.
13. If it is necessary to adjust the end float to bring it
27 - 252 9813/9400-1 27 - 252

27 - Driveline
Disassemble
Figure 862.
D
C
L
B M1
N
S
P
A Q
V R
T
M2
J
E
F
G
H

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
27 - 253 9813/9400-1 27 - 253

27 - Driveline
P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1
1. Carefully remove the piston ring seals. 11. Turn the assembly over and knock the clutch
shaft on a piece of aluminium (or wood) to loosen
1.1. If the piston ring seals are excessively worn the piston.
then check for burrs or damage on shaft
grooves. If necessary remove burrs with a 11.1. If the piston does not loosen, then hand
fine grade abrasion paper and oil. pump air down the shaft oil inlet hole.
2. Use a puller or press to remove the taper roller Special Tool: Hand Pump Pressure Test
bearing 1. (Qty.: 1)
3. Remove gear 1 and gear 2. Before removal make Figure 864.

a record of the orientation of the gears.
4. From the opposite end of the shaft remove the
taper roller bearing 2 with a suitable puller.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and the shims (If
applicable).
7. Remove the friction plates and counter plates.
7.1. Keep them together in sets, do not mix the

considerable force. Make sure you take care to 12. Remove the piston.
13. Remove and discard the piston O-ring.
14. Remove and discard the shaft O-ring.
15. Remove the circlip 3 and the remove the clutch
spring and remove the circlip 2.
housing from the shaft.
Figure 863.
16. Remove and discard the O-ring 1.
Assemble
1. Install the new O-ring 1.
2. Press the clutch housing onto the shaft spline
and install the circlip 3.
3. Install the new piston and shaft O-rings.
that the spring seats in the piston correctly.
6. Install the spring retaining plate. The 4 speed
9. Remove the spring retaining plate. The 4 speed transmissions have a different shaped spring
transmissions have a different shaped spring retaining plate installed.
retaining plate installed.
10. Remove the spring and oil baffle. install the circlip 2.
27 - 254 9813/9400-1 27 - 254

27 - Driveline

plate.
9. Install the pressure end plate. Make sure that the
the clutch pack.
lubrication slots in the housing.
12. Install the friction and counter plate retaining
circlip 1.
pressure end plate. The value should be within
the specified range.
Figure 865.

6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
end plate, with either a shim or an extra counter
pressure end plate.
clutch.
16. Apply gearbox oil onto the taper roller bearing 2
and press the bearing onto the shaft.
17. At the opposite end of the shaft press gear 1 and
gear 2 onto the shaft spline.
18. Make sure that the gears are installed in their
correct orientation.
19. Apply gearbox oil onto the taper roller bearing 1
and press the bearing onto the shaft.
27 - 255 9813/9400-1 27 - 255

27 - Driveline
10 - Clutch - 6 Speed
10 - Clutch - 6 Speed Introduction

Check (Condition) ........................................ 27-259
Disassemble and Assemble ........................ 27-260 Each gear on the gearbox has an associated clutch

shaft.

27 - 256 9813/9400-1 27 - 256

27 - Driveline
Figure 866.
AA
C N
Q
P
B
A
R
S
U
V
A
D
F
G
H
L
J
M
E
K
A Piston ring seal B Taper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
27 - 257 9813/9400-1 27 - 257

27 - Driveline
L Thrust bearing 2 M Thick thrust washer 2

N Circlip 1 P Pressure end plate
Q Shim R Friction plates
S Counter plates T Disc spring
U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring
27 - 258 9813/9400-1 27 - 258

27 - Driveline
Check (Condition)
Do a visual check of the friction and counter plates:
Counter Plates
1. Counter plates- light scoring or polishing is
permissible, plates that are not flat, worn or
heavily marked or scored must be replaced with
a new one.
Friction Plates
one.

27 - 259 9813/9400-1 27 - 259

27 - Driveline
Disassembly 11. Remove the friction plates and the counter

plates. Keep them together in a set.
1. Carefully remove the piston ring seals from each
end of the shaft. 12. Do not mix the plates with those from other
clutches assemblies.
2. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 13. Remove the disc spring.
grooves. If necessary remove burrs with a fine
grade abrasion paper and oil. 14. Put the clutch assembly in a suitable press to
compress the piston spring, then remove the
3. Use a collet tool to push and remove the taper circlip 2.
roller bearing.
4. Remove the gear and make a note of, in which
orientation the gear is installed. 16. Remove the spring and the oil baffle.
5. Use a puller to remove the clutch end bearing 17. Turn the assembly over and hit the clutch shaft
from the opposite end. gently on a piece of aluminium (or wooden) block
to loosen the piston.
6. Remove the gear and the splined hub together
with the thick thrust washer 1, thin thrust washer 18. If the piston does not loosen when you hit the
1 and the thrust bearing 1. clutch shaft then hand pump air down the shaft
oil inlet hole.
7. Remove the needle roller bearing.
19. Remove the piston.
8. Remove the thin thrust washer 2, thrust bearing
2 and the thick thrust washer 2. 20. Remove the piston O-ring and the shaft O-ring.
9. Remove the friction and the counter plate Before you assemble the clutch assembly check
retaining circlip 1. the condition of the clutch assembly. Refer to
Semi- Automatic Gearbox, Clutch- 6 Speed, Check
10. If installed, remove the pressure end plate and Condition (PIL 27-06-10).
shims.
27 - 260 9813/9400-1 27 - 260

27 - Driveline
Figure 867.
AA
C N
Q
P
B
A
R
S
U
V
A
D
F
G
H
L
J
M
E
K
A Piston ring seal B Tapper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
L Thrust bearing 2 M Thick thrust washer 2
N Circlip 1 P Pressure end plate
Q Shim R Friction plates
27 - 261 9813/9400-1 27 - 261

27 - Driveline
S Counter plates T Disc spring

U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring
27 - 262 9813/9400-1 27 - 262

27 - Driveline
Assembly 16. Use an air line to check the operation of the

clutch.
1. Install both the piston O-ring and the shaft O-ring.
17. Install the thick thrust washer 2, thrust bearing 2,
2. Lubricate the piston with hydraulic oil and push and the thin thrust washer 2.
fully into the bore of the clutch housing.
18. Install the needle roller bearing.
3. Install the oil baffle and the piston spring. Make
sure that the spring seats in the piston. 19. Carefully use a thin rod (or screwdriver) to align
the teeth of the clutch plates.
20. Install the gear and splined hub.
5. Compress the spring and install the circlip 2.
21. Install the thin thrust washer 1, thrust bearing 1
6. If applicable, install the disc spring assembly. and the thick thrust washer 1.
7. Make sure that the disc spring is installed with 22. Smear the clutch end bearing with gearbox oil
the teeth facing towards the clutch pack. and push the bearing onto the shaft.
8. Make sure that the teeth are not aligned with the 23. At the opposite end, push the gear onto the shaft
lubrication slots in the housing. spline. Make sure that the gear is installed in the
9. Install the counter plates and friction plates
alternately, starting with a counter plate and finish 24. Smear the tapper roller bearing with gearbox oil
with a friction plate. and push the bearing onto the shaft.
10. Install the pressure end plate. Do not install the 25. Install new piston ring seals at each end of the
shims at this stage. shaft.
11. Make sure that the chamfered face is installed, Refer to: PIL 27-06-45.
facing the clutch pack.
13. Install the clutch friction and counter plate
retaining circlip 1.
14. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate and it should
be within the specified limit.
Figure 868.
15. If it is necessary to adjust the end float to bring

it within specified limit mentioned in step 14,
Install a 6.0mm (0.23in) or 6.5mm (0.25in) thick
pressure end plate together with a shim or an
extra counter plate, between the retaining circlip
and the pressure end plate.
27 - 263 9813/9400-1 27 - 263

27 - Driveline
11 - Clutch - Forward (Input) Introduction

Clean ........................................................... 27-269
Check (Condition) ........................................ 27-269 Each gear on the gearbox has an associated clutch
shaft.

27 - 264 9813/9400-1 27 - 264

27 - Driveline
For: PS750 MK4 ..................... Page 27-265

For: PS764, PS766 ................. Page 27-267
(For: PS750 MK4)
Figure 869.
L
J X Y
W
C E
A
P
H
K
A
G F V
D U
T R
S
B
R
N
S
Y T
U H
V J
W P
Q
M
X
L
M
N
Q
Z
AB
AA
AC
G
AD
AE
27 - 265 9813/9400-1 27 - 265

27 - Driveline
Table 374.
Item Description
A Piston ring seal 1
B Clutch end bearing
C Gear
D Needle roller thrust bearing 1
E Thrust washer 1
F Gear and splined hub 1
G Needle roller bearing 2
H Thrust washer 2
J Needle roller bearing thrust washer
K Thrust washer 3
L Friction/counter plates retaining circlip
M Shim
N Pressure end plate
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 1
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X O-ring 1
Y O-ring 2
Z Piston seal rings 2
AA Bearing 1
AB Thrust washer 4
AC Needle roller bearing 3
AD Thrust washer 5
AE Gear and splined hub 2
27 - 266 9813/9400-1 27 - 266

27 - Driveline
(For: PS764, PS766)
Figure 870.
L
J X Y
W
C E
A
P
H
A K
G F V
D U
T R
S
A B
R
N
S
Y T
U
V H
J
Q P
W
M
L
M
N
Q Z
AB
AA
AC
AF
AD
AE
Item Description
Table 375. C Gear
Item Description D Thrust bearing 1
A Piston ring seal 1 (For- E Thin thrust washer 1
ward and reverse clutch F Gear and splined hub 1
only) G Needle roller bearing 1
B Clutch end bearing 1
27 - 267 9813/9400-1 27 - 267

27 - Driveline
Item Description
H Thick thrust washer 1
J Thrust bearing 2
K Thin thrust washer 2
L Friction and counter
plate retaining circlip
M Shim
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 2
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AF Needle roller bearing 2
27 - 268 9813/9400-1 27 - 268

27 - Driveline

Consumables
Description Part No. Size Carry out a visual inspection of the friction and
Surface Cleaning Fluid 4103/1204 1L counter plates:
1. Carefully remove all traces of gasket or gasket Counter plates

faces. 1. Light scoring or polishing is permissible, plates
1.1. Use a gasket removal product such as must be replaced with a new set.
Loctite Chisel when you remove the gasket
compound. Friction plates
1.2. Make sure that the mating faces are not 1. The cross hatching should be clearly visible,
damaged. plates that are not flat, have friction material
1.3. Clean the mating faces with a fine damage or scoring must be replaced with a new
carborundum paper. set.
1.4. Use a solvent cleaner and a clean cloth to 2. DO NOT mix old and new plates, if a plate is
finally remove all traces of oil or debris. damaged or worn install a complete new set.
Consumable: Surface Cleaning Fluid 3. Needle roller bearings should slide into position
2. Use a suitable degreasing agent to clean the freely, do not bend or distort the cage to install. If
inside of the case. the cage has been distorted install new bearings.
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
27 - 269 9813/9400-1 27 - 269

27 - Driveline
Remove and Install
The layshaft clutch, 2WD / 4WD clutch, reverse

all part of the mainshaft assembly.

27 - 270 9813/9400-1 27 - 270

27 - Driveline
For: PS750 MK4 ..................... Page 27-271

For: PS764, PS766 ................. Page 27-275
(For: PS750 MK4)

Special Tools Description Part No. Qty.
Description Part No. Qty. Spring Compressor 892/00916 1
Hand Pump Pressure 892/00223 1 Tool
Test
27 - 271 9813/9400-1 27 - 271

27 - Driveline
Disassemble
Figure 871.
H
X
K Y
W
L
E
P
J
B F
G
V
A D U
T
S
C
R
S
N
R
Y T
U
V
H
W P J
Q
M
X
L
M
N
Z
Q
AA
AC
AF
AE
AB
AD
A Piston ring seals 1 B Clutch end bearing 1

C Gear D Thrust bearing 1
E Thin thrust washer 1 F Gear and splined hub 1
G Needle roller bearing 1 H Thrust bearing 2
27 - 272 9813/9400-1 27 - 272

27 - Driveline
J Thick thrust washer 1 K Thin thrust washer 2

L Circlip 1 M Pressure end plate
N Shim (If installed) P Friction plates
Q Counter plates R Disc spring
S Circlip 2 T Spring retaining plate
U Spring V Oil baffle
W Piston X O-ring 1 (Piston)
Y O-ring 2 (Shaft) Z Piston ring seals 2
AA Clutch end bearing 2 AB Thrust bearing 3
AC Thick thrust washer 2 AD Thin thrust washer 3
AE Gear and splined hub 2 AF Needle roller bearing 2
1. Carefully remove the piston ring seals1. Figure 872.

then check for burrs or damage on the shaft
2. Remove the clutch end bearing 1 and gear with
a suitable puller and press.
3. Remove the thrust bearing 1 and thin thrust
washer 1.
4. Remove the gear and splined hub 1 assembly
with the needle roller bearing 1.
5. Remove the thrust bearing 2, thick thrust washer
1 and thin thrust washer 2.
10.2. If a press is not available use the spring
6. Remove the retaining circlip 1 of the friction and compressor tool A (892/00916) to remove
counter plates. the circlip 2.
7. Remove the pressure end plate and shim (if Special Tool: Spring Compressor Tool
installed). (Qty.: 1)
8. Remove the friction plates and counter plates. 11. Lift off the spring retaining plate.
8.1. Keep them together in sets, do not mix the 12. Remove the spring and oil baffle.
13. Turn the assembly over and knock the clutch
9. Remove the disc spring assembly shaft on a piece of aluminium (or wood) to loosen
the piston.
considerable force. Make sure you take care to 13.1. If the piston does not loosen, then hand
avoid damage or injury. pump air down the shaft oil inlet hole.
10. Put the clutch assembly in a suitable press. (Qty.: 1)
27 - 273 9813/9400-1 27 - 273

27 - Driveline
Figure 873. 8. Install one counter plate followed by one friction

plate.
9. Install the pressure end plate. Make sure the
the clutch pack.
circlip 1.
14. Remove the piston. 13. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate. The value
15. Remove and discard the piston O-ring 1. should be within the specified range.
16. Remove and discard the shaft O-ring 2. Length/Dimension/Distance: 1.9–2.5mm
17. To disassemble the opposite clutch, carefully Figure 874.

remove the piston ring seals 2.
18. Remove the bearing 2 with a suitable puller.
21. Do the steps 5 to 16 to disassemble the clutch
assembly.
Assemble
1. Install the new O-ring 1 onto the piston. within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
2. Install the new O-ring 2 onto the shaft. end plate, with either a shim or an extra counter
3. Lubricate the piston with oil and press fully into plate between the retaining circlip 1 and the
the bore of the clutch housing. pressure end plate.
4. Install the oil baffle and piston spring. Make sure 15. Use an airline to check the operation of the
that the spring is positioned properly in the piston. clutch.
5. Install the spring retaining plate. 16. Install the thick washer 1, thin washer 2, and the
thrust bearing 2.
CAUTION! The spring (or springs) apply 17. Carefully align the teeth of the clutch plates using
considerable force. Make sure you take care to a thin rod (or screwdriver) and install the gear and
avoid damage or injury. splined hub 1.
6. Compress the spring with a cut away tube and 18. Install the needle roller bearing 1.
19. Install the thrust bearing 1 and thin thrust washer
7. Install the disc spring assembly. 1.
7.1. Make sure that the disc spring is installed 20. Apply gearbox oil on the clutch end bearing 1 and
with the teeth towards the clutch pack. install the gear and bearing 1 onto the shaft.
7.2. Make sure that the teeth are not aligned with
the lubrication slots in the housing. 21. Install the new piston ring seals 1.
27 - 274 9813/9400-1 27 - 274

27 - Driveline
22. To assemble the opposite clutch do the steps 1 8.1. Keep them together in sets, do not mix the
to 19. plates with those from other clutches.
23. Carefully align the teeth of the clutch plates using 9. If installed, remove the disc spring assembly.
a thin rod (or screwdriver) and install the gear and
splined hub 2. 10. Put the clutch assembly in a suitable press.
24. Install the needle roller bearing 2. 10.1. With a cut away tube compress the piston
25. Install the thrust bearing 3, thick washer 2, and
thin washer 3. Figure 875.

install the gear and bearing 2 onto the shaft.
27. Install the new piston ring seals 2.
(For: PS764, PS766)

Special Tools
Test
This procedure is the same for the input and reverse

clutch assemblies. If there are any differences it will
be identified in the procedure.
Disassembly
12. Remove the spring and the oil baffle.
The illustrations show a reverse clutch assembly for
13. Turn the assembly over and knock the clutch
a 6 speed gearbox. 4 speed gearbox clutches have
shaft on a piece of aluminium (or wood) to loosen
fewer friction and counter plates. Procedures are
the piston.
applicable for both 4 and 6 speed variants.
13.1. If the piston does not loosen, then hand
1. Carefully remove the piston ring seals 1. pump air down the shaft oil inlet hole.
1.1. If the piston ring seals are excessively worn Special Tool: Hand Pump Pressure Test
then check for burrs or damage on the shaft (Qty.: 1)
fine grade abrasion paper and oil. Figure 876.
1.2. The input shaft does not have piston ring
seals installed at this end of the shaft.
2. Use a suitable puller and press to remove the
clutch end bearing 1 and the gear.
3. Remove the thrust bearing 1 and thin thrust
washer 1.
6. Remove the friction and counter plates retaining
circlip. 14. Remove the piston.
7. If installed, remove the pressure end plate and 15. Remove and discard the piston O-ring 1.
shim.
16. Remove and discard the shaft O-ring 2.
8. Remove the friction plates and counter plates.
27 - 275 9813/9400-1 27 - 275

27 - Driveline
17. To disassemble the opposite clutch, carefully 19. Remove the thrust bearing 3, thick thrust washer
remove the piston ring seals 2. 2 and thin thrust washer 3.
17.1. The input shaft has four piston ring seals 20. Remove the gear and splined hub 2 assembly
installed at this end of the shaft. with the needle roller bearing 2.
18. Loosen the clutch end bearing 2 and use a 21. Do the steps 5 to 16 to disassemble the opposite
suitable puller to remove it. side clutch assembly.
Figure 877.
L
J X Y
W
C E
A
P
H
A K
G F V
D U
T R
S
A B
R
N
S
Y T
U
V H
J
Q P
W
M
L
M
N
Q Z
AB
AA
AC
AF
AD
AE
27 - 276 9813/9400-1 27 - 276

27 - Driveline
7.1. Make sure that the disc spring is installed

Table 376. with the teeth towards the clutch pack.
Item Description 7.2. Make sure that the teeth are not aligned with
A Piston ring seal1 (For- the lubrication slots in the housing.
ward and reverse clutch
only) 7.3. In PS760 variant no disc spring is installed.
B Clutch end bearing 1 8. Install one counter plate followed by one friction
C Gear plate.
D Thrust bearing 1 8.1. Continue to install alternate counter and
E Thin thrust washer 1 friction plates, finishing with a friction plate.
F Gear and splined hub 1
G Needle roller bearing 1 9. Install the pressure end plate. Make sure the
H Thick thrust washer 1 the clutch pack.
J Thrust bearing 2
K Thin thrust washer 2 10. Make sure that the teeth are not aligned with the
L Friction and counter
plate retaining circlip 11. Do not install the shim at this stage.
M Shim
circlip.
P Friction plates
Q Counter plates 13. Use a DTI to measure the end float of the
R Disc spring assembly pressure end plate. For PS760 variant the value
should be within the specified range.
S Circlip 1
T Spring retaining plate Dimension: 1.9–2.5mm
U Spring Figure 878.
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AF Needle roller bearing 2
14. If it is necessary to adjust the end float to
Assembly bring it within tolerance, then you can choose
either 6.0mm (0.23in) or 6.5mm (0.25in) thick
1. Install the new piston O-ring onto the piston. pressure end plate, with either a shim or an extra
counter plate between the retaining circlip and
2. Install the new shaft O-ring onto the shaft. the pressure end plate.
3. Lubricate the piston with oil and push fully into 15. Use an airline to check the operation of the
the bore of the clutch housing. clutch.
4. Install the oil baffle and the piston spring. Make 16. Install the thick thrust washer 1, thin thrust
sure that the spring is positioned properly in the washer 2, and the thrust bearing 2.
piston.
17. Use a thin rod (or screwdriver) to carefully align
5. Install the spring retaining plate. the teeth of the clutch plates and install the gear
6. Compress the spring with a cut away tube and and splined hub 1.
secure with circlip 2. 18. Install the needle roller bearing 1.
7. Install the disc spring assembly.
27 - 277 9813/9400-1 27 - 277

27 - Driveline
19. Install the thrust bearing 1 and thin thrust washer

1.
20. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 1 onto
the shaft.
21. Install the piston ring seals 1.
21.1. The input shaft does not have piston ring
seals installed at this end of the shaft.
22. To assemble the opposite side clutch do the
steps 1 to 15 again.
23. Use a thin rod (or screwdriver) to carefully align
the teeth of the clutch plates and install the gear
and splined hub 2.
24. Install the needle roller bearing 2.
25. Install the thrust bearing 3, thick thrust washer 2,
and thin thrust washer 3.
26. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 2 onto
the shaft.
27. Install the piston ring seals 2.
27.1. The input shaft has four piston ring seals
installed at this end of the shaft.
27 - 278 9813/9400-1 27 - 278

27 - Driveline
15 - Solenoid Control Valve Introduction

Introduction .................................................. 27-279 The solenoid control valves provides the switching
Check (Condition) ........................................ 27-280 for forward drive and reverse drive to select the
Remove and Install ..................................... 27-280 direction of travel.
On some transmission systems the solenoid control

valves are also used for gear selection and 2WD
(Two Wheel Drive) / 4WD (Four Wheel Drive)
selection.
27 - 279 9813/9400-1 27 - 279

27 - Driveline

For: PS750 MK4 ..................... Page 27-280
If damage to any component or distortion of the
For: PS764, PS766 ................. Page 27-282
spool is evident the complete valve assembly must
be renewed. Great care should be taken when
dismantling and assembling the valve to avoid the (For: PS750 MK4)
following: Consumables
• Contamination Description Part No. Size
• Damage to spools JCB Transmission Fluid 4000/2601 5L
• Damage to seal grooves EP SAE 30 4000/2605 20L
4000/2603 200L
with the operation of the valve. There are two types of solenoid installed.
Solenoid valve - nut retained - this has a nut securing

the solenoid coil to the stem.
Solenoid valve - bolt retained - the solenoid is

enclosed in a metal casing and the casing is bolted
to the transmission housing.
Solenoid Valve - Nut retained

The procedure for the solenoid control valves is
the same. The following procedure is for one valve.
The gearbox shown has three solenoid valves, other
gearbox variants may contain a different quantity of
valves.
Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector (if
installed) at the solenoid coil 1 and coil 2.
3. Record the position of the solenoid coil electrical
connectors on the valve stem.
4. Clean the area around the solenoid valves. Do
not allow particles of grit to fall into the gearbox..
5. Remove the nut, coil 1, spacer and coil 2. Make
sure that you record the orientation of the spacer
for correct installation.
6. Clean the area around the valve stem and the
gearbox case to prevent contamination of the
gearbox. Plug all the open ports and hoses to
prevent contamination.
7. Remove the valve stem from the gearbox case.
27 - 280 9813/9400-1 27 - 280

27 - Driveline
Figure 879. gauze is defective, replace the valve with a new

one.
4. Inspect the O-ring seals for damage. Refer to
Check Condition (PIL 27-06-15).
5. Put some clean gearbox oil on the O-ring seals.
30
6. Use an extended socket to tighten the valve stem
to the correct torque value. Refer to Table 377.
7. Install the solenoid coils and spacer in the correct
orientation.
8. Put the solenoid coil electrical connectors in the
correct position on the valve stem.
9. Tighten the nut to the correct torque value. Refer
to Table 377.
10. Connect the electrical harness connectors at the
solenoid coils in the correct positions.
Solenoid Valve - Bolt retained

Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector.
3. Clean the area around the solenoid valve. Do not
allow particles of grit to fall into the gearbox.
4. Remove the bolts and valve from the gearbox
housing. Make sure that you record the
orientation of the solenoid for correct installation.
A Valve 1 4.1. Take care not to grip the unit by its electrical
B Valve 2 connector block. The connector block is not
C Valve 3 designed as a leverage point.
D Solenoid coil 1 4.2. Slowly rotate and at the same time pull
E Solenoid coil 2 the valve to remove it from the gearbox
F Nut housing.
G Spacer
H O-ring 5. Plug all the open ports and hoses to prevent
J Valve stem contamination.
Install
steps.
2. Inspect the gauze filters (if installed) on the valve
stem for contamination and damage.
3. Do not touch the gauze. Remove contamination
by rinsing the valve stem in clean gearbox oil.
If this fails to remove the contamination or the
27 - 281 9813/9400-1 27 - 281

27 - Driveline
Figure 880. Table 377. Torque Values

Item Nm
L F 6
J 27
K L 6
M (For: PS764, PS766)
Remove
1. Put tags on the electrical harness connectors.
L 2. Disconnect the connectors from the solenoids.

3. Clean the area around the solenoid valve block.
Do not allow particles of dirt to fall into the
gearbox.
4. Remove the socket head cap screws along with
the washers and lift off the valve block assembly.
5. Do not use a screwdriver to lift the valve block,
the sealing faces will get damaged.
5.1. If it is difficult to remove the valve block,
lightly tap the manifold block with a soft
faced hammer.
6. If any of the individual solenoid valve cartridges
N are to be removed, take care not to grip the unit
by its electrical connector block. The connector
N block is not designed as a leverage point.
N 7. Remove and discard the valve block sealing

gasket.
K Electrical harness connector
L Retaining bolts 7.1. The gasket may disintegrate on removal,
M Valve make sure that all traces are removed and
N O-ring seals discarded.
Install
steps.
2. Replace the O-ring seals.
3. Put some clean gearbox oil on the O-ring seals.
30
4. Install the solenoid in the correct orientation.
Refer to Table 377.
27 - 282 9813/9400-1 27 - 282

27 - Driveline
Figure 881. 6. If any of the individual solenoid valve cartridges

are to be replaced, take care not to grip the unit
by its electrical connector block. The connector
block is not designed as a leverage point.
B 7. Install the electrical harness connectors to the
solenoid valve cartridge connector block.
A Table 378. Torque Values
Item Nm
A 35
D
C
A Capscrews
B Solenoid valve block
C Valve cartridge
D Valve cartridge connector block
Install
1. Install two guide studs at the valve interface on
the front case.
2. Install a new valve block sealing gasket. Care is
needed as the gasket is thin.
Figure 882.
A
177
/10
813
E Gasket
3. Put the valve block in position against the front
case.
4. Install the socket head capscrews and the
washers.
5. Progressively tighten the screws to the correct
torque value.
27 - 283 9813/9400-1 27 - 283

27 - Driveline
Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due
to a fault in the system.
The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.
27 - 284 9813/9400-1 27 - 284

27 - Driveline
21 - Pressure Maintenance Valve

(PMV)
Remove and Install
(For: PS750 MK4) 2. Do not allow particles of grit to fall into the
gearbox.
Remove 3. Remove the plug then the sealing washer, the
spring and the valve spool.
1. Clean the area around the valve and the gearbox
case.
Figure 883.
B
C
D
A Plug B Sealing washer

C Spring D Valve spool
27 - 285 9813/9400-1 27 - 285

27 - Driveline
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
27 - 286 9813/9400-1 27 - 286

27 - Driveline
24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) ........................................ 27-287
(For: PS750 MK4, PS764, PS766)
Check (Condition)
A pump which is damaged or worn can cause
damage to the gearbox.
1. Remove the screws and then remove the pump

body.
2. Carefully check for any signs of wear or damage
on the gear teeth, white metal bearing and gear
mating faces. If any signs of wear or damage is
visible then you must replace the pump with a
new one.
3. Carefully remove and discard the oil seal.
Figure 884.
A
B
C
A Screw
B Oil seal
C Pump housing
4. Make sure that the seal housing is not damaged.
5. Install a new seal.
6. Install the seal the correct way around. Push the
seal flush with the front of the housing.
7. Assemble the pump again.
8. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.
27 - 287 9813/9400-1 27 - 287

27 - Driveline
24 - Oil Pump
Remove and Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
5. Install the bolts together with the new sealing
(For: PS750 MK4, PS764, PS766) washers.
Consumables
Description Part No. Size 6. Progressively tighten the bolts to the correct
torque value.
and Sealer (Medium 4101/0251 0.05L 7. Put some clean, new, oil into the pump at the
Strength) location shown.
Remove Table 380. Torque Values

Item Nm
1. Clean the area around the pump. Do not allow
A 28
any dirt or contamination to fall into the gearbox.
2. Remove the fixing bolts and lift the pump
assembly off the input shaft.
3. Remove the sealing washers and the pump
sealing ring.
4. Discard the washers and sealing ring.
Figure 885.
B A
F
D
E
A Bolt
B Oil pump
C Sealing washer
D Input shaft
E Sealing ring
F Oil filling location
Install
1. If the existing pump is to be installed then inspect
the pump for damage.
2. Install a new sealing ring.
3. Install the pump over the input shaft. Make sure
that the bolt holes are aligned.
4. Apply sealant to the threads of the bolts.
27 - 288 9813/9400-1 27 - 288

27 - Driveline
27 - Speed Sensor
27 - Speed Sensor Introduction

Introduction .................................................. 27-289 The sensor sends a varying frequency signal to
Component Identification ............................. 27-290 the Transmission ECU to determine the current
Operation ..................................................... 27-293 rotational speed of the input shaft or torque
Diagram ....................................................... 27-294 converter. The ECU uses the input shaft speed to
determine the slippage across the torque converter
Remove and Install ..................................... 27-296 and potentially to determine the rate of slippage
across the clutches. This information is vital to
regulate the application of the torque converter lock-
up clutch smoothly and effectively.
27 - 289 9813/9400-1 27 - 289

27 - Driveline
27 - Speed Sensor
For: PS750 MK4 ..................... Page 27-290

For: PS764, PS766 ................. Page 27-291
(For: PS750 MK4)

Figure 886. Location
A
A Ground speed sensor
Wires and Connectors
Figure 887. Ground Speed Sensor
6 1
5 2
4 3
1 Signal A - power (red) 2 Signal A - earth (black)

3 Signal A - output (white) 4 Signal B - power (orange)
27 - 290 9813/9400-1 27 - 290

27 - Driveline
27 - Speed Sensor
5 Signal B- earth (brown) 6 Signal B - output (yellow)
(For: PS764, PS766)
A Ground speed sensor B Input speed sensor
Figure 889. Ground Speed Sensor
6 1
5 2
4 3
1 Signal A - power (red) 2 Signal A - earth (black)

3 Signal A - output (white) 4 Signal B - power (orange)
5 Signal B- earth (brown) 6 Signal B - output (yellow)
27 - 291 9813/9400-1 27 - 291

27 - Driveline
27 - Speed Sensor
Figure 890. Input Speed Sensor
B A
A Earth B Power
C Signal output
27 - 292 9813/9400-1 27 - 292

27 - Driveline
27 - Speed Sensor
Operation
(For: PS750 MK4, PS764, PS766)

Machines with PS766 and PS750 transmission have
a Ground Speed Sensor and an Input Speed Sensor.
Machines with PS750 transmission only use the

Ground Speed Sensor.
Ground Speed Sensor Operation

The ground speed sensor is a magnetic induction
type. The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The ground speed sensor installation senses the

rotation of the gearbox output gear.
The speed sensor incorporates two sensor elements

and a dual output signal to enable diagnosis if there
is a disagreement between the two sensor outputs.
Input Speed Sensor Operation

The input speed sensor is a magnetic induction type.
The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The input speed sensor senses the rotation of the

gearbox input shaft via the reverse clutch driven
gear.
27 - 293 9813/9400-1 27 - 293

27 - Driveline
27 - Speed Sensor
Diagram
For: PS750 MK4 ..................... Page 27-294 3 Signal A - output (white)

For: PS764, PS766 ................. Page 27-295 4 Signal B - power (orange)
5 Signal B- earth (brown)
6 Signal B - output (yellow)
(For: PS750 MK4)
Figure 891. Ground Speed
Sensor Internal Schematic
1
5
R R 3
A 6
B 2
4
A Sensor element
B Diagnostic element
R Resistor
1 Signal A - power (red)
2 Signal A - earth (black)
Figure 892. Speed Sensor Connections
ECU J1
ECU J2
6
3 1
5 4 F
ECU J5
2
B +
A Hydraulic control ECU (Electronic Control Unit) B Ground speed sensor

F Fuse
27 - 294 9813/9400-1 27 - 294

27 - Driveline
27 - Speed Sensor
(For: PS764, PS766) Figure 894. Input Speed

Figure 893. Ground Speed B
1 R
5 R
1 C
R
R R 3
A 6
2
R
A
B 2
4
A Sensor element A Earth

B Diagnostic element B Power
R Resistor C Signal output
1 Signal A - power (red) R Resistor
2 Signal A - earth (black) 1 Sensor element
3 Signal A - output (white) 2 Diagnostic element
4 Signal B - power (orange)
5 Signal B- earth (brown)
6 Signal B - output (yellow)
Figure 895. Speed Sensor Connections
ECU
A
A
B
C
D
ECU J2
6
3 1
5 4 F
ECU J5
2
C +
B
A Transmission ECU B Hydraulic control ECU

C Ground speed sensor D Input speed sensor
F Fuse
27 - 295 9813/9400-1 27 - 295

27 - Driveline
27 - Speed Sensor
Remove and Install
For: PS750 Mk4, PS750 MK4 3. Do not allow particles of grit to fall into the
................................................. Page 27-296 gearbox.
For: PS764, PS766 ................. Page 27-297
4. Remove the screw 1.
(For: PS750 Mk4, PS750 MK4) 5. Remove the speed sensor 1 from the housing.
Speed sensors are installed depending on the Install

machine application. The gearbox has provision for
two speed sensors. 1. Installation is the opposite of the removal
procedure. At the time of installation do the
Speed sensor 1 following steps.
2. If the O-ring 1 is damaged replace it with a new
Remove one.
1. If connected, disconnect the speed sensor 3. Install the screw 1.
electrical connector.
4. Tighten the screw 1 to the correct torque value.
2. Clean the area around the speed sensor.
Figure 896.
B
A
G B
27 - 296 9813/9400-1 27 - 296

27 - Driveline
27 - Speed Sensor
5. Install the screw 2.
Table 381. 6. Tighten the screw 2 to the correct torque value.

Item Description Table 382. Torque Values
A Speed sensor 1
Item Description Nm
B Speed sensor 2
C Screw 1 28
C Screw 1
E Screw 2 12
D O-ring 1
E Screw 2
(For: PS764, PS766)
F O-ring 2
G Shims or spacers Speed sensors are installed depending on the
machine application. The gearbox has provision for
Speed sensor 2 two speed sensors.
Remove Speed sensor 1

1. If connected, disconnect the speed sensor Remove
1. If connected, disconnect the speed sensor
2. Clean the area around the speed sensor. electrical connector.
3. Do not allow particles of grit to fall into the 2. Clean the area around the speed sensor.
gearbox.
3. Do not allow particles of grit to fall into the
4. Remove the screw 2. gearbox.
5. Remove the speed sensor 2 from the housing. 4. Remove the screw 1.
6. If installed remove the shims or the spacers with 5. Remove the speed sensor 1 from the housing.
the sensor 2.
Install
Install
1. Installation is the opposite of the removal
1. Installation is the opposite of the removal procedure. At the time of installation do the
procedure. At the time of installation do the following steps.
following steps.
2. If the O-ring 1 is damaged replace it with a new
2. If the O-ring 2 is damaged replace it with a new one.
one.
3. If the spacers or the shims were removed replace
them correctly. 4. Tighten the screw 1 to the correct torque value.
4. The speed sensor may be damaged or fail to

operate correctly if it is not at the correct distance
inside the housing.
27 - 297 9813/9400-1 27 - 297

27 - Driveline
27 - Speed Sensor
Figure 897.
B
A
G B
3. Do not allow particles of grit to fall into the

Table 383. gearbox.
Item Description 4. Remove the screw 2.
A Speed sensor 1 (Input
Speed) 5. Remove the speed sensor 2 from the housing.
B Speed sensor 2 (Ground
6. If installed remove the shims or the spacers with
Speed)
the sensor 2.
C Screw 1
D O-ring 1 Install
E Screw 2
F O-ring 2
G Shims or spacers following steps.
Speed sensor 2 2. If the O-ring 2 is damaged replace it with a new

one.
Remove 3. If the spacers or the shims were removed replace
them correctly.
1. If connected, disconnect the speed sensor
2. Clean the area around the speed sensor.
27 - 298 9813/9400-1 27 - 298

27 - Driveline
27 - Speed Sensor
4. The speed sensor may be damaged or fail to

operate correctly if it is not at the correct distance
inside the housing.
6. Tighten the screw 2 to the correct torque value.

Item Description Nm
C Screw 1 28
E Screw 2 12
27 - 299 9813/9400-1 27 - 299

27 - Driveline
30 - Oil Pressure Sensor Introduction

Introduction .................................................. 27-300 The transmission pressure sensor is a form of switch
Component Identification ............................. 27-301 that closes an electrical contact when a certain
Remove and Install ..................................... 27-302 set pressure has been reached on its input. The
switch may be designed to make contact either on a
pressure rise or on a pressure fall.
27 - 300 9813/9400-1 27 - 300

27 - Driveline
Component Identification (For: PS764, PS766)

For: PS750 MK4 ..................... Page 27-301 Figure 900. Location
For: PS764, PS766 ................. Page 27-301
A
(For: PS750 MK4)
A Transmission Oil Pressure Switch

Figure 899. Wires and Connectors
A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch

A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch
27 - 301 9813/9400-1 27 - 301

27 - Driveline

For: PS750 MK4 ..................... Page 27-302 1. Installation is the opposite of the removal
For: PS764, PS766 ................. Page 27-303
following steps.
(For: PS750 MK4) 2. The oil pressure switch is non serviceable. If it is
faulty or damaged, it must be replaced with new
Remove one.
1. Clean off all debris, dirt and grit from around the 3. Replace the sealing washer.
pressure switch. 4. Tighten the pressure switch to the correct torque
2. There must be no signs of debris, dirt or grit value.
inside the gearbox.
3. Remove the pressure switch and discard the Item Description Nm
sealing washer.
A Pressure switch 16
4. Put caps on all the open ports of the gearbox.
Figure 902.
A Pressure switch
B Sealing washer
27 - 302 9813/9400-1 27 - 302

27 - Driveline
(For: PS764, PS766) 4. Disconnect the harness electrical connector from

the switch.
Remove 5. Remove the switch and discard the sealing
washer.
Figure 903.
A
Install
B
steps.
2. The switch is non serviceable. If it is faulty or
damaged, it must be replaced with new one.
4. Tighten the switch to the correct torque value.
Refer to Table 386.

Item Nm
A 10

B Seal
C Transmission Oil Pressure harness electrical
connector
switch.
3. There must be no signs of debris, dirt or grit
inside the gearbox.
27 - 303 9813/9400-1 27 - 303

27 - Driveline
33 - Oil Temperature Sensor Introduction

Introduction .................................................. 27-304 The transmission oil temperature sensor sends
Technical Data ............................................. 27-305 an analog signal to the instrument panel ECU
Component Identification ............................. 27-307 (Electronic Control Unit) to warn if the transmission
Remove and Install ..................................... 27-310 oil temperature is outside of specified limits.
The resistance of the sensor will change according

to the temperature of the oil - therefore the signal
to the ECU will change. The ECU will calculate the
resistance and the temperature that is sensed by the
sensor. For resistance and temperature values refer
to Technical Data (PIL 27-06-33).
If outside of the specified limits the instrument panel

ECU will broadcast a message on the machine
CAN (Controller Area Network)bus to other machine
ECUs and fault codes and displays will be triggered
to prevent damage to the transmission.
27 - 304 9813/9400-1 27 - 304

27 - Driveline
Technical Data
For: PS750 MK4 ..................... Page 27-305

For: PS764, PS766 ................. Page 27-305
(For: PS750 MK4)

Table 387. Sensor Resistance Values
Temperature °C (°F) Sensor Resistance Ω
-40 89,665
-30 47,304
-20 26,017
-10 14,862
0 8,790
10 5,365
20 3,372
30 2,176
40 1,439
50 973
60 672
70 473
80 339
90 247
100 183
110 137
120 104
130 80
140 63
150 49
(For: PS764, PS766)
540-170 and 540-140 Machines

-40 89,665
-30 47,304
-20 26,017
-10 14,862
0 8,790
10 5,365
20 3,372
30 2,176
40 1,439
50 973
60 672
70 473
80 339
90 247
100 183
27 - 305 9813/9400-1 27 - 305

27 - Driveline

110 137
120 104
130 80
140 63
150 49
Other Machines
-40 332,094
-35 239,900
-30 175,200
-25 129,287
-20 96,358
-15 72,500
-10 55,046
-5 42,157
0 32,554
5 25,339
10 19,872
15 15,698
20 12,488
25 10,000
30 8,059
35 6,535
40 5,330
45 4,372
50 3,605
55 2,989
60 2,490
65 2,084
70 1,753
75 1,481
80 1,256
85 1,070
90 915.4
95 786
100 677.3
105 585.7
110 508.3
115 442.6
120 386.6
125 338.7
130 297.7
135 262.4
140 231.9
145 205.5
150 182.6
27 - 306 9813/9400-1 27 - 306

27 - Driveline
For: PS750 MK4 ..................... Page 27-307

For: PS764, PS766 ................. Page 27-309
(For: PS750 MK4)
B A
A Transmission Oil Temperature Sender B Transmission Oil Cooler
27 - 307 9813/9400-1 27 - 307

27 - Driveline
2 1
1 2
Figure 906.
ECU
A Transmission ECU (Electronic Control Unit)

B Transmission Oil Temperature Sender
27 - 308 9813/9400-1 27 - 308

27 - Driveline
(For: PS764, PS766)

A Transmission Temperature Sender

1 2
ECU
2
1
1 Transmission ECU
2 Temperature Sender
27 - 309 9813/9400-1 27 - 309

27 - Driveline
Remove and Install
For: PS750 MK4 ..................... Page 27-310

For: PS764, PS766 ................. Page 27-311
(For: PS750 MK4)
Remove
Figure 909.
C B
A Temperature Sender harness electrical B Temperature Sender

connector
C Transmission Oil Cooler
1. Make the machine safe. Refer to (PIL 01-03). 2. The sender is non serviceable. If it is faulty or
2. Access to the transmission oil cooler is made
easier if the engine cover base is removed. Refer 3. Replace the sealing washer.
to (PIL 06-06-06).
4. Tighten the sender to the correct torque value.
3. Clean off all debris, dirt and grit from around the Refer to Table 390.
sender.
4. Disconnect the harness electrical connector from
the sender. Item Nm
B 27
5. When removing the sender there may be some
transmission oil spillage.
6. Remove the sender from the oil cooler.
7. Put caps on all the open ports of the cooler.
Install
steps.
27 - 310 9813/9400-1 27 - 310

27 - Driveline
(For: PS764, PS766) 4. Disconnect the harness electrical connector from

the switch.
Remove 5. Remove the switch and discard the sealing
washer.
Figure 910.
A
Install
B
steps.
2. The switch is non serviceable. If it is faulty or
4. Tighten the switch to the correct torque value.
C Refer to Table 391.

Item Nm
A 16
A Temperature Switch
B Seal
C Temperature Switch harness electrical
connector
switch.
3. There must be no signs of debris, dirt or grit
inside the gearbox.
27 - 311 9813/9400-1 27 - 311

27 - Driveline
39 - Filter
Introduction .................................................. 27-312 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-313 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 - 312 9813/9400-1 27 - 312

27 - Driveline
39 - Filter
Remove and Install Consumable: JCB Transmission Fluid EP SAE

30
Special Tools
Description Part No. Qty. 2. Screw the filter on until it just contacts the filter
head.
Oil Filter Removal Tool 892/00292 1
3. Turn the filter at least another 3/4 of a turn.
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20L
4000/2603 200L
For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).
Remove
1. Clean the area around the filter. Do not allow
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 911.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
27 - 313 9813/9400-1 27 - 313

27 - Driveline

Introduction .................................................. 27-314 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-315 large and coarse particles entering the transmission
system.
27 - 314 9813/9400-1 27 - 314

27 - Driveline

Item Nm
Consumables
Description Part No. Size B 12
Strength)
Remove
1. Clean the area around the strainer. Do not allow
2. Place a container, of suitable size beneath the
suction strainer. Remove the bolts. Remove the
strainer and the gasket. Allow the oil to drain into
the container. Be aware that the oil may be hot.
Refer to Gearbox, Drain and Fill (PIL 27-06).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 912.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
threads of the bolts. Tighten the bolts to the
(Medium Strength)
27 - 315 9813/9400-1 27 - 315

27 - Driveline
45 - Piston Ring Seal Introduction

Introduction .................................................. 27-316 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-317 the outer diameter of a piston
27 - 316 9813/9400-1 27 - 316

27 - Driveline
Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Assemble procedure (PIL 27-06).
Install
1. Wind the PTFE piston ring seal around your
finger as shown, so that the seal forms a coil.
Figure 913.
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 914.
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 - 317 9813/9400-1 27 - 317

27 - Driveline
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................. 27-318 Oil seals close spaces between components in
Remove and Install ..................................... 27-319 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 - 318 9813/9400-1 27 - 318

27 - Driveline
47 - Oil Seal

Remove is clean and free from wear or damage.
1. Bend back the stake nut locking ring. 2. Install a new oil seal. Locate the seal in the
position shown, the seal does not locate to the
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
3. Remove the oil seal. Do not damage the seal
housing. 4. Install the yoke, refer to Gearbox, Yoke- Remove
and Install (27-06-95).
Figure 915.
torque value.

Item Nm
B 400
A Yoke
B Stake nut
C Oil seal
E Washer
F Locking ring
27 - 319 9813/9400-1 27 - 319

27 - Driveline
52 - Driveshaft
52 - Driveshaft Introduction
Introduction .................................................. 27-320 The driveshaft is a mechanical component for
Remove and Install ..................................... 27-321 transmitting torque and rotation, it is used to connect
other components of the driveline that cannot be
connected directly because of the distance or the
need to allow for relative movement between them.
27 - 320 9813/9400-1 27 - 320

27 - Driveline
52 - Driveshaft
Remove and Install
(For: PS764, PS766) 1.2. Draw the pump away from the gearbox,
disengage the drive shaft.
Remove 1.3. Lift the pump clear.
1. If the main hydraulic pump has not already been 2. Remove the circlip and the bearing.
removed proceed as follows:
3. Remove the driveshaft.
1.1. Support the pump, and remove the bolts.
4. Remove the sealing ring from the shaft.
Figure 916.
A
A
B E
F
C
A Bolts B Pump
C Circlip D Ball bearing
E Driveshaft F Sealing ring
27 - 321 9813/9400-1 27 - 321

27 - Driveline
52 - Driveshaft
Install
1. Install a new sealing ring to the shaft.
2. Apply clean oil to the sealing ring and install the
shaft inside the gearbox.
3. Apply clean oil to the ball bearing.
4. Install the bearing followed by the circlip.
5. Install the pump as follows:
5.1. Engage the pump with the driveshaft.
5.2. Support the pump and install the bolts.
27 - 322 9813/9400-1 27 - 322

27 - Driveline
54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-323 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-324 and transmits the power to other components in the
Remove and Install ..................................... 27-324 gearbox.
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 323 9813/9400-1 27 - 323

27 - Driveline
54 - Main Shaft

1. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
(For: PS750 MK4)
or damage is evident, the components must be
renewed. Remove
2. Make sure that all oil way cross drillings are clear 1. Carefully lift out the clutch/shaft assemblies in the
and free from debris. Blocked oil ways are a following order.
common cause of bearing failure. If necessary
use an air line to blow through the oil ways. 1.1. Layshaft clutch assembly.
1.2. 2/4 wheel drive clutch or the permanent
4WD (Four Wheel Drive) shaft, as
applicable.
Figure 917.
P
K
M
N
L
K Layshaft clutch assembly

L 2/4 wheel drive clutch
M Reverse clutch assembly
N Main shaft clutch assembly
P Input clutch assembly
Q Bearing outer cups 1
R Shims
1.3. Reverse clutch assembly.
1.4. Main shaft clutch assembly.
1.5. Input clutch assembly.
2. Remove the bearing outer cups 1 and shims from
the rear case. Record the position of the cups
and shims to make sure the correct assembly.
27 - 324 9813/9400-1 27 - 324

27 - Driveline
54 - Main Shaft
Clutch Disassemble and Assemble 2.3. With the help of an assistant slightly raise
Procedures and tilt the input clutch and main shaft
clutch, install the reverse clutch.
For detailed disassemble and assemble procedures 2.4. Install the 2/4 wheel drive clutch or
refer to the following procedures: permanent 4WD shaft, as applicable.
• Reverse clutch - refer to (PIL 27-06-06) 2.5. Install the layshaft clutch.
• 2WD (Two Wheel Drive) / 4WD clutch - refer to
(PIL 27-06-07) 3. Install the correct bearing outer cups 2 to the
• Layshaft clutch - refer to (PIL 27-06-08) clutch shaft bearings.
• Mainshaft clutch - refer to (PIL 27-06-09) 4. Install the main shaft bearing outer cup to the
• Forward / input clutch - refer to (PIL 27-06-11) centre of the output shaft.
Install
1. Install the shims and the bearing outer cups 1 at
their correct locations in the rear case.
2. Install the clutch assemblies as follows.
2.1. Lubricate the clutch shaft bearings.
2.2. Install the input clutch and at the same time
install the main shaft clutch into the front
case.
Figure 918.
P
V
K
V
M V
V
N
L
K Layshaft clutch assembly

L 2/4 wheel drive clutch
M Reverse clutch assembly
N Main shaft clutch assembly
P Input clutch assembly
Q Bearing outer cups 1
R Shims
V Bearing outer cups 2
W Main shaft bearing outer cup
27 - 325 9813/9400-1 27 - 325

27 - Driveline
56 - Layshaft
56 - Layshaft
Introduction
The layshaft is an intermediate shaft within a gearbox

that carries gears, but does not transfer the primary
drive of the gearbox either in or out of the gearbox.
27 - 326 9813/9400-1 27 - 326

27 - Driveline
57 - Input Shaft
57 - Input Shaft
Introduction
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 327 9813/9400-1 27 - 327

27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-328 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-329 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-330 single shaft within the gearbox. This single shaft is
called the main shaft.
The input and output ends of this combined shaft

rotate independently, at different speeds, which is
possible because one piece slides into a hollow bore
in the other piece, where it is supported by a bearing.
Sometimes the term main shaft refers to just the input
shaft or just the output shaft, rather than the entire
assembly.
In many gearboxes the input and output components

of the main shaft can be locked together to create a
1:1 gear ratio, causing the power flow to bypass the
layshaft. The main shaft then behaves like a single,
solid shaft: a situation referred to as direct drive.
27 - 328 9813/9400-1 27 - 328

27 - Driveline
58 - Output Shaft
Calibrate
(For: PS750 MK4, PS764, PS766)

Refer to the individual Remove and Install tasks of
the Output Shaft for the calibration procedure.
27 - 329 9813/9400-1 27 - 329

27 - Driveline
58 - Output Shaft
Remove and Install
For: PS750 MK4 ..................... Page 27-330 Figure 919.

For: PS764, PS766 ................. Page 27-334
B
(For: PS750 MK4) A
Special Tools
Setting Tool Kit 892/00918 1
Spacer Kit 921/52600 1
Flange Spanner 992/04800 1 D
End Float Setting Tool 993/70100 1 H E
Kit
(10-100Nm) J
Remove K
Before removing the output shaft and its bearings
remove all the clutch assemblies.
1. Remove the output shaft as follows: Refer to

Figure 919.
1.1. Hold the brake disc (or output yoke) with the
service tool.
1.2. Remove the output shaft nut.
Special Tool: Flange Spanner (Qty.: 1)
1.3. Support the output shaft from inside the
case and remove the brake disc (or output
yoke). F
1.4. Remove the output shaft.
1.5. Remove and discard the oil seal. G
C
1.6. Remove the outer taper roller bearing.
1.7. Remove the spacer and keep for assembly.
1.8. Use a suitable puller to remove the output
shaft inner bearing.
A Brake disc
1.9. If required, the park brake bracket can B Output shaft nut
be removed at this stage. Before removal, C Output shaft
mark the position of the bracket with respect D Oil seal
to the case. E Outer taper roller bearing
1.10. Note: Due to different ratio options, some F Spacer
gearboxes may have a larger diameter G Inner taper roller bearing
output gear. When you remove the output H Bolt 1
shaft the gear may touch the gearbox J Park brake bracket
housing, preventing removal. Refer to K Rear case
Section- Output Shaft Removal- Larger
Diameter Gears within this procedure. Install
1. If removed, the park brake bracket must be
installed at this stage as follows: Refer to Figure
920.
27 - 330 9813/9400-1 27 - 330

27 - Driveline
58 - Output Shaft
H E
M
J
L K
H Bolt1
J Park brake bracket
K Rear case
L 82mm
M 75mm
1.1. Put the bracket in position marked during
disassembly.
F
1.2. Attach the park brake bracket with the bolts
1.
1.3. Tighten the bolts to the correct torque value. C
1.4. Drill a hole of the specified diameter at the G
location shown to enable the installation of
the service tool for checking the end float.
Dimension: 12.5mm
C Output shaft
Special Tool: End Float Setting Tool Kit
D Oil seal
(Qty.: 1)
E Outer taper roller bearing
2. Pre-assemble the output shaft as follows: Refer F Service spacer
to Figure 921. G Inner taper roller bearing
K Rear case
2.1. Apply oil on the inner bearing and cup and
install on the output shaft.
2.2. Install the bearing cups into the case.
2.3. Install the service spacer onto the output
shaft and install the output shaft into the
case.
Special Tool: Spacer Kit (Qty.: 1)
2.4. Apply oil on the outer bearing and cup and
install onto the output shaft.
2.5. Do not install the oil seal at this stage.
3. Measure the output shaft assembly end float.
3.1. Install the service tool sleeve (which
temporarily replaced the disc brake) and
secure it with the service nut. Refer to
Figure 922.
Special Tool: Setting Tool Kit (Qty.: 1)
27 - 331 9813/9400-1 27 - 331

27 - Driveline
58 - Output Shaft
3.2. Tighten the service tool nut to the correct Figure 923.
torque value.
Torque: 50N·m S
3.3. Install the service tool support pillar so that
the fork end engages in the service tool nut.
3.4. Tighten the bolt 2.
Figure 922.
Q T
S DTI
P T Torque wrench
3.7. Select the right size spacer based on the
N example given in the table. Refer to Table
394.
3.8. Note: If the measurement obtained is
outside the spacer kit range, then check the
assembly of the bearings.
3.9. Disassemble the service tools and install
the correct size spacer. Assemble the
transfer gear output shaft.
3.10. Install the service tool sleeve and secure
it with the service nut.
3.11. Tighten the service tool nut to the correct
torque value.
N Service tool sleeve
P Service tool nut Torque: 50N·m
Q Support pillar 3.12. Make sure that there is no end float and
R Bolt2 the rolling torque is less than the specified
3.5. Install the DTI (Dial Test Indicator). Refer to value.
Figure 923. Torque: 1.5N·m
3.6. Set the torque wrench to the specified value 3.13. If the rolling torque exceeds the specified
and measure the end float while you rotate value then check that the output shaft is
the output shaft. installed correctly.
Torque: 35N·m 3.14. If the rolling torque is too high, install the
Special Tool: Torque Wrench (10-100Nm) next largest spacer.
(Qty.: 1)
3.15. If the rolling torque is too low, install the
next smallest spacer.
3.16. Remove the service tool nut and the
service tool sleeve.
4. Output shaft final assembly. Refer to Figure 924.
27 - 332 9813/9400-1 27 - 332

27 - Driveline
58 - Output Shaft
Figure 924. 4.4. Install the brake disc (or output yoke) with
reference to the alignment marks made
A B during disassembly.
4.5. Note: Do not excessively hammer the disc
during assembly or damage to the shaft
bearings could occur. If necessary, press
D fit the parts. Fully support the shaft during
assembly.
4.6. Install the new retaining nut and washer.
4.7. Progressively tighten the nut to the correct
torque value.
4.8. The combined seal and bearing rolling
torque should not exceed the specified
value when fully torque tightened, provided
the correct size spacer has been selected.
A Brake Disc Torque: 2N·m
B Output shaft nut
F Oil seal 4.9. If the rolling torque is too high, install the
next largest spacer.
4.1. Lubricate the seal lips of a new oil seal.
4.10. If the rolling torque is too low, install the
4.2. Install the new oil seal. next smallest spacer.
4.3. Make sure that the seal is pushed square to 4.11. Stake the nut into the slot in the shaft with
the housing. a square ended staking tool.
Table 394. Spacer Selection Example

Service spacer 13.7
Subtract end float 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15

Item Nm
B 300
H 166
Output Shaft Removal - Larger Diameter bearing inner cup and taper rollers will be forced
Gears partially up the output shaft, it will not be possible
to remove them at this stage.
In the event that the output gear fouls against the
2. Pull the output shaft up and position suitable
gearbox housing at position 1 when attempting to
spacers between the taper rollers and bearing
remove the output shaft, proceed as follows:
outer cup as shown.
Note: The following procedure will be required 3. Push the output shaft down again, the inner cup
when dismantling the gearbox, and also after initial and taper rollers will be forced further up the shaft
assembly, since the output shaft will need to be allowing them to be removed.
removed when setting the end float.
4. If the inner cup and taper rollers are still engaged
To enable the output shaft removal past the case at on the output shaft repeat steps 2 and 3 using
position 1, the bearing inner cup and taper rollers thicker spacers.
must first be removed from the output shaft.
5. With the bearing inner cup and taper rollers
1. Push the output shaft down until the gear removed, the output shaft and gear can be
contacts the housing at position 1, take care not lowered and tilted to one side, allowing the gear
to damage the housing or gear. Although the to clear the housing and the shaft to be removed.
27 - 333 9813/9400-1 27 - 333

27 - Driveline
58 - Output Shaft
Figure 925. 1.1. Remove the plug.

1.2. Remove the spring and valve spool from the
rear case.
C C 2. If required, remove the speed sensor as follows:

1
2.1. Remove the bolt 1.
2 2.2. Remove the sensor and its O-ring from the
rear case.
3. Hold the output yoke with the service tool.
3
4. Remove the bolt 2 and the thick washer.
4.1. The bolt is very tight, the help of an assistant
will be required.
A
5. Remove the yoke.
6. Remove and discard the oil seal. Make sure that
you do not damage the seal housing.
B
1 Output shaft 7. Support the transfer gear shaft assembly and
2 Taper rollers remove the gear from inside the rear case.
3 Bearing outer cup
A Gear 8. The gear assembly will come down along with
B Position 1 the following components:
C Spacers 8.1. Inner taper roller bearing.
Note: If the output shaft is being removed after initial 8.2. Inner taper bearing outer cup.
assembly, typically to set the end float, take extreme 8.3. Solid spacer.
care to avoid damage to the bearing outer cup and
inner cup and taper rollers. Use only soft spacers 9. Remove the outer taper rolling bearing and the
such as aluminium, Do not use hardened steel items outer bearing outer cup.
such as screwdrivers.
9.1. Note: If the inner and outer taper roller
If the bearing is damaged a new bearing MUST be bearings are to be used again, keep the
installed. The tolerance difference between the new bearings together with their respective outer
bearings is expected to be less than the difference cups in their original relationships.
between the solid spacer sizes so changing a
bearing should not affect the end float. 9.2. Put tags on the bearings to make sure that
assembly of them in their original positions.
(For: PS764, PS766) 9.3. If any of the two bearings is worn or
damaged, both the bearings must be
Special Tools replaced and a new solid spacer be
Description Part No. Qty. selected and installed.
Spanner 10. Remove the layshaft bearing outer cup from the
rear case.
Transfer Gear 892/01083 1
Assembly Tool
Bearing Assembly Tool 892/01084 1
Before Removal
1. Remove the front case and the clutch shafts.
Remove
1. Remove the pressure maintenance valve as
follows:
27 - 334 9813/9400-1 27 - 334

27 - Driveline
58 - Output Shaft

F
G H
R
P
E
Q
D
R Layshaft bearing outer cup
C
M
B
N
A
L
K
A Plug
B Spring
C Spool
D Bolt 1
E Speed sensor
F Bolt 2
G Thick washer
H Yoke
J Oil seal
K Transfer gear shaft assembly
L Inner taper roller bearing
M Inner bearing outer cup
N Solid spacer
P Outer taper roller bearing
Q Outer bearing outer cup
27 - 335 9813/9400-1 27 - 335

27 - Driveline
58 - Output Shaft
Install 3. Measure the transfer gear output shaft assembly

end float as follows: Refer to Figure 929.
1. Install the layshaft outer bearing cup into the rear
case. Figure 929.
2. Assemble the transfer gear output shaft as

follows:
2.1. Install the outer bearing outer cup into the Z
case. U
2.2. Apply oil onto the inner taper bearing. V
2.3. Push the inner bearing onto the transfer
gear/shaft. W
X
2.4. Install a service spacer of the specified
dimension. T
Dimension: 13.7mm
2.5. Install the inner bearing outer cup into the
case.
Y
2.6. Put the transfer gear assembly in position
against the case from inside. Z
2.7. Use the service tool to hold the transfer gear V
in position. Refer to Figure 928.
Special Tool: Transfer Gear Assembly Tool
(Qty.: 1) X
Figure 928.
S
K
T Service tool sleeve

U Service tool 1
V Service tool 2
W Bolt 3
X Support bracket
Y DTI
Z Torque wrench
3.1. Install the service tool sleeve over the
H Transfer gear transfer output shaft and secure with the
S Transfer gear retaining tool service tool 1.
3.2. Tighten the service tool 1 to the correct
2.8. If the gear is not held in position torque value.
the bearings may get damaged during
assembly. Torque: 50N·m
2.9. Apply oil onto the outer bearing. 3.3. Temporarily loosen the service tool sleeve.
2.10. Use the service tool to push the outer 3.4. Install the support bracket to the gearbox
bearing into the rear case. case.
Special Tool: Bearing Assembly Tool (Qty.: 3.5. Install the service tool 2 so that the fork end
1) engages in the groove of the service tool 1.
2.11. Do not install the oil seal at this stage. 3.6. Tighten the bolt 3 to secure the service tool
2 to the support bracket.
27 - 336 9813/9400-1 27 - 336

27 - Driveline
58 - Output Shaft
3.7. Install a DTI to measure the end float of the 3.19. Remove the service tool 1 and the service
output shaft. tool sleeve.
3.8. Set the torque wrench to the specified 4. Transfer gear output shaft final assembly.
torque value and measure the end float
while you rotate the output shaft. 4.1. Use special tool to install a new oil seal.
Make sure the seal is pushed square to the
3.9. Select the right size spacer based on the
housing.
example given in the table. Refer to Table
396. 4.2. Install the yoke, the thick washer and the
bolt 2.
3.10. Note: If the measurement obtained is
outside the spacer kit range, then check 4.3. Hold the yoke with the tool.
the assembly of the bearings.
Special Tool: Drive Coupling Spanner (Qty.:
3.11. Disassemble the service tools and install 1)
the correct size spacer. Assemble the
4.4. Tighten the bolt to the correct torque value.
transfer gear output shaft.
4.5. The combined seal and bearing rolling
3.12. Install the service tool sleeve over the
torque should not exceed the specified
output shaft and secure with the service
value when fully torque tightened provided,
tool 1.
the correct size spacer has been selected.
3.13. Tighten the service tool 1 to the correct Torque: 2N·m
torque value.
Torque: 50N·m 5. If removed, install the speed sensor as follows:
3.14. Make sure that there is no end float and 5.1. Install the O-ring on the sensor. Make sure
the rolling torque is less than the specified that it is correctly installed.
value.
5.2. Attach the sensor with the bolt 1.
Torque: 1.5N·m
5.3. Tighten the bolt 1 to the correct torque
3.15. If the rolling torque exceed the specified value.
value then check that the output shaft is
installed correctly. 6. Install the pressure maintenance valve as
follows:
3.16. If the rolling torque is too high, install the
next largest spacer. 6.1. Apply oil to the spool and install to the case.
3.17. If the rolling torque is too low, install the 6.2. Install the spring.
next smallest spacer.
6.3. Use a new sealing washer and install the
3.18. Use the service tool to hold the transfer plug.
gear in position. Refer to Figure 928.
6.4. Tighten the plug to the correct torque value.
Table 396. Spacer Selection Example

Service spacer 13.7
Subtract end float obtained at step 3.7 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15
After Installation
1. Instal the clutch shafts and the front case.

Item Nm
A 56
D 28
F 300
27 - 337 9813/9400-1 27 - 337

27 - Driveline
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
27 - 338 9813/9400-1 27 - 338

27 - Driveline
85 - Oil Feed Pipe
85 - Oil Feed Pipe
Remove and Install
Remove
1. Remove the adaptor bolts 1.
2. Remove all the sealing washers 1 (x4).
3. Remove the external oil feed pipe.
Figure 930.
C
B
B External oil feed pipe

C Adaptor bolts 1 (x2)
D Sealing washers 1 (x4)
Install
1. Install the external oil feed pipe with the adaptor
bolts 1 and the sealing washers 1.
2. Tighten the bolts 1 to the correct torque value.

Item Description Nm
C Adaptor bolts 1 26.5
27 - 339 9813/9400-1 27 - 339

27 - Driveline
86 - Oil Transfer Pipe
86 - Oil Transfer Pipe
Remove and Install
The oil transfer pipe is located on the rear case, if

the pipe is damaged or the gearbox is contaminated
then the pipe must be removed for cleaning or
replacement.
Remove
1. Remove the adaptor bolts 2.
2. Remove all the sealing washers 2.
3. Remove the oil transfer pipe.
Figure 931.
S
T
U
U
S Adaptor bolts 2 (x2)

T Oil transfer pipe
U Sealing washers 2 (x4)
Install
1. Install the oil transfer pipe with the adaptor bolts
2 and sealing washers 2.
2. Tighten the bolts 2 to the correct torque value.

Item Description Nm
S Adaptor bolts 2 26.5
27 - 340 9813/9400-1 27 - 340

27 - Driveline
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-341
Check (Condition) ........................................ 27-342
Remove and Install ..................................... 27-342 - General purpose
solvent based parts
cleaner
1. Carefully remove all traces of gasket or gasket

faces. When removing gasket compound use a
gasket removal product such as Loctite Chisel.
Take care not to damage the mating faces. Clean
the faces with a fine carborundum paper. Use
a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris
2. Clean the inside of the cases using a suitable
degreasing agent.
27 - 341 9813/9400-1 27 - 341

27 - Driveline
90 - Front Case

Consumables For: PS750 MK4 ..................... Page 27-342
Description Part No. Size For: PS764, PS766 ................. Page 27-345
and Sealer (Medium 4101/0251 0.05L (For: PS750 MK4)
Strength)
Consumables
1. If the gearbox cases are to be renewed, be Description Part No. Size
sure to install blanking plugs and adaptors as JCB Multi-Gasket 4102/1212 0.05L
required. Inspect the original cases and identify
the blanking plug and adaptor positions. Transfer
the plugs and adaptors to the new cases. Apply Before removal
JCB Threadlocker and Sealer to the threads
before installation. Before splitting the front and rear case do the
following procedures.
(Medium Strength) • Remove the oil filter. Refer to (PIL 27-06-39).
• Remove the suction strainer. Refer to (PIL
27-06-40)
• Remove the solenoid control valves. Refer to
(PIL 27-06).
• Remove the 4WD (Four Wheel Drive) yoke and
seal. Refer to (PIL 27-06-95).
• Remove the speed sensors. Refer to (PIL
27-06-27).
• Remove the torque converter relief valve. Refer
to (PIL 27-14-09).
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken.
• Remove deposits of dirt, grit and oil from the

outer cases and components.
• Prevent dirt, grit and debris falling into the
gearbox.
• Put caps on all open ports, hoses, pipes and
orifices.
Use lifting equipment to locate the gearbox in a

work cradle as shown. Do not try to disassemble the
gearbox further unless it is safely located in a work
cradle.
27 - 342 9813/9400-1 27 - 342

27 - Driveline
90 - Front Case
Figure 932. 2. Use lifting equipment to carefully lift off the rear
case.
3. Remove the shaft bearing outer cups. The cups
will be left on the bearings, or inside the front
case.
Figure 934.
H
H
H H
A H
A Cradle
Remove the external oil feed pipe. Refer to (PIL

27-06-85).
J
Remove
J
Front and rear case
1. Remove all the case fixing screws. H Bearing outer cups
J O-ring seals
Figure 933.
4. Keep the cups with their associated bearings.
5. Remove and discard the O-ring seals from the
front case.
F After removal
Remove the oil transfer pipe. Refer to (PIL 27-06-86).
Remove the clutch assemblies - refer to the following

procedures:
E • Mainshaft - (including layshaft clutch assembly,

2WD (Two Wheel Drive) / 4WD clutch
assembly, reverse clutch assembly, mainshaft
F clutch assembly and forward/input clutch
assembly) - refer to (PIL 27-06-54).
For detailed clutch disassemble and assemble

procedures refer to the following procedures:
• Reverse clutch - refer to (PIL 27-06-06)

• 2WD / 4WD clutch - refer to (PIL 27-06-07)
G • Layshaft clutch - refer to (PIL 27-06-08)
• Mainshaft clutch - refer to (PIL 27-06-09)
E Case fixing screws (x22) • Forward / input clutch - refer to (PIL 27-06-11)
F Rear case
G Front case
27 - 343 9813/9400-1 27 - 343

27 - Driveline
90 - Front Case
Before installation Figure 936.

• If you remove the output shaft and bearing then
install them. Refer to (PIL 27-06-58).
• Make sure the clutch assemblies are correctly
J
assembled and are free from defects. Refer to
(PIL 27-06). J
• Replace the clutch shaft piston ring seals with
new ones. Make sure that the piston ring seals X
are correctly installed in the shaft grooves.
Use lifting equipment to locate the gearbox in a work

cradle as shown. Do not try to assemble the gearbox
further unless it is safely located in a work cradle.
Figure 935.
J O-ring seals
X Friction counter plates
Y JCB Multigasket
2. Apply a continuous bead of JCB Multigasket to
the front case mating face.
A 3. Use two small rods or screwdrivers to align all the
friction counter plates in the main shaft clutch.
4. Use suitable lifting equipment to carefully lower
A Cradle the rear case and to align the output gear splines
with the main shaft clutch friction plates.
Clean and check the condition of all components
before you install them.
Install the oil transfer pipe. Refer to (PIL 27-06-86).
Install the clutch shaft assemblies. Refer to (PIL

27-06).
Install the front and rear case

1. Install new O-ring seals in the front case.
27 - 344 9813/9400-1 27 - 344

27 - Driveline
90 - Front Case
Figure 937. The Disassembly and Assembly procedures given

illustrate and describe the 6x4 gearbox. Procedures
for the 4x4 version of the gearbox are identical
in most respects. Where there are differences,
procedures are identified under the heading 4x4
Gearbox.
F
With the gearbox removed from the machine, place
assembly. If the gearbox is installed with an integral
park brake the brake assembly must be removed
before you disassemble the gearbox. Refer to (PIL
27-06).
E
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and
F interconnecting pipe. These components must be
removed before dismantling the gearbox.
Disassemble
1. Remove the main hydraulic pump and driveshaft.
2. Remove the solenoid control valve. Refer to (PIL
G 27-06-15).
E Case fixing screws (x22) 3. Use suitable lifting equipment to put the gearbox
F Rear case in a work cradle. Refer to Figure 938.
G Front case Special Tool: Gearbox Assembly Cradle (Qty.: 1)
5. If necessary rotate the output shaft a small 3.1. Clamp the gearbox at the three clamping
amount to align the splines. points on the rear case.
6. Apply sealant to the threads of the case fixing Figure 938.
bolts and install them.
After installation
Install the external oil feed pipe.

Item Description Nm A
E Case fixing screws 56
A Clamping points (x3)
(For: PS764, PS766) 4. Do not attempt to disassemble the gearbox
Special Tools further until it is safely positioned in a suitable
Description Part No. Qty. work cradle.
Gearbox Assembly 892/01082 1 5. Remove the torque converter housing as follows:
Cradle Refer to Figure 939.
Consumables
JCB Multi-Gasket 4102/1212 0.05L
Strength)
27 - 345 9813/9400-1 27 - 345

27 - Driveline
90 - Front Case
C F
D
F Front case
G Bolt 2
E
8.2. With suitable lifting equipment carefully lift
B Bolt1 the front case.
C Torque converter housing
8.3. Make sure you remove all the shaft bearing
D O-ring 1 (x5)
outer cups.
E O-ring 2 (x3): Only for lock-up torque converter
variants 8.4. The cups may be left on the bearings, or
inside the front case. Keep the cups with
5.1. Remove the bolts 1. their relative bearings.
5.2. Lift off the housing. 8.5. Remove and discard the sealing O-rings
5.3. Remove and retain the O-rings 1 (x5). from the front case.
5.4. For lock-up torque converter variants: 8.6. Remove the oil transfer pipes from the front
Remove and retain the O-rings 2 (x3). case only when they are damaged or the oil
is contaminated. Refer to Figure 941.
6. Remove the gearbox oil pump. Refer to (PIL
27-06-24).
7. Remove the 4WD clutch assembly. Refer to (PIL
27-06-07).
8. Separate the front and rear cases as follows:
8.1. Remove the bolts 2 that attach the cases.
27 - 346 9813/9400-1 27 - 346

27 - Driveline
90 - Front Case
Figure 941. 9.3. Forward/Input clutch shaft.

9.4. Layshaft clutch.
H 9.5. Main shaft clutch.
10. Remove the bearing outer cups from the rear
case and centre of the transfer gear. Refer to
Figure 943.
Figure 943.
R
Q S
T
H Transfer pipes (x3)

9. Carefully remove the clutch shaft assemblies in
the sequence given below: Refer to Figure 942.
Figure 942.
L M K Q Bearing cups
N R Rear case
S Transfer gear
P T Layshaft bearing cup
11. The layshaft bearing cup cannot be removed until
the transfer gear output shaft has been removed.
12. Keep the bearings cups together with their
relative bearings.
Install
1. Make sure that the sealing rings (x4) on the
clutch pack shafts are in good condition and
lubricated with oil.
2. Install the bearing outer cups at their correct
positions in the rear case and centre of the
J transfer gear.
J O-rings 3 3. Install the clutch shaft assemblies in the
K 6 Speed clutch (not installed on 4x4 gearbox) sequence given below: Refer to Figure 944.
L Reverse clutch unit
M Forward/Input clutch shaft
N Layshaft clutch
P Main shaft clutch
9.1. 6 Speed clutch (not installed on 4x4
gearbox).
9.2. Reverse clutch unit.
27 - 347 9813/9400-1 27 - 347

27 - Driveline
90 - Front Case
Figure 944. 5.1. Make sure that the O-rings are correctly
installed to the rear case. Refer to Figure
L M K 944.
N 5.2. Apply a thin bead of sealant to the rear case
mating face as shown in the figure. Refer to
P
Figure 946.
Figure 946.
J O-rings 3 V
K 6 Speed clutch (not installed on 4x4 gearbox) V Sealant
L Reverse clutch unit
M Forward/Input clutch shaft 5.3. Make sure that the shaft bearing outer cups
N Layshaft clutch are correctly installed in the front case.
P Main shaft clutch 5.4. Carefully lower the front case over the
3.1. Main shaft clutch. clutch shafts until it mates with the rear
case. Do not use excessive force when you
3.2. Layshaft clutch. Take care not to damage install the case.
the rear bearing on the transfer gear teeth
when you install the layshaft clutch. 5.5. Install the bolts 2 that attach the cases
together. Refer to Figure 947.
3.3. Forward/Input clutch shaft.
Figure 947.
3.4. Reverse clutch unit.
3.5. 6 Speed clutch (not installed on 4x4 F
gearbox).
4. Before you install the rear case make sure that
the sealing rings (x4) on the clutch pack shafts
are in good condition and lubricated with oil.
Figure 945.
U
G
F Front case
G Bolt 2
U Sealing rings (x4)
5. Assemble the front and rear cases as follows:
27 - 348 9813/9400-1 27 - 348

27 - Driveline
90 - Front Case
6. Measure the end float of the clutch shafts except 7.2. The end float of the shaft should be within
the input shaft as follows: Refer to Figure 948. the specified range.
6.1. For 4x4 gearbox: Remove the plug 1. Length/Dimension/Distance: 0.02–0.16mm
6.2. For 6x4 gearbox: Remove plug 1 and plug 8. Provided components are assembled correctly
2. the end float will be within the limits given. Check
that the shafts can be rotated by hand (turn the
6.3. Install a bolt to the threaded hole in the end input shaft and output yoke). The shafts should
of the shaft. rotate smoothly. The end floats can be checked
6.4. Pull the bolt to detect excessive end float. to confirm correct assembly.
Remove the bolt.
9. Install the 4WD clutch assembly.
6.5. The end float of the shafts should be within
the specified range. 10. Install the gearbox oil pump.
Length/Dimension/Distance: 0.02–0.16mm 11. Install the torque converter housing as follows:
6.6. Apply sealant to the plug 1 and plug 2 (for Refer to Figure 949.
6x4 gearbox only).
11.1. Make sure that the front case and torque
Consumable: JCB Threadlocker and Sealer converter housing mating faces are clean,
(Medium Strength) dry and not damaged.
6.7. Tighten the applicable plugs to the correct 11.2. Install the O-rings 1 (x5) to the front case.
torque value.
11.3. For gearboxes installed with lock up
Figure 948. torque converter: Install the O-rings 2 (x3)
to the front case.
L W X K
M N Figure 949.
E
P
D Y
D O-ring 1 (x5)
E O-ring 2 (x3): Only for Lock up torque converter
variants
W Loctite 509
K 6 Speed clutch (not installed on 4x4 gearbox)
L Reverse clutch unit 11.4. Apply a bead of Loctite 509 of the specified
M Forward/Input clutch shaft thickness to the front case.
N Layshaft clutch Dimension: 3mm
P Main shaft clutch
W Plug 1 11.5. According to the gearbox configuration
X Plug 2 Install the 13 or 14 bolts 2. Refer to Figure
950. or Refer to Figure 951.
7. Measure the end float of the input shaft as
follows: Refer to Figure 948.
7.1. Pull the input shaft to detect excessive end
float.
27 - 349 9813/9400-1 27 - 349

27 - Driveline
90 - Front Case
Figure 950. 13 Bolts Configuration

C
B Bolt 1 (x13)
Figure 951. 14 Bolts Configuration
C
B Bolt 1 (x14)
11.6. Tighten the bolts to the correct torque
value.
12. Install the solenoid control valve.
13. Install the main hydraulic pump and driveshaft.

Item Description Nm
B Bolt 1 56
G Bolt 2 56
W-X Plug 102
27 - 350 9813/9400-1 27 - 350

27 - Driveline
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-351 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-352
27 - 351 9813/9400-1 27 - 351

27 - Driveline
91 - Rear Case
Refer to Front Case - Check Condition (PIL (For: PS750 MK4)

27-06-90).
The front and rear case are separated at the same
time. Refer to the removal procedure of the front
case. Refer to (PIL 27-05-90).
27 - 352 9813/9400-1 27 - 352

27 - Driveline
95 - Coupling Yoke 4WD
95 - Coupling Yoke 4WD Introduction

Introduction .................................................. 27-353 The drive yoke is an important component of a
Remove and Install ..................................... 27-354 driveshaft assembly. The drive yoke assembly allows
a driveshaft or PTO to flex or slip with their given
application. The drive yoke is also essential for
allowing u-joints to rotate properly with the driveshaft.
27 - 353 9813/9400-1 27 - 353

27 - Driveline
Special Tools
Spanner
Remove
2. Clean the area around the yoke. Do not allow
3. Use service tool 892/00812 to hold the yoke and
at the same time undo the nut. The nut is very
tight, the help of an assistant will be required.
Discard the nut.
4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
the seal housing.
A Yoke
B Stake nut
C Oil seal
E Washer
F Locking ring
Install
is clean and free from wear or damage.
2. If necessary install a new oil seal. Locate the seal
in the position shown, the seal does not locate to
the back of the housing.
4. Install the yoke.
5. Install the stepped washer the correct way
around with the plan face facing the stake nut as
shown.
27 - 354 9813/9400-1 27 - 354

27 - Driveline

torque value.

Item Nm
B 400
27 - 355 9813/9400-1 27 - 355

27 - Driveline
12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-357
27 - 356 9813/9400-1 27 - 356

27 - Driveline
00 - General
Introduction .................................................. 27-357 The transfer gearbox is a system of gears used in
Component Identification ............................. 27-358 4WD (Four Wheel Drive) vehicles, which transfers
Clean ........................................................... 27-361 torque from the transmission to the front and rear
Check (Condition) ........................................ 27-361 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Calibrate ...................................................... 27-362 wheels.
Disassemble and Assemble ........................ 27-371 Transfer gearboxes typically have two gear ranges,
High and Low.
• High Range is used for typical road use.

• Low Range is used for off-road conditions.
27 - 357 9813/9400-1 27 - 357

27 - Driveline
00 - General
Unit Identification order for parts replacement, always give the details
mentioned on the unit identification plate. In the case
The gearbox serial number is stamped on the unit of gear replacements, always check the part number
identification plate as shown. When you make an stamped on the gear, and the number of teeth.
27 - 358 9813/9400-1 27 - 358

27 - Driveline
00 - General
Main Component Identification
Figure 953. Component Identification (For: Bevel Gearbox)
AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
27 - 359 9813/9400-1 27 - 359

27 - Driveline
00 - General
Table 403.
Item Description
A Gearbox case
B Bolt 1
C Pinion gear case
D Extraction holes
E Shim set 1
F Nut 1
G Spacer 1
H O-ring 1
J Pinion gear
K Bearing 1
L Bearing 2
M Spacer 2
N Triple lip seal 1
P O-ring 2
Q Mounting bushes
R Housing bosses
S Bolt 2
T Bevel gear case
U Extraction holes
V Shim set 2
W Nut 2
X Washer
Y Drive flange
Z O-ring 3
AA Bevel gear
AB Bearing 3
AC Bearing 4
AD Spacer 3
AE Triple lip seal 2
AF O- ring 4
27 - 360 9813/9400-1 27 - 360

27 - Driveline
00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
solvent based parts Strength)
cleaner
Surface Cleaning Fluid 4103/1204 1L Inspection
1. Carefully remove all traces of the gasket Before you assemble the gearbox, do a full
or gasket compound from the dropbox case inspection of all the components. It may be easy to
mating faces. Note: When removing the gasket find out a component failure but the cause behind
compound use a gasket removal product such the failure may not be as easy to find out. It is also
as Loctite Chisel. Take care not to damage the possible that a failed component may have caused
mating faces. damage to other areas of the gearbox.
2. Clean the faces with a fine carborundum paper. 1. General inspection.
Use a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris. 1.1. Carefully inspect all the gears, bearings and
shafts for any signs of excessive wear or
damage. If you find any damage during the
3. Clean the inside of the dropbox case using a inspection, components must be replaced.
suitable degreasing agent. 1.2. Make sure that all oil way cross drillings
Consumable: Cleaner/Degreaser - General are clear and free from contamination and
purpose solvent based parts cleaner foreign particles. Blocked oil ways are
a common cause of bearing failure. If
necessary use an air line to blow through
the oil ways.
2. Case inspection
2.1. If the gearbox case is to be replaced, then
make sure that all the necessary blanking
plugs and the adaptors are installed.
2.2. Check the original case and locate all the
locations of the blanking plugs and adaptors
on the case.
2.3. Move the plugs and adaptors to the new
cases. Apply sealant to the threads.
(Medium Strength)
2.4. New plugs may be supplied with a sealant
patch, in which case sealant is not
necessary.
27 - 361 9813/9400-1 27 - 361

27 - Driveline
00 - General
Calibrate
Figure 954.
AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1
27 - 362 9813/9400-1 27 - 362

27 - Driveline
00 - General
C Pinion gear housing D Extraction holes

E Shim set 1 F Nut1
G Spacer 1 H O-ring 1
J Pinion gear K Bearing 1
L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
End Float Measurement 6. If the pinion gear housing becomes difficult to

turn by hand, then stop tightening the vice and
The end float measurement procedure given below install the next largest spacer.
is applicable for both the pinion drive gear and the
bevel gear. 7. The rolling torque can be measured as a rolling
force. Use a spring balance and a cord wrapped
1. Install the bearings into the pinion gear housing. around the pinion gear housing.
1.1. Note: The taper roller bearings1 and 2 must Figure 956.
be preloaded 0.01 to 0.06 mm to give a
rolling torque of 0.5 to 1.5 Nm. The correct
pre-load is achieved by selecting a spacer
of the correct thickness.
2. Select the largest spacer and assemble with the
bearings in a vice. Use a suitable socket as a
clamping spacer.
Figure 955.
AQ M,AD
AR
AR 75mm
8. Pull the spring balance until the pinion gear
housing stops to rotate and then record the
reading.
Weight/Force: 6.9–19.6N
9. If the rolling force is too low, assemble again
using the next smallest size spacer.
M Spacer 2
AD Spacer 3 10. When the correct spacer has been selected,
AQ Socket remove the assembly from the vice and measure
the dimension shown.
3. Tighten the vice and measure the end float on the
housing. To select the correct size spacer Refer
to Table 404. for the calculation.
4. Select the nearest size spacer and assemble
again in a vice.
5. Carefully tighten the vice and make sure that the
pinion gear housing is free to rotate.
27 - 363 9813/9400-1 27 - 363

27 - Driveline
00 - General
Figure 957. Table 404. Spacer size calculation

Largest spacer 8
End float (example) 0.42
7.58
Pre-load required 0.04
Spacer required 7.54
Backlash Adjustment
Figure 958.
1. Carefully install the gear assemblies into their (use the bolt and lock nut as a reference point).
correct positions with the shim sets. Refer to Figure 958.
1.1. Note: Do not install the O-rings 2 and 4 at 5. Take measurements at four positions and
this stage. Make sure that the shims are calculate the average. The average should be
correctly aligned with the non-symmetrical between the specified values.
bolt holes. Length/Dimension/Distance: 0.13–0.2mm
2. Turn the gear shafts slightly to make sure that the 6. Adjust the shim sets equally from each drive gear
gears mesh with each other. to calculate the correct backlash.
3. Attach each drive gear in position with three
bolts. Gear Meshing Check
4. Hold the pinion drive gear stationary and do a 1. Apply engineers marking compound on the teeth
backlash check at the bevel gear drive flange of the gears.
27 - 364 9813/9400-1 27 - 364

27 - Driveline
00 - General
2. With the gearbox under load, rotate the gears in Figure 960.
both directions.
2.1. Note: It is recommended that the gearbox is
secured to the engine to provide a load.
3. When the pinion is too deeply (Refer to Figure
959. ) in mesh with the bevel gear do the
following:
Figure 959.
J
AA
J
AA
4.1. Decrease the shim thickness between the

pinion drive assembly and the main case.
4.2. Increase the shim thickness between the
bevel gear assembly and the main case
equally to maintain backlash.
5. When the correct gear meshing is achieved,
calculate the backlash check.
3.1. Increase the shim thickness between the Shim Selection Methods
pinion drive assembly and the main case.
3.2. Decrease the shim thickness between the Three methods of shim selection are used which
bevel gear assembly and the main case depends on the parts replaced during assembly:
equally to maintain backlash.
• Method A: Assembly using all the original
4. When the pinion is too far (Refer to Figure 960. ) components.
out of mesh with the bevel gear do the following: • Method B: Assembly using complete new gear/
bearing assemblies or gearbox case.
• Method C: Comparing relevant sizes of old and
replacement components and then adjusting
the shim pack accordingly. This method must
be used when you replace the taper roller
bearings. It can also be of use if some deviation
markings are illegible.
Method A
1. As the original gears and bearings are being
installed use the shims that were removed during
disassembly in their original positions.
2. Set the backlash.
27 - 365 9813/9400-1 27 - 365

27 - Driveline
00 - General
Method B
Figure 961.
AH AL
V
E
AK
AG
AN AP
AJ AM
E Shim set 1 V Shim set 2

AG Pinion assembly deviation AH Pinion gear deviation
AJ Pinion housing deviation AK Bevel assembly deviation
AL Bevel gear deviation AM Bevel housing deviation
AN When installing replacement pinion drive gear AP When installing replacement bevel drive gear
assemblies, the sum of AG and AH is marked assemblies, the sum of AK and AL is marked
at AN. at AP.
When you assemble the new gear/bearing Table 405. Pinion Drive Gear Assembly
assemblies it is possible to arrive at a nominal shim
Item Description Devia-
stack thicknesses by calculation.
tion/Thick-
Due to component tolerancing some deviation is ness
built up from base dimensions. These deviations AG Pinion assembly deviation 0
are marked on the relevant components during AH Pinion gear deviation +18
manufacture. Typical locations of deviation markings AN
(1)
=18
are shown. Refer to Figure 961.
AJ Pinion housing deviation +19
If some of the markings are not visible then it will Total =37
not be possible to calculate shim thicknesses. In Constant +40
this event start by installing 0.5mm nominal shims to Shim stack thickness 0.77
each gear assembly, then set the backlash.
(1) When installing replacement pinion drive gear
Calculate the shim stack thickness. Refer to Table assemblies, the sum of AG and AH is marked at AN.
405. and Refer to Table 406.. When you note down Table 406. Bevel Gear Assembly
the pinion gear housing and bevel gear housing
deviations a positive value becomes a negative value Item Description Devia-
and a negative value becomes a positive value, e.g. tion/Thick-
-19 becomes +19 in the pinion gear calculation. Refer ness
to Table 405. AK Pinion assembly deviation 17
AL Pinion gear deviation +60
AP
(1)
=77
27 - 366 9813/9400-1 27 - 366

27 - Driveline
00 - General
Item Description Devia- Figure 962.

tion/Thick-
ness
AM Pinion housing deviation +27
Total =104
Constant +20
Shim stack thickness 1.24
(1) When installing replacement pinion drive gear
assemblies, the sum of AK and AL is marked at AP.
Select shims to make up the nearest thickness for

each gear assembly.
Important: In all cases use the calculations as a

starting point. Verify with the backlash and gear tooth
mark checks.
X
Method C
1. When the taper roller bearings are replaced: 1.3. Subtract the value derived in step 1.2 from
the relevant shim stack.
1.1. Measure and record the thickness of the
existing shim stack. Length/Dimension/Distance: 0.33mm
1.2. Compare the old and new dimension
measured during assembly. Refer to Table
407.
Table 407.
Old = 40.65
New = 40.32
Result = 0.33
1. When the pinion and bevel gears are replaced: 1.3. Subtract the value derived in step 1.2 from
1.2. Compare the old and new gear deviations.

Refer to Table 408.
Table 408.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Result = +0.1
1. When the gearbox case is replaced: 1.4. Subtract the value derived in step 1.2 from
1.2. Compare the old and new housing Figure 963.

deviations. Refer to Table 409.
1.3. When you record the housing deviation 0
a positive figure becomes a negative
figure and a negative value becomes a
positive value, e.g. -19 becomes +19 in a -8 + 19
calculation. Refer to Table 409. - 27
27 - 367 9813/9400-1 27 - 367

27 - Driveline
00 - General
Table 409.
AJ Old (Pinion gear) = 30
AJ New (Pinion gear) = 40
Result The deviation has altered from +19
to -8, a total of -27 units. Refer to
Figure 963.
If the case deviation markings are not visible it will Figure 964.
not be possible to calculate shim stack adjustment.
In this event start by installing 0.5mm nominal shims
to each gear assembly, then set the backlash.
1. Replacement of the gear assemblies when the

deviation markings are not visible:
existing shim stack.
1.2. Remove the gear and measure the new
dimension.
1.3. Compare the old and new dimension (old

dimension measured during dismantling,
see gear disassembly procedure).
1.4. Compare the old and new gear deviations.
1.5. Subtract the value derived in step 1.4 from
Table 410.
Old = 40.65
New = 40.32
Result = -0.33
Table 411.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Difference = +0.1
Add difference from Refer to Table = -0.33
410.
Result = -0.23
27 - 368 9813/9400-1 27 - 368

27 - Driveline
00 - General
Remove and Install
Remove 3. Remove the torque converter. Refer to driveline-

torque converter, refer to (PIL 27-14).
1. Because of the configuration of the engine
and the transmission mounting system, we 4. Remove the hydraulic pump. Refer to hydraulic
recommend to remove the engine and the system- gear pump, refer to (PIL 30-11).
transmission as a full assembly.
5. Support the bevel gearbox with suitable lifting
2. Remove the gearbox. Refer to driveline- semi- equipment and remove the flywheel housing
automatic gearbox, refer to (PIL 27-06). bolts on the engine.
6. Take out the gearbox from the engine.
Figure 965.
A Flywheel housing bolts
27 - 369 9813/9400-1 27 - 369

27 - Driveline
00 - General
Install
removal procedure.

Item Nm
A 70
27 - 370 9813/9400-1 27 - 370

27 - Driveline
00 - General
Special Tools Special Tool: Reaction Block Fixture (Qty.:

Description Part No. Qty. 1)
Heavy Duty Socket 892/00912 1 1.5. With a heavy duty socket of the specified
46mm A/F value, remove the stake nut 1.
Heavy Duty Socket 892/00914 1 Dimension: 55mm
55mm A/F Special Tool: Heavy Duty Socket 55mm A/
Reaction Block Fixture 892/00915 1 F (Qty.: 1)
Consumables 1.6. Remove the spacer 1.

Description Part No. Size 1.7. Remove the O-ring 1 and then remove the
Special HP Grease 4003/2017 0.4kg pinion gear. Make sure you also remove the
4003/2006 12.5kg bearing 1 and spacer 2.
4003/2005 50kg 1.8. Remove the triple-lip seal 1 and the O-ring
2.
Machines (Before 2011) 1.9. Important: If the bearings or the gear
assembly is to be replaced, measure and
Earlier (before 2011) and later (after 2011) record the dimension as shown below.
procedures are shown. Make sure you refer to the Make sure you use suitable measuring
correct procedures for your machine. equipment with an accuracy of the specified
value.
Disassemble Dimension: 0.01mm
Remove the gearbox from the machine, place Figure 966.
assembly.
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken. Wash the
exterior of the gearbox assembly, refer to Transfer
Gearbox-Clean (PIL 27-12).
Make sure you note the orientation of the mounting

bushes if their replacement is required. Use a
suitable tube to press the outer steel ring of the
bushes during removal/installation of the mounting
bushes. Make sure the new bushes are installed in
their correct orientation and are positioned properly
in the housing bosses.
Disassemble the gear assembly as follows (For X

Machines before 2011).
1. Remove the pinion drive gear assembly. 1.10. Remove the bearing cups from the pinion
gear housing.
1.1. Remove the bolts 1 that attach the
pinion drive gear assembly to the gearbox 1.11. Put a suitable drift through the two holes
housing. in the pinion gear and then remove the
bearing2 from the gear.
1.2. If necessary, use a jacking bolt in the tapped
extraction holes on the pinion gear housing. 2. Remove the bevel gear assembly.
1.3. Remove the shim set 1 and put a label as 2.1. Remove the bolts 2 that attach the bevel
'for use with the pinion gear assembly.' gear assembly to the gearbox housing.
1.4. Use a reaction block to hold the gear 2.2. If necessary, use a jacking bolt in the tapped
assembly in a vice. extraction holes on the bevel gear housing.
27 - 371 9813/9400-1 27 - 371

27 - Driveline
00 - General
2.3. Remove the shim set 2 and put a label as Figure 967.
'for use with the bevel gear assembly.'
2.4. Use a reaction block to hold the gear
assembly in a vice.
Special Tool: Reaction Block Fixture (Qty.:
1)
2.5. With a heavy duty socket of the specified
value, remove the stake nut 2.
Dimension: 46mm
Special Tool: Heavy Duty Socket 46mm A/
F (Qty.: 1)
2.6. Remove the washer, drive flange 1, and the
O-ring 3.
2.7. Remove the bevel gear. Make sure you also
remove the bearing 3 and spacer 3.
X
2.8. Remove the triple-lip seal 2 and the O-ring
4.
2.10. Remove the bearing cups from the bevel
2.9. Important: If the bearings or the gear gear housing.
assembly is to be replaced, measure and
record the dimension as shown below. 2.11. Put a suitable drift through the two holes
Make sure you use suitable measuring in the pinion gear and then remove the
equipment with an accuracy of the specified bearing 4 from the gear.
value.
Dimension: 0.01mm
27 - 372 9813/9400-1 27 - 372

27 - Driveline
00 - General
Figure 968. Gearbox (Before 2011)

AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1

C Pinion gear housing D Extraction holes
E Shim set 1 F Nut 1
G Spacer 1 H O-ring 1
27 - 373 9813/9400-1 27 - 373

27 - Driveline
00 - General
J Pinion gear K Bearing 1

L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange 1 Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
27 - 374 9813/9400-1 27 - 374

27 - Driveline
00 - General
Assemble Figure 969.
The bevel gear and the pinion drive gear are a

matched pair and must be replaced as a set if
one of the two gears is damaged or excessively
worn. It is recommended that complete built-up gear/
bearing assemblies are installed in the event of gear
replacement.
Important: When you assemble the gearbox with

replacement or original components, the rolling
torques, backlash, shim stacks and gear meshing 2.15. Use the reaction block to hold the
must be checked and adjusted as required. assembly in the vice.
1. Make sure all bearings are lubricated before Special Tool: Reaction Block Fixture (Qty.:
installation. Rotate the bearings while you set 1)
them. Make sure the oil ways in the bearing
2.16. Install the nut 1.
carriers and gearbox housing are clean and
clear. This is particularly important if bearings 2.17. Tighten the nut to the correct torque value
have failed. Make sure you install new o-rings with a socket of the specified dimension.
and stake nuts. Dimension: 55mm
2. Assemble the pinion drive gear (for machines 2.18. Do not stake the nut 1 at this stage.
before 2011):
2.19. Measure the bearing rolling torque. Make
2.1. Check the pinion drive gear assembly end sure the rolling torque is between the
float. specified value.
2.2. Press the inner bearing 2 onto the pinion Torque: 0.5–2.5N·m
gear. 2.20. Excessive rolling torque indicates an
2.3. Install the spacer 2 selected in step 2.1. incorrectly installed seal.
2.4. Install the pinion gear and the bearing 2 into 2.21. Stake the nut 1 with a square ended
the pinion gear housing. staking tool.
2.5. Install the inner bearing 1 onto the pinion Figure 970.
gear.
2.6. Use the reaction block to hold the pinion
gear assembly in a vice.
2.7. Install the spacer 1 and nut 1.
2.8. Tighten the nut to the correct torque value
with a socket of the specified dimension.
Dimension: 55mm
2.9. Do not stake the nut 1 at this stage.
2.10. Measure the bearing rolling torque. Make F
sure the rolling torque is between the
specified value. 2.22. For figure, Refer to Figure 968.
Torque: 0.5–1.5N·m 3. Assemble the bevel gear assembly (for
2.11. Remove the nut 1 and the spacer 1. machines before 2011).
2.12. Install the new O-ring 1. 3.1. Check the bevel gear assembly end float.
2.13. Install a new triple lip seal 1 with a 3.2. Press the inner bearing 4 onto the bevel
suitable mandrel. Make sure that the seal gear.
is installed correctly in its housing.
3.3. Install the spacer 3 selected in step 3.1.
2.14. Carefully install the spacer 1 inside the
triple lip seal 1. Make sure that the outer 3.4. Install the pinion gear and the bearing 4 into
lip of the seal is against the housing. the bevel gear housing.
27 - 375 9813/9400-1 27 - 375

27 - Driveline
00 - General
3.5. Install the inner bearing 3 onto the bevel 3.18. Do not stake the nut 2 at this stage.
gear.
3.19. Measure the rolling torque. Make sure
3.6. Use the reaction block to hold the bevel the rolling torque is between the specified
gear assembly in a vice. value.
Special Tool: Reaction Block Fixture (Qty.: Torque: 0.5–2.5N·m
1)
3.20. Excessive rolling torque indicates an
3.7. Install the drive flange 1, washer, and the incorrectly installed seal.
nut 2.
3.21. For figure, Refer to Figure 968.
3.8. Tighten the nut 2 to the correct torque value
with a socket of the specified dimension. Table 413. Torques (Before 2011)
Dimension: 46mm Item Torque
3.9. Do not stake the nut 2 at this stage. B 85
F 300
3.10. Measure the bearing rolling torque. Make
sure the rolling torque is between the S 85
specified value. W 300
Machines (After 2011)
3.11. Remove the nut 2, washer, and the drive
flange 1. Disassemble
3.12. Install the new O-ring 3.
Disassemble the gear assembly as follows (for
3.13. Install a new triple lip seal 2 with a machines after 2011).
suitable mandrel. Make sure that the seal
is installed correctly in its housing. 1. Remove the bolted bevel gear assembly.
3.14. Carefully install the drive flange 1 inside 1.1. Remove the screws that attach the adaptor
the triple lip seal 2. Make sure that the to the drive flange.
outer lip of the seal is against the housing.
1.2. Remove the adaptor.
Figure 971.
assembly in a vice.
1)
1.4. Remove the set screw.
1.5. Remove the drive flange.
1.6. Remove the pinion gear.
1.7. Remove the triple lip seal and the O-ring 2.
3.15. Use the reaction block to hold the 1.8. Remove the O-ring 1.
assembly in the vice.
1.9. Remove the bearing and spacer.
1) 1.10. Put a suitable drift through the two holes
in the pinion gear and then remove the
3.16. Install the washer and the nut 2. bearing 8 from the gear.
3.17. Tighten the nut 2 to the correct torque
value with a socket of the specified
dimension.
Dimension: 46mm
27 - 376 9813/9400-1 27 - 376

27 - Driveline
00 - General
Figure 972. Bevel Gear Assembly (Bolt)

8
2
9
20
16 17 5 4 2 3 1
1 Bevel gear 2 Bearing

3 Spacer 4 Carrier- bearing
5 Triple lip seal 8 O-ring 1
9 O-ring 2 16 Drive flange
17 Setscrew 20 Adaptor
1. Remove the bevel gear assembly (nut). Refer to

Figure 973.
assembly in a vice.
1)
1.2. Remove the stake nut.
1.3. Remove the pinion gear from the bearing
carrier.
1.4. Remove the triple lip seal 3 and the O-ring
5.
1.5. Remove the O-ring 6.
1.6. Remove the bearing 6 and spacer 5.
1.7. Put a suitable drift through the two holes
in the pinion gear and then remove the
bearing 6 from the gear.
27 - 377 9813/9400-1 27 - 377

27 - Driveline
00 - General
Figure 973. Bevel Gear Assembly (Nut) AM Spacer 4

AN Stake nut 3
AP O-ring 6
AQ O-ring 5
Make sure you do not discard any component at this

stage.
Inspect the gearbox assembly. Refer to (PIL 27-12).
AN
AM
AQ
AL
AK
AP
AJ
AH
AG
AG Pinion gear 2
AH Bearing 6
AJ Spacer 5
AK Bearing 5
AL Triple lip seal 3
27 - 378 9813/9400-1 27 - 378

27 - Driveline
00 - General
Figure 974. Gearbox (After 2011)
4
8
3 2 5 16
17 20
11 2
5 9
6
7
1
8 2
2 3
459-10234-2
1 Bevel gear 2 Bearing- taper roller

3 Kit- bearing spacer 4 Carrier- bearing
5 Seal- triple lip 6 Spacer- seal ring
7 Nut- stake M36 (55 mm head) 8 O-ring seal
9 O-ring seal 11 Bevel gear
16 Flange- drive 17 Setscrew
20 Adaptor
Assemble sure the bearings are rotated whilst being

set.
1. Assemble the bevel gear assembly (bolt). (For
Consumable: Special HP Grease
machines after 2011)
1.2. Make sure the lubrication route and seal
1.1. Make sure the bearing rollers are packed vents in the bearing hub are not blocked
with the correct grease before setting. Make by excess grease. Do not overpack the
bearings.
27 - 379 9813/9400-1 27 - 379

27 - Driveline
00 - General
1.3. Pack the cavity between the seal lips with 1.17. Excessive rolling torque indicates an
the correct grease before assembly. incorrectly installed seal. Renew the seal
if it is damaged.
1.4. Select a bearing spacer to achieve the
specified preload. 1.18. Install the adaptor. Tighten the fastenings
to the correct torque. Refer to (PIL 72).
1.5. Press the bearings into the bearing carrier 2. Assemble bevel pinion drive gear (nut). (For
Make sure you install the spacer. Refer to machines after 2011). Refer to Figure 973.
Figure 974. and Refer to Figure 973.
2.1. Make sure the bearing rollers are packed
1.6. Install the triple lip seal. with the correct grease before setting. Make
sure the bearings are rotated whilst being
1.7. Install the pinion gear the bevel gear
set.
bearing housing.
1.8. Carefully install the drive flange 2 inside the
triple lip seal 4. Make sure that the outer lip 2.2. Make sure the lubrication route and seal
of the seal is against the housing. vents in the bearing hub are not blocked
by excess grease. Do not overpack the
Figure 975. bearings.
2.3. Pack the cavity between the seal lips with
the correct grease before assembly.
2.4. Select a bearing spacer to achieve the
specified preload.
2.5. Press the bearings into the bearing carrier.
Make sure you install the spacer. Refer to
Figure 974. and Refer to Figure 973.
1.9. Use the reaction block to hold the bevel 2.6. Install the triple lip seal.
2.7. Install the pinion gear in the bevel gear
bearing housing.
1)
2.8. Install the O-ring 5.
1.10. Take up the free play on the setscrew.
2.9. Carefully install the spacer 4 inside the triple
1.11. Check the seal drag is within specified
lip seal 3. Make sure that the outer lip of the
limits.
seal is against the housing.
Figure 976.
1.12. If the seal drag is within limits, tighten the
setscrew to the specified torque value.
Torque: 395N·m
the rolling torque is between the specified
value.
1.14. Use the reaction block to hold the bevel
2.10. Install the O-ring 6.
1.15. Install the set screw and tighten it to the
specified torque value. 2.11. Use the reaction block to hold the bevel
Torque: 395N·m
1.16. Measure the rolling torque. Make sure 1)
value. 2.12. Take up the free play on the stake nut. Do
not stake the nut.
27 - 380 9813/9400-1 27 - 380

27 - Driveline
00 - General
2.13. Check the seal drag is within specified 6. Set the backlash. Refer to driveline, transfer
limits. gearbox, calibrate (PIL 27-12-00).
Torque: 0.4–0.75N·m 7. Examine the gear meshing. Refer to driveline,
2.14. If the seal drag is within limits, tighten the transfer gearbox, calibrate (PIL 27-12-00).
stake nut to the specified torque value.
Torque: 395N·m
value.
2.16. Excessive rolling torque indicates an
incorrectly installed seal. Renew the seal
if it is damaged.
2.17. If the rolling torque is correct, stake the nut.
The nut is to be split axially using a square
ended tool.
Figure 977.
3. Install the bevel gear assemblies into the

gearbox case. Tighten the bolts to the correct
torque value.
4. Measure the correct thickness required for the
bevel gear assembly shim sets 1 and 2.
5. Important: Correct gear meshing and backlash
settings are essential for the reliable operation of
the gearbox. The settings are obtained by means
of variable shim stacks. Three methods of shim
selection are used which depends on the parts
replaced during assembly:
5.1. Method A: Assembly using all the original
components.
5.2. Method B: Assembly using complete
new gear/bearing assemblies or gearbox
casing.
5.3. Method C: Shim pack thickness can be
calculated by comparing relevant sizes of
old and replacement components and then
adjusting the shim pack accordingly. This
method must be used when you replace the
taper roller bearings. It can also be of use if
some deviation markings are not visible.
27 - 381 9813/9400-1 27 - 381

27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ......................................................................................................................... 27-383

27-14-06 Control Valve ................................................................................................................ 27-391
27-14-09 Relief Valve .................................................................................................................. 27-393
27 - 382 9813/9400-1 27 - 382

27 - Driveline
00 - General
Introduction .................................................. 27-383 The torque converter is a type of fluid coupling that
Component Identification ............................. 27-384 is used to transfer rotating power from the engine to
Operation ..................................................... 27-384 a rotating driven load.
Check (Operation) ....................................... 27-385
The torque converter normally takes the place of
Remove and Install ..................................... 27-389 a mechanical clutch in a vehicle with an automatic
transmission, allowing the load to be separated from
the power source.
It is usually located between the engine flywheel and

the transmission.
The key characteristic of a torque converter is its

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.
27 - 383 9813/9400-1 27 - 383

27 - Driveline
00 - General

Figure 978. The torque converter is similar to a fluid coupling,
which utilises the centrifugal force exerted in the
transmission oil to transmit power from the engine to
D the gearbox. It multiplies the torque from the engine
and functions as a combined clutch and infinitely
variable reduction gearbox.
The torque converter is enclosed in a casing and

consists of three basic parts, the impeller, reaction
member and turbine.
A
The impeller is driven by the engine.
B The reaction member does not rotate. Its hub
engages with a splined tube on the gearbox oil pump
and is held stationary.
The turbine is engaged with the splined end of the

G C gearbox input shaft.
The impeller driven by the engine, forms one set

of shaped blades, it can be likened to a centrifugal
pump imparting energy to the transmission oil. This
F E energy is transferred to another set of shaped
blades, which form the turbine. The turbine is
connected to the gearbox and converts the energy
back to a mechanical torque.
H
When the impeller is rotating faster than the turbine,
the fixed reaction member causes some of the
energy in the oil to be transferred back to the impeller.
This has the effect of multiplying the torque available.
When the impeller (input) is running much faster

than the turbine (output) there is a substantial
circulation of transmission oil around the blades. The
oil circulation is maximum when the turbine (output)
is stalled, and is almost zero when the impeller and
turbine speeds are equal i.e. the ratio is near 1:1.
If the turbine (output) is stalled whilst the impeller
(input) is revolving, all the power is dissipated as
A Impeller heat.
B Turbine
C Reaction member Because of the absence of a direct mechanical
D Drive plate (engine driven bevel gearbox) connection between the engine and the gearbox,
E Drive to gearbox input shaft the flexibility of the torque converter drive greatly
F Spline location for reaction member reduces wear on the transmission, absorbing shocks
G Direct drive from the engine to the gearbox oil and torsional vibration from the engine. The engine
pump cannot be stalled due to overload, as the fluid
H Direction of oil flow coupling slips.
For illustration refer to Component Identification (PIL

27-14-00).
27 - 384 9813/9400-1 27 - 384

27 - Driveline
00 - General
Check (Operation)
CAUTION Do not stall the converter for longer torque converter. This is the point at which, due to
than 10 seconds or the transmission fluid will torque applied by the engine the torque converter
overheat. Make sure the transmission oil level stops transmitting drive to the gearbox.
is correct before and after carrying out the test.
Make sure you check the oil level at normal The engine speed at which stalling occurs is
operating temperature. compared to speeds recorded for a machine in
normal condition.
Notice: Before starting the stall test, make sure
that the mainline and clutch pressures are correct. Stall tests can be used to diagnose faults with the
If the pressures are not correct, the clutches transmission.
could slip, resulting in premature wear of the
transmission friction plates. Also make sure the
machine neutral circuit and steer circuit pressures Technical Data Check List
are correct.
Record the test results in a check list for easy fault
identification. This section includes a blank check list
Stall Test to copy and use as required. Refer to Figure 979.
The purpose of the stall test is to check the The check list will help the engineer to identify the
performance of the transmission by stalling the cause of a gearbox fault, and if required, can be sent
to the JCB Technical Service Team via e-mail.
27 - 385 9813/9400-1 27 - 385

27 - Driveline
00 - General
Figure 979.
27 - 386 9813/9400-1 27 - 386

27 - Driveline
00 - General
Procedure 4. When fully engaged, the park brake electrically

disconnects the transmission drive. This
The purpose of the stall test is to check the prevents the machine from being driven with
performance of the transmission by `stalling' the the park brake on. Therefore, so that we can
torque converter. This is the point at which, due to complete the test, move the park brake lever
torque applied by the engine, the torque converter fractionally forward until the warning light is just
stops transmitting drive to the gearbox. The engine extinguished.
speed at which `stalling' occurs is compared to
speeds recorded for a machine in normal condition. 5. Hold the lever in this position for the duration of
Abnormal stall speed results can be used to identify the test.
possible faults as follows: 6. Do not move the lever too far forward, otherwise
the park brake will not be fully operational.
1. Poor engine performance
7. Do not disconnect the switch at the park brake.
2. Faulty torque converter
8. Select the 1st speed forward drive and open
3. Faulty gearbox hydraulic clutches
throttle fully. Record the engine speed from the
4. Faulty torque converter relief valve tachometer.
5. Transmission hydraulic leaks 9. Repeat the test in reverse drive.
6. Faulty hydraulic system relief valves 10. Repeat the test with the machine in each
configuration as described in the stall data tables.
For normal stall speed values refer to driveline- semi- Refer to driveline- semi-automatic gearbox, refer
automatic gearbox, refer to (PIL 27-06). to (PIL 27-06).
Do not stall the converter for longer than 10 seconds 11. For the machines with powershift gearboxes,
or the transmission fluid will overheat. Make sure repeat the test in 2nd and 3rd gears in both
that the oil level is correct and at normal operating forward and reverse drive.
temperature.
12. All recorded readings should be as specified.
If the machine is installed with a variflow hydraulic Refer to driveline- semi-automatic gearbox, (PIL
pump, make sure that the hydraulic oil temperature is 27-06).
above 50°C (121.9°F). Also make sure that the valve
block LSRV (Load Sense Relief Valve) pressure and Interpreting the Test Results
the variflow pump Delta P pressure are set correctly.
If all the engine speeds are below the stated figures
Before completing the following test, remove the either the engine is losing power and should be
transmission dipstick. If there is any sign of serviced/ overhauled or the torque converter reaction
smoke emitting from the dipstick tube stop the member clutch is slipping. To check the engine,
test immediately and dismantle the transmission for select neutral, open throttle fully and operate a
servicing. hydraulic service to 'blow off' the main relief valve.
Engine speed should fall to slightly below the
1. Check all engine fluid levels. Run the engine at maximum governed speed. Refer to (PIL 15-00). If
maximum speed and check the no load speed. engine speed is correct the torque converter reaction
Refer to Engine, General, General, Technical member clutch is slipping.
Data, (PIL 15-00-00).
If all the engine speeds are higher than the stated
2. Make sure that the engine and transmission are figures in all gears the torque converter safety relief
at normal working temperature (the transmission valve may be faulty. Alternatively there may be
oil must be above the specified temperature). internal oil leakage.
Run engine at maximum speed and check the
engine speed is correct (High Idle/ maximum If the engine speeds are higher than the stated
governed speed). Refer to engine- general, refer figures in some gears, check the transmission for
to (PIL 15-00). clutch slippage or internal leakage.
The example given below shows how the results can
3. Apply the park brake and foot brake firmly. be used to isolate a suspect clutch.
If necessary, set the machine against a fixed
obstruction.
27 - 387 9813/9400-1 27 - 387

27 - Driveline
00 - General
Table 414.
Stall Test Results- 4 Speed Powershift
Gear Clutches engaged
Forward RPM (Revolutions Reverse RPM
Per Minute)
1st T, Z 1990 W, Z 1980
2nd U, Z 2060 V, Z 1975
3rd T, Y 1985 W, Y 1990
In the example shown, the engine speed is

abnormally high when 2nd gear forward drive is
selected, indicating a slipping clutch, possibly U or
Z. We can now use the results to determine which
clutch is at fault.
As per the details from the table, there is no problem

with clutch Z since it is engaged in other gears,
the stall speeds for those gears are normal. This
indicates that the clutch U is slipping.
Clutches may slip for several reasons. Hydraulic

leakage is possible and this can be confirmed by
carrying out a pressure test. Refer to driveline- semi-
27 - 388 9813/9400-1 27 - 388

27 - Driveline
00 - General
Remove and Install
Consumables 2. Remove the gearbox. Refer to (PIL 27-06).

3. Prise out the access panel from the bevel
JCB Threadlocker 4101/0250 0.01L gearbox torque converter housing.
Strength) 4. Rotate the engine so as to gain access to the
torque converter retaining bolts (x4).
Remove
5. Support the torque converter. Loosen and
1. Due to the configuration of the engine and the remove the bolts (x4). Remove the torque
transmission mounting system, we recommend converter.
to remove the engine and the transmission as a
full assembly.
Figure 980.
D
F
B
A Access panel B Retaining bolt

C Drive plate D Spigot
E Bolts F DTI (Dial Test Indicator)
27 - 389 9813/9400-1 27 - 389

27 - Driveline
00 - General
Install
steps.
1.1. Make sure that the drive plate and the
torque converter mating faces are perfectly
clean.
1.2. If removed, make sure that the drive plate
mating faces are clean and free from burrs
before you install it over the spigot on the
drive flange.
1.3. Install the bolts with JCB Threadlocker and
Sealer. Tighten to the correct torque value.
(Medium Strength)
1.4. Make sure that there are no burrs on the
torque converter spigot or to any of the
mating faces adjacent to the drive plate.
1.5. Install the torque converter spigot on the
recess in the bevel box output shaft.
1.6. Install a DTI.
1.7. Rotate the torque converter and measure
the run out of the drive shaft. Make sure that
the run out does not exceed the specified
value.

Item Nm
B 46
E 28
27 - 390 9813/9400-1 27 - 390

27 - Driveline
06 - Control Valve
06 - Control Valve Figure 981.

E
Remove and Install
C
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and an
interconnecting pipe. Before you disassemble the
gearbox the pipe and valve must be removed.
C
Remove D
1. Remove the pipe nuts and lift off the pipe.
2. Remove the capscrews and remove the solenoid
control valve.
3. Make sure to remove the O-rings (x3) from the
bottom of the valve. D D
C A
B
A Nuts
B Pipe
C Control valve
D Capscrews (x3)
E O-rings (x3)
Install
1. Make sure that the valve sealing interface is not
damaged.
2. Install new O-rings to the valve.
3. Carefully put the valve in position against the
gearbox.
3.1. Make sure that the O-rings are not loose in
their seat.
4. Attach the valve with the capscrews.
5. Tighten the capscrews to the correct torque
value.
27 - 391 9813/9400-1 27 - 391

27 - Driveline
06 - Control Valve
6. Install the pipe and tighten the nuts to the correct

torque value.

Item Nm
A 56
D 9
27 - 392 9813/9400-1 27 - 392

27 - Driveline
09 - Relief Valve
09 - Relief Valve
Remove and Install
(For: PS750 MK4) 2. Do not allow particles of grit to fall into the
gearbox.
Remove 3. Remove the plug, sealing washer, spring and the
poppet.
1. Clean the area around the valve and the gearbox
case.
Figure 982.
B
C
A Plug B Sealing washer

C Spring D Poppet
27 - 393 9813/9400-1 27 - 393

27 - Driveline
09 - Relief Valve
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
27 - 394 9813/9400-1 27 - 394

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-397

27-27-03 Upper Trunnion ............................................................................................................ 27-406
27-27-60 Swivel ........................................................................................................................... 27-408
27-27-66 Wheel Stud ................................................................................................................... 27-416
27 - 395 9813/9400-1 27 - 395

Notes:
27 - 396 9813/9400-1 27 - 396

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-397 The hub is the part of the axle where the wheel
Calibrate ...................................................... 27-398 is mounted and where the axle shaft (if installed)
Disassemble and Assemble ........................ 27-398 passes through.
Some hubs are not driven and rotate due to motion

of the machine and some driven hubs may also have
reduction gearing installed.
The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.
27 - 397 9813/9400-1 27 - 397

27 - Driveline
27 - Hub
00 - General
Calibrate Disassemble and Assemble
Refer to the relevant Disassemble and Assemble (For: Dana 223 Series, Rear)
procedure (PIL 27-27).
Consumables
JCB High Strength 4102/0551 0.05L
Threadlocker
Strength)
Dismantle
1. Remove check screws from the planetary gear
carrier cover.
Figure 983.
1 Screw
2. Insert a lever in the slots provided and prise to
remove the planetary gear carrier.
Figure 984.
2 Planet gear carrier

3 Hub carrier
3. Remove the complete planet gear carrier.
27 - 398 9813/9400-1 27 - 398

27 - Driveline
27 - Hub
00 - General
2 Planet gear carrier

4. Loosen and remove the nuts that lock the gear 7. Partially draw out the wheel hub by using a
ring flange plastic hammer.
4 nuts 7 Wheel hub

5 Gear ring flange
8. Remove the external bearing.
5. Remove the safety flange
Figure 990.
Figure 987.
8 External bearing
6 Safety flange
9. Draw out the wheel hub.
6. Remove the complete gear ring flange by using a
puller and applying counter pressure to the studs.
27 - 399 9813/9400-1 27 - 399

27 - Driveline
27 - Hub
00 - General
10 Planetary gears
10. Take out the pins and remove the steering case. 13. Remove the snap ring of the gear ring.
For more information see Driveline, Rear Hub,
Swivel (PIL 27-28-60) Figure 995.
Figure 992.
12 Snap ring
13 Gear ring
3 steering case
14. Remove the gear ring flange.
11. Remove the snap rings.
Figure 996.
Figure 993.
14 Gear ring flange.

9 Snap ring
15. Remove the seal ring from the wheel hub. Make
12. Using a puller, remove the planetary gears. sure you mark the seal ring position.
27 - 400 9813/9400-1 27 - 400

27 - Driveline
27 - Hub
00 - General
Figure 997. 18. Using a puller, remove seal ring from steering
case. Make sure you note down the seal ring
orientation.
Figure 1000.
15 Seal ring
16. Remove the bearing.
Figure 998. 17 Seal ring
19. Using the Dana service tool, extract the guide
bushing of the twin U-joint.
20. Remove the defective studs, which will need to
be replaced.
Figure 1001.
16 Bearing
17. Remove the outer thrust cups of both bearings
by inserting and hitting a pin-driver in the slots
provided on the hub. Make sure you drive the
bearing races evenly to avoid damage.
Figure 999.
T5 Dana service tool
Assemble
1. Install the bushing in the steering case using the
Dana service tool.
7 Hub
8 Bearing outer race
16 Bearing outer race
27 - 401 9813/9400-1 27 - 401

27 - Driveline
27 - Hub
00 - General
18 Bush 16 Bearing (outer race)

T6 Dana service tool T8 Dana service tool
2. Apply a coat of AREXONS rubber cement to the 5. Install the bearing.
outer metal surface of the seal ring.
6. Apply Arexons seal rubber cement to the outer
3. Position the seal ring and, using tool the Dana surface of seal ring.
service tool, install it in the appropriate seat.
Make sure the direction of installation is correct. 7. Position the seal ring in the hub. Make sure you
check the seal ring orientation carefully.
Figure 1003.
Figure 1005.

17 Seal ring 7 Hub
15 Seal ring
4. Position the wheel hub under a press; lubricate 16 Bearing outer race
the outer seat of bearing and, using the Dana
service tool, install the thrust block of bearing. 8. Position tool the Dana service tool and press the
seal ring into its seat.
27 - 402 9813/9400-1 27 - 402

27 - Driveline
27 - Hub
00 - General
15 Seal ring 12 Snap ring

T9 Dana service tool 13 Gear ring
14 Flange
9. Turn the hub cover, lubricate bearing seat and
use the Dana service tool to install the thrust 11. Mount the gears onto the pins of the planetary
block of the bearing. cover. To insert gears, use tool the Dana service
tool. Make sure the radiused part of the bearings
Figure 1007.
inner ring must faces the bottom of the pin.
Figure 1009.
7 Hub cover
10. Install the flange in the gear ring and lock into 2 Planetary cover
position with the snap ring. Make sure that the 9 Snap rings
snap ring is fully inserted in the slot of the gear 10 Gears
ring. T21 Dana service tool
12. Lock the gears into position by installing the snap
rings.
27 - 403 9813/9400-1 27 - 403

27 - Driveline
27 - Hub
00 - General
9 Snap ring 3 Steering hub

10 Gear 7 Wheel hub
13. Oil the seal ring and bushing. Slip the steering 17. Install the outer bearing. Make sure you push the
case onto the twin U-joint, install the pivot pins bearing as far as it will go by tapping with a plastic
and connect the steering link arm. hammer all around the rim.
3 Steering case 8 Outer bearing

14. For more information see Driveline, Rear Hub, 18. Install the complete gear ring flange. To engage
Swivel (PIL 27-28-60). the flange, use a plastic hammer and hit
alternately at several equally spaced points.
15. If studs have been removed, apply a coat of JCB
Locking Fluid to the fastened end of the studs Figure 1015.
and apply Tecnolube 101 to ground nut end;
tighten the studs as far as they will go
Figure 1012.
19 Stud 5 Flange
16. Install the wheel hub onto the steering case. 19. Make sure that faces are thoroughly clean, and
then mount the safety flange.
27 - 404 9813/9400-1 27 - 404

27 - Driveline
27 - Hub
00 - General
6 Safety flange 2 Planetary gear cover

14 Flange 7 Wheel hub
20. Apply JCB Locking Fluid to the studs and tighten 23. Lock the planetary cover with the screw and
nuts. tighten to the specified torque.
Consumable: JCB Threadlocker and Sealer Torque: 40–50N·m
(Medium Strength)
Figure 1019.
21. Tighten the nuts in two stages using the criss-
cross method using the specified torques.
Figure 1017.
1 Screw
2 Planetary gear cover
4 Nuts
21.1. Initial tightening torque:
Torque: 250N·m
21.2. Final tightening torque:
Torque: 460–465N·m
22. Install the planetary cover on the wheel hub.
Make sure you check the condition and position
of the O-ring.
27 - 405 9813/9400-1 27 - 405

27 - Driveline
27 - Hub
03 - Upper Trunnion
03 - Upper Trunnion Figure 1022.
(For: Dana 223 Series, Rear)
Disassembly
Figure 1020.
3. Position the trunnion support under a press and

remove the complete bushing.
D Figure 1023.
C
B
A
A Cap
B Grease nipple
C Trunnion support (x2)
D Bush
1. Remove the trunnion support.
2. Remove the trunnion support on the side

opposite the drive. Assembly
1. If the bushing is worn and needs replacing, note
down the assembly side of the connection notch.
27 - 406 9813/9400-1 27 - 406

27 - Driveline
27 - Hub
03 - Upper Trunnion

E
C
E Notch
2. Position the trunnion support under a press and
insert the complete bushing.
Figure 1026.
3. Install the trunnion support.

Figure 1027.
4. Install the trunnion support on the side opposite

the drive.
27 - 407 9813/9400-1 27 - 407

27 - Driveline
27 - Hub
60 - Swivel
60 - Swivel Figure 1030.
Remove and Install

For: Dana 213 Series, Front .... Page 27-408
For: Dana 223 Series, Rear ..... Page 27-413
3
(For: Dana 213 Series, Front)
2
Consumables
Extreme Performance 4003/1327 0.4kg
Moly Grease 4003/1326 12.5kg
JCB Threadlocker 4101/0250 0.01L 2 Screws 1
and Sealer (Medium 4101/0251 0.05L 3 Lower pivot pin
Strength)
4. Insert a screwdriver or lever alternately in the
Remove slots provided and prise the lower pivot pin along
with the dust ring 1. Refer to Figure 1031.
1. Disconnect the pivot of the steering link arm from
the steering swivel. Figure 1031.
2. Sling the whole unit and connect it to a hoist.

Slightly tension the sling rope. Refer to Figure
1029.
Figure 1029.
1
3 Lower pivot pin

5. Make sure you replace the dust ring 1 when you
disassemble each time.
6. Loosen and remove the screws 2 of the upper
1 Steering link arm pivot pin. Refer to Figure 1032.
3. Loosen and remove the screws 1 of the lower Figure 1032.

pivot pin. Refer to Figure 1030.
5
6
5 Screws 2
6 Upper pivot pin
27 - 408 9813/9400-1 27 - 408

27 - Driveline
27 - Hub
60 - Swivel
7. Insert a screwdriver or lever alternately in the Figure 1035.

slots provided and prise the upper pivot pin along
with the dust ring 2.
8. Make sure you replace the dust ring 2 when you
disassemble each time. Refer to Figure 1033.
Figure 1033.
12
6 8
7
11
11 Upper bushing
12 Lower ball bushing
11. When the bushings are pulled out, the distance
pieces are removed as well.
12. Remove the dust ring 1 from the lower pivot pin.
6 Upper pivot pin Refer to Figure 1036.
7 Shims
8 Dust ring 2 Figure 1036.
9. Remove the complete steering swivel by drawing

it out from the twin joint. Refer to Figure 1034. 4
Figure 1034.
4 Dust ring 1
13. Note down direction of installation. Refer to
10 Figure 1037.
9 Steering swivel
10 Twin joint
10. Using a puller for inner parts, remove the upper
bushing and the lower ball bushing. Refer to
Figure 1035.
27 - 409 9813/9400-1 27 - 409

27 - Driveline
27 - Hub
60 - Swivel
6 12
4
12
4
3
3 Lower pivot pin 3 Lower pivot pin
4 Dust ring 1 12 Lower ball bushing
6 Upper pivot pin
12 Lower ball bushing 2. Install a new dust ring 1 onto the lower pivot pin.
Make sure you check the orientation carefully.
14. If the round cap needs replacement, remove the Refer to Figure 1040.
round cap from the lower pivot pin. Refer to
Figure 1038.
4
12
3 4 Dust ring 1
3 Lower pivot pin 3. Lubricate the upper bushing and the round
12 Lower ball bushing lower bushing. Install them in the fulcrum holes
provided on the arm, using a suitable tool. Refer
to Figure 1041.
Install
Figure 1041.
1. If the pivot pin has been disassembled, put the
lower pivot pin under a press and install the round
cap. Refer to Figure 1039.
12
11
11 Upper bushing
12 Lower ball bushing
27 - 410 9813/9400-1 27 - 410

27 - Driveline
27 - Hub
60 - Swivel
4. Install distance pieces using the same tools. Figure 1044.

Figure 1042. 6
13
6 Upper pivot pin

13
8. Temporarily lock the upper pivot pin complete
13 Distance piece with the dust ring 2, but with out shims with four
screws 2. Refer to Figure 1045.
5. Lubricate the end part of twin U-joint and mount
the steering swivel. Make sure you do not Figure 1045.
damage the seal ring of the twin joint. Refer to
Figure 1043.
Figure 1043. 6
10 6 Upper pivot pin

9. Fill the seat of the lower pivot pin with grease and
insert the complete lower pivot pin.
9 Steering swivel Consumable: Extreme Performance Moly
10 Twin joint Grease
6. Make sure that the holes for the upper and lower 10. Apply JCB sealant to the screws 1 and tighten
fulcrum pins are aligned. until the lower pivot pin is secured.
7. Install the upper pivot pin. Refer to Figure 1044. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
11. Loosen upper pivot pin screws 2 by the specified
value.
12. Tighten the screws 1 to the specified torque
using the criss-cross tightening method. Refer to
Figure 1046.
27 - 411 9813/9400-1 27 - 411

27 - Driveline
27 - Hub
60 - Swivel
3 Lower pivot pin

13. Tighten the screws 2 of the upper pivot pin with 17. Remove the upper pivot pin along with the dust
the crisscross method until you notice a slight ring 2.
increase in the torque of the steering swivel.
18. Fill the seat of the upper pivot pin with grease.
14. Using a feeler gauge, check clearance between Consumable: Extreme Performance Moly
the upper pivot flange and the steering swivel. Grease
Check at several points. Refer to Figure 1047.
19. Position the pack of shims previously calculated.
Figure 1047.
20. Reinstall the upper pivot pin along with the dust
ring 2.
6 5
21. Apply JCB sealant to the screws 2.
(Medium Strength)
22. Tighten the screws 2 to the specified torque value
using the criss-cross tightening method. Refer to
Figure 1049.
9 Figure 1049.
5 Screws 2
6 Upper pivot pin 6 7
9 Steering swivel
15. Calculate the average of measurements taken 8
and subtract the specified value from the
resulting measure until you have rounded off to
the lower decimal figure.
Length/Dimension/Distance: 0–0.1mm
16. Make up the pack of shims choosing among the
available shims. Refer to Figure 1048.
6 Upper pivot pin
7 Shims
8 Dust ring 2
23. Check that the steering swivel is free to rotate
and has no vertical clearance. If necessary,
recalculate shims as described earlier. Refer to
Figure 1050.
24. Thoroughly lubricate the two pivot pins with
grease.
27 - 412 9813/9400-1 27 - 412

27 - Driveline
27 - Hub
60 - Swivel
Consumable: Extreme Performance Moly Figure 1052.

Grease
Figure 1050.
10
19
10 Sealing ring
19 Bottom articulation pin
5 Screws 2 3. Using two levers, remove the top articulation pin
complete with the front seal and the shims. Refer
Table 418. Torque Values to Figure 1053.
Item Description Nm
Figure 1053.
2 Screws 1 136
5 Screws 2 136

4
Remove
1. Loosen and remove the installed screw 1 and 9
screw 2 from the bottom actuation pin and the top
actuation pin. Refer to Figure 1051.
Figure 1051.
3
3 Shims
4 Top articulation pin
4 9 Front seal
4. Take care not to damage the surfaces.
8 5. Remove the complete steering case. Refer to
Figure 1054.
15 19 Figure 1054.
4 Top articulation pin 1

8 Screw 2
15 Screw 1
19 Bottom articulation screw
2. Remove the bottom articulation pin complete
with the front sealing ring. Refer to Figure 1052.
1 Steering case
27 - 413 9813/9400-1 27 - 413

27 - Driveline
27 - Hub
60 - Swivel
Install Figure 1057.
1. Lubricate the terminal of the U-joint and install

the steering case. Refer to Figure 1055.
Figure 1055. 4
3
3 Shims
1 8. Lubricate the unit in the steering case. Refer to
Figure 1058.
1 Steering case
Figure 1058.
2. Take care not to damage the dust cover rings and
the sealing rings.
3. Install a series of shims of the specified thickness
under the top articulation pin. Refer to Figure
1056.
Figure 1056.
4
9. Install the bottom articulation pin in the steering

case.
10. Position the screws 2 and tighten to a necessary
torque.
3 11. Check for the correct assembly side of the

sealing ring. Refer to Figure 1059.
3 Shims
4. Install a new seal on to the top articulation pin.
5. Lubricate and install the unit in the steering case.
6. Position the screws 2 and tighten to the specified
torque value.
7. Check the correct assembly side of the seal.
27 - 414 9813/9400-1 27 - 414

27 - Driveline
27 - Hub
60 - Swivel
12
10
19
1
1 Steering case
10 Sealing ring 15. The torque of the bottom and top articulation pins
12 Bearing should be of the specified value.
19 Bottom articulation pin
16. If the preliminary measured value is too high,
12. Tighten the new installed screws 1 of the top and increase the shims.
bottom articulation pins to the specified torque
value. Refer to Figure 1060. Figure 1062.
Figure 1060.
15
15 Screws 1 Table 419. Torque Values

13. Using a lever check for the vertical gap. Item Description Nm
4 Top articulation pin 60
14. If there is any gap, determine the width and
8 Screw 2 140
reduce it by removing the shims. Refer to Figure
1061. 15 Screws 1 140
19 Bottom articulation pin 60
27 - 415 9813/9400-1 27 - 415

27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 1064.

B
Remove and Install
This remove and install procedure is the same for all

wheel studs.
WARNING! If, for whatever reason, a wheel stud

is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may A
have been damaged.
Remove
C
A Wheel stud
2. Follow the general health and safety procedures. B Wheel stud hole
Refer to (PIL 01-03). C Hub carrier
3. Remove the wheel from the hub. Refer to (PIL 2. Use a nut and washer to pull the stud into the hub
27-29). carrier.
4. Push out the wheel stud. 3. Check the stud and make sure that it is installed
correctly.
Figure 1063.
A 4. If the stud is loose replace the whole hub carrier
assembly.
A
A Wheel stud
5. Remove and discard all the wheel studs.
Check the condition of the wheel stud holes in the

hub carrier. If the holes are defective do not use the
hub carrier. Replace the hub carrier with a new one.
Install
1. Install the stud into the hub carrier hole.
27 - 416 9813/9400-1 27 - 416

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-419
27 - 417 9813/9400-1 27 - 417

Notes:
27 - 418 9813/9400-1 27 - 418

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-419 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-420 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-420 hours until they stay correct. Every day, before
starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value, refer to Technical Data.
27 - 419 9813/9400-1 27 - 419

27 - Driveline
29 - Wheel
00 - General
Health and Safety Remove and Install

WARNING If, for whatever reason, a wheel stud
is renewed, all the studs for that wheel must be (For: 512-26 [T4F])
changed as a set, since the remaining studs may
have been damaged. WARNING Whenever a wheel has been
changed, check the nut torques every two hours.
WARNING Wheels and tyres are heavy. Take When the nuts stay tight for 8h, the interval for
care when lifting or moving them. Store with care checking can revert to the period stated in the
to ensure that they cannot fall and cause injury. servicing schedule.
WARNING An exploding tyre can kill. Inflated WARNING Run flat inserts are installed in the
tyres can explode if over-heated or over-inflated. rear wheels. These must remain installed to the
Follow the instructions given when inflating the rear wheels to ensure machine stability is not
tyres. Do not cut or weld the rims. Use a tyre/ compromised in the event of a deflated tyre.
wheel specialist for all repair work.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine. Remove (One Wheel)
Air pressure in the tyres can cause the tyre and 1. Make the machine safe. Refer to (PIL 01-03).
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner 2. Follow the general health and safety procedures.
and outer wheel halves together when there is air Refer to (PIL 01-03).
pressure in the tyre. Always wear safety glasses.
3. Put chocks 1 under the rear wheels.
WARNING Wheels installed with semi-solid tyres
are heavy. Removing and installing them requires 4. Loosen the five wheel nuts by half a turn.
special equipment and training. Have the work
carried out by your JCB dealer or a tyre specialist. 5. Put a jack under the axle arm. Use the correct
WARNING Do not install pneumatic tyres on a jack.
wheel made for a solid tyre. Do not install a solid 6. Use the jack to lift the machine until the front
tyre on a wheel made for a pneumatic tyre. If wheel is off the ground.
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a 7. Put chocks 2 under the axle arm.
trained specialist.
8. Hold the wheel and remove the wheel nuts.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the 9. Remove the wheel.
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required.
Where run flat inserts have been specified for use,
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
27 - 420 9813/9400-1 27 - 420

27 - Driveline
29 - Wheel
00 - General
Figure 1065.
E
C
D
B
A Chocks 1
B Wheel nuts
C Jack
D Front wheel
E Chocks 2
Install
steps.
1.1. Make sure that the mating surfaces of the
wheel and axle hub are clean.
1.2. Tighten the wheel nuts to the correct torque
value.

Item Torque value
B 650N·m
27 - 421 9813/9400-1 27 - 421

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-423
27 - 422 9813/9400-1 27 - 422

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-423 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-424 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-424 ground.
Tyre materials are usually synthetic rubber, natural

rubber, fabric and wire, along with other compound
chemicals. They consist of a tread and a body.
The tread provides traction while the body ensures
support.
Make sure that the tyres are kept in good condition.

Refer to Health and Safety and Check Condition (PIL
27-33).
27 - 423 9813/9400-1 27 - 423

27 - Driveline
33 - Tyre
00 - General

DANGER Make sure that all tyres are inflated
to the correct pressure. Refer to the machine Always drive with consideration for the condition
operator manual. of the tyres. Incorrect tyre pressures will affect the
stability of the machine. Check the tyres daily for
WARNING An exploding tyre can kill. Inflated the correct tyre pressure and signs of damage. For
tyres can explode if over-heated or over-inflated. example:
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/ • Signs of distortion (bulges).
wheel specialist for all repair work. • Cuts or wear.
WARNING Wheels and tyres are heavy. Take • Embedded objects (nails, etc.).
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury. Install the valve caps firmly to prevent dirt from
entering the valve. Inspect for leaks when you check
WARNING Do not use the machine with the tyre pressures.
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed Inspect the tyre valve for leaks, when you check the
limitation of the tyres installed and do not operate tyre pressures.
at more than their recommended maximum
speed.
Tyre Inflation
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which Always try to maintain the tyre pressure to the
at high speeds may endanger life. recommended settings. Using a machine with under-
WARNING Deflate the tyre you wish to change inflated tyres means:
before removing the wheel from the machine.
• Decreasing the machines stability.
Air pressure in the tyres can cause the tyre and
• Higher tyre temperatures.
rim sections to explode causing serious injury or
• Excessive strain of the tyre fabric.
death. Never loosen the nuts that hold the inner
• Causes bulging of the sidewalls.
and outer wheel halves together when there is air
• Shortens the tyres life.
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a Using the machine with over-inflated tyres is
wheel made for a solid tyre. Do not install a solid dangerous:
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for • It causes excessive tensile loads in the fabric:
your machine, contact your local JCB dealer or a this makes a tyre more susceptible to cuts and
trained specialist. punctures.
WARNING When ordering tyres, you must Do not cut or weld on the rim of an inflated tyre.
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are After checking or amending the tyre pressure always
shown in the Operator's Manual. On no account replace and secure the valve cap.
should you use tyres of other designations
without first gaining approval from the machine Always deflate the tyre before removing foreign
manufacturer. obstacles from the tread.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully Procedure
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode. These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure,
call in a qualified tyre mechanic. The tyre mechanic
should use a tyre inflation cage and the correct
equipment to do the job.
1. Prepare the wheel. Before you add air to the tyre,

make sure it is correctly installed on the machine
or installed in a tyre inflation cage.
27 - 424 9813/9400-1 27 - 424

27 - Driveline
33 - Tyre
00 - General
Figure 1066.
2. Prepare the equipment.

2.1. Use only an air supply system which
includes a pressure regulator. Set the
regulator no higher than 1.38 bar (20 psi)
above the recommended tyre pressure.
2.2. Use an air hose fitted with a self-locking air
chuck and remote shut-off valve.
3. Add the air.
3.1. Make sure that the air hose is correctly
connected to the tyre valve. Clear other
people from the area. Stand behind the
tread of the tyre while adding the air.
3.2. Inflate the tyre to the recommended
pressure. Do not over-inflate.
27 - 425 9813/9400-1 27 - 425

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-427
27 - 426 9813/9400-1 27 - 426

27 - Driveline
47 - Propshaft
00 - General

Check (Condition) ........................................ 27-427 1. Make the machine safe. Refer to (PIL 01-03).
Lubricate ...................................................... 27-428
2. Check the propshaft tube for damage or cracks.
3. Check the centre bearing (if installed) for
security, cracks or damage.
4. Check the universal joints for security, cracks
or damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
5. Check the sliding joints for security, cracks or
damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
6. Check any sensor or sensor ring for security,
cracks or damage (if installed).
7. Make sure the correct fasteners are installed and
tightened to the correct torque.
8. Renew any defective component as needed.
27 - 427 9813/9400-1 27 - 427

27 - Driveline
47 - Propshaft
00 - General
Lubricate
2. Make sure you have the correct grease.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
propshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
4. Remove any excess grease.
27 - 428 9813/9400-1 27 - 428

27 - Driveline
47 - Propshaft
00 - General
Remove and Install
For: Front, HM560 Variable Transmission, Description Part No. Size

Rear ........................................ Page 27-429 Special MPL-EP 4003/1501 0.4kg
For: Front, Rear ...................... Page 27-430 Grease 4003/1506 12.5kg
4003/1510 50kg
(For: Front, HM560 Variable Transmission,
Rear) WARNING Before disconnecting any propshaft,
Consumables make sure you block both sides of all wheels
to prevent machine movement. The park brake
Description Part No. Size will become ineffective or may only operate on 2
JCB Threadlocker 4101/0250 0.01L wheels (depending on machine specification).
Strength)
Remove
Figure 1067.
A
A Chassis B Front propeller shaft

C Rear propeller shaft D Dual Tech Variable Transmission
27 - 429 9813/9400-1 27 - 429

27 - Driveline
47 - Propshaft
00 - General
E Bolts F Strap
1. Make the machine safe with the lift arm raised. Figure 1068.
2. Install the maintenance strut. Refer to (PIL X
06-69).
3. Remove the central access panels. refer to (PIL
06-06).
4. Put marks on all propshaft joints and the
sliding joints before removal to help during the Y
replacement procedure.
5. Support the propshaft.
6. Remove the bolts and straps to disconnect the
propshaft from the axles.
Install Z

At the time of installation follow the steps below.
1. Lubricate the sliding joints with the specified X Same plane (correct)
grease only, then align the shafts against Y Right angle (not correct)
identification marks previously made or, in Z Intermediate angle (not correct)
the case of a shaft being replaced use the 5. Tighten the bolts to the correct torque value.
manufacturer's alignment markings.
Consumable: Special MPL-EP Grease Table 421. Torque Values
2. Apply sealant to the threads of all the flange Item Description Nm

bolts. A Bolts 1 70
(Medium Strength) (For: Front, Rear)
3. Straps must always be replaced with new ones. Consumables
4. The propshaft must have both ends exactly on JCB Threadlocker 4101/0250 0.01L
the same plane as shown below. Refer to Figure and Sealer (Medium 4101/0251 0.05L
1068. Strength)
4.1. The yokes must not be at right angles or Special MPL-EP 4003/1501 0.4kg
at an intermediate angle. Refer to Figure Grease 4003/1506 12.5kg
1068. 4003/1510 50kg
WARNING Before disconnecting any propshaft,

make sure you block both sides of all wheels
to prevent machine movement. The park brake
will become ineffective or may only operate on 2
wheels (depending on machine specification).
Remove
1. Make the machine safe with the lift arm
raised. Refer to (PIL 01-03). Install the lift arm
maintenance strut, refer to (PIL 06-69).
2. Remove the central access panels. refer to (PIL
06-06).
27 - 430 9813/9400-1 27 - 430

27 - Driveline
47 - Propshaft
00 - General
3. Put marks on both propshaft companion flanges 4.2. Remove the nuts and the bolts 1 to
and the sliding joints before removal to help disconnect the propshaft coupling from the
during the replacement procedure. transmission.
4. Machines without RAS (Rear Axle Stabilization): 4.3. Remove the bolts 2 and straps to
disconnect the propshaft form the axles.
4.1. Support the propshaft.
5. Machines with RAS:
Figure 1069.
5.1. Support the auxiliary speed sensor plate.
5.2. Support the propshaft.
5.3. Remove the bolts 1 to disconnect the
propshaft coupling from the transmission.
5.4. Remove the auxiliary speed sensor plates
from behind the park brake disc.
5.5. Remove the bolts 2 and straps to
disconnect the propshaft coupling from the
B axle.
Consumable: Special MPL-EP Grease
A
A Bolts 1
B Bolts 2
C Strap
27 - 431 9813/9400-1 27 - 431

27 - Driveline
47 - Propshaft
00 - General
Figure 1070.
F D E
A
A Bolts 1 D Park brake disc

E Propshaft F Auxiliary speed sensor plate
Install 3. Straps must always be replaced with new ones.
Installation is the opposite of the removal procedure. 4. The propshaft must have both ends exactly on
At the time of installation follow the steps below. the same plane as shown below. Refer to Refer
to Figure 1071.
1. Lubricate the sliding joints with the specified
4.1. The yokes must not be at right angles or
grease only, then align the shafts against
at an intermediate angle. Refer to Refer to
identification marks previously made or, in
Figure 1071.
the case of a shaft being replaced use the
manufacturer's alignment markings.
Consumable: Special MPL-EP Grease
2. Apply sealant to the threads of all the flange
bolts.
(Medium Strength)
27 - 432 9813/9400-1 27 - 432

27 - Driveline
47 - Propshaft
00 - General
Figure 1071.
X Same plane (correct)

Y Right angle (not correct)
Z Intermediate angle (not correct)
5. Tighten the bolts 1 and bolts 2 to the correct
torque value.

Item Description Nm
A Bolts 1 137
B Bolts 2 70
27 - 433 9813/9400-1 27 - 433

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-435
27 - 434 9813/9400-1 27 - 434

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-435 The driveshaft is a mechanical component for
Remove and Install ..................................... 27-436 transmitting torque and rotation, usually used to
Disassemble and Assemble ........................ 27-440 connect other components of the driveline that
cannot be connected directly because of distance
or the need to allow for relative movement between
them.
27 - 435 9813/9400-1 27 - 435

27 - Driveline
51 - Driveshaft
00 - General
Remove and Install 5. Introduce compressed air at specified pressure

into the service brake line to hold brake discs in
For: Dana 213 Series, Front .... Page 27-436 position.
For: Dana 223 Series, Rear ..... Page 27-438 Pressure: 7bar (101.4psi)
6. Remove the snap ring 1 of the bushing kit. Refer
(For: Dana 213 Series, Front) to Figure 1074.
Consumables
Description Part No. Size Figure 1074.
Strength)
Remove
4
1. Loosen and remove the check nut of the dowel.
Remove the dowel. Refer to Figure 1072.
Figure 1072.
1 2 4 Snap ring 1
5 Bushing
7. Put the U-joint under a press and remove the
complete bushing. Refer to Figure 1075.
Figure 1075.
1 Check nut
2 Dowel
5
2. Remove the driveshaft and the twin U-joint. Refer
to Figure 1073.
Figure 1073.
5 Bushing
8. Remove the snap ring 2 of the bearing.
9. Remove the O-ring and, using a puller for inner
parts, remove the bearing and the seal ring. Note
down the direction of installation of the seal ring.
3
3 U-joint
3. If required, use a plastic hammer or lever to ease
extraction of the twin U-joint.
4. The twin U-joint can only be removed once
the steering swivel has been removed. Refer to
driveline- front hub, refer to (PIL 27-27).
27 - 436 9813/9400-1 27 - 436

27 - Driveline
51 - Driveshaft
00 - General
6 7
6 7
9
8
6 Snap ring 2 6 Snap ring 2

7 Bearing 7 Bearing
8 O-ring
9 Seal ring 3. Install the complete bushing onto the twin U-joint
and set the bushing into position with a plastic
hammer.
Install
4. Make sure you tap around the whole rim. Refer
1. Using the Dana tools T3 and T4, put the seal
to Figure 1079.
ring and the bearing into the bushing. Check the
direction of installation of the seal carefully. Refer Figure 1079.
to Figure 1077.
Figure 1077.
5
T3 T4
5 Bushing
5. Install the snap ring of the bushing kit. Put the O-
T3 Dana tool T3 ring also in position. Refer to Figure 1080.
T4 Dana tool T4
5 Bushing Figure 1080.
2. Install the snap ring to the bearing. Refer to

Figure 1078.
4 Snap ring 1
5 Bushing
27 - 437 9813/9400-1 27 - 437

27 - Driveline
51 - Driveshaft
00 - General
6. Install the twin U-joint into the arm and lock into (For: Dana 223 Series, Rear)
position with the dowel coated with JCB sealant.
Consumables
Consumable: JCB Threadlocker and Sealer Description Part No. Size
(Medium Strength)
7. Tighten the dowel to the specified torque value. and Sealer (Medium 4101/0251 0.05L
Refer to Figure 1081. Strength)
Figure 1081. Remove

1. Remove the steering swivel. Refer to driveline-
rear hub, refer to (PIL 27-28).
2 2. Removal is carried out with the axle arm resting
on the bench.
3. Introduce compressed air of the specified
pressure into the service brakingline to hold the
3 brake discs in position.
4. Loosen and remove the check nut of the dowel.
2 Dowel 5. Remove the dowel. Refer to Figure 1083.

3 U-joint
Figure 1083.
8. Apply JCB sealant to the protrusion position of
the dowel and tighten the nut.
(Medium Strength)
A B
9. Tighten the nut to the specified torque value while
holding the dowel in position. Refer to Figure
1082.
Figure 1082.
1 2
1,2 A Check nut

B Dowel
6. Pull out the whole driveshaft together with the
twin U-joint. Refer to Figure 1084.
Figure 1084.
1 Check nut
2 Dowel

Item Description Nm
A Check nut 65
B Dowel 15 C
C U-joint
27 - 438 9813/9400-1 27 - 438

27 - Driveline
51 - Driveshaft
00 - General
7. If necessary use plastic hammer or lever to pull Table 424. Torque Values
out the twin U-joint.
Item Description Nm
A Check nut 70
Install
B Dowel 15
1. Insert the twin U-joint into the axle arm and lock
into position with the dowel coated with JCB
sealant.
(Medium Strength)
2. Tighten the dowel to the specified torque value.
Figure 1085.
2 Dowel
3 U-joint
3. Apply JCB sealant to the protruding portion of the
dowel.
(Medium Strength)
4. Hold the dowel in position and tighten the nut to
the specified torque value. Refer to Figure 1086.
Figure 1086.
A
B
A,B
A Check nut
B Dowel
27 - 439 9813/9400-1 27 - 439

27 - Driveline
51 - Driveshaft
00 - General
Disassemble and Assemble Figure 1089.
Disassemble
1. Remove the rear driveshaft. Refer to driveline-
rear driveshaft, refer to (PIL 27-52).
C D
2. Remove the snap ring 1 from the bushing kit. F
Refer to Figure 1087. E
Figure 1087.
C Snap ring
D Bearing
E O-ring
F Seal ring
A Assemble
1. Using the Dana tool T3 and the Dana tool T4,
install the seal ring and the bearing into the
bushing.
2. Check the direction of installation of the seal.
B Refer to Figure 1090.
A Snap ring 1 Figure 1090.
B Bushing kit
3. Place the U-joint under a press and remove the
complete bushing. Refer to Figure 1088.
Figure 1088.
T3 T4
3. Install the snap ring 2 of the bearing. Refer to

Figure 1091.
4. Remove the snap ring 2 of the bearing.

5. Remove the O-ring.
6. Using a puller remove the bearing and the seal
ring.
7. Mark the direction of installation of the seal ring.
27 - 440 9813/9400-1 27 - 440

27 - Driveline
51 - Driveshaft
00 - General
Figure 1091.
C D
4. Install the complete bushing onto the twin U-

joint. Set the bushing into position with a plastic
hammer. Refer to Figure 1092.
Figure 1092.
5. Tap around the whole rim.

6. Install the snap ring 1 on the bushing kit. Position
the O-ring. Refer to Figure 1093.
Figure 1093.
7. Install the rear driveshaft. Refer to driveline- rear

driveshaft, refer to (PIL 27-52).
27 - 441 9813/9400-1 27 - 441

Notes:
27 - 442 9813/9400-1 27 - 442

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-30
30-00-09 Levelling System ............................................................................................................ 30-34
30-00-49 Schematic Symbols ........................................................................................................ 30-39
30-00-50 Schematic Circuit ........................................................................................................... 30-43
30-03 Tank
30-03-00 General ......................................................................................................................... 30-113
30-04 Filter
30-04-00 General ......................................................................................................................... 30-121
30-04-03 Main .............................................................................................................................. 30-122
30-04-09 Return Line ................................................................................................................... 30-125
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-127
30-11 Gear Pump
30-11-00 General ......................................................................................................................... 30-131
30-12 Variable Displacement Pump
30-12-00 General ......................................................................................................................... 30-143
30-13 Hydrostatic Pump
30-13-00 General ......................................................................................................................... 30-157
30-15 Cylinder / Ram
30-15-00 General ......................................................................................................................... 30-167
30-15-06 Lift Arm ......................................................................................................................... 30-179
30-15-07 Lift Extension ................................................................................................................ 30-182
30-15-08 Lift Compensating ........................................................................................................ 30-185
30-15-11 Lift Arm Crowd ............................................................................................................. 30-189
30-15-34 Steering ........................................................................................................................ 30-196
30-15-63 Sway ............................................................................................................................. 30-199
30-15-99 Seal Kit ......................................................................................................................... 30-202
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-207
30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-211
30-21 Oil Cooler
30-21-00 General ......................................................................................................................... 30-221
30-30 Manifold
30-30-00 General ......................................................................................................................... 30-229
30-51 Lift Arm Control Valve Block
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-231
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-232
30-51-21 Load Sense Relief Valve .............................................................................................. 30-235
30-51-24 Flow Regulator ............................................................................................................. 30-237
30-51-27 Pressure Compensator Valve ...................................................................................... 30-240
9813/9400-1
2017-10-22
30-53 Servo System Control Valve Block
30-53-00 General ......................................................................................................................... 30-243
30-53-36 Load Hold Check Valve ............................................................................................... 30-261
30-53-80 Spool ............................................................................................................................ 30-262
30-54 Parallel Circuit Control Valve Block
30-54-00 General ......................................................................................................................... 30-267
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-299
30-60-12 Electro Proportional Control ......................................................................................... 30-301
30-60-15 Joystick ......................................................................................................................... 30-314
30-60-18 Shuttle .......................................................................................................................... 30-322
30-60-27 Auxiliary Circuit ............................................................................................................ 30-323
30-60-82 Sway ............................................................................................................................. 30-324
30-60-90 Flow Regulator ............................................................................................................. 30-326
30-61 Counterbalance Valve
30-61-00 General ......................................................................................................................... 30-329
30-61-06 Lift Arm ......................................................................................................................... 30-334
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-339
30-70 Pilot Pressure Supply Valve
30-70-00 General ......................................................................................................................... 30-343
30-93 Hose
30-93-00 General ......................................................................................................................... 30-353
30-93-03 Lift Arm ......................................................................................................................... 30-361
30-96 Pipe
30-96-03 Lift Arm ......................................................................................................................... 30-363
30-97 Connectors
30-97-03 Quick Release Coupling .............................................................................................. 30-365
30-97-09 Adaptor ......................................................................................................................... 30-367
30-97-24 Push Lock Fitting ......................................................................................................... 30-369
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-370
9813/9400-1
2017-10-22
Acronyms Glossary
ARV Auxiliary Relief Valve

BSP British Standard Pipe
DTVT Dual Technology Variable
Transmission
HBCV Hose Burst Check Valve
HVCS Hydraulic Variable Control Solenoid
Valve
LED Light Emitting Diode
LHCV Load Hold Check Valve
LLMC Longitudinal Load Moment Control
LS Load Sense
LSD Limited Slip Differential
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PRV Pressure Relief Valve
QRC Quick Release Coupling
SAE Society of Automotive Engineers
9813/9400-1
2017-10-22
Notes:
9813/9400-1
2017-10-22
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-30
30-00-09 Levelling System ............................................................................................................ 30-34
30-00-49 Schematic Symbols ........................................................................................................ 30-39
30-00-50 Schematic Circuit ........................................................................................................... 30-43
30 - 1 9813/9400-1 30 - 1
Notes:
30 - 2 9813/9400-1 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3
Health and Safety ........................................... 30-4
Technical Data ................................................. 30-5
Operation ....................................................... 30-11
Operation (Hydraulic) .................................... 30-17
Diagram ......................................................... 30-18
Fault-Finding .................................................. 30-21
Discharge and Pressurise ............................. 30-23
Clean ............................................................. 30-24
Check (Level) ................................................ 30-25
Check (Pressure) .......................................... 30-26
Table 425. Valve Block and Pump Options

Machine Valve Block Options Hydraulic Pump Options
506-23
Option Mechanical - Gear -
Option - Electro servo - Variable
509-23
Option Mechanical - Gear -
Option - Electro servo- - Variable
512-26
- - Electro servo - Variable
30 - 3 9813/9400-1 30 - 3
00 - General
00 - General
Health and Safety

Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
service line has been vented before connecting or
removing hoses. Make sure the machine cannot be
started while the hoses are open.
WARNING! Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well clear of
pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot.
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
the machine if a hose or hose fixture is damaged.
Notice: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress.Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
30 - 4 9813/9400-1 30 - 4
00 - General
00 - General
Technical Data
For: 512-26 [T4F] ........................ Page 30-5 Circuit Restriction Relief Valve
For: 509-23 [T4F] ........................ Page 30-6 Setting
For: 506-23 [T4F] ........................ Page 30-7 Lift End The lift circuit 260bar
is limited to the (3,768.1psi)
(For: 512-26 [T4F]) MRV pressure
Lift End The extension 260bar
circuit is limit- (3,768.1psi)
Table 426. System Pressures ed to the MRV
pressure
Circuit Restriction Relief Valve
Setting Lift End The tilt circuit 260bar
is limited to the (3,768.1psi)
Neutral Circuit Pressure lim- 260bar MRV pressure
ited by main (3,768.1psi) during normal
valve block operation and
MRV (Main Re- the parallel lift
lief Valve) function when
Neutral Circuit Fan Motor Cir- 230bar the tilt ram end
cuit limited by (3,333.3psi) stops is limited
the ARV (Aux- by the ARV
iliary Relief Auxiliaries / Auxiliary circuit 220bar
Valve) Hitch is limited by the (3,188.4psi)
Neutral Circuit Trailer Brake 145bar ARV
Circuit limited (2,101.4psi) Steer Circuit Steer circuit is 175bar
by the ARV limited by the (2,536.2psi)
Neutral Circuit Sway Circuit 220bar ARV
limited by the (3,188.4psi)
ARV
30 - 5 9813/9400-1 30 - 5
00 - General
00 - General
Figure 1094.
A B 4
A B 3
A B 2
A B 1
P T
332/H5263-2
1 Spool 1, lift arm, electric control 2 Spool 2, tilt, electric control

3 Spool 3, lift arm extend / retract, electric control 4 Spool 4, auxiliary, electric control
(For: 509-23 [T4F]) Circuit Restriction Relief Valve

Setting
Gear Pump Machines Lift End Pressure limited 260bar
by main valve (3,768.1psi)
Double Pump Machines block MRV set
at
Lift End Pressure limited 260bar
Table 427. System Pressures (Gear by main valve (3,768.1psi)
Pump- 2 Section) EN15000 Multi Lever block MRV set
Circuit Restriction Relief Valve at
Setting Lift End The tilt circuit is 138bar
Neutral Circuit Pressure limited 260bar limited to MRV (2,000.0psi)
by main valve (3,768.1psi) pressure dur-
block MRV ing normal op-
eration and
Neutral Circuit Fan Motor Cir- 230bar the parallel lift
cuit limited by (3,333.3psi) function when
the ARV the tilt ram end
Neutral Circuit Trailer Brake 150bar stops is limited
Circuit limited (2,173.9psi) by the ARV to
by the ARV
Neutral Circuit Sway Circuit 220bar
ARV
30 - 6 9813/9400-1 30 - 6
00 - General
00 - General
Circuit Restriction Relief Valve (For: 506-23 [T4F])

Setting
Auxiliaries / Auxiliary circuit 220bar Valve 25/411600 Mechanical Lever
Hitch is limited by the (3,188.4psi) Control, (Non SRS).
ARV to
Steer Circuit Steer circuit is 190bar Figure 1095.
limited by the (2,753.6psi) F
ARV to
Triple Pump Machines

B
Table 428. System Pressures (Gear

Pump- 3 Section) EN15000 Single Lever A
Circuit Restriction Relief Valve
1 2 3 4
Setting
Neutral Circuit Pressure limited 260bar
by main valve (3,768.1psi)
block MRV
Neutral Circuit Fan Motor Cir- 230bar
cuit limited by (3,333.3psi) C
the ARV
Neutral Circuit Trailer Brake 150bar
Circuit limited (2,173.9psi)
by the ARV D
Neutral Circuit Sway Circuit 220bar E
limited by the (3,188.4psi) 1 Lift spool (double acting)
ARV 2 Extend spool (double acting)
Lift End The lift circuit is 260bar 3 Tilt spool (double acting)
limited to MRV (3,768.1psi) 4 Auxiliary spool (double acting)
pressure A Port A
Lift End The extension 260bar B Port B
circuit is limited (3,768.1psi) C Top outlet section
to MRV pres- D Linkage assemby
sure E MRV position
Lift End The tilt circuit is 138bar F Top inlet
limited to MRV (2,000.0psi)
pressure dur- Table 429.
ing normal op-
eration and MRV pressure 241.3bar (3,497.1psi)
the parallel lift
function when
the tilt ram end
stops is limited
by the ARV to
Auxiliaries / Auxiliary circuit 220bar
Hitch is limited by the (3,188.4psi)
ARV to
Steer Circuit Steer circuit is 190bar
ARV to
30 - 7 9813/9400-1 30 - 7
00 - General
00 - General
Valve 25/407900 Mechanical Single Lever

Control, (Non SRS).
Figure 1096.
K L M
1 2 3 4 C
F
A
E
D
1 Lift spool (double acting)
2 Tilt spool (double acting)
3 Extend spool (double acting)
4 Auxiliary spool (double acting)
A Port A
B Port B
C Top outlet section
D Solenoid operated pilot section
E Port restrictors
F Accumulator port
G Top outlet (plugged)
H 10bar (144.9psi) pilot generating inlet section
J Top inlet
K MRV position
L Accumulator port
M Port restrictors
Table 430.
MRV pressure 241.3bar (3,497.1psi)
30 - 8 9813/9400-1 30 - 8
00 - General
00 - General
(For: 506-23 [T4F], 509-23 [T4F])
Figure 1097.
G B
A
E
F
A1 A2 A3
K N
L P
M
K Oil from pump section 1 L Oil from pump section 2

M Oil suction line from the tank to the pump N Return to tank
sections
P Oil from pump section 3
Item Description Notes

Table 431. A3 Pump section 3 -
Item Description Notes B Control valve Parallel valve
A Pump assembly Two or three block block
section C Hydraulic oil fil- Positioned in
gearpump ter the return line
A1 Pump section 1 - to tank
A2 Pump section 2 - D Hydraulic tank -
30 - 9 9813/9400-1 30 - 9
00 - General
00 - General

E Fan motor Driven by pump
section 2
F Hydraulic oil Oil from pump
cooler section 2 flows
through the oil
cooler
G Single lever -
control
30 - 10 9813/9400-1 30 - 10
00 - General
00 - General
Operation
Hydraulic pump cooling fan hydraulic motor. On sway machines a

changeover valve switches oil supply between the
Oil is drawn from the hydraulic tank by the hydraulic sway ram service and the fan motor.
pump assembly. The pump assembly is mounted on
the rear of the bevel gearbox and is driven by the Some smaller machines may have a hydraulic pump
engine. with only two sections, in this case the larger pump
section 1 has the integral priority valve, and operates
The pump has three sections, Oil from the larger in the same way as section 2.
pump section 1 flows direct to the control valve block.
Pump section 2 has an integral priority valve which In neutral circuit conditions (i.e. no service selected),
always gives priority demand to the steer circuit. the oil flows through the control valve block neutral
With the steering in the straight ahead position (i.e. gallery into the return or exhaust line and back to the
with no steering demand), oil from pump section 2 tank through an in-tank filter.
flows through the priority valve and joins with the flow
from pump section 1 to feed the control valve block. Some machine variants also have a hydraulic oil
Pump section 3 is dedicated to driving the cooling cooler in the return line from the fan hydraulic motor,
fan. Oil from pump section 3 flows directly to the to cool the system hydraulic oil as it is continually
circulated around the cooling fan circuit.
30 - 11 9813/9400-1 30 - 11
00 - General
00 - General
Figure 1098.
G H
C
J
A
E
Q
A1 A2 A3
K N
L P
M
Item Description
Table 432. E Fan motor Driven by pump
section 2
Item Description
Q Hydraulic oil Oil from pump
A Pump assembly Two or three cooler section 2 flows
section through the oil
gearpump cooler
A1 Pump section 1 -
A2 Pump section 2 -
Table 433. Hydraulic connections colour key
A3 Pump section 3 -
B Control valve Parallel valve Item Description
block block K Oil from pump section 1
C Hydraulic oil fil- Positioned in L Oil from pump section 2
ter the return line M Oil suction line from the
to tank tank to the pump sec-
D Hydraulic tank - tions
30 - 12 9813/9400-1 30 - 12
00 - General
00 - General
Item Description spools. A third lever operates the auxiliary service

N Return to tank spool. The levers operate the spools via mechanical
linkages. For machines with stabilisers two more
P Oil from pump section 3 levers are installed to operate the stabiliser service
spools (6 spool control valve).
Control valve block
Single lever control
The control valve block controls the boom hydraulic
services. For machines with stabilisers, the valve has Machines with single lever control use a lever which
two more spools to control the stabiliser hydraulic moves in two axis and operates two service spools
services. via mechanical linkages. Buttons on the control lever
operate solenoid valves on the remaining two spools.
When the control valve spools are actuated, oil from
the pump passes into the service ports, operating the
relevant hydraulic ram.
Parallel lift
The parallel lift system is used to make sure that
The control valve contains MRV (Main Relief Valve)
when the boom raise/lower or extend/retract services
and ARV (Auxiliary Relief Valve). These valves
are operated, the forks remain parallel to the ground.
prevent the hydraulic pressure increasing to a
level which would cause damage to the hydraulic
components and pipework. Boom regenerative valve (3 stage
booms)
The control valve block inlet section also includes
valves which are used for the LLMC (Longitudinal The regenerative valve is installed to the outer
Load Moment Control) system. extension ram to increase the speed of the boom
during the extend cycle, under light load conditions.
Dual lever control Hydraulic oil is displaced from the rod side of the
inner extension ram to supplement the pump flow to
Machines with dual lever control use two control the head side of the outer extension ram. The speed
levers for operation of the three loader service of the extending boom is increased.
Figure 1099.
Q S
R
Q Outer extension ram HBCV (Hose Burst Check R PRV (Pressure Relief Valve)
Valve)
S Pilot operated check valve T Non-return valve
The only servicing possible in the event of external Boom extend cycle
oil leakage is the renewal of oil seals, or the renewal
of a faulty screw-in cartridge. Light load (Regenerative cycle)
As the boom extends with the forks lightly loaded,

oil from the valve block flows through the outer
30 - 13 9813/9400-1 30 - 13
00 - General
00 - General
extension ram HBCV to the head side of the outer to the head side of inner extension ram. The inner
extension ram. extension ram starts to extend and oil is displaced
from the rod side of the cylinder. A PRV prevents oil
Oil is displaced from the rod side of outer extension leaving the regenerative valve block and returning to
ram and passes through inner extension ram HBCV tank.
Figure 1100.
U1
Y
V U
Z
U Inner extension ram U1 Counterbalance valve

V Outer extension ram W Outer extension ram HBCV
X PRV Y Pilot operated check valve
Z Check valve
A pilot operated check-valve opens to allow the oil to ram HBCV to the head side of the outer extension
supplement the main pump flow through the check ram.
valve and the speed of extension.
Oil is displaced from the rod side of outer extension
Heavy load ram and passes through the inner extension ram
HBCV to the head side of inner extension ram.
As the boom extends, oil under high pressure closes The inner extension ram starts to extend and oil
the check valve. Oil flows through the outer extension is displaced from the rod side of the cylinder. Pilot
pressure opens the PRV.
30 - 14 9813/9400-1 30 - 14
00 - General
00 - General
Figure 1101.
W
U1
V
Y
U
Z

Z Check valve
Oil displaced from the rod side of the inner Boom retract cycle
extension ram now passes through the extension
spool and back to tank. This oil is prevented from As the boom is retracted, oil flows through the PRV to
supplementing the main pump flow by the pilot the rod side of inner extension ram. Oil is prevented
operated check-valve. from entering the regenerative valve block by the
pilot operated check-valve. Oil is displaced from the
The boom will extend slower, but with more force head side of inner extension ram through the HBCV
than the regenerative cycle. and back to tank through the extension spool. Oil
cannot flow through the regenerative valve because
the check valve is closed.
Figure 1102.
U1
V
Y
U
Z
30 - 15 9813/9400-1 30 - 15
00 - General
00 - General

Z Check valve
30 - 16 9813/9400-1 30 - 16
00 - General
00 - General
Operation (Hydraulic) and leakage and can lead to major problems. The
main contaminants can be classified as follows:
The hydraulic system is a power transmission system 1. Solid Particles - Sand, fibres, metallic particles,
that uses the force of flowing liquids to transmit power welding scale, sealing materials and wear
to specific components in a machine. particles etc.
To help you trace specific hydraulic problems to a 2. Liquid - Usually water and incompatible oils and
faulty unit (valve, actuator, ram etc.), refer to Fault greases.
finding. Refer to: PIL 30-00-00.
3. Gases - Air, sulphur dioxide etc. which can create
Once you have traced the faulty unit, refer to corrosive compounds if dissolved in the fluid.
the relevant section for removal, disassembly and
checking instructions. These contaminants can appear during
manufacture, assembly and operation.
To help identify circuits, valves, rams etc. mentioned
in the fault finding procedures. Refer to the hydraulic
schematic diagrams. Refer to: PIL 30-00-50.
• Before you begin fault finding, read the Health

and Safety Information. Refer to: PIL 30-00-00.
• Make simple checks before you remove or
disassemble a major component.
• Make sure that the hydraulic fluid is at the
correct working temperature 50°C (121.9°F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
and Hydraulic System - Clean. Refer to: PIL
30-00-00.
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
30 - 17 9813/9400-1 30 - 17
00 - General
00 - General
Diagram
(For: 506-23 [T4F], 509-23 [T4F])
Neutral
Figure 1103.
D
E
G
F F
C K
H J
B L
AA
M AB
AC
AD
AE
A
A Tank B Primary pump

D Control valve E Valve spool
H Isolation proportional solenoid J Variable orifice pilot valve
Colour code Description

AC Exhaust
Table 434. Colour codes
for oil flow and pressure AD Servo
AE Load sense line
AA Full Pressure
AB Neutral
30 - 18 9813/9400-1 30 - 18
00 - General
00 - General
One service operated
Figure 1104.
D
E
G
F F
C
K
H J
B L
AA
M
AB
AC
AD
AE
A
A Tank E Valve spool

G Ram

AC Exhaust
for oil flow and pressure AD Servo
AE Load sense line
AA Full Pressure
AB Neutral
30 - 19 9813/9400-1 30 - 19
00 - General
00 - General
Main system pressure relief
Figure 1105.
D
E
G
F F
C K
H J
B L
M AA
AB
AC
AD
A AE
K Main relief valve

for oil flow and pressure
AA Full Pressure
AB Neutral
AC Exhaust
AD Servo
AE Load sense line
30 - 20 9813/9400-1 30 - 20
00 - General
00 - General
Fault-Finding
Fault
One service fails, or is slow to operate. Table 437. Page 30-21
The engine tends to stall when hydraulics are under load. Table 438. Page 30-21
Forks creep down Table 439. Page 30-22
Parallel lift faulty Table 440. Page 30-22
Ram creep Table 441. Page 30-22
Table 437. One service fails, or is slow to operate.

Cause Remedy
LLMC (Longitudinal Load Moment Control) Active. Ensure operator fully understand the characteristics
of the LLMC system.
Boom and stabiliser interlocks engaged. Educate the operator. Make sure operator fully
(Construction machines) understands the characteristics of the interlock
system.
Related service pipework or hoses leaking, Check the pipework and hoses. Replace as
damaged, trapped or kinked. necessary.
ARV (Auxiliary Relief Valve) out of adjustment or Check and adjust as necessary.
defective.
Related ram leaking. Carry out ram leakage checks. Renew seals as
necessary.
Related service spool not operating correctly. Manual Spools: Check that the control lever
and related linkage is operating the spool to full
displacement, rectify as necessary.
Servo Operated Spools: Check the condition of
the related harness wiring and the connectors for
damage. Check the solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Renew
the solenoid coil
Servo Operated Spools: Check the condition of
the related harness wiring and the connectors
for damage. Renew the electronic control lever
assembly.
Pressure compensator piston sticking due to Disassemble and inspect the related pressure
contamination. compensator piston.
Service spool or related load hold check valves Disassemble and inspect the related service spool or
damaged or sticking due to contamination. load hold check valves.
Electronic fault Use Servicemaster to find the problem. Refer to
servicemaster, refer to (PIL 33-57).
Counterbalance valve not working correctly. Check operation of the related counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of the lift ram pressure sensor.
working correctly
Table 438. The engine tends to stall when hydraulics are under load.
Cause Remedy
MRV (Main Relief Valve) or LSRV (Load Sense Check and adjust as necessary.
Relief Valve)not adjustable or defective.
Poor engine performance. Check engine performance.
Check engine high and low idle speeds.
Check MRV/LSRV setting and adjust as necessary.
Check ARV setting and adjust as necessary.
Machines with Variflow Pump: Variflow pump fault.
30 - 21 9813/9400-1 30 - 21
00 - General
00 - General
Table 439. Forks creep down

Cause Remedy
Circuit routed incorrectly. Check if any work has been Check the circuit. Re-route the hoses if necessary.
done on the machine recently.
Tilt ram HBCV (Hose Burst Check Valve) leaking, Check for leakage in the tilt ram circuit.
tilt ram seals leaking, control valve spool leaking or
valve block section leaking internally.
Table 440. Parallel lift faulty

Cause Remedy
Displacement/lift link valve broken or leaking. Examine the valve. Check for damages on the ball.
Fit blank to isolate valve from circuit.
Fit latest type valve.
Check pipes, tilt spool, HBCV for missing ball.
Tilt section ARVs set incorrectly, causing oil to leak Check tilt ARV setting. Adjust if necessary.
from tilt/compensating ram circuit.
Tilt section ARVs could be sticking open due to Clean or install new as necessary.
contamination.
Leaking seals in tilt ram or compensation ram. Check tilt/compensation rams for leakage (use hand
pump if available). Install new seals as necessary.
working correctly.
Table 441. Ram creep

Cause Remedy
Associated ram or pipe lines from ram leaking. Check and rectify as necessary.
Check valve. Check operation and rectify as necessary.
working correctly
30 - 22 9813/9400-1 30 - 22
00 - General
00 - General
Discharge and Pressurise Figure 1106. Vent switch (If installed)
WARNING Depending on your machines

specification, other hydraulic systems will require
additional venting. These may include (but not
limited to) SRS, refer to (PIL 30-18-00) and power
brakes, refer to (PIL 24-03-00).
CAUTION Do not run the machine with the
hydraulic tank filler cap removed.
CAUTION Allow the hydraulic fluid temperature to
cool before removing the hydraulic tank filler cap.
Open the cap slowly to prevent oil being forced
out of the filler neck.

2. Operate the controls to remove the hydraulic
pressure from the service hose lines.
2.1. For manually operated services, operate
the controls several times of the service to
be disconnected.
2.2. For 550-80 machines without hydraulic
venting switch - make sure the battery
is connected and the battery isolator is
set to on. Turn the ignition key to the on
position and operate the lift arm raise and 1 Position 1- Off
lower controls several times. On 550-80 2 Position 2- Vent position, hold switch down
machines the lift arm lower and retract for on position (battery connected, isolator on,
service are still operative when the engine ignition switch set to on, engine off)
is not running until the hydraulic pressure 3. Make sure that the pressure is vented correctly.
is fully released. Make sure that the lift arm Electrical and pilot services have a limited
is lowered or supported fully on the safety amount of accumulated pressure available for
strut. venting.
2.3. For electrical and servo operated services,
make sure the battery is connected and 4. Depending on your machines specification, other
the battery isolator is set to on. Turn the systems will require additional venting. These
ignition key to the on position and operate may include (but not limited to) SRS (Smooth
the controls several times of the service to Ride System), refer to (PIL 30-18-00) and power
be disconnected. brakes, refer to (PIL 24-03-00).
2.4. For machines installed with a vent switch, 5. Clean the top of the tank around the filler cap.
make sure the battery is connected and
the battery isolator is set to on. Turn the 6. Slowly remove filler cap to allow the system to
ignition key to the on position and push and vent fully and to prevent the oil from being forced
hold the vent switch while you operate the out of the filler neck.
controls of the service to be vented. Make
6.1. Some filler caps have a side mounted barrel
sure you operate the controls several times
lock, operated by the ignition key. Your
while the vent switch is set to on. While the
machine may differ from the one shown.
vent switch is on, a buzzer will sound and
the venting symbol will be displayed on the 7. Make sure that the seal is in good condition and
dash. installed correctly in the cap. Replace the seal if
necessary.
30 - 23 9813/9400-1 30 - 23
00 - General
00 - General
Figure 1107. Hydraulic tank filler cap - Clean

machines without external sight gauge
Special Tools
A Description Part No. Qty.
Hydraulic Flushing Rig 892/01255 1
Cleaning Operation
The purpose of cleaning oil is to remove
contaminants of all types and sludge by filtering
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
manual.
A Filler cap Procedure
Figure 1108. Hydraulic tank filler cap 1. Connect the Hydraulic flushing rig in place of the
- machines with external sight gauge hydraulic filter.
Special Tool: Hydraulic Flushing Rig (Qty.: 1)
A 2. Run the system for sufficient time to pump all the

hydraulic fluid through the unit.
3. Disconnect the cleaning unit and reconnect the
filter.
4. Top up the system with clean hydraulic fluid as
required.
Figure 1109.
A Filler cap
A Hydraulic flushing rig
Contaminant Standards
Dirt that damages your system is in many cases
too small to be seen with the eye. The particle
size is measured in microns (1 micron = 0.001 mm
(0.0000394 in).
Listed below are a few typical comparisons:
30 - 24 9813/9400-1 30 - 24
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Level)

0.000315 in)
• Human Hair = 70 microns (0.07 mm, 0.00275
in) 1. Make the machine safe.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 Refer to: PIL 01-03.
in)
2. Machines may be installed with a sight tube or a
The smallest particle visible to the naked eye is dipstick for hydraulic fluid level display.
40 microns (0.00157) approximately. Standards will
often be quoted to ISO (International Standards Machines with a Sight Tube
Organisation) for which literature can be obtained.
1. Look at the hydraulic fluid in the sight tube. If
the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
2. The level of hydraulic fluid should be between the
two marks on the sight tube.
3. If necessary, add the recommended hydraulic
fluid:
3.1. Discharge the pressure from the hydraulic
tank. Refer to (PIL 30-00).
3.2. Get safe access to the hydraulic filler port.
3.3. Use a suitable container to add the
hydraulic fluid through the filler port.
3.4. Check the level of hydraulic fluid.
Machines with a Dipstick

1. Open the rear cover if installed. Refer to (PIL
06-06-14).
2. Discharge the pressure from the hydraulic tank.
3. Get access to the hydraulic dipstick / breather.
Remove the dipstick from the hydraulic tank.
4. If the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
5. Check the hydraulic oil level. The level of
hydraulic fluid should be between the two marks
on the dipstick
6. If necessary, add the recommended hydraulic
fluid:
6.1. Get safe access to the hydraulic filler port.
6.2. Use a suitable container to add the
hydraulic fluid through the filler port.
6.3. Check the level of hydraulic fluid.
30 - 25 9813/9400-1 30 - 25
00 - General
00 - General
Check (Pressure)
(For: 506-23 [T4F], 509-23 [T4F]) Figure 1111. Test Point (Typical Triple Pump)
Special Tools
Pressure Test Kit
Testing MRV Pressure

30-00).
3. Connect the digital hydraulic pressure test kit to A
the pressure test point.
(Qty.: 1)
4. Start the engine and bring the hydraulic system A Pressure test point
to the specified working temperature.
Testing ARV's Set Lower than the MRV
5. Select the lift arm lower service and hold the ram
fully closed. 2. Discharge the hydraulic pressure. Refer to (PIL
30-00).
6. Gradually increase the engine speed to 2200
RPM (Revolutions Per Minute) while checking 3. Connect the digital pressure test kit to the
the maximum gauge reading. Refer to (PIL pressure test point.
30-00).
4. Start the engine and bring the hydraulic system
Figure 1110. Test Point (Typical Double Pump) to the specified working temperature.
5. Set the engine to idle RPM and operate the
relevant service to full travel. Hold and check
the maximum gauge reading. Refer to Technical
Data (PIL 30-00).
6. Make sure that the engine is not run at the
maximum speed as a significant increase in
pressure will be recorded.
7. If the pressure is not correct, adjust the relevant
ARV (Auxiliary Relief Valve).
A Pressure test point
30 - 26 9813/9400-1 30 - 26
00 - General
00 - General
Figure 1112. Test Point (Typical Double Pump) tilt ram ARVs. Because the tilt ram is smaller than the
lift ram, higher hydraulic pressure is required on one
side of the tilt ram to prevent the load tilting the forks
forward.
Check the pressure setting and the ARV location for

the applicable machine.

2. Raise the lift arm and install the safety strut.
3. Tilt the forks fully forward.
4. Follow the general safety precautions for the
hydraulic system. Refer to (PIL 30-00).
A
30-00).
A Pressure test point 6. Locate the hydraulic line for the high pressure
side of the tilt ram. Refer to Figure 1114. , Refer
Figure 1113. Test Point (Typical Triple Pump)
to Figure 1115. and Refer to Figure 1116.
7. Install a tee piece in the hydraulic line. Connect
the digital pressure test kit to the tee piece.
8. Locate a connection in the tilt ram circuit at the
rear of the lift arm.
9. Start the engine and tilt the forks fully back.
10. Remove the safety strut and slowly lower the
lift arm. As the lift arm is lowered, the pressure
gauge will show the ARV pressure, which should
be as stated. Refer to Technical Data (PIL 30-00).
A
11. If the pressure is incorrect, adjust the ARV. Refer
to (PIL 30-00).
WARNING! Take care when disconnecting

A Pressure test point hydraulic hoses and fittings as the oil will be hot.
12. After you complete the test, fully lower the

Testing ARV's Set Higher than the MRV lift arm. Switch off the engine and release
(P1) the hydraulic pressure. Disconnect the pressure
gauge and connect the tilt ram hose again.
Some ARVs are set at a higher pressure than the
MRV (Main Relief Valve). This is usually one of the
30 - 27 9813/9400-1 30 - 27
00 - General
00 - General
Figure 1114. Tilt ram hose at the rear lift arm bulkhead bracket
A Hose B Connector
Figure 1115. Tilt ram hose forward of the lift arm pivot
A Hose B Connector
30 - 28 9813/9400-1 30 - 28
00 - General
00 - General
Figure 1116. Tilt ram hose on the displacement ram hose, lift arm underside
A Hose B Connector
30 - 29 9813/9400-1 30 - 29
00 - General
03 - Smooth Ride System (SRS)
03 - Smooth Ride System (SRS) Operation

Operation ....................................................... 30-30
Diagram ......................................................... 30-32
(For: 506-23 [T4F], 509-23 [T4F])
Discharge and Pressurise ............................. 30-33 WARNING Do not attempt to use the boom to
raise the front of the machine. With the Smooth
Ride System activated, the machine will drop
suddenly when the control lever returns to the
neutral position. Switch off SRS before working
on the machine.
The SRS (Smooth Ride System) enhances the

comfort of the ride by damping the forces imposed
on the machine by the movement of the boom as
the machine travels over uneven surfaces. This is
achieved by connecting the head side of the lift
ram to pressurised piston type accumulator. This is
achieved by connecting the head side of the lift ram
to pressurised piston type accumulator.
Piston type accumulators operate as a liquid springs

absorbing displaced fluid from the lift ram. The
system is controlled by the hydraulic control ECU
(Electronic Control Unit).
To activate the SRS system, the pressure in the lift

ram must be less than 20bar (289.9psi), typically
when the boom is fully lowered. This is sensed by the
pressure transducer E which is mounted on the SRS
valve block.
Figure 1117.
A
A/M
E
D
G
A SRS switch B Accumulator solenoid valve

C Drain solenoid valve D SRS valve block
E Pressure transducer F Accumulators
G Lift ram
The SRS mode is selected using the operator switch at speeds over 4km/h (2.5mph). It will de-activate
in the cab. When Auto SRS is on, the SRS system when the machine is travelling at speeds below 2km/
will become active when the machine is travelling h (1.2mph).
30 - 30 9813/9400-1 30 - 30
00 - General
When the switch is in the “manual” position the SRS

will become active when the machine is travelling at
speeds over 4km/h (2.5mph). It will not deactivate
until the switch is set to off position or the ignition key
is turned to off.
When SRS is active the accumulator solenoid valve

is energised and connects the piston head side of
the lift ram with the accumulators. The drain solenoid
valve will also energise and connect the rod side of
the lift ram to the valve block return line to make up
or dissipate oil as required.
If the pressure in the lift ram is greater than the

specified limit when the SRS is active, the system
will not be activated (the solenoid valves will not
energise).
Once the SRS system is activated, the boom can

then be raised to the travelling position as required.
30 - 31 9813/9400-1 30 - 31
00 - General
Diagram
Figure 1118.
A
D
V2
B
G
C
V1
A Control valve block B Lift ram

C Pressure transducer D Accumulator solenoid
E Drain solenoid F Accumulators
G Pilot operated lift counterbalance valve
30 - 32 9813/9400-1 30 - 32
00 - General
Discharge and Pressurise
Refer to Hydraulic System, Accumulator, Smooth

Ride System (SRS), (PIL 30-18-06).
30 - 33 9813/9400-1 30 - 33
00 - General
09 - Levelling System
Operation
Table 442. Parallel Lift- Typical Systems

Parallel Lift- System 1 Example of a system with single displacement ram at
the rear of the lift arm pivot
Parallel Lift- System 2 Example of a system with single and twin displace-
ment rams forward of the lift arm pivot
Parallel lift (S1) When the boom ram lifts or lowers the boom, the
displacement ram extends or retracts. The ram
Ram operation displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
The schematic diagrams show a typical system. with the ground.
Your system may be different. Refer to the relevant
machine schematic diagram, (PIL 30-00-50). Boom raise cycle
The parallel lift system operates when the boom lifts When the spool is in the lift position, the neutral
or lowers. circuit is blocked and oil feeds to the pilot operated
counterbalance valve. Check valve1 opens and
Figure 1119. supplies oil to the head side of the boom lift ram.
Oil is forced out of the head side of displacement

D ram as the boom lifts. The oil cannot flow past the tilt
spool, as the spool is not selected. Instead, it flows
to the head side of tilt ram. Oil displaced from the
rod side of the tilt ram increases pilot pressure in the
HBCV (Hose Burst Check Valve). This allows oil to
feed back to the rod side of the displacement ram.
A C
A C
A Displacement ram
C Boom ram
D Tilt ram
E Forks
30 - 34 9813/9400-1 30 - 34
00 - General
Figure 1120.
Q
H J
R
S
K
L P
N
F
F Spool G Counter balance valve

H Pilot valve J Boom lift ram
K Displacement/lift link valve L HBCV
M Displacement ram N Tilt ram
P Tank Q Check valve 1
R Check valve 2 S Check valve 3
The displacement/lift link valve is installed between accidentally leak back into the circuit when a load
lift service and tilt service lines. The function of this is on the boom. The lower service will only operate
valve is to allow a restricted flow of oil into the tilt when there is sufficient pilot pressure provided by the
circuit to increase the lift force available by utilising hydraulic pump or stored in the pilot accumulator. If
the displacement ram. there is no pilot pressure the pilot valve will not open
and the boom will not lower.
Boom lower cycle
Check valve 3 creates a circuit when the ram return
When the lift spool is selected, the neutral line is in cavitation.
circuit is blocked and oil feeds the pilot operated
counterbalance valve. The pilot pressure used to As the boom lowers, oil is forced from the rod side of
operate the spool acts upon the pilot valve. The pilot the displacement ram. The oil cannot flow past the tilt
valve allows a return to tank via check valve 2 and spool, as the spool is not selected. Instead, it flows
the valve block which enables the boom to lower. through the free flow direction of the HBCV to the rod
This is to make sure that the ram pressure cannot side of the tilt ram.
30 - 35 9813/9400-1 30 - 35
00 - General
Figure 1121.
Q
H J
R
S
G
K
L P
N
F
F Spool G Pilot operated counter balance valve

Displaced oil from the displacement ram closes the

check valve in displacement/lift link valve.
The circuit created between the displacement ram,

lift ram and tilt ram prevents cavitation/vacuum.
Parallel lift (S2)

Ram operation
The schematic diagrams show a typical system.
Your system may be different. Refer to the relevant
machine schematic diagram, (PIL 30-00-50).
The parallel lift system operates when the boom lifts

or lowers.
30 - 36 9813/9400-1 30 - 36
00 - General
Figure 1122. When the boom ram lifts or lowers the boom, the
displacement ram extends or retracts. The ram
D displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
B with the ground.
Machines have a single or twin displacement rams,

dependant on the machine variant.
E
Boom raise cycle
A C The illustration below shows twin displacement rams.
The operation is similar on machines with single
D displacement rams.
When the spool is in the lifted position, the neutral

B circuit is blocked and oil feeds to the pilot operated
counterbalance valve. Check valve 1 opens and
supplies oil to the head side of the boom lift ram.
E
Oil is forced out of the rod side of displacement ram
as the boom lifts. The oil cannot flow past the tilt
A C spool, as the spool is not selected. Instead, it flows
A Boom ram to the head side of the tilt ram. Oil displaced from the
B Boom pivot rod side of the tilt ram increases pilot pressure in the
C Displacement ram HBCV. This allows oil to feed back to the head side
D Tilt ram of the displacement ram.
E Forks
Figure 1123.
Q
J
R H
S
G
K
L
P
F N

30 - 37 9813/9400-1 30 - 37
00 - General
Displaced oil from the displacement ram closes the counterbalance valve. The pilot pressure used to
check valve in displacement/lift link valve is installed operate the spool acts upon the pilot valve. The
between lift service and tilt service lines. The function pilot valve allows oil to return to the tank via the
of this valve is to allow a restricted flow of oil into the check valve 2 and the valve block which enables
tilt circuit to increase the lift force available by utilising the boom to lower. This is to make sure that the
the displacement ram. ram pressure cannot accidentally leak back into
the circuit when a load is on the boom. The lower
Boom lower cycle service will only operate when there is sufficient pilot
pressure provided by the hydraulic pump or stored in
The illustration below shows twin displacement rams. the pilot accumulator. If there is no pilot pressure the
The operation is similar on machines with single valve will not open and the boom will not lower.
displacement rams.
Check valve 3 creates a circuit when the ram return
When lift spool is selected, the neutral circuit line is in cavitation.
is blocked and oil feeds to the pilot operated
Figure 1124.
Q
H
J
R
S
G
K
L
P
N
F
M7

As the boom lowers, oil is forced from the rod side of The circuit created between the displacement ram,
the displacement ram. The oil cannot flow past the tilt lift ram and tilt ram prevents cavitation/vacuum.
spool, as the spool is not selected. Instead, it flows
through the free flow direction of the HBCV to the rod
side of the tilt ram.
Displaced oil from the displacement ram closes the

check valve in displacement/lift link valve.
30 - 38 9813/9400-1 30 - 38
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-39 Complex hydraulic components and circuits can
Diagram ......................................................... 30-40 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 - 39 9813/9400-1 30 - 39
00 - General
Diagram Table 446. Directional control valves

Symbol Description
Used to enclose sever-
Table 443. 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 444. 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 445. 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 - 40 9813/9400-1 30 - 40
00 - General
Table 447. 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 448. 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 - 41 9813/9400-1 30 - 41
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 - 42 9813/9400-1 30 - 42
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-43 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-44 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 - 43 9813/9400-1 30 - 43
00 - General
Diagram

................................................... Page 30-44
For: 512-26 [T4F] ...................... Page 30-49
For: 506-23 [T4F] ...................... Page 30-56
For: 509-23 [T4F] ...................... Page 30-84

Figure 1125. DTVT Transmission 334/D1133-11 (sheet 1 of 1)............................................. Page 30-45
30 - 44 9813/9400-1 30 - 44
00 - General
Page 30-46 Figure 1125. DTVT Transmission

334/D1133-11 (sheet 1 of 1) Page 30-47
30 - 45 9813/9400-1 30 - 45
00 - General
30-46 30-47
Page 30-47
30 - 46 9813/9400-1 30 - 46
00 - General
30-46 30-47
Page 30-46
30 - 47 9813/9400-1 30 - 47
00 - General
Table 449. 334/D1133-8

Item Description
10 Variable power pump-19cc gear
20 Power brake valve
30 Variable fan motor
40 Priority accumulator charging valve
50 Valve Block 5Ad/R Ag Electric
55 Valve block 5Aa Ag Electric
60 Pilot valve
70 DTVT (Dual Technology Variable Transmission)
transmission
80 Poppet valve assembly - 2 Port
90 Pilot operated counterbalance valve- lift cylinder -
SRS (Smooth Ride System)
100 Cylinder lift SRS 140 X 75 P492
110 Cylinder lift SRS 130X70
120 Tilt cylinder 120 X 60
130 120 X 60 Displacement cylinder
140 Cylinder extension 70X50 P492
150 Trailer brake valve
160 Power track rod
170 Hitch cylinder
180 Cylinder- hydraulic pin locking
190 Ball valve
200 Suction strainer
220 Return filter
230 Accumulator 21.4bar (310.1psi)
240 Accumulator 25bar (362.3psi)
250 Cooling pack -81 P414
260 Bi-directional check valve
270 Quick release coupling 06 male - 6 SAE (Society of
Automotive Engineers)
280 Quick release coupling 06 female - 6 SAE
290 Steer mode valve
310 Counter balance cartridge
320 Pilot operated counterbalance valve- extension cylin-
der
330 Steer valve + shocks
340 Accumulator 0.24L5bar (72.5psi)
350 Adaptor. G1/4A - 7/16 SAE
360 6-Way solenoid change over valve
370 Hydraulic oil filler cap
380 Pressure transducer
400 Check valve & body assembly
410 Oil cooler fluid to fluid
420 Oil cooler and brackets
30 - 48 9813/9400-1 30 - 48
00 - General
(For: 512-26 [T4F])

Figure 1126. ...........................................................................................................................Page 30-51
334/D7578-7
30 - 49 9813/9400-1 30 - 49
Notes:
30 - 50 9813/9400-1 30 - 50
00 - General
Page 30-52 Figure 1126. Page 30-53
410
415
260
70 70
60
370
375
250
380 90 420
385 40
60 80
390 100
70
400 110
A
90
120
B 150
310
350
430 130 130 140
160 170
C
D
E
360 180 190
30 200
E
E
180
10
E
290 280 E
180
TA TB TE TF TG TI TJ TL
300 E
T TC 230
20 240 E 220
TD
50 TH
210
270 TH
T TB
TE TL
90 TC TI TG
TH TA TJ
TD TF
334-d7578-7
30 - 51 9813/9400-1 30 - 51
00 - General
30-52 30-53
410
415
260
370
375
250
380
385 40
390
400
A
B
310
350
430
C
Page 30-53
D
360
30
10
290 280
TA TB TE TF TG TI TJ TL
300
T TC 230
20
TD
50 TH
270
90
30 - 52 9813/9400-1 30 - 52
00 - General
30-52 30-53
70 70
60
90 420
40
60 80
100
70
110
A
90
120
B 150
130 130 140

160 170
C
Page 30-52
D
E
180 190
200
E
E
180
E
180 E
E
230
240 E 220
210
TH
T TB
TE TL
TC TI TG
TH TA TJ
TD TF
334-d7578-7
30 - 53 9813/9400-1 30 - 53
00 - General
Table 450. 334/D7578-7

Item Description
A Control valve lift section
B Control valve tilt section
C Control valve extend section
D Control valve auxiliary section
E Hydraulic quick release connectors
T Hydraulic tank
TA Hydraulic tank port- TA
TB Hydraulic tank port- TB
TC Hydraulic tank port- TC
TD Hydraulic tank port- TD
TE Hydraulic tank port- TE
TF Hydraulic tank port- TF
TG Hydraulic tank port- TG
TH Hydraulic tank port- TH
TJ Hydraulic tank port- TJ
TL Hydraulic tank port- TL
10 Hydraulic oil filler
20 Suction filter element
30 Hydraulic pump
40 Hydraulic control valve
50 Return filter
60 Dual counterbalance valve- lift
70 Lift cylinder
80 SRS manifold
90 SRS pressure transducer
100 Accumulator - SRS
110 Accumulator- SRS
120 Adaptor- check- lift assist
130 Displacement cylinder
140 Counterbalance valve - tilt
150 Tilt cylinder
160 Counterbalance valve - extend
170 Extend cylinder
180 6 way solenoid change over valve
190 Ball valve
200 Hydraulic hitch cylinder
210 Ball valve
220 Hydraulic locking pin cylinder
230 Servo system control valve
240 Accumulator- servo
250 Steering control valve
260 Manual steer mode valve
270 Charge valve- brakes
280 Brake pressure transducer
290 Brake charge accumulator
310 Trailer brake valve- if installed
30 - 54 9813/9400-1 30 - 54
00 - General
Item Description
360 Hydraulic oil cooler
370 Axle- pad mount 38°
375 Axle- pad mount- LSD (Limited Slip Differential) - 38°
380 Axle- pad mount 32°
385 Axle- pad mount- LSD - 32°
390 Axle- trunnion mount 38°
400 Axle - trunnion mount- LSD - 38°
410 Axle - trunnion mount 32°
415 Axle- trunnion mount- LSD - 32°
420 Auto SRS manifold
430 Check valve
30 - 55 9813/9400-1 30 - 55
00 - General
(For: 506-23 [T4F])

Figure 1127. Parallel Dual Lever Control 334/L1242-9 ......................................................... Page 30-57
Figure 1128. Parallel Single Lever Control 334/L1247-10 .....................................................Page 30-63
Figure 1129. Variflow 333/G4103-9 ....................................................................................... Page 30-69
Figure 1130. HM650 Transmission 334/D1133-11 ................................................................ Page 30-75
Figure 1131. Agri Xtra 334/L7029-7 ...................................................................................... Page 30-79
Table 451. Applications

Machine Variant Part Number Refer to
506-23 - Mechanical Dual Lever 334/L1242 Refer to Figure 1127.
Control
506-23 - Single Lever Control 334/L1247 Refer to Figure 1128.
506-23 - Variflow Pump - Pilot 333/G4103 Refer to Figure 1129.
Counter Balance Valve
506-23 - Machines with HM560 334/D1133 Refer to Figure 1130.
Transmission
506-23 - Agri Xtra 334/L7029 Refer to Figure 1131.
334/L1242
30 - 56 9813/9400-1 30 - 56
00 - General
Page 30-58 Figure 1127. Parallel Dual

Lever Control 334/L1242-9 Page 30-59
J
J
J
A J
J
B
E
F
G
H
30 - 57 9813/9400-1 30 - 57
00 - General
30-58 30-59
Page 30-59
D
G
H
30 - 58 9813/9400-1 30 - 58
00 - General
30-58 30-59
J
J
J
A J
J
B
C
Page 30-58
E
F
G
H
30 - 59 9813/9400-1 30 - 59
00 - General
Note The schematic shows the sway option. On

non sway machines the pump flow goes
directly to the fan motor.
Table 452. Parallel Dual Lever Control 334/L1242-9

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
E Proportional valve
F MRV (Main Relief Valve)
G Compensator valve
H Pilot pressure valve
J Quick release couplings
1 Hydraulic pump - 2 section - dou-
ble pump
8 Poppet valve - 2 port SRS - rod side drain
9 Poppet valve - 2 port, 2 position SRS
10 Lift cylinder SRS lift
11 Lift cylinder Non SRS lift
12 Tilt cylinder Tilt
13 Displacement cylinder Displacement
14 Extend cylinder Extend
16 Steering power track rod Steering
18 Hydraulic pin locking cylinder Carriage
19 Ball valve Hydraulic pin lock
20 Filter element Fan return
21 Suction strainer In tank
23 Filter head Fan return
30 Counterbalance cartridge Lift
31 Counterbalance cartridge Tilt
32 Counterbalance cartridge Extend
35 Adaptor Lift assist
36 6-Way solenoid change over valve Auxiliary
37 Pressurised hydraulic oil filler / Tank
breather
38 Pressure transducer SRS
40 Fan motor - 19cc 55kW
41 Variable fan motor - reversing 81–108kW
42 Variable fan motor - 11cc 81–93kW
50 Accumulator Pilot
51 Accumulator SRS
52 Accumulator SRS
55 Steering control valve Orbitrol
56 Steer mode valve Manual
57 Steer mode valve Auto / electrical
60 Sway valve Sway
61 Sway cylinder Sway
30 - 60 9813/9400-1 30 - 60
00 - General

62 Check valve - low leak Sway
63 Pilot piston Sway
64 Restrictor Sway
65 Check valve
334/L1247
30 - 61 9813/9400-1 30 - 61
Notes:
30 - 62 9813/9400-1 30 - 62
00 - General
Page 30-64 Figure 1128. Parallel Single

J
J
J
J
J J
J
A
F
E
G
H
30 - 63 9813/9400-1 30 - 63
00 - General
30-64 30-65
Page 30-65
D
30 - 64 9813/9400-1 30 - 64
00 - General
30-64 30-65
J
J
J
J
J J
J
A
C
Page 30-64
F
E
G
H
30 - 65 9813/9400-1 30 - 65
00 - General

non sway machines, the pump flow goes
direct to the fan motor
Table 453. Parallel Single Lever Control 334/L1247-10

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
1 Hydraulic pump - 3 section - triple
pump
17 Hitch cylinder
30 Counterbalance valve Lift
breather
51 Accumulator SRS
52 Accumulator SRS
52 Accumulator Trailer brake
30 - 66 9813/9400-1 30 - 66
00 - General

58 Bi-directional check valve AG tyre option
59 Check valve
333/G4103
30 - 67 9813/9400-1 30 - 67
Notes:
30 - 68 9813/9400-1 30 - 68
00 - General
Page 30-70 Figure 1129. Variflow 333/G4103-9 Page 30-71
D
E E
E
E
E
30 - 69 9813/9400-1 30 - 69
00 - General
30-70 30-71
Page 30-71
D
30 - 70 9813/9400-1 30 - 70
00 - General
30-70 30-71
C
Page 30-70
D
E E
E
E
E
30 - 71 9813/9400-1 30 - 71
00 - General
Table 454. Variflow 333/G4103-9

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release connectors
10 Variable displacement pump
20 Variable displacement pump -
power control
60 Servo system control valve Pilot feed
70 Trailer brake valve Trailer brake
80 Poppet valve - 2 port SRS rod side drain
90 Counterbalance valve SRS
100 Lift cylinder SRS Lift
110 Lift cylinder Non SRS Lift
160 Steering power track rod
170 Hitch cylinder Hydraulic hitch
200 Counterbalance valve
210 Suction filter element In tank
220 Return filter In tank
230 Accumulator Pilot valve
240 Sway valve Sway
260 Hydraulic oil cooler - t4
270 Bi-directional check valve For 28" wheels
300 Counterbalance valve - non SRS Lift
320 Counterbalance valve Extend.
330 Steer control valve Orbitrol
340 Accumulator SRS
360 6-way solenoid change over valve Auxiliary
370 Pressurised hydraulic filler / Tank
breather
400 Fan motor 11cc 81 ± 93kW
410 Variable fan motor - reversing 81 ± 108kW
30 - 72 9813/9400-1 30 - 72
00 - General

420 Accumulator SRS
430 Check valve
334/D1133
30 - 73 9813/9400-1 30 - 73
Notes:
30 - 74 9813/9400-1 30 - 74
00 - General
Page 30-76 Figure 1130. HM650 Transmission 334/D1133-11 Page 30-77
30 - 75 9813/9400-1 30 - 75
00 - General
30-76 30-77
Page 30-77
30 - 76 9813/9400-1 30 - 76
00 - General
30-76 30-77
Page 30-76
30 - 77 9813/9400-1 30 - 77
00 - General
Table 455. HM650 Transmission 334/D1133-8

Item Description
60 Pilot valve
70 DTVT transmission
SRS
160 Power track rod
170 Hitch cylinder
190 Ball valve
220 Return filter
270 Quick release coupling 06 male - 6 SAE
der
334/L7029
30 - 78 9813/9400-1 30 - 78
00 - General
Page 30-80 Figure 1131. Agri Xtra 334/L7029-7 Page 30-81

H
H
H
H
H
A
B
H
C
D
30 - 79 9813/9400-1 30 - 79
00 - General
30-80 30-81
A
B
C
D
Page 30-81
30 - 80 9813/9400-1 30 - 80
00 - General
30-80 30-81
H
H
H
H
H
A
B
H
C
D
G
Page 30-80
30 - 81 9813/9400-1 30 - 81
00 - General
Table 456. Agri Xtra 334/L7029-7

A Steer priority valve
B Flow regulator valve
C LSRV (Load Sense Relief Valve)
D Auxiliary spool
E Tilt spool
F Extend spool
G Lift spool
H Quick release couplings
1 Hydraulic pump - variable displace-
ment
2 Hydraulic control valve 531-70
3 Hydraulic control valve 536-70 and 541-70
4 Flushing valve
8 3 port diverter valve Hitch
10 Lift cylinder SRS lift 531-70
11 Lift cylinder SRS lift 536-70 and 541-70
17 Hitch cylinder
22 Return filter Fan return
25 Hydraulic oil cooler 97kW
27 Accumulator SRS 541-70
30 Dual counterbalance valve Lift
32 Valve block Extend
36 6-Way solenoid change over valve Twin Auxiliary
37 LS (Load Sense) directional valve Rear Auxiliary
breather
30 - 82 9813/9400-1 30 - 82
00 - General

40 Fan motor - 11cc 81–93kW
42 Variable fan motor - 19cc 55kW
43 Check valve
44 Check valve
30 - 83 9813/9400-1 30 - 83
00 - General
(For: 509-23 [T4F])

Figure 1132. Parallel Dual Lever Control 334/L1243-10 ....................................................... Page 30-85
Figure 1133. Parallel Single Lever Control 334/L1246-11...................................................... Page 30-91
Figure 1134. Variflow 333/G1967-8 ....................................................................................... Page 30-97
Figure 1135. HM650 Transmission 334/D1133-11 .............................................................. Page 30-103
Figure 1136. Agri Xtra 334/L7029-7 .................................................................................... Page 30-107
Table 457. Applications

Machine Variant Part Number Refer to
509-23 - Mechanical Dual Lever 334/L1243 Refer to Figure 1132.
Control
509-23 - Single Lever Control 334/L1246 Refer to Figure 1133.
509-23 - Variflow Pump - Pilot 333/G1967 Refer to Figure 1134.
Counter Balance Valve
509-23 - Machines with HM560 334/D1133 Refer to Figure 1135.
Transmission
509-23 - Agri Xtra 334/L7029 Refer to Figure 1136.
334/L1243
30 - 84 9813/9400-1 30 - 84
00 - General
Page 30-86 Figure 1132. Parallel Dual

J
J
J
A J
J
B
F
E
G
H
30 - 85 9813/9400-1 30 - 85
00 - General
30-86 30-87
Page 30-87
D
G
H
30 - 86 9813/9400-1 30 - 86
00 - General
30-86 30-87
J
J
J
A J
J
B
C
Page 30-86
F
E
G
H
30 - 87 9813/9400-1 30 - 87
00 - General

direct to the fan motor.
Table 458. Parallel Dual Lever Control 334/L1243-10

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
F MRV
G Compensator valve
1 Hydraulic pump - 2 section - dou-
ble pump
breather
51 Accumulator SRS
52 Accumulator SRS
60 Sway valve Sway
30 - 88 9813/9400-1 30 - 88
00 - General

64 Restrictor Sway
65 Check valve
334/L1246
30 - 89 9813/9400-1 30 - 89
Notes:
30 - 90 9813/9400-1 30 - 90
00 - General
Page 30-92 Figure 1133. Parallel Single

J
J
J
J
J
A
E F
G
H
30 - 91 9813/9400-1 30 - 91
00 - General
30-92 30-93
Page 30-93
D
G
H
30 - 92 9813/9400-1 30 - 92
00 - General
30-92 30-93
J
J
J
J
J
A
C
Page 30-92
E F
G
H
30 - 93 9813/9400-1 30 - 93
00 - General

direct to the fan motor
Table 459. Parallel Single Lever Control 334/L1246-11

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
1 Hydraulic pump - 3 section - triple
pump
5 Hydraulic control valve EN 15000
17 Hitch cylinder
breather
51 Accumulator SRS
52 Accumulator SRS
30 - 94 9813/9400-1 30 - 94
00 - General

59 Check valve
333/G1967
30 - 95 9813/9400-1 30 - 95
Notes:
30 - 96 9813/9400-1 30 - 96
00 - General
Page 30-98 Figure 1134. Variflow 333/G1967-8 Page 30-99
C
E
E
D
E
E E
E
E
30 - 97 9813/9400-1 30 - 97
00 - General
30-98 30-99
Page 30-99
C
30 - 98 9813/9400-1 30 - 98
00 - General
30-98 30-99
B
Page 30-98
C
E
E
D
E
E E
E
E
30 - 99 9813/9400-1 30 - 99
00 - General
Table 460. Variflow 333/G1967-8

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release connectors
10 Variable displacement pump
20 Variable displacement pump -
power control
60 Servo system control valve Pilot feed
70 Trailer brake valve Trailer brake
80 Poppet valve - 2 port SRS rod side drain
90 Counterbalance valve - SRS
100 Lift cylinder SRS Lift
110 Lift cylinder Non SRS Lift
170 Hitch cylinder Hydraulic hitch
200 Check valve
210 Suction filter element In tank
220 Return filter In tank
230 Accumulator SRS
240 Sway valve Sway
260 Hydraulic oil cooler t4
270 Bi-directional check valve For 28" wheels
300 Counterbalance valve - non SRS Lift
320 Counterbalance valve Extend
330 Steer control valve Orbitrol
340 Accumulator Pilot valve
360 6-way solenoid change over valve Auxiliary
370 Pressurised hydraulic filler / Tank
breather
400 Fan motor 11cc 81–93kW
30 - 100 9813/9400-1 30 - 100

00 - General

410 Variable speed fan motor - revers- 81–108kW
ing
420 Accumulator SRS
430 Check valve
334/D1133
30 - 101 9813/9400-1 30 - 101

Notes:
30 - 102 9813/9400-1 30 - 102

00 - General
Page 30-104 Figure 1135. HM650 Transmission 334/D1133-11 Page 30-105
30 - 103 9813/9400-1 30 - 103

00 - General
30-104 30-105
Page 30-105
30 - 104 9813/9400-1 30 - 104

00 - General
30-104 30-105
Page 30-104
30 - 105 9813/9400-1 30 - 105

00 - General
Table 461. HM650 Transmission 334/D1133-8

Item Description
60 Pilot valve
70 DTVT transmission
SRS
160 Power track rod
170 Hitch cylinder
190 Ball valve
220 Return filter
270 Quick release coupling 06 male - 6 SAE
der
334/L7029
30 - 106 9813/9400-1 30 - 106

00 - General
Page 30-108 Figure 1136. Agri Xtra 334/L7029-7 Page 30-109

H
H
H
H
H
A
B
H
C
D
30 - 107 9813/9400-1 30 - 107

00 - General
30-108 30-109
A
B
C
D
Page 30-109
30 - 108 9813/9400-1 30 - 108

00 - General
30-108 30-109
H
H
H
H
H
A
B
H
C
D
G
Page 30-108
30 - 109 9813/9400-1 30 - 109

00 - General
Table 462. Agri Xtra 334/L7029-7

A Steer priority valve
B Flow regulator valve
C LSRV
D Auxiliary spool
E Tilt spool
F Extend spool
G Lift spool
H Quick release couplings
1 Hydraulic pump - variable displace-
ment
2 Hydraulic control valve 531-70
3 Hydraulic control valve 536-70 and 541-70
4 Flushing valve
8 3 port diverter valve Hitch
10 Lift cylinder SRS lift 531-70
11 Lift cylinder SRS lift 536-70 and 541-70
17 Hitch cylinder
22 Return filter Fan return
25 Hydraulic oil cooler 97kW
30 Dual counterbalance valve Lift
32 Valve block Extend
36 6-Way solenoid change over valve Twin Auxiliary
37 LS directional valve Rear Auxiliary
breather
30 - 110 9813/9400-1 30 - 110

00 - General

40 Fan motor - 11cc 81–93kW
42 Variable fan motor - 19cc 55kW
43 Check valve
44 Check valve
30 - 111 9813/9400-1 30 - 111

03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ......................................................................................................................... 30-113

30 - 112 9813/9400-1 30 - 112

03 - Tank
00 - General
Introduction .................................................. 30-113 The hydraulic tank holds excess hydraulic oil to
Drain and Fill ............................................... 30-114 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 - 113 9813/9400-1 30 - 113

03 - Tank
00 - General
Drain and Fill
Remove 4. Drain the hydraulic tank.
1. Make the machine safe. Refer to (PIL 01-03). 4.1. Clean the area around cover plate and the
drain plug below the tank.
2. Open the rear cover (if installed). Refer to (PIL
4.2. Put a suitable size container below the drain
06-06-14).
plug.
3. Discharge the hydraulic pressure from the 4.3. Remove drain plug and allow the hydraulic
system. Refer to (PIL 30-00). oil to drain.
Figure 1137.
A Hydraulic tank drain plug
30 - 114 9813/9400-1 30 - 114

03 - Tank
00 - General
Install
1. Install the drain plug and tighten the drain plug to
2. Fill the hydraulic system to the correct oil level.
3. Install the filler cap.
4. Close the rear cover (if installed).

Item Description Nm
A Drain plug 122
30 - 115 9813/9400-1 30 - 115

03 - Tank

Introduction .................................................. 30-116 The suction strainer is a component used for trapping
Remove and Install ..................................... 30-117 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 - 116 9813/9400-1 30 - 116

03 - Tank
Remove and Install
Remove 6. Carefully lower the cover plate away from the

machine.
06-06-14). 8. Remove the strainer.
3. Discharge the hydraulic pressure. Refer to (PIL 8.1. Use a spanner of the specified size-
30-00). measured across the flats - to remove the
strainer.
4. Drain the hydraulic tank.
4.1. Clean the area around cover plate and the 8.2. Carefully remove the strainer from pipe.
drain plug below the tank.
9. Use a suitable cleaning fluid to clean the suction
4.2. Put a suitable size container below the drain
strainer at every applicable service interval.
plug.
4.3. Remove drain plug and allow the hydraulic 10. Make sure that the strainer is free from
oil to drain. contamination. If the strainer is defective replace
it with a new one.
5. Hold the cover plate and remove the bolts.
11. At the applicable service interval replace the
suction strainer with a new one.
30 - 117 9813/9400-1 30 - 117

03 - Tank
Figure 1138.
B D C
A Suction strainer B Cover plate

C Drain plug D Bolts
E Gasket
30 - 118 9813/9400-1 30 - 118

03 - Tank
Install
1. Install strainer.
1.1. Screw the strainer onto the pipe by hand.
1.2. Tighten the strainer to the correct torque
value.
2. Install new gasket.
3. Install the cover plate and secure the cover plate
with the bolts.

Item Nm
A 12
C 122
D 9.9
30 - 119 9813/9400-1 30 - 119

04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ......................................................................................................................... 30-121

30-04-03 Main .............................................................................................................................. 30-122
30-04-09 Return Line ................................................................................................................... 30-125
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-127
30 - 120 9813/9400-1 30 - 120

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 - 121 9813/9400-1 30 - 121

04 - Filter
03 - Main
03 - Main 1.4. Install the element assembly in the

hydraulic tank.
Remove and Install 1.5. Install the spring and gasket.

1.6. Install the cover plate and tighten the
For: 512-26 [T4F] .................... Page 30-122 screws.
For: 506-23 [T4F], 509-23 [T4F]
................................................. Page 30-122 2. Check oil level and replenish as required through
filler.
(For: 512-26 [T4F]) 3. Install and lock the filler cap.
CAUTION When the strainer is removed, oil will
gush out. Keep to one side when you remove the 3.1. When the key is removed the cap turns and
strainer. can not be undone.
4. Close the rear cover.
Remove Figure 1139.
1. Make the machine safe with the lift arm raised,
2. Open rear cover. Refer to (PIL 06-06).
3. Discharge the hydraulic system pressure. Refer
to (PIL 30-00).
4. Clean the top of the tank around the filter.
5. Either disconnect the hose or undo clip to enable
cover plate removal.
6. Remove the element assembly:
6.1. Remove the screws. Remove the cover
plate and gasket, discard the gasket.
6.2. Remove the spring.
6.3. Hold the handle and pull the element
assembly from the hydraulic tank.
7. Remove the element from its canister: A Screws
B Cover plate
7.1. Hold the canister.
C Gasket
7.2. Hold the handle and rotate the element 90° D Spring
counter-clockwise. E Handle
F Canister
7.3. Pull on handle, the element should separate
G Element
from its canister. Discard the old element.
H Seal 1
7.4. Remove and discard the seal. J Seal 2
K Hose
7.5. Clean the inside of canister.
Install (For: 506-23 [T4F], 509-23 [T4F])

CAUTION When the strainer is removed, oil will
1. Install the new element. gush out. Keep to one side when you remove the
strainer.
1.1. Install a new seal 1.
1.2. Make sure that seal 2 is installed in the new
element. Canister Type Filter
1.3. Push the element into its canister and rotate Remove
the element 90° to lock it into position.
Check that the element has locked into The canister filter is installed under the chassis,
position by pulling on the handle. located to the rear of the front axle.
30 - 122 9813/9400-1 30 - 122

04 - Filter
03 - Main
1. Make the machine safe with the lift arm lowered, Oil Filter (Hydraulic Oil Tank, Top
refer to (PIL 01-03). Mounting)
2. Discharge the hydraulic system pressure. Refer
to (PIL 30-00). Remove
3. Clean the area around the filter body. 1. Make the machine safe with the lift arm raised,
4. Place a container of suitable size beneath the
machine to catch the oil. 2. Open rear cover. Refer to (PIL 06-06).
5. From under the machine, unscrew and remove 3. Discharge the hydraulic system pressure. Refer
the element. The element will contain hydraulic to (PIL 30-00).
fluid; keep your face clear of spilling fluid.
4. Clean the top of the tank around the filter.
Install 5. Either disconnect the hose or undo clip to enable
cover plate removal.
1. Install the new element.
6. Remove the element assembly:
1.1. Clean the mating faces on the new element
and filter holder. 6.1. Remove the screws. Remove the cover
1.2. Smear the seal with clean new hydraulic plate and gasket, discard the gasket.
fluid. 6.2. Remove the spring.
1.3. Screw the new element in place, hand-tight 6.3. Hold the handle and pull the element
only. assembly from the hydraulic tank.
2. Check oil level and replenish as required through 7. Remove the element from its canister:
filler. Refer to (PIL 30-00).
7.1. Hold the canister.
7.2. Hold the handle and rotate the element the
4. Check for leaks: specified angle counter clockwise.
Figure 1140. Angle: 90°

7.3. Pull on handle, the element should separate
from its canister. Discard the old element.
7.4. Remove and discard the seal.
7.5. Clean the inside of canister.
Install
1. Install the new element.
1.1. Install a new seal 1.
1.2. Make sure that seal 2 is installed in the new
element.
1.3. Push the element into its canister and rotate
the element 90° to lock it into position.
Check that the element has locked into
position by pulling on the handle.
1.4. Install the element assembly in the
hydraulic tank.
A Canister filter
C Seal 1.5. Install the spring and gasket.
4.1. Run the engine for a few minutes. 1.6. Install the cover plate and tighten the
screws.
4.2. Make the machine safe.
2. Check oil level and replenish as required through
4.3. Check for leaks at the filter. filler.
30 - 123 9813/9400-1 30 - 123

04 - Filter
03 - Main

4. Close the rear cover.
Figure 1141.
A Screws
B Cover plate
C Gasket
D Spring
E Handle
F Canister
G Element
H Seal 1
J Seal 2
K Hose
30 - 124 9813/9400-1 30 - 124

04 - Filter
09 - Return Line
09 - Return Line
Remove and Install
Special Tools 4.1. Clean the area around cover plate and the
Description Part No. Qty. drain plug below the tank.
Special Spanner (66 332/F2828 1 4.2. Put a suitable size container below the drain
mm) plug.
WARNING Personal injury can result from being 4.3. Remove drain plug and allow the hydraulic
struck by parts propelled by a released spring oil to drain.
force. Make sure to wear all necessary protective 5. Hold the cover plate and remove the bolts.
equipment. Follow the recommended procedure
and use all recommended tools to release the 6. Carefully lower the cover plate away from the
spring force. machine.
Remove
8. Remove the filter element.
8.1. Use a spanner to remove the filter element.
06-06-14). 8.2. Carefully remove the filter from pipe.
8.3. Make sure you hold the filter tightly. When
3. Discharge the hydraulic pressure from the
you remove the filter from the return pipe,
system. Refer to (PIL 30-00).
the spring 2 can cause the filter to move
4. Drain the hydraulic tank. suddenly.
Figure 1142.
G
K
E
L
B D C
Table 465.
Item Description
B Cover plate
C Drain plug
30 - 125 9813/9400-1 30 - 125

04 - Filter
09 - Return Line
Item Description
D Bolts
E Gasket
F Filter element
G Pipe
H Spring 2
J Spring 1
K Spanner
L Distance between handle and ratchet.
Install
1. Install a new filter element.
1.1. Screw the filter onto the pipe by hand.
1.2. Make sure you install spring 2 together with
the filter.
1.3. Use the correct special spanner together
with a torque wrench and extension.
Because the torque wrench handle is
extended by the spanner care must be used
to obtain the correct torque on the filter.
Special Tool: Special Spanner (66 mm)
(Qty.: 1)
1.4. Set the torque wrench to the specified
value.
Torque: 33N·m
1.5. Operate the wrench, holding the handle at
a specified distance from the ratchet.
Distance: 300mm
1.6. Torque tighten the filter.
2. Install new gasket.
3. Install the cover plate and secure the cover plate
with the bolts.

Item Description Nm
C Drain plug 122
D Bolt 9.9
30 - 126 9813/9400-1 30 - 126

04 - Filter
60 - Pilot Pressure Supply Main
60 - Pilot Pressure Supply Main Figure 1145.
Remove and Install

E
Remove
1. This procedure applies to servo pilot pressure
valves installed from machine serial number
2472234 onwards.
3. Remove the cab side panel. Refer to Figure
1143.
Figure 1143. E Servo pilot pressure valve - Old
Figure 1146.
A Cab side panel

4. Identify the servo pilot pressure valve under the
cab. Refer to Figure 1144. F Servo pilot pressure valve - New
Figure 1144. 7. Unscrew and remove the filter cartridge. Be

aware that there could be some residual
hydraulic pressure. Refer to Figure 1147.
B Servo pilot pressure valve

5. Discharge the hydraulic pressure .
Refer to: PIL 30.
6. Refer to Refer to Figure 1145. and Refer to Figure
1146. for old and new servo pilot pressure valves.
30 - 127 9813/9400-1 30 - 127

04 - Filter
60 - Pilot Pressure Supply Main
Figure 1147.
G Filter cartridge location

8. Clean the filter cartridge. Refer to Figure 1148.
Figure 1148.
Install
1. Install the filter cartridge and tighten to the correct
torque.
Torque: 65N·m
2. Make sure that the servo pilot pressure is of the
specified value.
3. Check the hydraulic fluid level and top up as
required.
4. Operate the machines hydraulic system. Check
for correct operation and leaks.
5. Install the cab side panel.
30 - 128 9813/9400-1 30 - 128

11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ......................................................................................................................... 30-131
30 - 129 9813/9400-1 30 - 129

Notes:
30 - 130 9813/9400-1 30 - 130

11 - Gear Pump
00 - General
00 - General Technical Data

Technical Data ............................................. 30-131 For: 506-23 [T4F], 509-23 [T4F]
................................................. Page 30-131
For: 506-23 [T4F], 509-23 [T4F]
Operation ..................................................... 30-134 ................................................. Page 30-132
Diagram ....................................................... 30-135 For: 512-26 [T4F] .................... Page 30-133
Check (Pressure) ........................................ 30-136
Remove and Install ..................................... 30-139 (For: 506-23 [T4F], 509-23 [T4F])
The pump installed on your machine will be one of
two types:
2 Section (Double pump)
Table 467. Double Pump

Mounting Gearbox
Direction of rotation Counter clockwise
Theoretical displace- 0.000036m³
ment per RPM (Revolu-
tions Per Minute)- Main
services pump (mount-
ing flange end)
ment per RPM-Cooling
fan pump
Flow- Main services 71.3L/min
pump
(1)
Flow- Cooling fan pump 31.7L/min

Maximum pressure- port 265 (3,840.6)
EF
P
Maximum speed 3000 RPM
Minimum speed 500 RPM
Weight 22.7kg
(1) At 2200 RPM and system pressure (90% min
displacement).
3 Section (Triple pump)
Table 468. Triple Pump

Mounting Gearbox
ment per RPM- Main
services pump (mount-
ing flange end)
fan pump
fan pump
30 - 131 9813/9400-1 30 - 131

11 - Gear Pump
00 - General
Flow- Main services 71.3L/min Direction of rotation Anti-clockwise

pump
(1)
Maximum speed 2200RPM
Flow- Steering pump 37.6L/min Minimum speed 500RPM
Flow- Cooling fan pump 31.7L/min Weight TBA
EF Table 474.
P Theoretical displace- Value
ment
Main services pump 45 cc/rev
Minimum speed 500 RPM (mounting flange end)
Weight 34.1kg Cooling fan pump 16 cc/rev
(1) At 2200 RPM and system pressure (90% min
displacement).
Table 475.
(For: 506-23 [T4F], 509-23 [T4F]) Flow at 2200RPM and Value
system pressure (90%
Depending on the specification of your machine, the min. displacement)
following pumps may be installed: Main services pump TBA
(mounting flange end)
Two section double pump (1) Cooling fan pump TBA
Table 469.
Table 476.
Type Double gear pump
Minimum pressure Value
Mounting Gearbox
Port EF 260bar (3,768.1psi)
Direction of rotation Anti-clockwise
Port P 180bar (2,608.7psi)
Three section triple pump (3)
Weight 22.7kg

Theoretical displace- Value Type Triple gear pump
ment Mounting Gearbox
Main services pump 36 cc/rev Direction of rotation Anti-clockwise
(mounting flange end) Maximum speed 2500RPM
Cooling fan pump 16 cc/rev Minimum speed 500RPM
Weight 34.1kg
Table 471.
Flow at 2200RPM and Value
Table 478.
min. displacement) Theoretical displace- Value
Main services pump 71.3L/min ment
(mounting flange end) Main services pump 36 cc/rev
Cooling fan pump 31.7L/min (mounting flange end)
Steering pump 19 cc/rev
Table 472. Cooling fan pump 16 cc/rev
Port EF 265bar (3,840.6psi) Table 479.
Port P 200bar (2,898.5psi) Flow at 2200RPM and Value
Two section double pump (2) min. displacement)
Main services pump 71.3L/min
Table 473. (mounting flange end)
Type Gear pump Steering pump 37.6L/min
Mounting Gearbox Cooling fan pump 31.7L/min
30 - 132 9813/9400-1 30 - 132

11 - Gear Pump
00 - General
Table 480. Component Identification

Port EF 265bar (3,840.6psi) Figure 1149. Typical Double Pump
Port P 200bar (2,898.5psi)
A
(For: 512-26 [T4F])
Your machine is installed with a double pump. One
pump is a gear type (for the cooling fan) and one is
a variable piston type (for the main services). They
are mounted together inline on the gearbox. Refer
to component identification, (PIL 30-00) and variable
displacement pump, (PIL 30-12).
Gear Pump (Fan Hydraulics)

Table 481. D
Mounting Gearbox (rear of vari- C
able pump)
Theoretical displace- 19 cc Figure 1150. Typical Triple Pump
ment per RPM
Flow
Maximum pressure
(1)
230 (3,333.3)
Maximum continuous 210 (3,043.5)
pressure
(1)

Weight (when assem- 42.7
bled to variable pump)
(1) Pump manufacturers specification
A
D
B
C
A Main services section
B Steering section (if fitted)
C Cooling fan section
D Steering priority valve
30 - 133 9813/9400-1 30 - 133

11 - Gear Pump
00 - General
Operation
The pump is a gear type and driven by the engine. the gears come into mesh the oil is forced through the
The separate sections of the gear pump assembly outlet port, or through an internal port into the integral
supply hydraulic oil to the main hydraulic circuits, to priority valve depending on the type of pump.
the steering circuit and to the hydraulic cooling fan
circuit. Some oil is allowed to circulate behind the bushes to
hold them in balance against the gears and minimise
The separate sections of the gear pump operate oil leakage.
individually as described below.
Lubrication is provided by the hydraulic oil,which is
The working principle of a gear pump depends on the directed around the unit via oil ways, by the motion
meshing of two spur gears. Oil is picked up on the of the meshing gears.
suction side of the pump by the gears and carried
round between the gear teeth and the pump body. As For the priority valve operation, refer to (PIL 25-03).
Figure 1151.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
Table 482. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 134 9813/9400-1 30 - 134

11 - Gear Pump
00 - General
Diagram
A typical triple pump layout is shown. For double

pump schematics and machine specific details refer
to the hydraulic systems and schematics (PIL 30-00).
Figure 1152.
LS P EF F G
C A
B
Item Description
Table 483. Main components EF Control valve block sec-
Item Description ondary feed
A Main pump section LS Steering load sense port
B Steering pump section
C Fan and pilot pump sec-
tion
D Priority steer valve
E Hydraulic tank
Table 484. Port details

Item Description
F Fan and pilot valve feed
G Test point
P Pump main output
30 - 135 9813/9400-1 30 - 135

11 - Gear Pump
00 - General
Check (Pressure) Figure 1154.
Special Tools
Flowmeter 892/00229 1 D
Load Valve 892/00270 1
Pressure Test Kit
Double pump
The gear pump assembly has isolated sections that
supply hydraulic oil to the main services circuits, to
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health D Hose 1
and safety information. Refer to (PIL 30-00).
5. Connect the flow meter, digital pressure test kit
3. Discharge the hydraulic pressure. Refer to (PIL and a load valve into the discharge line from the
30-00). cooling fan pump as follows:
Figure 1153. 5.1. Disconnect the hose 2 from the pump.

B 5.2. Install the flowmeter and the load valve
between the hose 2 and the pump 2.
Figure 1155.
C A
A Flowmeter
B Pressure gauge
C Load valve
4. Connect the flowmeter, digital pressure test kit E
and a load valve into the discharge line from the
main service pump as follows:
Special Tool: Load Valve (Qty.: 1)
Special Tool: Flowmeter (Qty.: 1)
(Qty.: 1) E Hose 2
4.1. Disconnect the hose 1 from the pump. 6. Make sure that the load valve and the flowmeter
4.2. Install the flow meter and the load valve is installed in the correct way with the direction
between the hose 1 and the pump 1. arrow pointing away from the pump.
7. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
30 - 136 9813/9400-1 30 - 136

11 - Gear Pump
00 - General
8. Start the engine and put the hydraulic system up 4.1. Install the flow meter and load valve in the
to working temperature. discharge line1 at an applicable place in the
hose and pipework. Make sure that there
are no other hydraulic connections between
9. Put the steering and control valve block spools to the pump and the load valve.
the neutral position. 4.2. Disconnect the valve from the steer priority
valve port.
10. Set the engine speed to 2200 RPM (Revolutions
Per Minute). 4.3. Install cap in the open hose.
11. Carefully adjust the load valve to make the gauge 4.4. Connect a slave hose to the hydraulic tank.
reading to the specified value. 4.5. Slowly remove the hydraulic tank filler cap
Pressure: 240bar (3,478.2psi) and place the end of the slave hose inside
the filler tube.
12. Check the flow reading.
Figure 1157.
13. If the flow reading is low, you will not get the
required pressure. Refer to (PIL 30-00).
14. Switch off the engine and allow to cool after the H
test.
15. Disconnect the test equipment and connect the
hydraulic hoses again. G
Triple pump F
The gear pump assembly has isolated sections that

supply hydraulic oil to the main services circuits, to
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health
3. Discharge the hydraulic pressure. Refer to (PIL F Discharge line 1
30-00). G Priority valve port
H Slave hose
Figure 1156.
5. Connect the flowmeter, digital pressure test kit
B
and a load valve into the discharge line 2 from
the steering pump as follows:
5.1. Install the flowmeter and load valve in the
discharge line 2 at an applicable place in the
the pump and the load valve.
C A
A Flow meter
B Pressure gauge
C Load valve
the main service pump as follows:
30 - 137 9813/9400-1 30 - 137

11 - Gear Pump
00 - General
Figure 1158. 10. Put the steering and control valve block spools to
the neutral position.
11. Set the engine speed to 2200 RPM.
12. Carefully adjust the load valve to make the gauge
reading to the specified value.
Pressure: 240bar (3,478.2psi)
J
13. Check the flow reading.
14. If the flow reading is low, you will not get the
required pressure. Refer to (PIL 30-00).
15. Test the priority valve. Refer to (PIL 25-03).
Figure 1160.
J Discharge line 2
the cooling fan pump as follows:
6.1. Install the flowmeter and load valve in the
discharge line 3 at an applicable place in the
the pump and the load valve.
Figure 1159.
16. Switch off the engine and allow to cool after the
test.
17. Disconnect the test equipment and connect the
hydraulic hoses again.
K Discharge line 3
7. Make sure that the load valve and the flowmeter
are installed in the correct way with the direction
arrow pointing away from the pump.
8. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
up to working temperature.
30 - 138 9813/9400-1 30 - 138

11 - Gear Pump
00 - General
Remove and Install 5. Plug all the open ports and hoses to prevent
contamination.
be removed or handled using a suitable lifting 6. Disconnect the feed hoses.
method and device.
contamination.
Before Removal
8. For triple pump, remove the socket head screws.
1. Make the machine safe. Refer to PIL (01-03).
8.1. Disconnect the outlet pipe from the pump
2. Make sure that you follow the hydraulic health body.
Figure 1162. Typical triple pump
3. Before you remove and disassemble the pump, A
check the flow and pressure. If either of these
are low and cannot be corrected at the relief
valve, replace the appropriate pump section
completely.
D
4. If you replace the pump component such as
gears, bearings and the housing will not effect a
permanent cure.
5. If the pump output is satisfactory but there is
external leakage, the pump should be removed B C
and disassembled for re-sealing only.
6. Before you remove or disassemble the pump,
make sure the exterior of the pump and working
area is thoroughly cleaned and free of possible A Flange bolts (x4)
sources of contamination. B Socket head screws
C Outlet pipe
Remove D Mounting bolts
1. Discharge the hydraulic pressure. Refer to (PIL 8.2. Plug all the open ports and hoses to prevent
30-00). contamination.
2. Drain the hydraulic fluid from the hydraulic tank 9. Use a sling to secure the pump body.
into a suitable clean container. 10. With the pump suitably supported, remove the
3. Put a label on the hoses to help installation. mounting bolts.
4. Remove the flange bolts and then disconnect the 11. Carefully remove the pump from the gearbox.
suction hose flange from the pump body. 12. Keep the drive coupling.
Figure 1161. Typical double pump
Install
A
steps.
1.1. Before assembly, make sure the pump
flange and gearbox mating faces are clean
and free from oil and grease.
1.2. Install new O-ring seals.
1.3. Install the drive coupling and then engage
the pump drive into the coupling.
D
1.4. Support the pump and secure the pump to
the gearbox with the mounting bolts.
A Flange bolts (x4)
D Mounting bolts
30 - 139 9813/9400-1 30 - 139

11 - Gear Pump
00 - General
1.5. Tighten the mounting bolts to the correct Disassemble and Assemble
torque value.
1.6. Make sure that the mounting bolts are 10.9 Do not try to disassemble this component. If this
grade M12 Tuf-Lok. component is defective a new one must be installed.
1.7. Make sure that correct bolts are installed.
1.8. Make sure that the hoses are correctly
installed, and phased in the same position
as removal to prevent chafing.
1.9. Check the hydraulic oil level and top up as
1.10. After you install a new or serviced pump
and before you start the engine, screw out
the MRV (Main Relief Valve) four full turns.
1.11. Adjust the MRV.
1.12. Check the fan motor speed. Refer to (PIL
21-03).
1.13. Check the hydraulic pressure. Refer to

Item Description Nm
A Flange bolts 46
B Socket head screws 46
D Mounting bolts 96
30 - 140 9813/9400-1 30 - 140

12 - Variable Displacement Pump
Contents Page No.
30-12-00 General ......................................................................................................................... 30-143
30 - 141 9813/9400-1 30 - 141

Notes:
30 - 142 9813/9400-1 30 - 142

00 - General
Introduction .................................................. 30-143 The most common variable displacement pump used
Technical Data ............................................. 30-144 in vehicle technology is the axial piston pump. This
Component Identification ............................. 30-145 pump has several pistons in cylinders arranged
Operation ..................................................... 30-147 parallel to each other and rotating around a central
shaft. A swashplate at one end is connected to the
Remove and Install ..................................... 30-149 pistons. As the pistons rotate, the angle of the plate
Disassemble and Assemble ........................ 30-155 causes them to move in and out of their cylinders.
A rotary valve at the opposite end from the

swashplate alternately connects each cylinder to
the fluid supply and delivery lines. By changing the
angle of the swashplate, the stroke of the pistons
can be varied continuously. If the swashplate is
perpendicular to the axis of rotation, no fluid will flow.
If it is at a sharp angle, a large volume of fluid will be
pumped.
Some pumps allow the swashplate to be moved in

both directions from the zero position, pumping fluid
in either direction without reversing the rotation of the
pump.
Piston pumps can be made variable-displacement

by inserting springs inline with the pistons. The
displacement is not positively controlled, but
decreases as the back-pressure increases.
30 - 143 9813/9400-1 30 - 143

00 - General
Technical Data
Your machine is installed with a double pump. One are mounted together inline on the gearbox. Refer
pump is a gear type (for the cooling fan) and one is to component identification, (PIL 30-00) and gear
a variable piston type (for the main services). They pump, (PIL 30-11).
Variable Pump (Main Services)

Table 486.
Displacement 11.1 cc to 63 cc/rev
Minimum speed 500 RPM (Revolutions Per Minute)
Maximum pressure
(1)
315 (4,565.2)
Maximum continuous pressure
(1)
250 (3,623.2)
ARV (Auxiliary Relief Valve)
(1)
290 (4,202.9)
(1) Pump manufacturers specification
30 - 144 9813/9400-1 30 - 144

00 - General
For: 506-23 [T4F], 509-23 [T4F], 512-26

[T4F] ........................................ Page 30-145
................................................. Page 30-146
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F])
Figure 1163.
G1
F1
G
F
A
J
H
B
A
E D
K L
L
C
Item Description
F1 Pressure cut off safety
Table 487.
valve adjuster cover (not
Item Description adjustable)
A Drive shaft. Driven from G Flow compensator valve
the bevel gearbox spool
B Inlet (suction) port G1 Flow compensator valve
C Outlet port adjuster cover (not ad-
D Separate gearpump justable)
(cooling fan circuit) dri- H Swash control piston
ven by drive shaft J Swash plate control
E Hydraulic control valve spring
F Pressure cut off safety K Swash plate
valve spool L Axial pistons
30 - 145 9813/9400-1 30 - 145

00 - General
Figure 1164. Hydraulic Services Pump- Dual Tech Variable Transmission

G
E D
M
D P
F
C M
C
H
B
A
B M
N C
C M
334/E2996-3 K
A Pump drive coupling B O-ring

C Pressure test point D Adapter
E Cap screw M12 x 35 12.9 grade F Set screw M12 x 35 12.9 grade
G Adapter- Tee H Temperature sensor- Hydraulic oil
J Suction adapter K Set screw M12 x 30 8.8 grade
L Fan suction pipe M Spring washer M12
N Variable displacement pump P Pump- fan
30 - 146 9813/9400-1 30 - 146

00 - General
Operation
(For: 506-23 [T4F], 509-23 [T4F]) controlled via the swash control piston. The piston
varies the angle of the tilting swash plate, which
The hydraulic services pump is a variable alters the displacement (stroke) of the pistons. This
displacement axial piston pump, which uses the has the effect of changing the hydraulic oil flow in the
swash plate design principle. system.
Rotation of the input drive shaft produces linear

movement of the axial pistons. The pump output is
Figure 1165.
Item Description
Table 488.
LS Load sense line
Item Description P Operating pressure
A Swashplate
B Spring1 The swash control piston is controlled by two
C Piston systems, as follows.
D Compensator spool • The flow compensator valve. The valve is
E Spring2 actuated by load sense hydraulic pressure. This
F Spring3 system controls the pump in response to the
G Pressure cut-off spool demands of the hydraulic services.
X Solenoid valve
30 - 147 9813/9400-1 30 - 147

00 - General
• The hydraulic control valve operates to make Pressure cut-off valve

sure that the torque required to turn the
pump does not exceed the maximum engine The pressure cut-off valve is a secondary safety
torque range. Two types of valve are installed device to limit the maximum operating pressure
depending on the machine variant. thereby protect the pump from over pressurisation.
If the pump operating pressure (i.e. main system
Pump control pressure) ever reaches the setting of the valve
spring3, the pressure cut-off spool will be pushed to
The pump output flow and operating pressure are the left, this in turn, increases the control pressure
controlled by varying the angle of the tilting swash acting on the swash control piston, which decreases
plate. The swashplate is moved in one direction the angle of the swash plate, and reduces the pump
by the force of the spring1, and in the opposite output flow to minimum. While the pressure cut-off
direction by control pressure (orange) acting behind valve is operating the pump will remain hydraulically
the swash control piston. The control pressure is stalled i.e. maintaining maximum operating pressure
derived from the pump operating pressure (red) at minimum flow.
by the action of the flow compensator spool. The
flow compensator spool regulates the angle of the Hydraulic variable control solenoid valve
swashplate automatically in response to changes in (HVCS)
the hydraulic load sense pressure (yellow) from the
hydraulic service. The proportional solenoid valve is part of the HVCS
(Hydraulic Variable Control Solenoid Valve). The
Flow compensator valve system automatically adjusts the pump performance
(power curve characteristic) to limit the hydraulic
When a hydraulic service is operated, boom lift for power available to the hydraulic services under
example, a pressure signal (demand) is generated conditions of high engine load or high hydraulic fluid
in the load sense line (LS) from the control valve temperature.
block. The increase in the load sense pressure,
combined with the force of the spring2 pushes the The solenoid valve is controlled by a current
flow compensator spool to the right, this in turn, signal output from an ECU (Electronic Control
allows some control pressure (orange) acting on the Unit). The solenoid valve works as a separate
swash control piston to vent back to tank via the case pressure regulating valve and increases the control
drain (green). The force of the spring1 increases the pressure acting on the swash control piston by a
angle of the swashplate and the pump output flow set amount, according to the valve current signal.
increases proportionally. Because the control pressure is regulated by the
solenoid valve independently (down stream) of the
When the output flow is enough to satisfy the flow compensator spool, this means that when it
flow demanded by the service, the pump operating is operating, it will alter the way that the pump
pressure (red) increases sufficiently to start to move swashplate normally responds to changes in the
the service ram. The increase in the pump operating hydraulic load sense pressure.
pressure pushes the flow compensator spool back
to the left, against the force of the spring2 and In this way, the hydraulic power curve of the pump
hydraulic load sense pressure; this in turn increases can be adjusted electrically by the current signal from
the control pressure acting on the swash control the ECU.
piston, which decreases the angle of the swash plate
against the force of spring1. As the swash plate angle
decreases, the output flow from the pump decreases.
In this way, the pump delivers only the minimum flow
needed to maintain the system pressure required to
operate the service.
The flow compensator spool is moving constantly,

thereby regulating the pump swash plate to balance
the pressures acting on each end of the spool.
The additional force of spring2 is factory set to be
equivalent to 25bar (362.3psi), therefore the pump
operating pressure (i.e. main system pressure) will
always be maintained at 25bar (362.3psi) above the
load sense pressure. This is sometimes referred to
as the 'Delta-P' pressure setting.
30 - 148 9813/9400-1 30 - 148

00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], 512-26 3. Drain the hydraulic fluid from the hydraulic tank
[T4F] ........................................ Page 30-149 into a suitable clean container.
................................................. Page 30-151 4. Disconnect the outlet hose from the fan pump.
5. Disconnect the electrical connector 1 from the
(For: 506-23 [T4F], 509-23 [T4F], 512-26 pump control solenoid.
[T4F])
6. Disconnect the electrical connector 2 from the
Consumables hydraulic fluid temperature switch.
JCB Threadlocker and 4101/0550 0.01L 7. Remove the clips and disconnect the suction
Sealer (High Strength) hose from the pump inlet manifold.
4101/0552 0.2L
8. Plug the open port and cap the hose to prevent
Working Under the Machine loss of fluid and ingress of dirt.
Make the machine safe before getting beneath it. 9. Remove flange bolts and remove the outlet hose
Make sure that any attachments on the machine are from the pump body.
the ignition key, disconnect the battery. If the machine 10. Plug the open port and cap the hose to prevent
has wheels use blocks to prevent unintentional loss of fluid and ingress of dirt.
movement.
11. Disconnect the load sense hose from the pump.
Hydraulic Pressure
Plug the open port and cap the hose to prevent
Hydraulic fluid at system pressure can injure you. loss of fluid and ingress of dirt.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service 12. Disconnect the case drain hose from the pump.
hose line must be vented. Make sure the hose Plug the open port and cap the hose to prevent
service line has been vented before connecting or loss of fluid and ingress of dirt.
started while the hoses are open. CAUTION! This component is heavy. It must only
The fan pump is bolted to the variflow pump. This method and device.
procedure describes removing the variflow pump and
fan pump as one unit. 13. Make sure you use a sling around the pump
assembly.
Before you remove the pump, make sure the exterior
of the pump and working area is thoroughly cleaned 14. With the pump correctly supported, remove the
and free of possible sources of contamination. mounting bolts and carefully remove the pump
from the gearbox.
Remove Two bolts are hexagon head and other two are
caphead bolts. Record the position of the bolts for
1. Make the machine safe. Refer to (PIL 01-03). correct installation.
30-00).
30 - 149 9813/9400-1 30 - 149

00 - General
Figure 1166.
H K J
Item Description
Table 489. F Flange bolts (x4)
G Load sense hose
Item Description
H Case drain hose
A Outlet hose
J Mounting bolts (x4)
B Fan pump
K Cap
C Electrical connector 1
D Electrical connector 2
E Clips
30 - 150 9813/9400-1 30 - 150

00 - General
Install Working Under the Machine

Before you start the engine the variflow pump body Make sure that any attachments on the machine are
must be filled with hydraulic fluid. If the engine is correctly attached. Engage the park brake, remove
started with no fluid in the pump, pump can be the ignition key, disconnect the battery. If the machine
damaged. has wheels use blocks to prevent unintentional
movement.
1. Make sure the pump flanges and gearbox mating
faces are clean and free from oil and grease Hydraulic Pressure
before installation. Hydraulic fluid at system pressure can injure you.
2. Install new O-ring seals to the pump to gearbox Before connecting or removing any hydraulic hose,
case mating face and inlet and outlet hose residual hydraulic pressure trapped in the service
flanges. hose line must be vented. Make sure the hose
3. Lubricate the O-rings with clean hydraulic fluid. removing hoses. Make sure the engine cannot be
4. Apply sealant to the flange bolts and tighten the
bolts to the correct torque value. Refer to Hydraulic System, Variable Displacement
Pump, General, Component Identification, refer to
(PIL: 30-12-00).
(High Strength)
5. Remove the cap and fill the pump case with clean This procedure uses illustrations from another
hydraulic fluid. Install the cap. transmission, however the removal procedure is
similar.
6. Reconnect the hydraulic hoses and suction hose
to the pump. The fan pump is bolted to the variflow pump. This
procedure describes removing the variflow pump and
7. Connect the electrical connectors with the fan pump as one unit.
hydraulic fluid temperature switch and the pump
control solenoid. Before you remove the pump, make sure the exterior
of the pump and working area is thoroughly cleaned
8. Fill the hydraulic tank to the correct level with and free of possible sources of contamination.
clean hydraulic fluid. Refer to (PIL 30-00).
9. Loosen cap and allow any trapped air to escape Remove
from the pump body and drain hose. Tighten the 1. Make the machine safe. Refer to (PIL 01-03).
cap.
30-00).
Item Value 3. Drain the hydraulic fluid from the hydraulic tank
into a suitable clean container.
J
(1)
87N·m
J
(2)
97N·m 4. Disconnect the outlet hose from the fan pump.
K
(1)
84N·m 5. Disconnect the electrical connector 1 from the
K
(2)
84–92N·m pump control solenoid.
(1) 550-80 machines only. 6. Disconnect the electrical connector 2 from the
(2) Other machines. hydraulic fluid temperature switch.
(For: HM560 Variable Transmission) 7. Remove the clips and disconnect the suction
hose from the pump inlet manifold.
Consumables
Description Part No. Size 8. Plug the open port and cap the hose to prevent
loss of fluid and ingress of dirt.
Moly Grease 4003/1326 12.5kg 9. Remove flange bolts and remove the outlet hose
from the pump body.
10. Plug the open port and cap the hose to prevent
30 - 151 9813/9400-1 30 - 151

00 - General
11. Disconnect the load sense hose from the pump. 13. Make sure you use a sling around the pump
Plug the open port and cap the hose to prevent assembly.
14. With the pump correctly supported, remove the
12. Disconnect the case drain hose from the pump. mounting bolts and carefully remove the pump
Plug the open port and cap the hose to prevent from the gearbox.
Two bolts are hexagon head and other two are
CAUTION! This component is heavy. It must only caphead bolts. Record the position of the bolts for
be removed or handled using a suitable lifting correct installation.
method and device.
30 - 152 9813/9400-1 30 - 152

00 - General
Figure 1167. Typical Pump Installation.
H K J
Item Description
Table 491. F Flange bolts (x4)
G Load sense hose
Item Description
H Case drain hose
A Outlet hose
J Mounting bolts (x4)
B Fan pump
K Cap
C Electrical connector 1
D Electrical connector 2
E Clips
30 - 153 9813/9400-1 30 - 153

00 - General
Install
Before you start the engine the variflow pump body
must be filled with hydraulic fluid. If the engine is
started with no fluid in the pump, pump can be
damaged.
1. Make sure the pump flanges and gearbox mating

faces are clean and free from oil and grease
2. Install new O-ring seals to the pump to gearbox
case mating face and inlet and outlet hose
flanges.
3. Make sure the pump drive coupling is greased
and installed before assembly.
Grease
4. Lubricate the O-rings with clean hydraulic fluid.
5. Apply JCB Medium strength locking fluid
4101/0200 to the flange bolts and tighten the
bolts to the correct torque value. Refer to (PIL
75-10-00).
6. Remove the cap and fill the pump case with clean
hydraulic fluid. Install the cap.
7. Reconnect the hydraulic hoses and suction hose
to the pump.
8. Connect the electrical connectors with the
hydraulic fluid temperature switch and the pump
control solenoid.
9. Fill the hydraulic tank to the correct level with
clean hydraulic fluid. Refer to (PIL 30-00).
10. Loosen cap and allow any trapped air to escape
from the pump body and drain hose. Tighten the
cap.

Item Value
J 87N·m
30 - 154 9813/9400-1 30 - 154

00 - General
Do not try to disassemble this component. If this

component is defective a new one must be installed.
30 - 155 9813/9400-1 30 - 155

13 - Hydrostatic Pump
Contents Page No.
30-13-00 General ......................................................................................................................... 30-157
30 - 156 9813/9400-1 30 - 156

00 - General
Introduction .................................................. 30-157 The A4VG is an axial piston variable pump with
Technical Data ............................................. 30-158 swashplate design for hydrostatic drives in closed
Component Identification ............................. 30-158 circuits. Flow is proportional to drive speed and
Operation ..................................................... 30-159 displacement. The flow can be changed smoothly by
controlling the swashplate.
Fault-Finding ................................................ 30-160
Disconnect and Connect ............................. 30-162 A hydraulic system is considered to be closed if the
Drain and Fill ............................................... 30-163 hydraulic fluid which flows back from the consumer
Check (Pressure) ........................................ 30-163 is directed directly back to the pump. Here, there
is a high-pressure side and a low-pressure side
Bleed ........................................................... 30-164 depending on the load direction (output torque on the
Remove and Install ..................................... 30-164 consumer).
For axial piston units with swashplate design, the
pistons are arranged axially with respect to the drive
shaft. They are guided in the rotating cylinder and
support themselves with the slipper pads on the non-
rotating swashplate. The drive shaft and cylinder are
connected to one another by means of gearing.
30 - 157 9813/9400-1 30 - 157

00 - General
Weight 115kg Figure 1168. Assembly of the Axial Piston Unit

D
For pressure specifications and test points refer to C
(PIL 27-05-00).
B E
A F
K J H G
A Drive shaft
B Retaining plate
C Stroke piston
D Control unit
E Control plate
F Auxiliary pump
G Suction port
H Cylinder
J Piston
K Slipper pad
L Swashplate
30 - 158 9813/9400-1 30 - 158

00 - General
Operation centered. Increasing the swivel angle increases the

displacement. Reducing the swivel angle reduces
the displacement.
Pump
Torque is applied to the pump drive shaft from the
engine. The pump cylinder turns with the drive shaft,
turning with it the pump pistons. On each rotation, the
pistons perform a stroke movement which is defined
by the pitch of the swashplate. The slipper pads are
held on and guided along the glide surface of the
swashplate by the retaining plate. During a rotation,
each piston moves over the bottom and top dead
centers back to its initial position. During this action,
the fluid volume defined by the piston surface and the
stroke is fed in or removed through the two control
slits in the control plate. On the low-pressure side,
fluid flows into the enlarging piston chamber – in
a closed circuit this is supported by the return and
boost pressures. At the same time, on the pressure
side the fluid is pushed out of the cylinder chamber
into the hydraulic system by the pistons.
Pressure Cut-Off
The operating pressure is limited by the pressure cut-
off.
The pressure cut-off corresponds to a pressure

regulator which reduces the pump capacity once the
set specified pressure value is reached so that the
set pressure is maintained but not exceeded.
High-Pressure Safeguarding
The pressure spikes which occur during very rapid
swiveling operations as well as the maximum
pressure are safeguarded by the superordinate high-
pressure relief valves. These valves open if the set
value is exceeded, thereby depressurizing the low
pressure side. The fluid quantity remains constant
in the closed circuit. The leakage at the pump and
motor is replaced by the auxiliary pump.
Auxiliary Pump
The auxiliary pump continuously supplies a sufficient
volume of fluid (boost volume) from a small tank to
the low-pressure side of the closed circuit via a check
valve to replenish the internal leakage of the variable
pump and consumer.
Control
The swivel angle of the swashplate is infinitely
variable. By changing the swivel angle, the piston
stroke and, therefore, the displacement change. The
swivel angle is controlled hydraulically via the stroke
piston. The swashplate is mounted for easy motion
in swivel bearings and the neutral position spring
30 - 159 9813/9400-1 30 - 159

00 - General
Fault-Finding
Fault
Pump Is Noisy Table 493. Page 30-160
No Or Insufficient Flow Table 494. Page 30-160
No Or Insufficient Pressure Table 495. Page 30-161
Pressure / Flow Fluctuations Table 496. Page 30-161
Pump Hydraulic Fluid Temperature Too High Table 497. Page 30-161
Table 493. Pump Is Noisy

Cause Remedy
Drive speed too high. Contact machine or system manufacturer.
Wrong direction of rotation. Ensure correct direction of rotation.
Insufficient suction conditions, e.g. air in the suction Contact machine or system manufacturer (e.g.
line, insufficient diameter of the suction line, viscosity optimize inlet conditions, use suitable hydraulic fluid).
of the hydraulic fluid too high, suction height too high, Completely air bleed axial piston unit, fill suction line
suction pressure too low, contaminants in the suction with hydraulic fluid.
line. Remove contaminants from the suction line.
Improper fixing of the axial piston unit. Check fixing of the axial piston unit according
to the specifications of the machine or system
manufacturer. Observe tightening torques.
Improper installation of the attachment parts, e.g. Install attachment parts according to the information
coupling and hydraulic lines. provided by the coupling or armature manufacturer.
Pressure-relief valve of the axial piston unit (boost Air bleed axial piston unit. Check viscosity of
pressure, high pressure, pressure cut-off). the hydraulic fluid. Contact machine or system
manufacturer.
Mechanical damage to the axial piston unit. Exchange axial piston unit. Contact machine or
system manufacturer.
Table 494. No Or Insufficient Flow

Cause Remedy
Faulty mechanical drive (e.g. defective coupling). Contact machine or system manufacturer.
Drive speed too low. Contact machine or system manufacturer.
Insufficient suction conditions, e.g. air in the suction Contact machine or system manufacturer. (e.g.
of the hydraulic fluid too high suction height too high, Completely air bleed axial piston unit, fill suction line
Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid specified by machine or
External control of the control device defective. Check external control. Contact machine or system
manufacturer.
Insufficient pilot pressure. Check pilot pressure. Contact machine or system
manufacturer.
Malfunction of the control device or controller of the Contact machine or system manufacturer.
axial piston unit.
Wear of axial piston unit. Exchange axial piston unit. Contact machine or
30 - 160 9813/9400-1 30 - 160

00 - General
Table 495. No Or Insufficient Pressure

Cause Remedy
Faulty mechanical drive (e.g. defective coupling). Contact machine or system manufacturer.
Drive power too low. Contact machine or system manufacturer.
Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid Contact machine or
External control of the control device defective. Check external control Contact machine or system
manufacturer.
Insufficient pilot pressure. Check pilot pressure. Contact machine or system
manufacturer.
Malfunction of the control device or controller of the Contact machine or system manufacturer.
axial piston unit.
Output unit defective (e.g. hydraulic motor or Contact machine or system manufacturer.
cylinder).
Table 496. Pressure / Flow Fluctuations

Cause Remedy
Axial piston unit not or insufficiently air bled. Completely air bleed axial piston unit.
Table 497. Pump Hydraulic Fluid Temperature Too High

Cause Remedy
Excessive inlet temperature at the axial piston unit. Contact machine or system manufacturer. Inspect
system, e.g malfunction of the cooler, insufficient
hydraulic fluid in the tank.
Malfunction of the pressure control valves (e.g. high- Contact machine or system manufacturer.
pressure relief valve, pressure cut-off, pressure
control).
Malfunction of the flushing valve. Contact machine or system manufacturer.
30 - 161 9813/9400-1 30 - 161

00 - General
Disconnect and Connect
Bypass Function Activation WARNING This component will be very hot during
and after towing.
WARNING When performing this procedure, the
machine will have no brakes. Make sure the Notice: While towing with the bypass function
machine is hitched to the towing vehicle(s) before activated, the closed hydraulic circuit empties
proceeding. itself. This can result in unintended functions
when restarting the travel drive.
Notice: Failure to place the machine in
'freewheel' mode before towing will cause serious Start the travel drive only after completely filling
damage to the pump, motor and hydraulic and bleeding the air from the hydraulic circuit.
system.
Notice: High towing speeds and long towing Before moving or recovering a disabled machine,
distances will result in too much heat and not make sure you refer to the correct operators manual
enough lubrication. This will damage the pump. for instructions on moving a disabled machine.
Make sure you only tow the machine out of the
This bypass procedure is provided for information
immediate danger zone.
only and may not be required.
Figure 1169. A4VG Series 40 Axial Piston Pump
A
1
1A
B
2 2B
A Shuttle Valve B Stop
Make sure you understand and take the correct Bypass Function Deactivation
action for your machine to prevent it moving when
the bypass function is activated. 1. Immediately after towing, set the bypass function
to off.
Make sure you know the maximum towing speed of
the machine. 2. Use the correct tool to turn the shuttle valve
clockwise to the stop. Tighten it to the specified
In all cases the machine may only be towed out of torque.
the immediate danger zone only. Torque: 50N·m
The pump flow can be altered using a bypass 3. The bypass function is now deactivated.
function in order to tow the vehicle out of an
immediate danger zone. Turning the correct screw 4. Make sure the hydraulic circuit is bled correctly
allows the hydraulic fluid to flow freely. before attempting to restart the transmission
system. Refer to hydraulic system, general,
1. To activate the bypass function, set the engine to bleed (PIL 30-00-00).
off.
2. Use the correct tool to turn the shuttle valve
counter clockwise to the stop.
3. The bypass is now active.
30 - 162 9813/9400-1 30 - 162

00 - General
Drain and Fill Check (Pressure)

Notice: The gearbox has separate hydraulic and
mechanical systems and they use different fluids. Pressure Test Point
Make sure you use the correct fluid.
Refer to hydraulic system, hydrostatic pump,
The gearbox hydrostatic drive system is supplied general, technical data (PIL 30-13-00).
from the machines hydraulic system. To drain and fill
the hydraulic system, refer to (PIL 30-03-00). Figure 1170. AVG085 Pump
B
The gearbox mechanical drive system oil supply is
separate form the hydraulic system. To drain and
fill the gearbox mechanical system, refer to (PIL
27-05-00).
B
A Hydrostatic pump
B Pressure test point
30 - 163 9813/9400-1 30 - 163

00 - General
Bleed Remove and Install

Refer to hydraulic system, general, general, bleed, be removed or handled using a suitable lifting
(PIL 30-00-00). method and device.
Removal
2. Vent the hydraulic system, refer to the machines
operator manual. Also refer to (PIL 30-00-00).
3. Isolate the machines battery, refer to (PIL
33-03-03).
4. Make sure the pump is cool enough to work on.
5. If required on your machine, seal the connection
to the tank to prevent loss of fluid.
6. Label and remove the hydraulic and electrical
connections. Use suitable containers to collect
the displaced fluid.
7. This component is heavy, make sure you
attach suitable lifting equipment and remove
the pump retaining bolts. Refer to hydraulic
system, hydrostatic pump, general, introduction,
technical data (PIL 30-13-00).
8. Empty the pump of fluid over a suitable container
and place the pump on a suitable surface.
9. Plug all openings to prevent the ingress of debris.
10. The pump may subsequently be moved by use
of a suitable eyebolt.
30 - 164 9813/9400-1 30 - 164

00 - General
Figure 1171. Lifting the Pump Disassemble and Assemble
Refer to JCB Service for advice.
A Pump lifted using a sling

B Subsequent movement of the pump using an
eye bolt.
Installation
Installation is the reverse of removal. In addition carry
out the following procedures:
1. Make sure the hydraulic fluid level is correct

when installation is complete.
2. Make sure all connections are correct according
to the labels made during removal.
3. Bleed the pump. Refer to hydraulic system,
general, bleed, (PIL 30-00-00).
30 - 165 9813/9400-1 30 - 165

15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ......................................................................................................................... 30-167

30-15-06 Lift Arm ......................................................................................................................... 30-179
30-15-07 Lift Extension ................................................................................................................ 30-182
30-15-08 Lift Compensating ........................................................................................................ 30-185
30-15-11 Lift Arm Crowd ............................................................................................................. 30-189
30-15-34 Steering ........................................................................................................................ 30-196
30-15-63 Sway ............................................................................................................................. 30-199
30-15-99 Seal Kit ......................................................................................................................... 30-202
30 - 166 9813/9400-1 30 - 166

15 - Cylinder / Ram
00 - General
Introduction .................................................. 30-167 A hydraulic cylinder ram is a mechanical actuator
Health and Safety ........................................ 30-168 that is used to give a single directional force
Technical Data ............................................. 30-170 through a single action stroke. It is used in many
Operation ..................................................... 30-171 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Check (Condition) ........................................ 30-174 consists of a cylinder barrel, in which a piston
Disassemble and Assemble ........................ 30-175 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 - 167 9813/9400-1 30 - 167

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 - 168 9813/9400-1 30 - 168

15 - Cylinder / Ram
00 - General
should be kept to a minimum. If leaving for

more than one week, apply a light coating
of suitable grease or petroleum jelly to the
exposed part of the ram piston rod.
2. Use genuine JCB parts when replacing parts.
2.1. If parts other than genuine JCB parts
are used, the desired results may not be
obtained. Use only genuine JCB parts.
3. Caution during dismantling and reassembly.
3.1. Dismantling the ram while it is still installed
on the machine can be dangerous as
unexpected movements of the machine can
occur. Remove the ram from the machine
and then dismantle.
3.2. If reassembled with dirty hands, foreign
matter can enter the ram causing a shorter
life span and also the other hydraulic
equipment may be damaged. Reassemble
in a clean state.
3.3. Follow the instructions in the diagrams
regarding torque tightening for screwed
parts. If the torque is too high or too low, it
can cause damage.
30 - 169 9813/9400-1 30 - 169

15 - Cylinder / Ram
00 - General
Technical Data
Table 498. Cycle Times (Seconds)

Operation 506-23 509-23 512-26
Lift 7.2 8.8 7.4
Lower 5.5 6.5 8.3
Extend 6.8 6.8 8.3
Retract 5 5 5.9
Shovel dump 3.5 3.5 2.8
Shovel crowd 2.9 2.9 3.0
All measurements taken with the machine at normal

operating temperature.
30 - 170 9813/9400-1 30 - 170

15 - Cylinder / Ram
00 - General
Operation
(For: 506-23 [T4F], 509-23 [T4F]) Ram- Cylinder end
Ram end damping A restrictor probe installed to the end of the cylinder,
aligns with a groove in the piston rod.
When you operate the lift and extension rams, it can
As the ram closes to full retract, the probe engages
cause a shake when the ram is at full travel. This
with the groove in the piston rod, the damping effect
could cause load instability and operator discomfort.
is caused as the orifice plate seats on the face of
the piston rod counterbore. The holes in the probe
control the speed of the ram by restricting the flow of
oil at a gradual rate until the ram is fully closed.
Figure 1172. Ram retracting (Cylinder end of ram)

A
C D E F G H
A Feed port C Cylinder end

D Orifice plate E Piston rod counterbore
F Piston rod G Restrictor probe
H Piston rod hole
To extend the ram, oil goes into the feed port and the oil pushes on the ram decreasing the pressure
through the centre of the probe to the hole in the necessary to extend the ram (pressure spike).
piston rod. This flow pushes the orifice plate away
from the counterbore increasing the area on which The flow rate, pressure, load and viscosity of the oil
have an effect on the damping rate.
30 - 171 9813/9400-1 30 - 171

15 - Cylinder / Ram
00 - General
Figure 1173. Ram extending (Cylinder end of ram)

A
C D E F G H
A Feed port C Cylinder end

D Orifice plate E Piston rod counterbore
F Piston rod G Restrictor probe
H Piston rod hole
30 - 172 9813/9400-1 30 - 172

15 - Cylinder / Ram
00 - General
Ram- Rod end flows through the four holes in the end cap through
the cylinder port. The O- ring compresses on the anti
The damping effect is caused by a tapered collar on extrusion ring which closes the four oil galleries on
the piston rod which engages with the end cap to the front of the end cap. The damping effect is caused
decrease the flow of oil. by the tapered collar gradually decreasing the area
between the piston rod and the end cap restricting
As the ram opens to full extend the tapered collar the flow of oil.
on the piston rod engages with the end cap, the oil
Figure 1174.
N J
J
Q K M
L
J End cap K Piston rod

L Oil feed port M Tapered collar
N Flats of the tapered collar P End cap front
Q Oil hole in the end cap
To retract the ram, oil flows through the feed port, this
pushes the anti extrusion ring and compresses the
O-ring and allow oil to flow through the four galleries
which pushes on the piston head. Also the oil flows
through the four holes in the end cap through the flats
of the tapered collar. The function of the flats and
oil pathways is to decrease the pressure necessary
to retract the ram from full open centres (pressure
spike).
Figure 1175.
R S
R O-ring
S Extrusion ring
30 - 173 9813/9400-1 30 - 173

15 - Cylinder / Ram
00 - General
Check (Condition)
Check the primary components for scoring, damage,

wear, distortion, uneven surface (i.e. polished or
pitted areas) and scratches. Replace all damaged
parts.
Check the components for burrs. Give special

attention to the traversing diameters, locking pin
holes and mounting chamfers. If minor burrs are
seen, remove them by polishing with a fine grade
abrasive paper.
Check pivot bushes for signs of wear or damage.

Replace if necessary.
If a cylinder is damaged it must be replaced. New

piston seals will fail after only a short period of time
if the cylinder is worn or damaged.
30 - 174 9813/9400-1 30 - 174

15 - Cylinder / Ram
00 - General

- General purpose
solvent based parts
cleaner
JCB Activator 4104/0251 0.2L
4104/0253 1L
JCB Threadlocker 4101/0250 0.01L 2. Use the correct size spanner to remove the end
and Sealer (Medium 4101/0251 0.05L cap and then remove the piston rod assembly
Strength) from the cylinder.
Lifting Equipment 3. Place the piston rod assembly on the bench in
You can be injured if you use incorrect or faulty lifting place of the ram cylinder.
equipment. You must identify the weight of the item to 4. Remove and discard the seal 1,seal 2 and the
be lifted then choose lifting equipment that is strong wear ring 1, wear ring 2 from the piston head.
equipment is in good condition and complies with all 5. Put appropriate sized screw threaded into the
local regulations. extractor hole to remove dowel from the piston
head.
Single piston rams
6. Use the correct size spanner to remove the
piston head from the rod and then discard the O-
Disassembly ring 1.
CAUTION If air or hydraulic pressure is used to
force out the piston assembly, ensure that the end 7. For extension ram, after removal of then piston,
cap is securely installed. Severe injury can be slide and remove the spacer from the piston rod.
caused by a suddenly released piston rod. 8. Remove the gland bearing and the end cap from
the piston rod.
The disassembly and assembly procedures for many
jcb hydraulic rams are same. 9. Remove the O-ring 2, wiper seal and the rod seal.
The ram must be removed from the machine before 10. Check the end cap bearing for damage, scores or
you disassemble it. nicks. If damaged, the bearing must be replaced
as part of the end cap assembly.
The ram shown in the illustration is not installed with
11. Make sure that the metal components are free
HBCV (Hose Burst Check Valve). If HBCV is installed
from scoring, nicks and burrs. A damaged piston
also with the ram, the disassembly and assembly
rod will reduce the life of gland seals.
procedure will remain unchanged and can be carried
out without the removal of the check valve. 12. Check the bore of the ram cylinder for damage.
1. Place the ram assembly on a locally
manufactured strip or on a rebuild bench.
30 - 175 9813/9400-1 30 - 175

15 - Cylinder / Ram
00 - General
Figure 1177.
T S
R
U
F
A
G
J
H
E
K
L
C B
D
Q
P
N
Table 499.
Item Description
A Wear ring 1
B Seal 1
C seal 2
D Wear ring 2
E Dowel
F Piston head
G O-ring 1
H Gland bearing and end cap
J O-ring 2
K Rod seal
L Wiper seal
M Piston rod
N Seal 3
30 - 176 9813/9400-1 30 - 176

15 - Cylinder / Ram
00 - General
Item Description
P
Q Seal 4
R Seal 5
S
T Seal 6
U Cylinder
Assembly Cold weather operation, When operating in

conditions which are consistently below freezing, it is
1. Use a wire brush to the clean the threads of the recommended that the rams are operated slowly to
piston rod, end cap and cylinder. their full extent before commencing normal working.
2. Use cleaner and degreaser to make sure that all
threads are free from grease, hydraulic oil and
Piston head retention
old sealing or retaining compounds. Install the locking dowel to piston as follows:
purpose solvent based parts cleaner Existing piston head and rod
3. Make sure the degreaser is fully dried. Align holes so that dowel can be installed with the
Duration: 15min tapped extractor hole, as shown.
4. Apply the sealant. New piston head and rod

(Medium Strength) Drill and ream piston head and rod to the diameter
and depth indicated, refer to the Refer to Table
5. Make sure that the O-rings or the seals do not 500.. Remove all swarf and contamination and install
come into the contact with the JCB activator or dowel with tapped extractor hole as shown.
anaerobic sealing and retaining compounds.
Make sure that the top of the dowel is below the level
6. Install new seals, O-rings and wear rings. of the bearing ring groove and use an undersized
pilot drill before you drill to final size.
7. Make sure that lubricants used during assembly
do not come into contact with de-greased Existing piston head and new rod
components or sealing or retaining compounds.
Drill through existing hole in piston head to the
8. Install the locking dowel to the piston. diameter and depth indicated, refer to the Refer to
9. Put the cylinder on the bench and then install the Table 500.. Remove all swarf and contamination and
piston rod assembly into the cylinder. insert dowel with tapped extractor hole as shown.
10. Apply JCB activator to threads of end cap and Make sure that the top of the dowel is below the level
cylinder. Allow JCB activator to dry for the of the bearing ring groove and use an undersized
specified time before bringing into contact with pilot drill before you drill to final size.
JCB threadlocker.
New piston head and existing rod
Duration: 15min
Consumable: JCB Activator Same as existing piston head and new rod but at 90°
to existing hole in rod.
11. Apply sealant to the threads of the cylinder and
tighten the end cap to the correct torque value.
(Medium Strength)
If hydraulic oil make contacts with locking fluid it

will weaken the bond. Cure times vary according
to the ambient temperature. The approximate cure
time for JCB threadlocker & sealer (high strength) or
JCB threadlocker with JCB activator is 1h, applies at
20°C (68.0°F) and is the minimum period between
assembly and filling the ram with oil.
30 - 177 9813/9400-1 30 - 177

15 - Cylinder / Ram
00 - General
Figure 1178.
AH
AJ
AH Diameter
AJ Depth
Table 500. Drilling dimensions

Ram size Diameter (AH) Depth (AJ)
50 x 25 6.02–6.1mm 23mm
90 x 50 8.02–8.1mm 28mm
100 x 60 12.02–12.1mm 33mm
110 x 60 12.02–12.1mm 33mm
120 x 60 12.02–12.1mm 38mm
130 x 70 12.02–12.1mm 38mm
130 x 75 12.02–12.1mm 38mm
140 x 75 12.02–12.1mm 48mm
160 x 80 12.02–12.1mm 48mm

Item Description Nm
F Piston head 405
H Gland bearing and end cap 678
30 - 178 9813/9400-1 30 - 178

15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm
Remove and Install
Special Tools 6. If installed, disconnect the remote greasing pipe.

Figure 1180.

method and device.
Remove
K
2. Remove any attachments from the carriage.
3. Lower the lift arm onto a suitable support. K Remote greasing pipe
Figure 1179. 7. Disconnect the lift ram hydraulic hoses. Put

adaptors on all the open ports.
9. Support the lift ram. Remove the nut, bolt and
washers (if installed).
10. Remove the pivot pin 1 from the rod end.
11. At this point it is advisable to remove the lift arm
in order to provide access for lifting out the ram.
12. Attach suitable lifting equipment to the ram rod
eye end. Support the ram.
13. Remove both the bolt 1 and bolt 2.
14. Remove the spacer and the lock plate.
15. Remove the pivot pin 2 from the cylinder end.
Refer to (PIL 01-03). 16. Remove ram from the machine.
30 - 179 9813/9400-1 30 - 179

15 - Cylinder / Ram
06 - Lift Arm
Figure 1181. Typical Lift Ram

J H
E
G
B
A
A Lift ram B Nut and bolt

C Pivot pin 1 D Hydraulic hoses
E Bolt 1 F Bolt 2
G Spacer H Lock plate
J Pivot pin 2
30 - 180 9813/9400-1 30 - 180

15 - Cylinder / Ram
06 - Lift Arm
Install
steps.
1.1. Grease the ram pivot pins.
1.2. Check the hydraulic fluid level.
1.3. Tighten all fastenings to the correct torque
value. Refer to (PIL 72).
30 - 181 9813/9400-1 30 - 181

15 - Cylinder / Ram
07 - Lift Extension
07 - Lift Extension
Remove and Install
For: 512-26 [T4F] .................... Page 30-182 5. Follow the general health and safety procedures.
For: 506-23 [T4F], 509-23 [T4F] Refer to (PIL 01-03).
................................................. Page 30-183
system. Refer to (PIL (30-00).
(For: 512-26 [T4F])
7. Remove the capscrew, lock plate and then
remove the extension ram rod end pivot pin.
method and device. 8. Put a label on the hoses to help installation.
9. Disconnect the extension ram hydraulic hoses.
Remove
1. Remove any attachments from the carriage. contamination.
2. Make the machine safe. Refer to (PIL 01-03). 11. Remove the nut and bolt, then remove the
extension ram pivot pin enough so that you can
3. Extend the lift arm sufficiently to gain access to
remove the displacement ram easily.
the extension ram rod end pivot pin.
12. Use suitable lifting equipment and remove the
4. Lower the lift arm to the ground.
extension ram from the lift arm.
Figure 1182.
A
C D
E F
A Extension ram rod end pivot pin B Capscrew

C Lock plate D Bolt
E Extension ram F Main pivot pin
30 - 182 9813/9400-1 30 - 182

15 - Cylinder / Ram
07 - Lift Extension
Install 7. Put a label on the hoses to help installation.
1. The installation procedure is the opposite of the 8. Disconnect the extension ram hydraulic hoses.
step. 9. Plug all the open ports and hoses to prevent
contamination.
1.1. Apply the correct grease to the pivot pins.
Refer to (PIL 75-06). 10. For 506-23 and 509-23 machines, to gain access
to the extension ram, remove the displacement
ram.
(For: 506-23 [T4F], 509-23 [T4F])
11. Remove the nut and bolt, then remove the
Remove extension ram pivot pin far enough so that you
can remove the displacement ram easily.
1. Remove any attachments installed on the
carriage. 11.1. Remember that the extension ram pivot
pin is also the main pivot for the lift arm.
2. Extend the lift arm sufficiently to gain access to
11.2. Make sure you use a dummy pivot pin to
the extension ram rod end pivot pin 1.
drive out the extension ram pivot pin so the
3. Lower the lift arm to the ground. other side of the lift arm is supported.
4. Discharge the hydraulic pressure from the CAUTION! This component is heavy. It must only
system. be removed or handled using a suitable lifting
method and device.
5. Make the machine safe. 12. Use suitable lifting equipment to remove the
extension ram from the lift arm.
6. Remove the capscrew, lock plate and then
remove the extension ram rod end pivot pin.
Figure 1183. Typical 2 Stage (2 Section) Lift Arm
A Extension ram rod end pivot pin B Capscrew

C Lock plate D Hydraulic hose
E Bolt F Main pivot pin
30 - 183 9813/9400-1 30 - 183

15 - Cylinder / Ram
07 - Lift Extension
Install
steps.
1.1. Apply the correct grease to the pivot pins.
1.2. Install the bolts and tighten to the correct
torque value.
30 - 184 9813/9400-1 30 - 184

15 - Cylinder / Ram
08 - Lift Compensating
Remove and Install
For: 506-23 [T4F], 509-23 [T4F] 3. Follow the general health and safety procedures.
................................................. Page 30-185 Refer to (PIL 01-03).
For: 512-26 [T4F] .................... Page 30-187
4. Lower the lift arm and the carriage to the ground.
(For: 506-23 [T4F], 509-23 [T4F]) 5. Discharge the hydraulic pressure. Refer to (PIL
30-00).
Special Tools
Description Part No. Qty. 6. Put a label on the hoses to help installation.
7. Disconnect the hydraulic hoses.
Consumables 8. Plug all the open hoses and ports to prevent
Description Part No. Size contamination.
Special MPL-EP 4003/1501 0.4kg
Grease 4003/1506 12.5kg 9. Support the displacement ram.
4003/1510 50kg 10. Remove the lock bolt/nut and washers (if
installed).
be removed or handled using a suitable lifting 11. Remove the pivot pin 1 from the rod end with a
method and device. slide hammer kit.
Remove 12. Remove the lock bolt.
1. Raise the lift arm to get access to the lower pivot 13. Remove the pivot pin 2 from the cylinder end with
of the displacement ram. Retract the lift arm fully. the slide hammer kit.
Support the front end of the lift arm.
14. Remove the ram from the machine.
30 - 185 9813/9400-1 30 - 185

15 - Cylinder / Ram
Figure 1184.
C
B
E
F
D
A Hydraulic hoses B Lock bolt/nut

C Pivot pin 1 D Lock bolt
E Pivot pin 2 F Displacement ram
30 - 186 9813/9400-1 30 - 186

15 - Cylinder / Ram
Install 11. Remove the pivot pin 1 from the displacement

rams with the slide hammer kit.
steps. 12. Attach suitable lifting equipment to the cylinder
end of the displacement rams. Support the rams.
1.1. Put grease on the ram pivot pins.
Consumable: Special MPL-EP Grease 13. Remove nut and bolt 2 and washers (if installed).
1.2. Check the hydraulic fluid level and top up as 14. Remove the pivot pin 2 from the rod end of the
required. Refer to (PIL 30-00). displacement rams. Remove the rams from the
machine.
(For: 512-26 [T4F])
Figure 1186.
Special Tools
Description Part No. Qty. B
Remove
C
2. Remove any attachments from the carriage.
3. Lower the lift arm onto a suitable support as
shown. Refer to Figure 1185.
Figure 1185.
A Displacement rams
B Nut and bolt 1
C Pivot pin 1
Figure 1187.
4. Follow the hydraulic system, health and safety D

procedures. Refer to (PIL 30-00).
5. Discharge the hydraulic pressure. Refer to (PIL E
30-00).
6. Put labels on the hoses to help installation.
D Pivot pin 2
7. Disconnect the hydraulic hoses to the rams. E Nut and bolt 2
contamination. Install
9. Support the displacement rams. 1. The installation procedure is the opposite of the
10. Remove nut and bolt 1 and washers (if installed). steps.
30 - 187 9813/9400-1 30 - 187

15 - Cylinder / Ram
1.1. Grease on the ram pivot pins.

1.2. Check the hydraulic fluid level and top up as
30 - 188 9813/9400-1 30 - 188

15 - Cylinder / Ram
11 - Lift Arm Crowd
11 - Lift Arm Crowd Bleed

Bleed ........................................................... 30-189
(For: 506-23 [T4F], 509-23 [T4F])
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to a convenient height to access
the tilt ram.
4. Stop the engine and remove the ignition key.
30-00).
6. Operate the controls back and forth several times
to discharge the residual hydraulic pressure.
7. Release the locknut and remove the screw.
8. Start the engine and operate the tilt lever several
times.
9. Tighten the screw and the locknut.
10. Operate the tilt lever several times again. Stop
the engine.
11. Repeat step 7 to step 10 if required.
12. Tighten the screw and the locknut to the specified
torque value.
30 - 189 9813/9400-1 30 - 189

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1188.
A Locknut
B Screw

Item Description Nm
A Locknut 12
B Screw 15
30 - 190 9813/9400-1 30 - 190

15 - Cylinder / Ram
11 - Lift Arm Crowd
Remove and Install
For: 506-23 [T4F], 509-23 [T4F] 6. Follow the general health and safety procedures.
................................................. Page 30-191 Refer to (PIL 01-03).
For: 506-23 [T4F], 509-23 [T4F]
................................................. Page 30-193 7. Discharge the hydraulic pressure from the
(For: 506-23 [T4F], 509-23 [T4F]) 8. Remove the lift arm nose cover (if installed).
Special Tools 9. Put a label on each hose to help installation.
Slide Hammer Kit 993/68100 1 10. Disconnect the tilt ram hydraulic hoses.
11. Plug all the open ports hoses to prevent
contamination.
method and device. 12. Support the tilt ram.
13. Remove the bolt.
Remove
14. Use the slide hammer kit to remove the pivot pin
1. Remove the attachments from the carriage. 1 from the rod end. Refer to (PIL 06-30).
2. Extend the tilt ram fully. Special Tool: Slide Hammer Kit (Qty.: 1)
3. Extend the lift arm to get access to the capscrew. 15. Remove the capscrew and the lock plate.
4. Lower the lift arm and carriage to the ground. 16. Use the slide hammer kit to remove the pivot pin
2 from the cylinder end. Refer to (PIL 06-30).
30 - 191 9813/9400-1 30 - 191

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1189.
C D
A F
Install
Table 503. 1. The installation procedure is the opposite of the
Item Description removal procedure. Additionally do the following
steps.
A Capscrew
B Hydraulic hoses 1.1. Grease the ram pivot pins.
C Bolt 1.2. Check the hydraulic fluid level and top up as
D Pivot pin 1 required. Refer to (PIL 30-00).
E Lock plate 1.3. Bleed the tilt ram. Refer to (PIL 30-15-11).
F Pivot pin 2
30 - 192 9813/9400-1 30 - 192

15 - Cylinder / Ram
11 - Lift Arm Crowd
(For: 506-23 [T4F], 509-23 [T4F]) 7. Remove the lift arm nose cover (if installed).
Special Tools 8. Put a label on the hoses to help installation.
9. Disconnect the tilt ram hydraulic hoses.
Remove contamination.
1. Remove any attachments from the carriage. 11. Support the tilt ram.
2. Extend the lift arm approximately to the specified 12. Remove the recessed capscrew.
limit.
13. Use the slide hammer kit to remove the pivot pin
Length: 600mm 1 from the rod end.
3. Lower the lift arm onto a suitable support so that Special Tool: Slide Hammer Kit (Qty.: 1)
the carriage is clear of the ground.
14. Remove the nut and bolt and washers (if
4. Make the machine safe. Refer to (PIL 01-03). installed).
5. Follow the general health and safety procedure. 15. Use the slide hammer kit to remove the pivot pin
Refer to (PIL 01-03). 2 from the cylinder end.
system. Refer to (PIL 30-00). 16. Remove the ram from the machine.
30 - 193 9813/9400-1 30 - 193

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1190.
A Capscrew B Pivot pin 1

C Tilt ram hydraulic hoses D Bolt
E Pivot pin 2
30 - 194 9813/9400-1 30 - 194

15 - Cylinder / Ram
11 - Lift Arm Crowd
Install
steps.
1.1. Grease the ram pivot pins. Refer to (PIL
06-30).
1.3. Bleed the tilt ram. Refer to (PIL 30-15-11).
30 - 195 9813/9400-1 30 - 195

15 - Cylinder / Ram
34 - Steering
34 - Steering Remove and Install

Remove and Install ..................................... 30-196 Working Under the Machine
Disassemble and Assemble ........................ 30-198 Make the machine safe before getting beneath it.
movement.
Remove
Before you remove the steer rams clean the area
around the axle and steer rams.
The following procedure applies to each of the

steering rams on the front and rear axles:

4. Disconnect all the three hoses.
5. Plug all the open ram ports and hoses to prevent
contamination.
6. Remove the screws and the pins from each end
of the ram.
7. Lift the ram from the axles.
Figure 1191.
B
C
A
A Hoses B Screws
C Pins
30 - 196 9813/9400-1 30 - 196

15 - Cylinder / Ram
34 - Steering
Install
steps.
1.1. Tighten the screws to the correct torque
value.
1.2. Before you drive the machine, bleed the
steering system. Refer to (PIL 25-00).

Item Description Nm
B Screws 56
30 - 197 9813/9400-1 30 - 197

15 - Cylinder / Ram
34 - Steering
Refer to Hydraulic system, cylinder ram, general (PIL

30-15-00).
30 - 198 9813/9400-1 30 - 198

15 - Cylinder / Ram
63 - Sway
63 - Sway Bleed
Bleed ........................................................... 30-199 Communications
Remove and Install ..................................... 30-200 Bad communications can cause accidents. If two
or more people are working on the machine, make
sure each is aware of what the others are doing.
Before starting the engine make sure the others are
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured
if these precautions are not taken.
Sway Ram Bleed Procedure

The sway ram has an integral bleed valve which can
be used to bleed the sway ram circuit.
Make sure that the lift arm is in lowered position when

the sway ram circuit is bled.
Two persons are required to do this procedure. One

person to operate the sway controls and another to
tighten the bleed screw when all air is removed. If this
procedure is done by one person, air may enter the
cylinder due to delay in dismounting from the cab to
attend the sway cylinder.

30-00).
4. Make sure that the sway ram bleed valve is
closed, because, if opened the machine may
sway unexpectedly.
4.1. Make sure to open the bleed valve only after
the machine is swayed fully to the left or
right.
4.2. Do not stand between the chassis and
the wheel because you can be trapped or
crushed when the sway is operated.
4.3. The bleed valve should only be completely
removed from the valve body to allow
cleaning of the integral orifice. The orifice
diameter is
Dimension: 1.2mm
6. Operate the sway lever to sway the machine fully
to the operator's left side (sway ram extended).
7. Stop the engine and discharge the hydraulic
pressure. Refer to (PIL 30-00).
30 - 199 9813/9400-1 30 - 199

15 - Cylinder / Ram
63 - Sway
8. Tell the assistant to carefully loosen the bleed Remove and Install
valve and expect hydraulic fluid to escape. Make
sure the bleed valve is not unscrewed more than
Length: 6.5mm (For: 506-23 [T4F], 509-23 [T4F])
9. Start the engine. Consumables
10. Operate the sway lever to sway the machine fully Special HP Grease 4003/2017 0.4kg
to the operator's left side. 4003/2006 12.5kg
11. Hold the lever in this position. 4003/2005 50kg
12. Make sure that the air is removed completely CAUTION This component is heavy. It must only
through the bleed valve. be removed or handled using a suitable lifting
method and device.
13. Return the control lever to the neutral position.
14. Tighten the bleed valve immediately to prevent Remove
air entering the circuit.
Figure 1192.
2. Lower the lift arm and the carriage to the ground.
30-00).
5. Operate the controls back and forth several times
to release the residual hydraulic pressure. There
will still be residual pressure in the ram. Make
sure you take care if you disassemble the ram.
A
6. Support the chassis on both sides of the
machine.
7. Put a label on each hose to help installation.
8. Disconnect the sway hydraulic hoses.
A Bleed valve
15. Operate the sway ram fully in both directions 10 contamination.
times.
10. Support the sway ram.
16. Repeat steps 7 to 17.
11. Remove the nut and bolt 1.
17. Stop the engine and remove the ignition key.
12. Remove the pivot pin 1 from the cylinder end.
18. Check the hydraulic fluid level and top up as
required. Refer to (PIL 30-00). 13. Attach suitable lifting equipment to the cylinder
end of the ram. Support the ram.
14. Remove nut and bolt 2.
15. Remove the pivot pin 2 from rod end.
16. Remove the ram from the machine.
30 - 200 9813/9400-1 30 - 200

15 - Cylinder / Ram
63 - Sway
Figure 1193.
C
D
E F
A Hydraulic hoses
B Sway ram
C Nut and bolt 1
D Pivot pin 1
E Nut and bolt 2
F Pivot pin 2
Install
steps.
1.1. Put grease on the ram pivot pins.
1.3. Bleed the sway hydraulic circuit. Refer to
(PIL 30-15).
30 - 201 9813/9400-1 30 - 201

15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 1194.
Remove and Install

Special Tools
Ram Protection Sleeve 892/00167 1
(90mm rod diameter)
Ram Seal Installation 892/00334 1 A Ram seal installation tool
Tool B Pins
Ram Protection Sleeve 892/01016 1 1.2. Open the seal installation tool and insert
(25mm rod diameter) the new rod seal. Install the seal behind the
Ram Protection Sleeve 892/01017 1 two front pins but in front of the rear pin as
(30mm rod diameter) shown.
Ram Protection Sleeve 892/01018 1 Figure 1195.
(40mm rod diameter)
(50mm rod diameter)
- Slew (50mm rod
diameter)
(60mm rod diameter)
- Slew (60mm rod
diameter)
A Rod seal
(65mm rod diameter) 1.3. Later ram end caps and piston heads
Ram Protection Sleeve 892/01024 1 have metric threads. The seals are also
(70mm rod diameter) different, make sure that the correct seals
Ram Protection Sleeve 892/01025 1 are installed. On metric threaded rams,
(75mm rod diameter) make sure that the seals are installed the
correct way around, as shown.
(80mm rod diameter) Figure 1196.
Ram Seal Assembly 892/01027 1
Tool
Remove
1. Remove and discard the old seals.
Install
1. Install new rod seals:
A Inner seal
1.1. Use the ram seal installation tool to install B Outer seal
rod seals, the size (diameter) and position
of pins is determined by the diameter and 1.4. Close the tool. The seal must form a
radial width of the rod seal being installed. reniform (kidney shape).
The pins are screwed into threaded holes
in the tool body, the spacing of the holes is
designed to suit small or large diameter rod
seals.
Special Tool: Ram Seal Installation Tool
(Qty.: 1)
30 - 202 9813/9400-1 30 - 202

15 - Cylinder / Ram
99 - Seal Kit
Figure 1197. Special Tool: Ram Protection Sleeve - Slew

(60mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
1.5. Before you install the rod seals, check that (80mm rod diameter) (Qty.: 1)
the seal grooves are free of contamination Special Tool: Ram Protection Sleeve
and sharp edges. (90mm rod diameter) (Qty.: 1)
1.6. Locate the seal in the end cap groove. Figure 1199.
When the seal is in position, open the tool
to release the seal. Make sure the seal is
correctly installed in its grooved and remove
the tool.
Figure 1198.
A Protection Sleeve (various sizes)

2. Install new head piston seals.
2.1. Use the Piston seal assembly tool to lever
the inner seal into the piston head seal
groove. Do not let the seal twist. There are
identification marks on the outer diameter
1.7. Install the rod wiper seal into the seal of the seal, make sure that the marks are
groove. Make sure that the seal is correctly visible and the seal is free to rotate, if not
installed as shown. Note: Some rod wipers, remove the seal and retry.
i.e. power track rod, may use a metal
encased seal which is pressed into the Special Tool: Ram Seal Assembly Tool
housing. Care must be taken to make sure (Qty.: 1)
that the seal is square before it is pressed Figure 1200.
in.
1.8. A special sleeve must be used to protect
the rod seals from damage, when installing
the end cap on to the piston rod. There are
various sizes of sleeve, make sure you use
the correct size sleeve and also make sure
that the hexagon on the end cap is towards
the eye end of the rod.
Special Tool: Ram Protection Sleeve - Slew A Piston seal assembly tool
(50mm rod diameter) (Qty.: 1) B Inner seal
Special Tool: Ram Protection Sleeve C Outer seal
30 - 203 9813/9400-1 30 - 203

15 - Cylinder / Ram
99 - Seal Kit
2.2. Use the same procedure to install the outer

seal as stated for the inner seal. Check that
the external grooves are visible.
2.3. Make sure that the O-ring is installed into
the internal seal groove on the piston head.
Screw the piston head on to the thread of
the piston rod and tighten to the correct
torque value.
2.4. Install the piston head retaining dowel.
2.5. Install wear rings, rotate the wear rings so
that the piston retention dowel is covered by
the wear ring, not as shown at C.
Figure 1201.
A Outer wear ring

B Inner wear ring
C Incorrect installation
3. Install the piston rod and head assembly into the
cylinder.
3.1. Insert the piston/rod assembly into the
cylinder ram. Align the rod and head
assembly until parallel with the cylinder ram
then push the assembly into the cylinder.
3.2. Install the end cap and assemble the ram
assembly.
30 - 204 9813/9400-1 30 - 204

18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-207

30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-211
30 - 205 9813/9400-1 30 - 205

Notes:
30 - 206 9813/9400-1 30 - 206

18 - Accumulator
00 - General
Introduction .................................................. 30-207 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-208 reservoir used to store hydraulic fluid, the non-
Component Identification ............................. 30-208 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ........................... 30-209 by a compressed nitrogen gas. It is designed to
increase or relieve pressure in the hydraulic system.
Accumulators enable a hydraulic system to cope with

extremes of demand using a less powerful pump, to
respond more quickly to a temporary demand, and
to smooth out pulsations.
It is not possible to disassemble the accumulators.

The extent of permissible servicing is limited to
checking the nitrogen gas pre-charge pressure. If an
accumulator is suspected as being faulty it must be
renewed as a complete assembly.
Make sure you have read and understood the Health

and Safety implications. Refer to: PIL 30-18-00.
There are three different types of accumulator

installed on JCB machines:
• Diaphragm (sealed for life) - Non

Rechargeable.
• Diaphragm (with gas valve) - Rechargeable.
• Piston Bladder - Rechargeable.
Although some accumulators are identical in

appearance, the accumulators are charged to
different pressures. When renewing an accumulator
make sure you know the correct charge pressure,
refer to the applicable Technical Data.
Upon installation of a new accumulator the correct

label stating the charge pressure must be attached.
The original label which states a zero charge must
be removed.
30 - 207 9813/9400-1 30 - 207

18 - Accumulator
00 - General

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 1202.
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
CAUTION To reduce pressure use the
recommended charging tool or the charge valve
could be damaged which may result in rapid C
discharge of the accumulator.
WARNING You must vent all the hydraulic
pressure from the accumulators before A
disconnecting them from the hydraulic system.
Replacement accumulators will only be supplied in B

an uncharged, non pressurised condition to meet
Health and Safety, and Air freight hazardous goods
requirements.
A Diaphragm (sealed for life)-Non Rechargeable

B Diaphragm (with gas valve)-Rechargeable
C Piston Bladder-Rechargeable
30 - 208 9813/9400-1 30 - 208

18 - Accumulator
00 - General
Discharge and Pressurise Figure 1203.
Special Tools
Accumulator Charging 892/01042 1 B
Kit (Diaphragm)
Accumulator Charging 892/01043 1 A
J
Adaptor

pressure from the accumulators before
C
DANGER Use only nitrogen gas to charge F
accumulators. The use of any other gas can H G
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your D
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
E
Before removing accumulators make sure hydraulic
pressure is released.
Even when the hydraulic pressure is released the A Adaptor

accumulator still contains pressurised nitrogen gas. B Filler plug
Do not attempt to discharge the gas pressure. C Gas bottle valve
D Pressure regulator
Do not transport accumulators charged with E Charging hose
pressurised gas by air freight. F Discharge plug
G Charging unit
Charging H Charging unit knob
J Pressure gauge
Important: The following charging procedure is only 1. Hold the accumulator vertical and remove the
applicable to accumulators supplied in a discharged plastic cap from the top of the accumulator.
state.
2. Note: Some accumulators are supplied with a
Operating charge pressures: Accumulators are measured quantity of oil inside the gas chamber.
charged to different operating pressures depending Take care to prevent oil loss.
on the application. Refer to: PIL 30-18. for the
correct charge pressure. 3. With a suitable allen key, slowly remove the filler
plug.
Charge the replacement accumulator with nitrogen
as follows: 3.1. Remove the sealing washer and plug.
3.2. Lightly oil the sealing washer.
3.3. Install the new plug.
3.4. Loosen the plug by 1/8 of a turn.
4. Connect the accumulator adaptor to the
accumulator.
Special Tool: Accumulator Charging Adaptor
(Qty.: 1)
5. Connect the charging unit to the accumulator
adaptor.
Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1)
30 - 209 9813/9400-1 30 - 209

18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 1204.

regulator on the nitrogen gas bottle with the
correct adaptor.
7. Set the pressure regulator on the gas bottle to
the minimum pressure.
8. Turn the charging tool knob to open the filler plug
by three turns.
9. Open the discharge valve on the charging unit.
10. Carefully open the nitrogen gas bottle valve and
A
make sure that the nitrogen gas flows freely
through the discharge valve.
C
11. Close the gas bottle valve and the discharge
valve. B
12. Carefully open the gas bottle valve.

13. Slowly increase the pressure using the gas bottle
pressure regulator and watching the gauge on
the charging unit, allow nitrogen to flow until
the pressure reading reaches the specified value A Label position
above the operating charge pressure. B Discharged state label
Pressure: 4bar (58.0psi) C Pressurised warning label
14. Important: Do not exceed the maximum working 25. Install the accumulator and make sure the
pressure of the accumulator. The maximum pressurised warning label is clearly visible.
working pressure is marked on the accumulator
body.
15. Close the gas bottle valve.
16. Wait for the specified duration to dissipate the
heat generated during charging.
Duration: 10min
17. Carefully open and close the discharge valve to
reduce the pressure in the accumulator to the
specified operating charge pressure.
18. Turn the charging tool knob to close the filler plug
and tighten to the correct torque value.
Torque: 20N·m
19. Open the discharge valve to release the pressure
from the charging hose.
20. Disconnect the charging unit and adaptor from
the accumulator.
21. Pour oil around the filler plug to make sure that
it is gas tight.
22. Replace the plastic cap.
23. Remove the discharged state label.
24. Attach the pressurised warning label on the
accumulator at the position shown.
30 - 210 9813/9400-1 30 - 210

18 - Accumulator
06 - Smooth Ride System (SRS) Technical Data

Technical Data ............................................. 30-211
Preparation .................................................. 30-212
Discharge and Pressurise ........................... 30-213
(For: 506-23 [T4F], 509-23 [T4F])

Table 505.
Charging gas Air free dry nitrogen
Accumulator capacity 1L
Accumulator weight 4.4kg
Table 506. Accumulator charge pressure

Accumulator Value
Accumulator1 10.3bar (149.3psi)
Accumulator2 20bar (289.9psi)
30 - 211 9813/9400-1 30 - 211

18 - Accumulator
Preparation Figure 1206. Small plate
Accumulators will only be supplied in an uncharged,

non pressurised condition to meet health and safety,
and air freight hazardous goods requirements.
Upon installation of new accumulator, the correct

decal stating charge pressure must be attached.
Remove original decal which states a zero charge
pressure. Decals may be in the form of a large plate
or small plate.
When you replace the lift ram or the HBCV (Hose

Burst Check Valve) on machines installed with SRS
(Smooth Ride System), it is important that all the
hydraulic pressure in the accumulators must be
discharged. Failure to do this may result in the valve
being forced out of the cavity as it is unscrewed.
Figure 1205. Large plate
30 - 212 9813/9400-1 30 - 212

18 - Accumulator

Accumulator Charging 892/00948 1
Kit (Piston Type)
Charge
1. Remove the accumulator(s) from the machine.
2. Remove gas valve guard and the gas valve cap.
A B
A Gas valve guard
B Gas valve cap
3. Screw the valve1 all the way out (counter
clockwise) before you attach the charging tool to
the accumulator gas valve.
Special Tool: Accumulator Charging Kit (Piston
Type) (Qty.: 1)
4. Close the bleed valve.
Figure 1208.
D
F
E
C Valve1 D Bleed valve

E Hand valve F Hose
5. Do not twist the hose, connect the charging tool 9. Check the charge pressure which should be set
to the gas valve. to suit the boom and the attachment installed to
the machine.
6. Tighten the tool to the specified torque value.
10. If charge pressure is low, release the hand
Torque: 1.36N·m
valve on the nitrogen bottle and slowly fill the
7. Connect the charging tool to a bottle of accumulators.
compressed nitrogen gas.
11. Close the hand valve when the charge pressure
8. Screw the valve1 all the way in (clockwise), this is reached on the gauge.
will push the core in the gas valve.
30 - 213 9813/9400-1 30 - 213

18 - Accumulator
CAUTION! To reduce pressure use the

recommended charging tool or the charge valve
could be damaged which may result in rapid
discharge of the accumulator.
12. Wait for the specified time to let the gas

temperature become stable.
Duration: 10–15min
12.1. If the pressure is exceeded, make sure
the gas bottle is closed, then open the
bleed valve and reduce the pressure as
necessary. Close the bleed valve when the
correct pressure is set.
13. When the accumulator charging is complete,
screw the valve1 all the way out (counter
clockwise) and open the bleed valve to vent the
hose.
14. Hold the gas valve to keep from turning, loosen
the nut and remove charging tool.
15. Install the gas valve cap and valve guard.
16. Install the accumulator(s) to the machine.
Discharge
1. Remove the accumulator(s) from the machine.
2. Remove the gas valve guard and the gas valve
cap.
3. Screw the valve1 all the way out (counter
clockwise) before you attach the charging tool to
the accumulator gas valve.
Special Tool: Accumulator Charging Kit (Piston
Type) (Qty.: 1)
4. Close the bleed valve.
5. Either connect the charging tool to a bottle of
compressed nitrogen gas which is turned off
or remove hose and install a suitable blank on
charging tool.
6. Screw the valve1 all the way in (clockwise), this
will push the core in the gas valve.
7. Open the bleed valve until all the gas charge
is vented from the accumulators. Remove the
charging tool.
8. Install the accumulator(s) to the machine.
30 - 214 9813/9400-1 30 - 214

18 - Accumulator
Remove and Install
For: 506-23 [T4F], 509-23 [T4F] while the engine is run at 1000 RPM (Revolutions
................................................. Page 30-215 Per Minute). The the accumulators will discharge
For: 512-26 [T4F] .................... Page 30-216 during this period.
4. With the engine still running and manual SRS
(For: 506-23 [T4F], 509-23 [T4F]) mode is active, use the lifting equipment to lift the
WARNING You must vent all the hydraulic boom. Do not use the hydraulic lift service.
pressure from the accumulators before
6. Loosen the nuts (x4).
Remove 7. Disconnect the hydraulic connections and plug
the ends.
8. Remove the nuts and washers (x4) and remove
2. Switch SRS (Smooth Ride System) to manual
the 'U' clamps (x2).
mode, make sure the right hand console is
indicating that manual mode is selected. Lift the 9. Remove the accumulators from their mounting
boom. brackets.
3. Use the control lever to lower the boom and
keep the lever in down position for 3 minutes
Figure 1209.
C
C
B A
A Hydraulic connections B Nuts (x4)

C 'U' clamps D Accumulators
E Washers (x4)
30 - 215 9813/9400-1 30 - 215

18 - Accumulator
Install 3. Use the control lever to lower the lift arm and
keep the lever in down position for the specified
1. The installation procedure is the opposite of the time while the engine is run at 1000 RPM. The the
removal procedure. Additionally do the following accumulators will discharge during this period.
steps.
Duration: 3min
1.1. Check the accumulator nitrogen pre-charge
4. With the engine still running and manual SRS
mode is active, use the lifting equipment to lift the
1.2. Operate the machines hydraulic system. boom. Do not use the hydraulic lift service.
Check for correct operation and leaks.
5. Install the lift arm safety strut. Refer to (PIL
1.3. Fill the hydraulic system with the 06-69).
recommended hydraulic fluid. Refer to (PIL
30-00). 6. Support the accumulators.
It is not possible to disassemble the accumulators. 7. Disconnect the electrical connectors from the
You can only check the nitrogen gas pre-charge solenoids and the pressure transducer.
pressure. If an accumulator is suspected as being
faulty it must be renewed as a complete assembly. 8. Disconnect the pipe.
9. Put label on the hoses to help installation.
Although identical in appearance, the accumulators
are charged to different pressures. When you install 10. Disconnect the hoses.
an accumulator make sure that it is charged to the
correct pressure. 11. Plug all the open ports and hoses to prevent
contamination.
(For: 512-26 [T4F])
12. Disconnect the hose from the port.
Remove 13. Plug all the open ports and hoses to prevent
contamination.
pressure from the accumulators before 14. Loosen the retaining clips.
15. Remove the accumulators and block from the
1. Make the machine safe. Refer to (PIL 01-03). retaining clips and the lift ram.
2. Switch SRS to manual mode- make sure the right

hand console is indicating that manual mode is
selected. Raise the lift arm.
30 - 216 9813/9400-1 30 - 216

18 - Accumulator
Figure 1210.
F
G
F
E
D
C
G
H
A
A Pipe B Solenoids
C SRS valve block D Port
E Pressure transducer F Retaining clips
G Accumulators
30 - 217 9813/9400-1 30 - 217

18 - Accumulator
Install
steps.
1.1. Check the accumulator nitrogen pre-charge
pressure. Refer to technical data (PIL
30-18).
1.2. Operate the machines hydraulic system.
1.3. Fill the hydraulic system with the
recommended hydraulic fluid. Refer to (PIL
30-00).
It is not possible to disassemble the accumulators.

The only permissible work you can do is check the
nitrogen gas pre-charge pressure. If an accumulator
is suspected as being faulty it must be renewed as a
complete assembly.
Although identical in appearance, the accumulators

are charged to different pressures. When you install
an accumulator make sure that it is charged to the
correct pressure.
30 - 218 9813/9400-1 30 - 218

21 - Oil Cooler
21 - Oil Cooler
Contents Page No.
30-21-00 General ......................................................................................................................... 30-221
30 - 219 9813/9400-1 30 - 219

Notes:
30 - 220 9813/9400-1 30 - 220

21 - Oil Cooler
00 - General
00 - General Component Identification

Operation ..................................................... 30-222
Figure 1211.
A B
A Hydraulic oil cooler matrix B Transmission oil cooler matrix
30 - 221 9813/9400-1 30 - 221

21 - Oil Cooler
00 - General
Operation
Hydraulic Oil Cooler Bypass System

Component location
Figure 1212.
A Hydraulic oil cooler bypass valve
30 - 222 9813/9400-1 30 - 222

21 - Oil Cooler
00 - General
Operation overview Figure 1214. By-Pass Active
The schematic diagrams show an overview of the

system. For machine specific schematics, refer to
hydraulic system- general, refer to (PIL 30-00).
F
When the hydraulic oil is not at full operating
temperature, the viscosity of the oil increases
causing higher hydraulic pressures.
To prevent damage to the fan circuit, a bypass valve

activates when the hydraulic pressure is greater than
3.4bar (49.3psi) and allows the oil to bypass the oil
cooler. The oil then returns straight to the tank. This
reduces the pressure in the fan circuit.
E
When the oil is at operating temperature, the
pressure reduces and the bypass valve is not active
and the fan return flows through the oil cooler.
D
Figure 1213. By-Pass Not Active
B
C
G H J
E
A Hydraulic tank
B Bypass valve
C Oil cooler
D D Main pump
E Fan direction valve (if installed)
B F Fan motor
C
G H J
A Hydraulic tank
B Bypass valve
C Oil cooler
D Main pump
E Fan direction valve (if installed)
F Fan motor
30 - 223 9813/9400-1 30 - 223

21 - Oil Cooler
00 - General
Table 507. Colour Key to Oil Flow and Pressure

G Full Pressure
H Neutral
J Exhaust
30 - 224 9813/9400-1 30 - 224

21 - Oil Cooler
00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], 512-26 2. If the engine is hot let it cool for the specified time.
[T4F] ........................................ Page 30-225
Duration: 1h
For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F], Agri, Agri-Plus, Agri-Super, Agri-Xtra 3. Discharge the hydraulic pressure from the
................................................. Page 30-226 system. Refer to health and safety (PIL 30-00)
(For: 506-23 [T4F], 509-23 [T4F], 512-26 4. Open the engine cover. Refer to (PIL 06-06).
[T4F]) 5. If installed, remove the fuel cooler.
The hydraulic oil cooler is a combination cooler. The 6. If installed, remove the air conditioning
right hand side is used for transmission oil cooling condenser. Refer to (PIL 12-15).
and the left hand side is used for hydraulic oil cooling.
If the transmission or hydraulic oil cooler has failed 7. Disconnect the hydraulic and transmission hoses
the complete unit must be replaced. from the matrix, at the 4 couplings.
8. Support the matrix.
Remove
10. Remove the matrix from the machine.
Figure 1215.
A A C
A Bolts B Matrix
C Couplings (x4)
30 - 225 9813/9400-1 30 - 225

21 - Oil Cooler
00 - General
Install 2. Install the safety strut. Refer to (PIL 06-69).
1. The installation procedure is the opposite of the 3. Follow the general health and safety procedures.
removal procedure. Additionally do the following Refer to (PIL 01-03)
steps.
1.1. Check the hydraulic fluid level. Refer to (PIL 30-00).
30-00).
5. Open the engine cover. Refer to (PIL 06-06).
1.2. Check the transmission oil level.
6. Remove the cooling pack from the machine.
1.3. When the installation procedure is complete Refer to (PIL 21-06).
start the engine and check for fuel leaks.
(For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F], Agri, Agri-Plus, Agri-Super, Agri-
Xtra) 9. Plug the open ports and hoses to prevent
contamination.
Hydraulic Oil Cooler Bypass Valve 10. Support the valve.
Remove 11. Remove the bypass valve from the cooling pack.
Figure 1216.
A
C
A Hydraulic hoses B Bolts

C Bypass valve
30 - 226 9813/9400-1 30 - 226

21 - Oil Cooler
00 - General
Install
steps.
1.1. Make sure all hoses are attached to the
correct ports.
1.2. Check the hydraulic fluid level. Refer to (PIL
30-00).
1.3. Check the coolant level. Refer to (PIL
21-06).
30 - 227 9813/9400-1 30 - 227

30 - Manifold
30 - Manifold
Contents Page No.
30-30-00 General ......................................................................................................................... 30-229
30 - 228 9813/9400-1 30 - 228

30 - Manifold
00 - General
00 - General
Remove and Install
Remove
1. Make the machine safe. Refer to PIL (01-03).
3. Raise the lift arm.
30-00).
7. Access the manifold. Refer to (PIL 06-06).
8. Make sure the area around the manifold is clean
and free of debris.
9. Put a container below the manifold to collect any
hydraulic fluid.
10. Remove the hydraulic filter. Refer to (PIL 30-04).
11. Hold the manifold block and remove the
hexagonal screws.
12. Lift the manifold block from the machine.
13. Remove and discard the O-rings.
Install
steps.
1.1. Install new O-rings. Make sure they stay in
the correct position during assembly.
1.2. Tighten the hexagonal capscrews (x4) to
the specified torque value.
Torque: 56N·m
1.3. If the filter has been removed, make sure
that it is installed correctly.
1.4. Check the hydraulic oil level and top up to
the correct level. Refer to (PIL 30-00).
1.5. Start the machine and check for leaks.
1.6. Check the operation of all the hydraulic
services.
30 - 229 9813/9400-1 30 - 229

51 - Lift Arm Control Valve Block
Contents Page No.

30-51-21 Load Sense Relief Valve .............................................................................................. 30-235
30-51-24 Flow Regulator ............................................................................................................. 30-237
30 - 230 9813/9400-1 30 - 230

03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Figure 1218.

D
N
Operation
The relief valve is located in the control valve, which EX

connects either the neutral and exhaust galleries
(Parallel Control Valves) or the load sense and A
exhaust galleries (Flowshare Control Valves). It is B
designed to prevent the circuitry from damage that
could be caused by excessive pressures.
Valve at rest
The services are in neutral and pressure in the
neutral gallery is not sufficient to operate the relief
valve which is held closed by its spring.
Figure 1217.
N A Control valve block
B Relief valve
D Hollow poppet
N Neutral gallery
EX
EX Exhaust gallery
A
B
A Control valve block

B Relief valve
C Spring
N Neutral gallery
EX Exhaust gallery
Poppet opens
A service has been selected and the pressure
generated exceeds the setting of the relief valve.
Pressure acts on the periphery of the hollow poppet
which is forced downwards against the spring
releasing the pressure into the exhaust gallery.
30 - 231 9813/9400-1 30 - 231

06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-232 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-233 complete valve must be replaced if it is defective.
Do not remove or damage the tamper proof cap as
this may invalidate a warranty claim.
30 - 232 9813/9400-1 30 - 232

Operation Figure 1220. Poppet opens
The ARV (Auxiliary Relief Valve) are located in the

control valve to limit potentially damaging pressures
within specified services due to external loadings.
ARV may also be used to limit the maximum pressure

in a specified service to less than the LSRV (Load
Sense Relief Valve) setting.
Valve at rest EX
A service is selected but pressure in the service

gallery has not reached the setting of the ARV which
is held closed by its spring. S
S Service gallery
Figure 1219. Valve at rest
EXExhaust gallery
Anti-cavitation mode
When a service is operated in such a way that low
pressure, or cavitation, exists in the service line, the
relatively high pressure oil in the exhaust gallery acts
on the lower poppet and flows into the service gallery
to make up the deficiency.
Figure 1221. Anti-cavitation mode

EX
S Service gallery
EXExhaust gallery
Poppet opens
The setting of the ARV is exceeded by the service EX
pressure which causes the poppet to rise against
spring force allowing the pressure to be released into
the exhaust gallery. S
S Service gallery
EXExhaust gallery
30 - 233 9813/9400-1 30 - 233

Consumables
A
JCB Hydraulic Fluid OP 4002/2001 5L
46 4002/2005 20L
4002/2003 200L
The ARV (Auxiliary Relief Valve)'s are not B

serviceable. The complete valve must be replaced if C
it is not operational.
D
Do not remove or damage the tamper proof cap as
this may void the warranty claim.
Remove
1. Remove the valve assembly from the valve
block. E
2. Remove the O-ring 1 and O-ring 2 then remove

the thrust ring.
3. Use a rounded tool to remove the O-rings, that F
will not cause any damage to the seal grooves.
4. Discard all O-rings and back-up rings. Do not use A Load hold check valve assembly
worn or damaged items. B O-ring 1
C Thrust ring
5. If necessary, remove the load hold check valve D O-ring 2
assembly. Refer to (PIL 30-54-39). E Valve assembly
F Tamperproof cap
Install
steps.
1.1. Make sure the tamperproof cap supplied
with the valve, is installed.
1.2. Replace all O-rings and back-up rings.
1.3. Before you assemble the parts, apply
lubricants on them.
1.4. If necessary, adjust the ARV pressure
setting. Refer to (PIL 30-00).

Item Description Nm
E Valve assembly 70
30 - 234 9813/9400-1 30 - 234

21 - Load Sense Relief Valve
21 - Load Sense Relief Valve Remove and Install

Remove
Do not remove or damage the tamperproof cap as
this may invalidate a warranty claim.
1. Follow all the hydraulic safety procedures. Refer

to (PIL 30-00).
block.
3. Remove the O-rings and the thrust ring. Make
sure you use a rounded tool that will not cause
any damage to the seal grooves. Discard all O-
rings and back-up rings. Do not use worn or
damaged items.
Figure 1223.
1 O-ring
2 Thrust ring
3 O-ring
4 Valve assembly
5 Tamperproof cap
Install
steps.
1.1. Make sure the tamperproof cap supplied
with the valve is installed.
1.2. Replace all O-rings and back-up rings.
1.3. Lubricate the parts with the correct clean
hydraulic fluid before installation.
1.4. Adjust the LSRV (Load Sense Relief Valve)
pressure setting as required.
30 - 235 9813/9400-1 30 - 235

21 - Load Sense Relief Valve
Table 509. Torque Data Disassemble and Assemble

Item Torque
4 45N·m The load sense relief valve is not serviceable.
Replace the complete valve with the correct valve if
it is defective.
30 - 236 9813/9400-1 30 - 236

24 - Flow Regulator
24 - Flow Regulator Check (Condition)

Check (Condition) ........................................ 30-237
Inspection
Disassemble and Assemble ........................ 30-239 1. Examine the valve components for scratches,
pitting, corrosion or any other damage.
2. Clean the filter gauze installed in the end of the
valve body.
3. If any part other than the O-rings are damaged,
replace the entire valve.
Figure 1224.
A Filler gauze
30 - 237 9813/9400-1 30 - 237

24 - Flow Regulator
Remove and Install 3. Remove the oil ring 1, oil ring 2 and the thrust
ring.
For: Oil Pilot Control (Parker)
................................................. Page 30-238 When you remove the O-rings and seals, use a
For: 506-23 [T4F], 509-23 [T4F], Agri-Xtra rounded tool that will not cause any damage to the
................................................. Page 30-238 grooves. Discard all the O-rings and the back-up
rings. Do not use worn or damaged items.
(For: Oil Pilot Control (Parker)) Figure 1225.
Remove A
B
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and C
engine being started. Block all four wheels. D
It is possible to remove a valve without removing the

valve block from the machine.

Refer to (PIL 01-03). E
2. Release the hydraulic pressure. Refer to (PIL
30-00).
3. Make sure that you follow all the health and A O-ring 1
safety information. Refer to Hydraulic System- B Thrust ring
Health and Safety (PIL 30-00). C O-ring 2
D Regulator filter
4. Disconnect and install caps on the hoses and E Valve assembly
pipes which may prevent the removal of the flow
regulator valve. Install
5. Remove the flow regulator valve from the valve
block. Cover the port to prevent the entry of dirt
and put it in a clean work area.
steps.
Install 1.1. Clean the valve components in an
applicable solvent.
The installation procedure is the opposite of the
removal procedure.
1.2. Replace all the O-rings and the back-up
(For: 506-23 [T4F], 509-23 [T4F], Agri- rings.
Xtra) 1.3. Lubricate the parts with JCB hydraulic fluid
Consumables
Description Part No. Size Table 510. Torque Values
Item Description Nm
The flow regulator valve is not serviceable and E Valve assembly 20
adjustable. replace the complete valve if found
defective.
Remove
block.
2. Remove and discard the regulator filter.
30 - 238 9813/9400-1 30 - 238

24 - Flow Regulator
Disassemble and Assemble 2.2. Lubricate the parts with JCB hydraulic fluid
before you assemble them. Make sure that
all the parts move freely.
Disassemble 2.3. Install new O-rings and back-up rings.
1. Loosen and remove the top plug. 2.4. Make sure to install the filter gauze in the
2. Carefully remove the shims, the spring and the
piston. Table 511. Torque Values
3. Remove the O-rings and the seals with the Item Description Nm
correct round tool. Make sure that no damage is F Valve body 20
caused to the seal grooves.
4. Discard all the O-rings and the back-up rings.
5. Do not use worn or damaged items.
Figure 1226.
A Top plug
B Shims
C Spring
D Piston
E Filter gauze
F Valve body
Assemble
2. When assembling do the following steps also:
2.1. Clean the valve components in the correct
solvent.
30 - 239 9813/9400-1 30 - 239

27 - Pressure Compensator Valve
27 - Pressure Compensator Valve Figure 1227.
Remove and Install A
B
(For: Oil Pilot Control (Parker))
Consumables
46 4002/0805 20L
4002/0803 200L
JCB Threadlocker 4101/0250 0.01L C
Strength)

correctly attached. Engage the park brake, remove A Compensator plug
the ignition key, disconnect the battery. If the machine B Compensator valve
has wheels use blocks to prevent unintentional C Hole
movement.
Install
Remove
1. To get access to the pressure compensator removal procedure. Additionally do the following
valves do the following steps. steps.
1.1. Remove the middle tie rod from the hole. 1.1. Clean the valve components in an
appropriate solvent.
1.2. To remove the middle, it may be necessary
to remove the valve block securing nuts, 1.2. Before you assemble, lubricate parts with
and pull the valve block away from the appropriate lubricant. Make sure that all the
chassis. parts move freely.
1.3. Make sure that other two tie rods securely Consumable: JCB Hydraulic Fluid HP 46
hold the valve sections together. 1.3. Replace all O-rings and back-up rings.
2. Use an Allen key of the specified diameter to 1.4. Before you install, apply sealant to the
remove the compensator plug. threads of the tie rod, and tie rod nut.
Dimension: 8mm Consumable: JCB Threadlocker and Sealer
(Medium Strength)
3. Use a magnet to extract the compensator valve
from its bore. Table 512. Torque Values
4. Check the valve components for scratches, Item Description Nm
pitting, corrosion or any other type of damage. A Compensator plug 60
Replace as necessary.
30 - 240 9813/9400-1 30 - 240

53 - Servo System Control Valve Block
Contents Page No.
30-53-00 General ......................................................................................................................... 30-243

30-53-80 Spool ............................................................................................................................ 30-262
30 - 241 9813/9400-1 30 - 241

Notes:
30 - 242 9813/9400-1 30 - 242

00 - General

Technical Data ............................................. 30-243 For: 512-26 [T4F] .................... Page 30-243
Component Identification ............................. 30-246 For: 506-23 [T4F] .................... Page 30-244
Fault-Finding ................................................ 30-248 For: 509-23 [T4F] .................... Page 30-244
(For: 512-26 [T4F])
Load Sense Pressure System (Agri, Agri-

Plus, Agri-Super Machines)
Figure 1228. 4 Spool control valve block
F
B
C
B4 A4
B3 A3
B2 A2
B1 A1
LS
D P E
T
G A
A LSRV (Load Sense Relief Valve)
B Auxiliary ram rod side
C Auxiliary ram head side
D Carriage tilt ram rod side
E Carriage tilt ram head side
F Flushing valve
G Steer priority valve
Table 513.
Type 4 Spool, load sense- pressure
compensated, double acting
spools
Spool 1 Lift arm raise & Integral propor-
lower service tional electro
servo pilot oper-
ated
Spool 2 Carriage tilt ser- Integral propor-
vice tional electro
servo pilot oper-
ated
Spool 3 Lift arm extend Integral propor-
& retract Ser- tional electro
vice servo pilot oper-
ated
Spool 4 Auxiliary ser- Integral propor-
vice tional electro
servo pilot oper-
ated
30 - 243 9813/9400-1 30 - 243

00 - General
Table 514. Relief valve pressures Spool 2 Carriage tilt ser- Integral propor-
Item Value vice tional electro
servo pilot oper-
LSRV
(1)
260bar (3,768.1psi) ated
ARV (Auxiliary Relief - Spool 3 Boom extend & Integral propor-
Valve) retract Service tional electro
Auxiliary ram rod side 220bar (3,188.4psi) servo pilot oper-
Auxiliary ram head side 220bar (3,188.4psi) ated
Carriage tilt ram rod side 260bar (3,768.1psi) Spool 4 Auxiliary ser- Integral propor-
Carriage tilt ram head 290bar (4,202.9psi) vice tional electro
side servo pilot oper-
ated
(1) Before you check the Load Sense relief valve
pressure, allow the hydraulic system to warm up to The maximum auxiliary service flow available is up
50°C (121.9°F) to make sure the reading is accurate. to 95L/min with 'manual' thumb wheel operation, and
Make sure you identify the machine variant correctly. up to 65L/min with 'constant' operation selected.
(For: 506-23 [T4F]) Table 516. Relief valve pressures

Item Value
Load Sense Pressure System LSRV
(1)
260bar (3,768.1psi)
Depending on the specification of your machine, ARV -
alternative valves may be installed. Refer to (PIL Auxiliary ram rod side 220bar (3,188.4psi)
30-54-00). Auxiliary ram head side 220bar (3,188.4psi)
Carriage tilt ram rod side 275bar (3,985.5psi)
Figure 1229. 4 Spool control valve block
F Carriage tilt ram head 140bar (2,029.0psi)
B side
C (1) Before you check the Load Sense relief valve
pressure, allow the hydraulic system to warm up to
50°C (121.9°F) to make sure an accurate reading.
B4 A4
Be sure to identify the machine variant correctly.
B3 A3
(For: 509-23 [T4F])
B2 A2
Load Sense Pressure System
B1 A1
Depending on the specification of your machine,
alternative valves may be installed. Refer to (PIL
LS
D P E 30-54-00).
T
G A
A LSRV
F Flushing valve
Table 515.
Type Spool, load sense- pressure
spools
Spool 1 Boom lift & low- Integral propor-
er service tional electro
servo pilot oper-
ated
30 - 244 9813/9400-1 30 - 244

00 - General
Figure 1230. 4 Spool control valve block Item Value

F Carriage tilt ram rod side 275bar (3,985.5psi)
B
C Carriage tilt ram head 140bar (2,029.0psi)
side
(1) Before you check the Load Sense relief valve
B4 A4
pressure, allow the hydraulic system to warm up to
50°C (121.9°F) to make sure an accurate reading.
B3 A3 Be sure to identify the machine variant correctly.
B2 A2
B1 A1
LS
D P E
T
G A
A LSRV
F Flushing valve
Table 517.
Type Spool, load sense- pressure
spools
Spool 1 Lift arm raise & Integral propor-
lower service tional electro
servo pilot oper-
ated
Spool 2 Carriage tilt ser- Integral propor-
vice tional electro
servo pilot oper-
ated
Spool 3 Lift arm extend Integral propor-
& retract Ser- tional electro
vice servo pilot oper-
ated
Spool 4 Auxiliary ser- Integral propor-
vice tional electro
servo pilot oper-
ated
The maximum auxiliary service flow available is up

to 95L/min with 'manual' thumb wheel operation, and
up to 65L/min with 'constant' operation selected.
Table 518. Relief valve pressures

Item Value
LSRV
(1)
260bar (3,768.1psi)
ARV -
Auxiliary ram rod side 220bar (3,188.4psi)
Auxiliary ram head side 220bar (3,188.4psi)
30 - 245 9813/9400-1 30 - 245

00 - General
Figure 1231. Dual Tech Variable Transmission Machines

B
C
D
E G
H
F
K J
L
M
Q
T P
R
S N
3 4
2
Z Y 5
U X
W 333/G3855-6
V 7
6
1
8
A Valve block B Port P1

C Port LS D Port DLS
E Port P F Port D
30 - 246 9813/9400-1 30 - 246

00 - General
G Port G H To steer orbitrol P port

J To steer orbitrol LS port K Main return
L Suction pipe M Variable displacement pump
N To pilot CCT (P port) P From pilot CCT (T port)
Q Case drain R Fan return
S Trailer brake valve T (Red)
U From steer CCY (Green/Yellow) V From fan drain (Orange)
W From brake return (Yellow) X From pilot CCT- T2 port
Y (White) 1 To brake accumulator
2 Trailer brake valve port R 3 Trailer brake valve port P
4 Trailer brake valve port N 5 Trailer brake valve port B
6 To trailer brake port A 7 To trailer brake port LS
8 To fan return 9 To fan feed
30 - 247 9813/9400-1 30 - 247

00 - General
Fault-Finding
Fault
All services lack power Table 519. Page 30-248
All services slow to operate Table 520. Page 30-249
The system pressure is too high Table 521. Page 30-249
A service stays selected Table 522. Page 30-249
System isolation not working Table 523. Page 30-250
All services inoperative Table 524. Page 30-250
Low flow from auxiliary service Table 525. Page 30-250
Lift arm operation is "Fierce" Table 526. Page 30-250
Servo operated spool services slow to operate or low auxiliary flow (The Table 527. Page 30-250
maximum auxiliary service flow available should be up to 95 L/min minimum
for 'manual' thumbwheel operation and up to 65 L/min with 'constant'
operation selected).
Table 519. All services lack power

Cause Remedy
Insufficient hydraulic fluid Check for leaks and top up as required.
LSRV (Load Sense Relief Valve) out of adjustment or Check and adjust as required.
defective
Internal leakage fault in the load sense circuit. Measure the load sense pressure.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
end section sticking open due to contamination.
Contamination in proportional solenoid valves or Dismantle and inspect valve block components.
mesh filters.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Machines with Variflow Pump: Insufficient output Check and adjust, or renew the LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS (Hydraulic Variable Control Solenoid sensor. Check condition of the associated electrical
Valve)) (if fitted) being permanently energised wiring for damage and short circuits.
and/or due to failure of the pump or internal tilting Install new pump and flush the hydraulic system to
swashplate mechanism because of contamination. remove all contamination.
Machines with Gear Pump: Low pump flow Check pump flow
Check for extra leaks, install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Electronic fault Use service master to determine the problem. Refer
to electrical system- electronic diagnostic, refer to
(PIL 33-57).
30 - 248 9813/9400-1 30 - 248

00 - General
Table 520. All services slow to operate

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as required.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
sticking open due to contamination.
Servo pilot pressure too low: Due to blocked Measure the servo pilot pressure and install new
servo pilot filter element and/or due to faulty servo servo pilot filter element.
regulating valve. Measure the servo pilot pressure and install new pilot
pressure supply valve.
Machines with Variflow Pump: Insufficient output Check and adjust, or install new LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS) (if fitted) being permanently sensor. Check condition of the associated electrical
energised and/or due to failure of the pump or wiring for damage and short circuits.
internal tilting swashplate mechanism because of Install new pump and flush the hydraulic system to
contamination. remove all the contamination.
Machines with GearPump: Low pump flow Check the pump flow.
Check for external leaks and install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Fault in electrical circuit wiring or joystick powerbase Check the condition of the associated electrical
ECU (Electronic Control Unit): Due to thumbwheel wiring for damage and that the fuses are intact.
switch defective/ solenoid at pilot pressure valve Then:
not energising/ solenoid coil faulty and/or faulty Check the function of the applicable thumbwheel
powerbase ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick powerbase ECU.
Table 521. The system pressure is too high

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Contamination in proportional solenoid valves, check Dismantle and inspect valve block components.
valve or mesh filters.
Table 522. A service stays selected

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Service spool or associated load hold check valves Dismantle and inspect the associated service spool
damaged or sticking due to contamination. or load hold check valves.
30 - 249 9813/9400-1 30 - 249

00 - General
Table 523. System isolation not working

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Blockage in unloader drain port. Clean port, replace inlet section if necessary.
Electronic fault Use service master to determine the problem. Refer
(PIL 33-57).
Table 524. All services inoperative

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Electronic fault. Use service master to determine the problem. Refer
(PIL 33-57).
Table 525. Low flow from auxiliary service

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 526. Lift arm operation is "Fierce"

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 527. Servo operated spool services slow to operate or low auxiliary flow (The maximum auxiliary
service flow available should be up to 95 L/min minimum for 'manual' thumbwheel operation and up
to 65 L/min with 'constant' operation selected).
Cause Remedy
Fault in the electrical circuit wiring, joystick controller Check the condition of the associated electrical
hydraulic control ECU. Due to defective thumbwheel wiring for damage and that the fuses are intact.
switch/ solenoid at the pilot pressure supply valve Then:
not energising/ faulty solenoid coil/ faulty joystick Check the function of the applicable thumbwheel
controller and/or faulty hydraulic control ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick controller.
Install new hydraulic control ECU.
Servo pilot pressure too low: Due to blocked servo Measure the servo pilot pressure and install new
pilot filter element/ faulty pilot pressure supply valve servo pilot filter element.
and/or due to proportional solenoid valve cartridge Measure the servo pilot pressure and install new pilot
damaged or sticking due to contamination. pressure supply valve.
Counterbalance valve not working correctly. Check operation of applicable counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of lift ram pressure sensor.
working correctly.
30 - 250 9813/9400-1 30 - 250

00 - General
Remove and Install
CAUTION This component is heavy. It must only 3. Discharge the hydraulic pressure. Refer to (PIL
be removed or handled using a suitable lifting 30-00).
method and device.
4. Remove the hydraulic filler cap.
Incorrect handling will result in permanent damage to 5. Mark and disconnect the hoses and pipes from
the valve assembly. The valve block should be lifted the valve assembly.
by holding the ends of the valve body, not the electric
solenoids. 6. Mark and disconnect the electrical connectors
from the valve block solenoids.
Remove 7. With the valve block correctly supported, remove
1. Make the machine safe with the lift arm raised. the mounting bolts. Carefully lift the valve block
Refer to (PIL 01-03). away from the bracket and clear of the machine.
Figure 1232.
A
A Mounting bolts B Valve block

C Valve block solenoids D Bracket
30 - 251 9813/9400-1 30 - 251

00 - General
Install
steps.
1.2. Fill the hydraulic system with the
recommended hydraulic fluid as necessary.
1.3. After installation check the MRV (Main
Relief Valve) and the ARV (Auxiliary Relief
Valve) pressures. Refer to (PIL 30-00).
30 - 252 9813/9400-1 30 - 252

00 - General
Consumables During disassembly and assembly, take care to avoid

Description Part No. Size the following:
46 • Contamination
4002/2005 20L • Damage to spools
4002/2003 200L • Damage to seal grooves
and Sealer (Medium 4101/0251 0.05L Disassemble
Strength)
1. Remove the valve block from the machine.
The valve block is a 'sectional' type, which is
made up of a number of separate sections. Make 2. Remove the tie rod nuts (x3).
sure you note the location of all components when
3. Carefully separate and remove the final element
followed by the remaining service sections.
appear to be identical, they are not interchangeable.
Make sure that components are assembled in their 4. If the inlet element is to be replaced, remove the
original positions. tie rod so that it can be installed in to the new
element.
Figure 1233.
B
A A
A
D
C
E
F
H
LS
P
J
K
T
A Valve section seals B Valve section

C Tie rod D Tie rod nut
E Final element F Auxiliary section
G Extend section H Tilt section
J Lift section K Inlet element
30 - 253 9813/9400-1 30 - 253

00 - General
Assemble
following steps.
1.1. Make sure that the mating faces of the
valve sections are thoroughly clean before
assembly.
1.2. Replace the O-rings located between the
valve sections. Make sure the O-ring seals
are not trapped or damaged.
1.3. Apply lubricant to all the parts before you
assemble them. Make sure that all the parts
move freely.
1.4. If the tie rods were removed from the inlet
section, apply threadlock to the threads
before installing the tie rod.
(Medium Strength)
1.5. Apply threadlocker to the threads of the nut.
(Medium Strength)

Item Description Nm
D Tie rod nut 42
30 - 254 9813/9400-1 30 - 254

Introduction
30 - 255 9813/9400-1 30 - 255


Introduction .................................................. 30-256 Refer to (PIL 30-51-06).
30 - 256 9813/9400-1 30 - 256

Remove and Install (For: 506-23 [T4F], 509-23 [T4F], Agri-

Xtra)
For: 512-26 [T4F] .................... Page 30-257
For: 506-23 [T4F], 509-23 [T4F], Agri-Xtra Refer to (PIL 30-51-06).
................................................. Page 30-257
(For: 512-26 [T4F])

The ARV (Auxiliary Relief Valve)'s are not adjustable.
If the pressure is incorrect, replace the valve. Each
ARV has its pressure setting stamped on the top
face, make sure you replace the ARV with one of the
same pressure setting.
The ARV shown is for illustration purposes. Refer to

Figure 1234. Make sure you select the correct ARV.
Refer to technical data, (PIL 30-53-00).
Remove
1. Raise the lift arm and make the machine safe.
2. Install the safety strut. Refer (PIL 06-69).
30-00).
4. Unscrew and remove the ARV from the valve
block.
Figure 1234.
A ARV
Install
1. Install a new ARV into the valve block and tighten

Item Nm
A 44.7
30 - 257 9813/9400-1 30 - 257

27 - Pressure Compensator Valve Operation

Operation ..................................................... 30-258
Pressure Compensation (Flowshare)
Each service spool incorporates a pressure
compensator valve. When services are operated
simultaneously the system ensures consistent
operating speed for all services, even when the limit
of the hydraulic pump performance is approached.
The oil from the main hydraulic pump arrives at

the inlet gallery. When the relevant service spool
is selected, the spool moves against the force of
the centring spring. This allows the oil flow to move
the required service. When the service spool is de-
selected, the centring spring returns the spool to the
neutral position.
When one or more services are selected, the

pressure compensator valve detects the service
generating the highest pressure and allows the pump
to deliver oil at sufficient pressure to move the load.
The load hold check valve prevents the load falling
back if the load pressure is greater than the pump
pressure.
The closed centre design ensures consistent service

operation regardless of load.
For information about service spool and pressure

compensator valve operation, refer to hydraulic
system- lift arm control valve block, refer to (PIL
30-51).
30 - 258 9813/9400-1 30 - 258

Figure 1235.
B A
F B
E C D F
A Service spool B Centering spring

C Pressure compensator valve D Load hold check valve
E Inlet gallery F Drain port
30 - 259 9813/9400-1 30 - 259

A
(For: 506-23 [T4F], 509-23 [T4F], Agri-
Xtra) B
Consumables C
- General purpose
solvent based parts D
cleaner
This procedure can be carried out with the valve

block removed or in position.
Remove
A Compensator plug
3. Follow the general health and safety procedures. B O-ring
Refer to (PIL 01-03). C Compensator piston
D Valve block section
30-00).
Inspection
5. Remove the hydraulic filler cap.
Examine the valve components for scratches, pitting,
6. Put a label on the hoses connected to the valve corrosion or damage. Replace if necessary.
slice to help installation.
7. Disconnect the hoses. Install
8. Plug all the open ports and hoses to prevent Although the pressure compensator valves look
contamination. identical, they are not interchangeable.
9. Remove the compensator plug from the valve 1. The installation procedure is the opposite of the
block section. removal procedure. Additionally do the following
steps.
10. Remove the compensator piston from the bore
with a magnet. 1.1. Clean the valve components in an
applicable solvent.
1.2. Replace all the O-rings and back-up rings.
1.3. Lubricate the parts with JCB Hydraulic Fluid
before assembling.

Item Description Nm
A Compensator plug 60
30 - 260 9813/9400-1 30 - 260

36 - Load Hold Check Valve
36 - Load Hold Check Valve 1. The installation procedure is the opposite of the
steps.
1.1. Clean the valve components in an
Consumables applicable solvent.
Cleaner/Degreaser 4104/1557 0.4L purpose solvent based parts cleaner
- General purpose
solvent based parts 1.2. Lubricate the parts with hydraulic fluid
cleaner before assembly.
JCB Hydraulic Fluid HP 4002/0801 5L Consumable: JCB Hydraulic Fluid HP 46
46 4002/0805 20L 1.3. Make sure that all the parts move freely.
4002/0803 200L
Remove Item Description Nm
D Load hold check valve plug 15
4. Remove the ARV (Auxiliary Relief Valve)
assembly.
5. Remove the LHCV (Load Hold Check Valve)
from the valve block section.
6. Remove the spring and the poppet.
Figure 1237.
B
D
A Valve block section

B Poppet
C Spring
D LHCV plug
Install
Examine the valve components for scratches, pitting,
corrosion or damage. Make sure the seating faces on
the poppets, and the mating faces in the valve block
are in good condition. Replace as necessary.
30 - 261 9813/9400-1 30 - 261

80 - Spool
80 - Spool Adjust
Adjust .......................................................... 30-262
(For: 506-23 [T4F], 509-23 [T4F])
The extend / retract and lift / lower valve slices have
a spool stroke limitation stop screw. During normal
operation this must not be adjusted.

2. Get access to the valve block.
3. Loosen the locknut.
4. Adjust the stop screw with an Allen key to adjust
the flow rate.
5. When the setting is correct, tighten the locknut.
Figure 1238.
A Stop screw
B Locknut
30 - 262 9813/9400-1 30 - 262

80 - Spool
(For: 506-23 [T4F], 509-23 [T4F]) 3. Remove the cover plate screws.
Consumables 4. Remove the housing and the O-ring from the
Description Part No. Size valve block.
5. Hold the spool assembly in a vice using the spool
- General purpose
clamp.
solvent based parts
cleaner 6. Remove the spool end screw, the centering
JCB Hydraulic Fluid HP 4002/0801 5L spring, the spring retainers and the spring cup.
46 4002/0805 20L If necessary pre-heat the spool to the specified
4002/0803 200L temperature in an oven or with a heat gun to
remove the spool end.
Disassemble Temperature: 200°C (391.7°F)
1. Remove the solenoid assembly. 7. Carefully remove the spool from the valve body.
Refer to: PIL 33-86-00. When you remove the O-rings and seals, use a
rounded tool that will not cause damage to the seal
2. Remove the mounting screws and the mounting grooves. Discard all the O-rings and back-up rings.
plate. Do not use worn or damaged items.
Figure 1239.
A B C E F
G
H J K L M
N
A Solenoid assembly B Mounting screws

C Mounting plate D O-ring 1
E O-ring 2 F Valve block
G Spool H Spring retainers
J Centering spring K Spring cup
L Spool end screw M O-ring 3
N Housing P Cover plate screws
30 - 263 9813/9400-1 30 - 263

80 - Spool
Figure 1240. Holding the Spool Assembly
X
Y
X Spool assembly
Y Spool clamp
Assemble
Before you assemble, check the valve components
for scratches, pitting, corrosion or other type of
damage. Replace if required.

following steps.
applicable solvent.
1.2. Lubricate the parts with hydraulic fluid
before assembling. Make sure that all the
parts move freely.
Consumable: JCB Hydraulic Fluid HP 46
1.3. Replace all O-rings.
1.4. Make sure that the spools are in the correct
position before installing into the valve block
body.

Item Description Nm
B Mounting screws 4.5
L Spool end screw 10
P Cover plate screws 4.5
30 - 264 9813/9400-1 30 - 264

54 - Parallel Circuit Control Valve Block
Contents Page No.
30-54-00 General ......................................................................................................................... 30-267

30 - 265 9813/9400-1 30 - 265

Notes:
30 - 266 9813/9400-1 30 - 266

00 - General

Technical Data ............................................. 30-267 For: 506-23 [T4F] .................... Page 30-267
Component Identification ............................. 30-270 For: 509-23 [T4F] .................... Page 30-268
Operation ..................................................... 30-274 For: 512-26 [T4F] .................... Page 30-269
Fault-Finding ................................................ 30-278
Adjust .......................................................... 30-279
(For: 506-23 [T4F])
Single lever control
Depending on the specification of your machine,
alternative valves may be installed. Refer to (PIL
30-53-00).
Table 533. 4 Spool, parallel

service, double acting spools
Spool 1 Lift arm raise & Manually oper-
lower service ated
Spool 2 Carriage tilt ser- Manually oper-
vice ated
Spool 3 Lift arm extend Solenoid, servo
& retract ser- pilot operated
vice
Spool 4 Auxiliary ser- Solenoid, servo
vice pilot operated

Relief valve Pressure value
MRV (Main Relief Valve) 240bar (3,478.2psi)
ARV (Auxiliary Relief -
Valve)
Carriage tilt ram head 138bar (2,000.0psi)
side
30 - 267 9813/9400-1 30 - 267

00 - General

A D D
A
4 B A
4 B A
3 B A
3 B A
B
2 B A C
2 B A
1 B A
1 B A
B C
T P
T P
A Auxiliary ram rod side
A Auxiliary ram rod side B Carriage tilt ram rod side
B Carriage tilt ram rod side C Carriage tilt ram head side
C Carriage tilt ram head side D Auxiliary ram head side
D Auxiliary ram head side T Test port
T Test port P Pressure port
P Pressure port
(For: 509-23 [T4F])
Table 535.
Pilot pressure range: Value Single lever control
(machines with single
lever controls) Depending on the specification of your machine,
All machines 10–30bar (144.9– alternative valves may be installed. Refer to (PIL
434.8psi) 30-53-00).

Dual lever control service, double acting spools
Table 536. 4 Spool, parallel lower service ated
Spool 1 Lift arm raise & Manually oper- vice ated
lower service ated Spool 3 Lift arm extend Solenoid, servo
Spool 2 Lift arm extend Manually oper- & retract ser- pilot operated
& retract ser- ated vice
vice Spool 4 Auxiliary ser- Solenoid, servo
Spool 3 Carriage tilt ser- Manually oper- vice pilot operated
vice ated
Spool 4 Auxiliary ser- Manually oper-
vice ated Table 539. Relief valve pressures
Table 537. Relief valve pressures MRV 260bar (3,768.1psi)
Relief valve Pressure value ARV -
MRV 240bar (3,478.2psi) Auxiliary ram rod side 220bar (3,188.4psi)
ARV - Auxiliary ram head side 220bar (3,188.4psi)
Auxiliary ram rod side 220bar (3,188.4psi) Carriage tilt ram rod side 276bar (4,000.0psi)
Auxiliary ram head side 220bar (3,188.4psi) Carriage tilt ram head 138bar (2,000.0psi)
Carriage tilt ram rod side 276bar (4,000.0psi) side
side
30 - 268 9813/9400-1 30 - 268

00 - General

A D D
A
4 B A 4 B A
3 B A 3 B A
2 B A B 2 B C
A
1 B A 1 B A
B C
T P T P
A Auxiliary ram rod side A Auxiliary ram rod side
B Carriage tilt ram rod side B Carriage tilt ram rod side
C Carriage tilt ram head side C Carriage tilt ram head side
D Auxiliary ram head side D Auxiliary ram head side
T Test port T Test port
P Pressure port P Pressure port
Table 540. (For: 512-26 [T4F])

Pilot pressure range: Value
(machines with single Depending on the specification of your machine,
lever controls) alternative types of valve(s) are installed. Refer to
(PIL 30-53-00).
All machines 10–30bar (144.9–
434.8psi)
Dual lever control

lower service ated
Spool 2 Lift arm extend Manually oper-
& retract ser- ated
vice
vice ated
Spool 4 Auxiliary ser- Manually oper-
vice ated

MRV 260bar (3,768.1psi)
ARV -
side
30 - 269 9813/9400-1 30 - 269

00 - General
For: 506-23 [T4F] .................... Page 30-270

For: Manual Lever (Parker) ..... Page 30-272
For: Electro Servo (Husco) ...... Page 30-273
(For: 506-23 [T4F])
Machines with dual lever controls
Figure 1245.
B
A
C D
H G
Item Description
F Hydraulic cooling fan
Table 543.
motor pipework
Item Description G Trailer brake valve
A Hydraulic tank H Sway Valve
B Control Valve J Hydraulic cooling fan
C Fan supply pump motor case drain line
D Main hydraulic supply K Trailer brake coupling
pump L Steer return line
E Sway ram
30 - 270 9813/9400-1 30 - 270

00 - General
Machines with single lever controls
Figure 1246.
B
A
C D E
J
H
K
M
Item Description
G Hydraulic cooling fan
Table 544.
motor pipework
Item Description H Trailer brake valve
A Hydraulic tank J Sway valve
B Control valve K Hydraulic cooling fan
C Steer pump motor case drain line
D Fan supply pump L Steer return line
E Main hydraulic supply M Trailer brake coupling
pump
F Sway ram
30 - 271 9813/9400-1 30 - 271

00 - General
(For: Manual Lever (Parker))
Figure 1247.
D E
Item Description
E Main hydraulic supply
Table 545.
pump
Item Description F Hydraulic cooling fan
A Hydraulic tank motor pipework
B Steer return G Hydraulic cooling fan
C Control valve motor case drain line
D Fan supply pump
30 - 272 9813/9400-1 30 - 272

00 - General
(For: Electro Servo (Husco))
Figure 1248.
A
B
C D
K
L
F
A Hydraulic tank B Steer valve return

C Fan supply pump D Main hydraulic supply pump
E Control Valve F Accumulator
G Hydraulic fan motor case drain H Hydraulic fan motor return
J Filler pipe K To steer valve (Load sense line)
L To steer valve (Feed)
30 - 273 9813/9400-1 30 - 273

00 - General
Operation Figure 1250. 4 Spool Control Valve

(Dual Lever Control) Schematic
For: 506-23 [T4F], 509-23 [T4F]
................................................. Page 30-274
(For: 506-23 [T4F], 509-23 [T4F])

A
B J
4 Spool Control Valve (Dual Lever
Control)
E E
When the spools are actuated, oil from the pump
passes into the service port 1 or service port A
2 and operates the relevant hydraulic ram. See H
B
the applicable hydraulic schematic for service port
connections.
E E
Depending on your machine, some sections are pilot
operated and controlled by an electrical switch. A
G
Figure 1249. 4 Spool Con- B
trol Valve (Dual Lever Control)
E E
A
J B F
B A
H
B A
E G D
B A
E
F
B A
T C
A Service port 1
B Service port 2 T C
C Inlet port A Service port 1
E ARV (Auxiliary Relief Valve) B Service port 2
F Spool 1 C Inlet port
G Spool 2 D MRV
H Spool 3 E ARV
J Spool 4 F Spool 1
T Tank port G Spool 2
H Spool 3
The oil from the pump enters the control valve at J Spool 4
the inlet port, passing the adjustable MRV (Main T Tank port
Relief Valve). As the spool 1, spool 2, spool 3 and
spool 4, are in neutral, the oil passes round their
central waists, the spool lands preventing the oil
from entering the service ports. On reaching the end
housing, the oil enters the exhaust gallery and is
discharged back to the tank. The control valve also
incorporates adjustable ARV's.
30 - 274 9813/9400-1 30 - 274

00 - General
4 Spool Control Valve (Single Lever Figure 1252. 4 Spool Control Valve
Control) (Single Lever Control) Schematic
When the spools are actuated, oil from the pump

passes into the service port 1 or the service port 2,
operating the relevant hydraulic ram.
See the applicable hydraulic schematic for service A

port connections. Refer to hydraulic system- general, J
refer to (PIL 30-00). B
Figure 1251. E E
E E
A
H
B
J A B
A B
H
A B A
G G
E E B
A B
F
E E
A
F
B
T C
A Service port 1
B Service port 2
C Inlet port
E ARV D
F Spool 1
G Spool 2
H Spool 3
J Spool 4
T Tank port
Oil from the pump enters the control valve through

the inlet port, passing the adjustable MRV.
The pressure reduction valve provides oil at pilot K

pressure for control of spool 3 and spool 4. L
As the spool 1, spool 2, spool 3 and spool 4, are
in neutral, the oil passes round their central waists, T
the spool lands preventing the oil from entering the C
service ports. On reaching the end housing, the oil
enters the exhaust gallery and is discharged back A Service port 1
to the tank. The control valve also incorporates B Service port 2
adjustable ARV's. C Inlet port
D MRV
An accumulator is attached to the accumulator E ARV
attachment port. The accumulator traps and stores F Spool 1
oil at pilot pressure and enables operation of the G Spool 2
service spools a limited number of times with the H Spool 3
engine stopped. J Spool 4
30 - 275 9813/9400-1 30 - 275

00 - General
K Pressure reduction valve T To tank

L Accumulator attachment port X Service port 1
T Tank port Y Service port 2
Figure 1254. 6 Spool Control Valve Schematic
M N
When the spools are actuated, the oil from the
pump passes into the service port 1 or service
port 2, operating the relevant hydraulic ram. See
the applicable hydraulic schematic for service port F
X
connections.
Y
The oil from the pump enters the control valve
through the inlet port, passing the adjustable MRV.
As the spools 1 to 6 are in neutral, the oil passes X E
round their central waists. The spool lands do not
allow the oil to enter the service ports. When the Y
oil reaches the end housing, it enters the exhaust
gallery and is discharged back to the tank. The
control valve also incorporates ARV 1, ARV 2, ARV X J H D
3 and ARV 4.
Y
The unloader section isolates the stabilisers when
the solenoid is energised.
X L K C
Figure 1253. Typical 6 Spool Control Valve
Y
M N
X B
F Y X Y
E Y X
X A
D Y X
J H
Y
C Y X
L K
B Y X
G
A Y X
T P
A Spool 1
B Spool 2
C Spool 3 T
P
D Spool 4
E Spool 5 A Spool 1
F Spool 6 B Spool 2
H ARV 1 C Spool 3
J ARV 2 D Spool 4
K ARV 3 E Spool 5
L ARV 4 F Spool 6
M Solenoid G Adjustable MRV
N Unloader section H ARV 1
P Inlet port J ARV 2
K ARV 3I was contacting for 3
L ARV 4
30 - 276 9813/9400-1 30 - 276

00 - General
M Solenoid
N Unloader section
P Inlet port
T To tank
X Service port 1
Y Service port 2
30 - 277 9813/9400-1 30 - 277

00 - General
Fault-Finding
Fault
Lack of power at all hydraulic functions Table 546. Page 30-278
All mechanically operated hydraulic services slow to operate Table 547. Page 30-278
All solenoid/servo operated hydraulic services slow to operate Table 548. Page 30-278
Is the machine experiencing boom extend or retract problems? Table 549. Page 30-278
Bleed air from the hydraulic cylinders - is it OK now? Table 550. Page 30-278
Table 546. Lack of power at all hydraulic functions

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as necessary.
Hydraulic leaks in system. Check hoses, If necessary replace with new one.
Engine performance. Check engine performance.
MRV (Main Relief Valve) setting not correct. Check and adjust as necessary.
Low pump flow. Check pump flow.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 547. All mechanically operated hydraulic services slow to operate

Cause Remedy
Neutral circuit or low pressure lines leaking, Check pipe lines and if necessary replace.
damaged, trapped or kinked.
MRV setting not correct. Check and adjust as necessary.
Low pump flow. Check pump flow.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 548. All solenoid/servo operated hydraulic services slow to operate

Cause Remedy
Refer to Table 2 -
Low pilot pressure Check that the pressure maintenance valve is not
sticking open.
Check the pressure reducing valve.
Solenoid power supply not present. Check fuse 2.
Table 549. Is the machine experiencing boom extend or retract problems?

Cause Remedy
YES = Go to Table 5, NO = done
Table 550. Bleed air from the hydraulic cylinders - is it OK now?

Cause Remedy
YES = Done, NO = Go to Table 6
30 - 278 9813/9400-1 30 - 278

00 - General
Adjust 6. Check spool displacement 2.

6.1. Use the control lever to move and hold the
spool in the position.
(For: 506-23 [T4F], 509-23 [T4F])
6.2. Measure spool displacement 2.
Communications
Bad communications can cause accidents. Keep 7. Repeat the procedure for each manual spool as
people around you informed of what you will be necessary.
doing. If you will be working with other people,
make sure any hand signals that may be used are Table 551. Manual Spool Displacement
understood by everybody. Worksites can be noisy, do Displacement Measurement
not rely on spoken commands. A 7–9mm
Two people are required to complete the procedure. B 7–9mm
One person should sit in the operator cab, while the
other person requires access to the control valve Adjustment
assembly.
Spool displacement is influenced by the control lever
1. Make the machine safe with the lift arm raised. linkage. Check, adjust and replace if necessary. If
Refer to (PIL 01-03). sufficient adjustment can not be achieved it may be
necessary to replace the spool assembly
3. Follow the general health and safety procedure.
30-00).
5. Check the spool displacement 1.
Figure 1255.
A Spool displacement 1
B Spool displacement 2
5.1. Use the control lever to move and hold the
spool in the position.
5.2. Measure the spool displacement 1.
30 - 279 9813/9400-1 30 - 279

00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F] 6. Remove the cab side cover (if installed) to get
................................................. Page 30-280 access to the valve block. Refer to (PIL 06-06).
(For: 506-23 [T4F], 509-23 [T4F]) 8. Disconnect the hydraulic hoses.
Remove and Install (P1) 9. Plug all the open ports and hoses to prevent
contamination.
be removed or handled using a suitable lifting 10. Remove the securing clip and pin.
method and device.
11. Disconnect the control lever rod from the spool
end.
Remove
12. Repeat step 7 and step 8 for other control
1. Make the machine safe. Refer to (PIL 01-03). linkages.
2. Follow the general health and safety procedures. 13. Put a label on the electrical connectors to help
Refer to (PIL 01-03). installation.
3. Install the safety strut. Refer to (PIL 06-69). 14. Disconnect all electrical connectors to the valve
block sensors.
4. Follow the hydraulic safety procedures. Refer to
(PIL 30-00). 15. After you support the valve block properly,
remove the mounting screws. Carefully lift the
5. Discharge the hydraulic pressure. Refer to (PIL valve block away from the bracket and clear of
30-00). the machine.
30 - 280 9813/9400-1 30 - 280

00 - General
Figure 1256.
B
B
C D
B
G
H
B
F
A Electrical connector B Mounting screws

C Control linkage D Locknut
E Control rod F Spool end
G Clip H Pin
30 - 281 9813/9400-1 30 - 281

00 - General
Install 2. Follow the general health and safety procedures.

removal procedure. Additionally do the following 3. Install the safety strut. Refer to (PIL 06-69).
steps.
4. Follow the hydraulic safety procedures. Refer to
1.1. After you install, check the operation of the (PIL 30-00).
mechanical control linkages. Operate the
control levers. Make sure that the lever 5. Discharge the hydraulic pressure. Refer to (PIL
travel is same in both the directions. To 30-00).
adjust the levers, remove the locknuts at 6. Remove the cab side cover (if installed) to get
each end of the control rod. Turn the access to the valve block. Refer to (PIL 06-06).
rod to increase or decrease the length as
necessary. Tighten locknuts. 7. Put a label on each hose to help installation.
1.3. Check and fill the hydraulic system with the 9. Plug all the open ports and hoses to prevent
recommended hydraulic fluid as necessary. contamination.
10. Remove the securing clip and pin.
1.4. After installation, check the ARV (Auxiliary
Relief Valve) and MRV (Main Relief 11. Disconnect the control lever rod from the spool
Valve) pressure. Refer to hydraulic system- end.
general, refer to (PIL 30-00).
12. Repeat step 7 and step 8 for other control
linkages.
Remove and Install (P2)
13. Put a label on the electrical connectors to help
installation.
method and device. 14. Disconnect all electrical connectors to the valve
block sensors.
Remove 15. After you support the valve block properly,
1. Make the machine safe. Refer to (PIL 01-03). remove the mounting screws. Carefully lift the
valve block away from the bracket and clear of
the machine.
30 - 282 9813/9400-1 30 - 282

00 - General
Figure 1257.
A B
B
C D
B
G
H
B
F
A Electrical connector B Mounting screws

C Control linkage D Locknut
E Control rod F Spool end
G Clip H Pin
30 - 283 9813/9400-1 30 - 283

00 - General

removal procedure. Additionally do the following 4. Discharge the hydraulic pressure. Refer to (PIL
steps. 30-00).
1.1. After you install, check the operation of the 5. Remove the cab side cover (if installed) to access
mechanical control linkages. Operate the the valve block. Refer to (PIL 06-06).
control levers. Make sure that the lever
travel is the same in both directions. To 6. Put a label on each hose to help installation.
adjust the levers, remove the locknuts at 7. Disconnect all the hydraulic hoses.
each end of the control rod. Turn the
rod to increase or decrease the length as 8. Plug all the open ports and hoses to prevent
necessary. Tighten locknuts. contamination.
9. Remove the stabiliser control lever knobs and the
gaiters from inside the cab.
1.3. Check and fill the hydraulic system with the
recommended hydraulic fluid as necessary. 10. Remove the securing clip and the pin.
11. Disconnect the control lever rod from the spool
1.4. After installation, check the ARV and MRV end.
12. Repeat the step 10 and the step 11 again for the
other control linkages.
CAUTION This component is heavy. It must only 13. Put a label on electrical connectors to help
be removed or handled using a suitable lifting installation.
method and device.
14. Disconnect all the electrical connectors to the
valve block sensors.
Remove
15. Support the valve block and remove the
1. Make the machine safe with the lift arm raised. mounting screws. Carefully lift the valve block
Refer to (PIL 01-03). away from the bracket and clear of the machine.
30 - 284 9813/9400-1 30 - 284

00 - General
Figure 1258.
A B
H
D
E
F
G
A
L
M
N
K
N
A
N J
A Mounting screws B Control lever knobs

C Control rod 1 D Securing clip
E Pin F Locknut 1
G Spool end H Electrical connectors
J Valve block K Bracket
L Locknut 2 M Control rod 2
N Control rod 3
30 - 285 9813/9400-1 30 - 285

00 - General
Install
steps.
1.1. After you install, check the operation of the
mechanical control rod 1 and control rod
3. Operate the control levers. Make sure
that the lever travel is the same in both
directions. To adjust the levers loosen the
locknut 1 or locknut 2 at each end of the
control rod 1 or control rod 2. Turn the
necessary. Tighten the locknuts.
1.2. Operate the hydraulic system. Check for
correct operation and leaks.
1.4. After installation, check the ARV and MRV
pressures. Refer to (PIL 30-00).
30 - 286 9813/9400-1 30 - 286

00 - General
For: 506-23 [T4F], 509-23 [T4F] appear to be identical, they are not interchangeable.
................................................. Page 30-287 Make sure that components are assembled in their
For: Manual Lever (Parker) ..... Page 30-290 original positions.
Great care should be taken when you disassemble

(For: 506-23 [T4F], 509-23 [T4F]) and assemble a valve to avoid the following:
Consumables
Description Part No. Size • Contamination.
• Damage to spools.
JCB Hydraulic Fluid HP 4002/0801 5L • Damage to seal grooves.
46 4002/0805 20L
4002/0803 200L Any of the above may result in possible problems
JCB Threadlocker and 4101/0550 0.01L with the operation of the valve.
Sealer (High Strength) 4101/0552 0.2L
Disassemble
Valve Block Sections 1. Remove the valve block from the machine.
Some valve sections and components are omitted
from the figure for illustration purposes. 2. Remove the tie rod nuts.
The valve block is a sectional type, which is made up 3. Carefully separate and remove the outlet section
of a number of separate sections. The illustration is followed by the remaining service sections. If the
intended as a guide to identify the components. inlet section is to be replaced, remove and retain
the tie rods.
Be sure to note the location of all components when
30 - 287 9813/9400-1 30 - 287

00 - General
Figure 1259.
A B
C
D
E
F
M
L
M
L
J
K H
K
J
P
R K
K
L B
1
3 2
A ARV (Auxiliary Relief Valve) B Outlet section

C Auxiliary section D Tilt section
E Extend section F Lift section
30 - 288 9813/9400-1 30 - 288

00 - General
G MRV (Main Relief Valve) H Inlet section

J Nut 1 K Nut 2
L Seals M Service sections
N Tie rods P Top tie rod identification
R Top tie rod
30 - 289 9813/9400-1 30 - 289

00 - General
Assemble Description Part No. Size

4002/2005 20L
the disassembly procedure. Additionally do the 4002/2003 200L
following steps. JCB Threadlocker 4101/0250 0.01L
1.1. Make sure that the mating faces of the Strength)
assembly. The valve block is a sectional type, which is made up
1.2. Renew the seals located between the valve of a number of separate sections. The illustration is
sections. Make sure that the seals are not intended as a guide to identifying the components.
trapped or damaged. Some valve components are omitted for illustration
purposes.
1.3. Lubricate parts with hydraulic fluid before
assembling. Make sure that all the parts Be sure to note the location of all components
move freely. when dismantling. Although some components may
Consumable: JCB Hydraulic Fluid HP 46 appear to be identical they are not interchangeable.
Make sure that components are assembled in their
1.4. If the tie rods were removed from the inlet original positions.
section, make sure that the tie rod with the
identification marker is used in the top hole Take care when you dismantle and assemble a valve.
and that the marker is in the inlet section. Make sure to avoid the following:
1.5. Apply sealant to the threads of nut 1 and • Contamination.
nut 2. Tighten the nuts to the correct torque • Damage to spools.
value in the sequence 1, 2, 3 and then 1 • Damage to seal grooves.
again to the specified torque value.
Consumable: JCB Threadlocker and Sealer Any of the above may result in possible problems
(High Strength) with the operation of the valve.
Table 552. Torque Values Disassemble

Item Description Nm
J Nut 1 40
K Nut 2 27 2. Remove the tie rod nuts.
3. Carefully separate and remove the outlet section
(For: Manual Lever (Parker)) followed by the remaining service sections. If you
Consumables replace the inlet section, remove and retain the
tie rods.
46
30 - 290 9813/9400-1 30 - 290

00 - General
Figure 1260.
L
A B R
C M
D
E T
M
F
G
H
J
K S
B
N
P 1
N
P
L N
M K
3 2
M
A ARV B Outlet section

C LH stabiliser section D RH stabiliser section
E Auxiliary section F Extend section
G Tilt section H Lift section
J MRV K Inlet section
L Top nut M Nuts
N Seals P Service sections
R Top tie rod S Tie rods
T Top tie rod identification marker
30 - 291 9813/9400-1 30 - 291

00 - General
Assemble
1.1. Make sure that the mating faces of the
assembly.
1.2. Renew the seals located between the valve
sections. Make sure the seals are not
trapped or damaged.
1.3. Lubricate parts with hydraulic fluid before
assembling. Make sure that all the parts
move freely.
1.4. If the tie rods were removed from the inlet
section, make sure that the tie rod with the
identification marker is used in the top hole
and that the marker is in the Inlet section.
1.5. Apply sealant to the threads of nuts. Tighten
the nuts to the correct torque value in the
sequence 1, 2, 3 and then 1 again.
(Medium Strength)

Item Description Nm
L Top nut 40
M Nuts 27
30 - 292 9813/9400-1 30 - 292

03 - Main Relief Valve (MRV) Introduction

30 - 293 9813/9400-1 30 - 293


(For: 506-23 [T4F], 509-23 [T4F]) removal procedure. Additionally do the following
steps.
The MRV (Main Relief Valve) is not serviceable.
1.1. Replace all the O-rings.
Replace the complete valve if it is defective.
1.2. Lubricate the parts with JCB hydraulic fluid
Remove before assembling.
1.3. Tighten the valve to the specified torque
value.
2. Discharge the hydraulic pressure. Refer to (PIL 1.4. Adjust the pressure setting as required.
30-00).
block. Item Description Nm
A Valve assembly 20
4. Remove the O-rings.
4.1. When you remove the O-rings and seals,
use a rounded tool that will not cause any
damage to the seal grooves.
4.2. Discard all the O-rings.
4.3. Do not use worn or damages items.
Figure 1261.
A Valve assembly
30 - 294 9813/9400-1 30 - 294


30 - 295 9813/9400-1 30 - 295

(For: 506-23 [T4F], 509-23 [T4F])

The ARV (Auxiliary Relief Valve) is not serviceable.
Replace the valve if it is defective.
Remove
1. Make the machine safe. Refer to (PIL 01-03) A
30-00).
block.
4. Remove the O-rings.
4.1. When you remove the O-rings and seals,
use a rounded tool that will not cause any
damage to the seal grooves.
4.2. Discard all the O-rings.
4.3. Do not use worn or damaged items.
A
A Valve assembly
Install
steps.
1.1. Replace all the O-rings.
1.2. Lubricate the parts with JCB hydraulic fluid
before assembling.
1.3. Tighten the valve assembly to the specified
torque value.
1.4. Adjust the pressure setting as required.

Item Description Nm
A Valve assembly 20
30 - 296 9813/9400-1 30 - 296

39 - Load Hold Check Valve
39 - Load Hold Check Valve Figure 1263.
B
Remove and Install
Consumables
and Sealer (Medium 4101/0251 0.05L C
Strength)
Remove
working on it. Park the machine on level ground A
and lower the loader arm. Stop the engine and
engine being started. Block all four wheels.
1. Remove the valve block securing nuts and pull

the valve blocks away from the chassis.
A Middle tie rod hole
2. Remove the middle tie rod from the hole to get B Compensator plug
access to the pressure compensator valves. The C Compensator valve
valve block sections are held together with the
remaining two tie rods. Install
3. Remove the compensator plug with an Allen key The installation procedure is the opposite of the
of specified value. removal procedure.
1. When installing do the following steps also:
4. Remove the compensator valve from the bore
with a magnet. 1.1. Clean the valve components with the
correct solvent.
5. Check the valve components for scratches,
pitting, corrosion or any other kind of damage. 1.2. Lubricate the parts with JCB hydraulic fluid
Replace if necessary. before you assemble them. Make sure that
all the parts move freely.
1.3. Install new O-rings and back-up rings.
1.4. Apply the specified sealant to the threads
of the tie rod and the tie rod nut before
installation.
(Medium Strength)

Item Description Nm
B Compensator plug 60
30 - 297 9813/9400-1 30 - 297

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-299

30-60-12 Electro Proportional Control ......................................................................................... 30-301
30-60-15 Joystick ......................................................................................................................... 30-314
30-60-18 Shuttle .......................................................................................................................... 30-322
30-60-27 Auxiliary Circuit ............................................................................................................ 30-323
30-60-82 Sway ............................................................................................................................. 30-324
30-60-90 Flow Regulator ............................................................................................................. 30-326
30 - 298 9813/9400-1 30 - 298

00 - General
00 - General
Introduction
Flow Control Valves Figure 1267.
Control valves are usually represented by one or

more square boxes.
The number of boxes indicates the number of

possible valve operating positions, (3 boxes, 3
positions etc).
Figure 1264.
1 Position 1 (P1 - P2, P3 - P4)

3 Position 3 (P1 - P4, P2 - P3)
In circuit diagrams the pipework is usually shown It must be noted that not all spools are of the
connected to the box which represents the same type. Their operating designs can be seen
unoperated condition. (Hydraulic circuit diagrams are by following the path the flow arrows take in their
usually shown in the unoperated condition). respective operating squares.
Figure 1265. Three typical JCB style spools are known as 'D'
spools, 'F' spools and 'N' spools.
The 'D' spools generally control rams because when

in the neutral position the outlet ports are blocked,
preventing ram movement.
'F' spools are often shown as four position spools

A valve described as a 3-position, 4-port control with the three normal positions for neutral and
valve. Port describes the openings to and from the service control; and the forth position, which has a
valve by which the hydraulic fluid enters or leaves. In detent, connects both sides of the ram together to
an unoperated condition all ports are blocked. allow the service to 'float'.
2 Position 2 (all 4 ports blocked)

'N' spools are sometimes used to control hydraulic
If the valve spool was moved to Position 1, motors, and it can be seen from the flow arrows, that
movement of the spool would connect Port P1 to Port in neutral position both service ports are connected
P2, and Port P3 to Port P4. to the exhaust oil port
If the valve spool was moved to Position 3, Figure 1269.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 299 9813/9400-1 30 - 299

00 - General
Figure 1270. Simple Schematic Circuit Example
A
B
C G
D E
A Hydraulic tank B Strainer

C Fixed displacement pump D Relief valve
E Spool F One way valve
G Double acting hydraulic ram
Some of the symbols described on the preceding

pages have been arranged into a simple schematic
circuit.
The hydraulic tank is a pressurised tank with an

internally mounted strainer on the suction line to the
fixed displacement pump. System pressure is limited
to the setting of relief valve.
The valve spool is an open-centre spool that is in

neutral position; flow from the pump passes through
the spool and returns to the hydraulic tank.
If the lever operated spool is moved away from

neutral position hydraulic fluid is directed to either
head side or rod side of hydraulic ram. Notice that
the fluid must first open one way valve before flowing
to the ram.
30 - 300 9813/9400-1 30 - 300

12 - Electro Proportional Control
12 - Electro Proportional Control Operation

Operation ..................................................... 30-301
Diagram ....................................................... 30-313
Electronic Servo Proportional Control
A summary of the proportional control functions are
as follows:
• System enable and isolation

• Constant auxiliary selection
• Constant auxiliary flow setting
• Constant auxiliary changeover
• System isolation switches i.e. tilt lock
• Operation of the lift arm services- raise, lower,
extend, retract, crowd and dump.
The control lever and attached thumbwheels operate

the hydraulic services using electrical signals.
This type of lever has two functions, proportional

thumbwheel control and electro servo lever control.
The control lever moves in two axies and also

includes two thumbwheel switches. The control
lever and thumbwheel switches control eight electro
proportional solenoid valves which operate the four
service spools in the valve block.
In the control lever assembly is the joystick

controller ECU (Electronic Control Unit). The ECU
receives analogue electrical inputs in relation to the
movement of the lever or thumbwheel switches. The
ECU changes the analogue signals and broadcasts
messages on the machine CAN (Controller Area
Network)bus.
The hydraulic control ECU recognises the CAN

messages and generates the correct PWM (Pulse
Width Modulation) signal for operation of the control
valve proportional solenoids.
The proportional solenoid valves operate as

pressure reducing valves. These supply servo pilot
oil to move the auxiliary, or extend retract service
spool. The supply is at a pressure in relation to
the amount the operator moves the joystick or
thumbwheel switch.
30 - 301 9813/9400-1 30 - 301

Figure 1271.
B4 A4
A
B3 A3
B2 A2
B1 A1
LS
D T
CANBus
A Control lever B Joystick controller ECU

C Hydraulic control ECU D Control valve proportional solenoid
Joystick and controller When you move the control lever, an electrical
signal is produced proportional to the control lever
All of the machine hydraulic services are actuated movement. The controller ECU monitors these
electrically. CAN enabled electronic control units signals (inputs) and converts the voltage into a
and proportional solenoid valves are central to the corresponding CAN message (output) which is
system. broadcast on the machine CANbus.
30 - 302 9813/9400-1 30 - 302

Figure 1272.
G F
A H J
K L
E
4 1
3 2
1 2 3 4 5 6
12 11 10 9 8 7
A Main control lever handle B CAN joystick control ECU

C Electrical connector- Thumbwheels D Electrical connector- Joystick buttons
E Electrical connector- CAN joystick control ECU F Constant flow button
G Auxiliary II button H Axis 3- Thumbwheel
J Axis 4- Thumbwheel K Axis 1- Raise lower
L Axis 2- Carriage tilt M Electrical connector- CAN joystick control ECU
30 - 303 9813/9400-1 30 - 303

Proportional signal generation System enable and isolation

When the control lever is operated, the plunger The system will not enable unless the switch is
pushes against the return spring. A variable resistor latched. When the switch is not latched, its input
position sensor is allocated to each axis. The slider is sensed by the hydraulic control ECU. The ECU
moves up or down when the lever is moved, energises the pump shut off valve solenoid coil.
changing the electrical voltage depending on lever
position. The tilt isolation switch state is sensed by inputs
at the hydraulic control ECU. The ECU isolates the
The position sensors are integral with the joystick joystick control by switching off the PWM signals to
controller ECU. If a sensor is defective, replace the the control valve tilt spool proportional solenoids.
controller ECU.
The joystick isolation switch state is sensed by inputs
Figure 1273. at the hydraulic control ECU. The ECU isolates the
joystick controls by switching off the PWM signals to
the control valve proportional solenoids.
A Control lever
B Plunger
C Return spring
D Slider
30 - 304 9813/9400-1 30 - 304

Figure 1274.
A
E1
ECU
D
E2
IGN +VE
A Pump shut off valve solenoid B Tilt isolation switch

C Hydraulic stop watch D Joystick controls isolation switch
E1 Hydraulic control ECU- connector1 E2 Hydraulic control ECU- connector2
30 - 305 9813/9400-1 30 - 305

Second auxiliary changeover A CAN message causes the LMS (Loadall

Monitoring System) display AUX II indicator LED
When you press the momentary switch, a signal is (Light Emitting Diode) to come ON.
sent to the joystick controller ECU. It responds by
broadcasting a message on the machine CAN bus When you press the momentary switch again, the
through the joystick controller. The CAN message hydraulic control ECU responds by de-energising
is read by the hydraulic control ECUCAN bus the relay. Auxiliary changeover solenoid coil is de-
interface. The ECU responds by energising the energised and the oil is diverted to the Auxiliary I
second auxiliary relay. The auxiliary changeover circuit.
solenoid coil is energised and the oil is diverted to
the AUX II circuit. A CAN message causes the LMS display AUX II
indicator LED to go OFF.
Figure 1275.
E1
A CAN H
CAN L
CAN L
CAN H
ECU
ECU ECU
ECU
B
D
G
C
E2
IGN +VE
A CAN joystick control ECU B Joystick auxiliary changeover switch

C Joystick connector D CAN joystick control ECU
30 - 306 9813/9400-1 30 - 306

E1 Hydraulic control ECU- connector1 E2 Hydraulic control ECU- connecotr2

F Second auxiliary changeover switch G LMS display ECU- connector
H Secondary fuse J Second auxiliary relay
30 - 307 9813/9400-1 30 - 307

Front/rear auxiliary changeover When the operator switch is moved into the rear
auxiliary position, the solenoid diverter valve is de-
When the operator switch is moved into the front energised and it supplies oil to the rear auxiliary
auxiliary position, the solenoid diverter valve is circuits.
energised and it supplies oil to the lift arm auxiliary
quick release couplings.
Figure 1276.
IGN +VE
A Secondary fuse B Front/rear auxiliary changeover switch

C Front/rear auxiliary changeover solenoid
30 - 308 9813/9400-1 30 - 308

Constant auxiliary When the momentary switch is pressed, a signal is

sent to the joystick controller ECU. It responds by
The constant auxiliary switch state is sensed by broadcasting a message on the machine CANbus.
inputs at the hydraulic control ECU. When constant The CAN message is read by the hydraulic control
auxiliary is enabled by the operator, the hydraulic ECU. The ECU responds by holding the auxiliary
control ECU holds the auxiliary spool on a constant spool in the position set by the operator (thumbwheel
position by means of the PWM signals to the spool switch position). The selected spool position is also
proportional solenoids. stored by the ECU and is automatically selected
again when the operator selects the constant
A CAN message causes the LMS display constant auxiliary function again.
auxiliary indicator LED to come ON.
Figure 1277.
G1
B CAN H
CAN L
CAN L
CAN H
ECU
ECU
C
E
D
A
F
ECU
G2
IGN +VE
A Secondary fuse B CAN joystick control ECU

C Joystick constant auxiliary switch D Joystick controller
E CAN joystick control ECU F Constant auxiliary enable switch
G1 Hydraulic control ECU- connecotr1 G2 Hydraulic control ECU- connector2
30 - 309 9813/9400-1 30 - 309

Extend/retract and auxiliary services the position of the thumbwheel switch. The ECU
(Thumbwheel switches) responds by broadcasting thumbwheel position as a
message on the machine CANbus.
The ECU provides the thumbwheel switch- auxiliary
service and the thumbwheel switch- extend/retract The CAN message is read by the hydraulic
service with a 5V power supply. control ECUCANbus interface. The ECU responds
by producing a PWM signal in proportion to the
The thumbwheels send a voltage between 0.7V and thumbwheel position to the proportional solenoid
4.3V to the ECU. The voltage is determined by coils for operation of the service spools.
Figure 1278.
F1
A CAN H
CAN L
CAN L
CAN H
ECU
ECU
G H
D
F2 J K
E
IGN +VE
A CAN joystick control ECU B Thumbwheel switch- auxiliary service

C Thumbwheel- extend/retract service D Joystick controller
E Secondary fuse F1 Hydraulic control ECU- connector1
F2 Hydraulic control ECU- connector2 G Proportional control valve solenoid- retract
service
H Proportional control valve solenoid- extend J Proportional control valve solenoid- auxiliary B
service service
30 - 310 9813/9400-1 30 - 310

K Proportional control valve solenoid- auxiliary A

service
30 - 311 9813/9400-1 30 - 311

Lift/lower and tilt services The CAN message is read by the hydraulic control
ECU CANbus interface. The ECU responds by
The ECU responds to operation of the joystick by producing a PWM signal in proportion to the
broadcasting the joystick position as a message on joystick position to the proportional solenoid coils for
the machine CANbus. operation of the service spools.
Figure 1279.
C1
CAN H
ECU
CAN L
CAN L
CAN H
A
ECU
D E
C2 F G
IGN +ve
A CAN joystick control ECU B Secondary fuse

C1 Hydraulic control ECU- connector1 C2 Hydraulic control ECU- connecotr2
D Proportional control valve solenoid- dump E Proportional control valve solenoid- crowd
service service
F Proportional control valve solenoid- lift service G Proportional control valve solenoid- lower
service
30 - 312 9813/9400-1 30 - 312

Diagram
(For: 506-23 [T4F], 509-23 [T4F]) pressure flows to the proportional solenoid valves at
each service spool.
Oil from the hydraulic pump flows to the pilot
pressure control valve via internal filters. Oil at pilot
Figure 1280.
C C
D
TP1 TP2
B
ACC
P P1
T T1
P2
T2
A
B Pilot pressure control valve C Proportional solenoid valves

D Service spool
Table 557. Hydraulic Connection Colour Key

A Oil at servo pressure
30 - 313 9813/9400-1 30 - 313

15 - Joystick
15 - Joystick Operation
Operation ..................................................... 30-314 For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F] ........................................ Page 30-314
Fault-Finding ................................................ 30-315
For: Manual Controls ............... Page 30-314
Disassemble and Assemble ........................ 30-321 (For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F])
For details of operation for Electro Proportional
Controls refer to (PIL 30-60-12).
(For: Manual Controls)
Figure 1281.
A
B
A Hydraulic control valve B Manual stabiliser control lever

C Manual control lever (Joystick) D Connecting rod
The levers are mechanically connected to the Movement of the lever moves the applicable valve
applicable spool on the hydraulic control valve. spool in the required direction enabling the hydraulic
service to operate.
The manual control lever - joystick - is connected
using rods.
The stabiliser control levers are a direct connection

to the valve spool.
30 - 314 9813/9400-1 30 - 314

15 - Joystick
Fault-Finding
For related fault finding information refer to (PIL
30-00).
Machines with an electronic instruments system will
log some system faults as a fault code. These fault
codes can be accessed with the correct diagnostics
software tool, using a laptop computer connected to
the machine CAN system. Refer to (PIL 33-57).
30 - 315 9813/9400-1 30 - 315

15 - Joystick
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], 512-26 Figure 1282.

[T4F] ........................................ Page 30-316
For: Manual Controls ............... Page 30-318 A
(For: 506-23 [T4F], 509-23 [T4F], 512-26 B

[T4F])

Remove C
J
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.

H
2. Release the hydraulic pressure. Refer to (PIL
30-00).
3. Prise the screw cover from the armrest.
4. Remove the screws 3 and washers. D
5. Lift away the arm rest and the trim assembly.
6. Remove the screws 1.
7. Remove the gaiter collar. E
8. Remove the screws 2 and lift the control
lever and power base assembly to access the G
electrical connectors.
9. Put label on the electrical connectors for correct F
installation.
10. Disconnect the electrical connectors. A Arm rest
B Screw cover
11. Remove the control lever from the housing. C Trim assembly
D Control lever
E Screws 1
F Housing
G Screws 2
H Gaiter collar
J Screws 3
Install
removal procedure.

Remove
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.
30 - 316 9813/9400-1 30 - 316

15 - Joystick
2. Release the hydraulic pressure. Refer to (PIL Figure 1283.

30-00).
3. Prise the screw cover from the armrest.
4. Remove the screws and washers 1.
B
5. Lift away the arm rest. C
6. Remove the rear screws and washers 2. C

A
7. Remove front screws and washers 3.
8. Remove the gaiter collar. E
9. Remove the pod top cover until you can access
the switch electrical connectors.
10. Put label on the electrical connectors for correct G
installation. M
11. Disconnect the switch connectors.

M H H
12. Disconnect the electrical connector 1, electrical
connector 2 and the electrical connector 3.
13. Remove the control lever from the pod.
15. Remove the control lever and the power base F
assembly.
D D J K L
A Arm rest
B Screws and washers 1
C Screws and washers 2
D Screws and washers 3
E Gaiter collar
F Power base
G Top cover
H Switch electrical connectors
J Electrical connector 1
K Electrical connector 2
L Electrical connector 3
M Screws 4
Install
removal procedure.
30 - 317 9813/9400-1 30 - 317

15 - Joystick
(For: Manual Controls) 5. Remove the cab side cover (if installed) to access
the valve block. Refer to (PIL 06-06).
Remove 6. Remove the stabiliser control lever knobs and the
gaiters from inside the cab.
Refer to (PIL 01-03). 7. Remove the securing clip and the pin.
2. Install the safety strut. Refer to (PIL 06-69). 8. Disconnect the control lever rod from the spool
end.
Refer to (PIL 01-03). 9. Repeat the step 7 and the step 8 again for the
other control linkages.
30-00).
Figure 1284.
A B
H
D
E
F
G
A
L
M
N
K
N
A
N J
30 - 318 9813/9400-1 30 - 318

15 - Joystick
A Mounting screws B Control lever knobs

C Control rod 1 D Securing clip
E Pin F Locknut 1
G Spool end H Electrical connectors
J Valve block K Bracket
L Locknut 2 M Control rod 2
N Control rod 3
30 - 319 9813/9400-1 30 - 319

15 - Joystick
Install
steps.
1.1. After you install, check the operation of the
mechanical control rod 1 and control rod
3. Operate the control levers. Make sure
that the lever travel is the same in both
directions. To adjust the levers loosen the
locknut 1 or locknut 2 at each end of the
control rod 1 or control rod 2. Turn the
necessary. Tighten the locknuts.
1.2. Check the lever and spool adjustment -
refer to Adjustment PIL (30-54-00)
1.3. Operate the hydraulic system. Check for
correct operation and leaks.
30 - 320 9813/9400-1 30 - 320

15 - Joystick
Do not attempt to dismantle the joystick. If the joystick

is defective, a new unit must be installed.
Externally facing seals, port adaptors, gaiters and

joystick handles may be replaced if the correct parts
are available and the correct cleanliness procedures
are followed.
30 - 321 9813/9400-1 30 - 321

18 - Shuttle
18 - Shuttle 1.2. Lubricate the parts with JCB hydraulic fluid

before assembling.
Remove and Install Consumable: JCB Hydraulic Fluid HP 46

1.3. Apply JCB sealant to the inner seat and
tighten it to the specified torque value into
(For: 506-23 [T4F], 509-23 [T4F], Agri- the housing.
Xtra) Consumable: JCB Threadlocker and Sealer
Consumables (Medium Strength)
Description Part No. Size 1.4. Put the shuttle ball into the housing.
1.5. Apply JCB sealant to the outer seat and
46 4002/0805 20L tighten it to the housing.
4002/0803 200L
JCB Threadlocker 4101/0250 0.01L (Medium Strength)
Strength) Table 558. Torque Values
Item Description Nm
Remove B Inner seat 20
30-00).
3. Use an Allen key to remove the outer seat from
the valve block.
4. Remove the shuttle ball and the inner seat.
Figure 1285.
A
B C
A Valve block
B Inner seat
C Outer seat
D Shuttle ball
Install
steps.
applicable solvent.
30 - 322 9813/9400-1 30 - 322

27 - Auxiliary Circuit
27 - Auxiliary Circuit
Refer to discharge and pressurise, (PIL 30-00).
30 - 323 9813/9400-1 30 - 323

82 - Sway
82 - Sway Figure 1286.
Remove and Install

A
WARNING A raised and badly supported
machine can fall on you. Position the machine B
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do C
not rely solely on the machine hydraulics or jacks
to support the machine when working under it.
Disconnect the battery, to prevent the machine
being started while you are beneath it.
Remove
Refer to (PIL 01-03). D

4. Put labels on the hydraulic hoses to help
installation.
6. Plug all the open ports and hoses to prevent E E
contamination.
A Bracket
7. Disconnect the electrical connector from the B Sway/fan selector solenoid
stabiliser sway/fan selector solenoid. C Sway direction control solenoids
D Sway/fan valve
8. Disconnect the electrical connectors from the E Bolts
sway direction control solenoids.
Figure 1287. Typical Sway Valve Harness
9. Make a note of the route of the harness.
10. Remove the harness retaining clips.
F
11. Support the sway/fan valve.
12. Release the bolts and remove the sway/fan valve
from the bracket.
F Harness retaining clips

G Harness
30 - 324 9813/9400-1 30 - 324

82 - Sway
Install
steps.
1.1. Discard the old seals and install new seals
and O-rings. When you install adaptors, do
not overtighten as this distorts the body and
the valve may fail to operate correctly.
1.2. Reconnect the hoses in the correct
positions as labelled during removal.
1.3. Make sure to route the harness correctly
and replace the retaining clips.
1.4. Reconnect the electrical harness.
1.5. After installation, check that the valve
operates correctly and there are no
hydraulic leaks.
30 - 325 9813/9400-1 30 - 325

90 - Flow Regulator
90 - Flow Regulator
Introduction
30 - 326 9813/9400-1 30 - 326

61 - Counterbalance Valve
Contents Page No.
30-61-00 General ......................................................................................................................... 30-329

30-61-06 Lift Arm ......................................................................................................................... 30-334
30 - 327 9813/9400-1 30 - 327

Notes:
30 - 328 9813/9400-1 30 - 328

00 - General
Introduction .................................................. 30-329
Operation ..................................................... 30-330
Operation overview
The lift, extend and tilt ram circuits include a
counterbalance valve.
When there is a load on the carriage, the weight of

the load could cause the lift arm to lower or dump.
This would be dangerous as the load could lower
suddenly or fall off the carriage.
To prevent this, counterbalance valves are installed

to make sure that only the pressure of flow from
the control valve spool will move the lift arm or the
carriage and the weight will not affect it. Therefore
when the lift/lower or crowd/dump services are not
operated, the valve is closed effectively locking the
ram in position regardless of the load.
30 - 329 9813/9400-1 30 - 329

00 - General
Operation
The extend and tilt ram circuits have a To prevent this, counterbalance valves are installed
counterbalance valve. to make sure that, only the pressure of flow from the
control valve spool will move the lift arm or carriage
When there is a load on the carriage, the weight of and the weight will not affect it. Therefore when the
the load could cause the lift arm to lower or dump. lift/lower or crowd/dump services are not operated,
This would be dangerous as the load may lower the valve is closed effectively locking the ram in
suddenly or fall off the carriage. position regardless of load.
Component Location
Figure 1288.
A Extend ram counterbalance valve B Tilt ram counterbalance valve
30 - 330 9813/9400-1 30 - 330

00 - General
Hydraulic Operation and Schematics to hydraulic system- general, schematic circuit, refer
to (PIL 30-00-50).
Valve schematic
The schematic diagrams show a typical system. For
information about machine specific schematics, refer
Figure 1289. Typical Valve Schematics
A B
A Extend counterbalance valve B Tilt counterbalance valve
30 - 331 9813/9400-1 30 - 331

00 - General
System schematic ram. The counterbalance valve housing contains two

valves to prevent the compression of the ram due to
The schematic diagrams show a typical system. For the pressure in the ram returning to tank. The check
information about machine specific schematics, refer valve only allows flow when the piston end service
to hydraulic system- general, schematic circuit, refer is operated. The pressure valve will only open and
to (PIL 30-00-50). allow a return to tank when there is pressure in the
+ line feeding the piston side of the ram. If there is
The figure shows no hydraulic service operated. no pressure in this line the pressure valve will remain
Refer to Figure 1290. There is a load on the carriage closed and the ram is locked in position.
and the weight of this load is tries to compress the
Figure 1290.
D
A
B
_
C
In this figure, the rod side service spool in the control pressure valve opens and allows the pressure from
valve is operated. Refer to Figure 1291. Pressure is the piston side of the ram to return to tank. The check
supplied to retract the ram. When the pressure in the valve remains closed.
+ line is greater than the pressure from the spring, the
Figure 1291.
D
A
C1 B
_
In this figure, the piston side service spool in the valve opens to supply the ram. The pressure valve
control valve is operated. Refer to Figure 1292. remains closed.
Pressure is supplied to extend the ram. The check
30 - 332 9813/9400-1 30 - 332

00 - General
Figure 1292.
D
A
B
+
C
Electrical Operation
There are no electrical devices used in this system.
30 - 333 9813/9400-1 30 - 333

06 - Lift Arm
06 - Lift Arm
Operation
The counter balance valve is used to hold the lift If the pressure in the circuit is less than 10bar
arm in position and for it not to lower under its own (144.9psi) and the crowd and lift service operate at
weight. Refer to hydraulic system- counterbalance the same time, the hydraulic ECU (Electronic Control
valve, refer to (PIL 30-61). Unit) deselects the crowd service. This allows the
pressure to increase in the lift ram circuit.
When you operate the crowd and lift arm raise
hydraulic services, there are rare occasions when When the pressure in the circuit raises to more than
the flow may divert through the displacement ram 20bar (289.9psi) the hydraulic ECU responds by
circuit and cause the lift arm to raise under the power restoring normal operation of the crowd service.
of the displacement ram.
On machines with SRS (Smooth Ride System), the
Pressure monitoring of the lift ram full bore (rod SRS pressure transducer is used. For information
end) maintains a minimum pressure ensuring correct about the SRS system, refer to hydraulic system-
operation of the lift arm service. A pressure general, refer to (PIL 30-00).
transducer is installed in the full bore (rod end) side
of the lift arm circuit. On machines without the SRS, a pressure transducer
is installed.
Component Location
Figure 1293.
30 - 334 9813/9400-1 30 - 334

06 - Lift Arm
A Pressure transducer B Lift ram
30 - 335 9813/9400-1 30 - 335

06 - Lift Arm
Electrical Operation For machines with SD, SE and SF engines, refer to

hydraulic system- cylinder ram, refer to (PIL 30-15).
On machines with SRS, the SRS pressure
transducer is used. For information about the SRS For machines with SH, SL and DH engines, refer to
system, refer to hydraulic system- general, refer to hydraulic system- cylinder ram, refer to (PIL 30-15).
(PIL 30-00).
Figure 1294.
1 4 4 1
2 3 3 2
30 - 336 9813/9400-1 30 - 336

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-339
30 - 337 9813/9400-1 30 - 337

Notes:
30 - 338 9813/9400-1 30 - 338

00 - General
Introduction .................................................. 30-339 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-340 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 339 9813/9400-1 30 - 339

00 - General
Check (Operation) 5.2. If the lift arm moves after the engine stops,
then the lift arm HBCV is faulty. Do not use
DANGER Before lowering the attachments to the the machine until you correct the fault.
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or Carriage tilt cylinder
close to the machine could fall and be crushed by
the attachments, or get caught in the linkages. 1. Pick up a load on the forks.
WARNING Maintenance must be done only by 2. Tilt the carriage fully back.
suitably qualified and competent persons.
Before doing any maintenance make sure the 3. Make sure to engage the park brake and put the
machine is safe, it must be correctly parked on transmission to neutral.
solid, level ground. 4. Raise the lift arm and put it in a position that, the
To prevent anyone starting the engine, remove carriage can be tilted forward fully.
the ignition key. Disconnect the battery when you
are not using electrical power. If you do not take 5. Run the engine at mid speed and operate the
these precautions you could be killed or injured. control lever to tilt the carriage forward. While the
carriage is moving, switch off the engine.
Check each movement in turn. 5.1. The carriage movement must slow as the
engine slows. The carriage movement must
Lift arm lift cylinders stop when the engine stops.
1. Start the engine. 5.2. If the carriage moves after the engine stops,
then the HBCV is faulty. Do not use the
2. Make sure to engage the park brake and put the machine until you correct the fault.
transmission to neutral.
Stabiliser cylinder (if installed)
3. Raise the lift arm to the specified angle.
Angle: 45° 1. Start the engine.
4. Run the engine at mid speed and operate the 2. Make sure to engage the park brake and put the
control lever to lower the lift arm. While the lift transmission to neutral.
arm is moving, switch off the engine. 3. Lower the stabilisers.
4.1. The lift arm movement must slow as the 4. Make sure that the stabiliser legs are in the down
engine slows. The lift arm movement must position and supports the machine weight. Make
stop when the engine stops. sure that the front wheels are lifted from the
4.2. If the lift arm moves after the engine stops, ground.
then both the lift arm HBCV (Hose Burst
Check Valve) are faulty. Do not use the 5. Stop the machine.
machine until you correct the fault.
6. Operate the stabiliser controls.
Lift arm extension cylinder 7. Make sure that the front wheels of the machine
do not lower to the ground.
7.1. If the machine moves when the stabiliser
2. Make sure to engage the park brake and put the controls are operated after the engine is
transmission to neutral. stopped, the HBCV are faulty. Do not use
the machine until you correct the fault.
3. Raise the lift arm fully.
4. Extend the lift arm fully.
5. Run the engine at mid speed and operate the
control lever to retract the lift arm. While the lift
arm is retracting, switch off the engine.
5.1. The lift arm movement must slow as the
engine slows. The lift arm movement must
stop when the engine stops.
30 - 340 9813/9400-1 30 - 340

00 - General
Figure 1295.
X Gap between the wheel and the ground
Sway cylinder (if installed)

2. Make sure to engage the park brake and put the
transmission to neutral.
3. Sway the machine body approximately halfway
to the left and release the sway control.
4. Stop the engine.
5. Operate the sway control to the left. Check that
the machine does not sway.
6. Do steps 1 to 5 again for right sway.
7. If the body moves when the sway control is
moved with the engine stopped, the hose burst
protection valves are faulty.
8. Do not use the machine until you correct the fault.
30 - 341 9813/9400-1 30 - 341

70 - Pilot Pressure Supply Valve
Contents Page No.
30-70-00 General ......................................................................................................................... 30-343
30 - 342 9813/9400-1 30 - 342

00 - General
Operation ..................................................... 30-343 For: 506-23 [T4F], 509-23 [T4F], Agri-Xtra
................................................. Page 30-343
Check (Pressure) ........................................ 30-346
For: 506-23 [T4F], 509-23 [T4F], Agri, Agri-
Remove and Install ..................................... 30-348 Plus, Agri-Super ...................... Page 30-344
For: 512-26 [T4F] .................... Page 30-344
(For: 506-23 [T4F], 509-23 [T4F], Agri-

Xtra)
The servo pilot pressure supply valve is supplied
from the fan section of the hydraulic pump.
The pressure regulating valve maintains servo pilot

pressure by regulating the incoming supply pressure.
Oil at servo pilot pressure is supplied to the main
control valve inlet section.
The pressure regulating valve incorporates an

accumulator. The accumulator traps and stores
servo pilot pressure to enable the service spools
to be operated for a limited period with a stopped
engine. This allows for attachments to be lowered
safely to the ground even after the engine stops.
The supply of pilot oil can be isolated from the main

control valve by de-energising the solenoid. The
solenoid is controlled by a switch in the cab. When
the valve is de-energised , the trapped pilot oil in the
main control valve is diverted to the tank. The service
spools are locked and services cannot be operated
with or without the engine running.
The oil stored in the accumulator is isolated from

the servo pilot system when the solenoid is de-
energised.
Figure 1296.
C
TP1 TP2
A ACC
P P1
T T1
P2
B
T2
30 - 343 9813/9400-1 30 - 343

00 - General
A Servo pilot pressure supply valve B Solenoid

C Accumulator
(For: 506-23 [T4F], 509-23 [T4F], Agri, to be operated for a limited period with a stopped
Agri-Plus, Agri-Super) engine. This allows for attachments to be lowered
safely to the ground when the engine stops.
from the fan section of the hydraulic pump. Supply of pilot oil can be isolated from the main
control valve by the de-energising solenoid. The
The pressure regulating valve maintains servo pilot solenoid is controlled by the switch in the cab. When
pressure by regulating the incoming supply pressure. the valve is de-energised, the trapped pilot oil in the
Oil at the servo pilot pressure is supplied to the main main control valve is diverted to the tank. The service
control valve inlet section. spools are locked and services cannot be operated
The pressure regulating valve incorporates the
accumulator. The accumulator traps and stores the The oil stored in the accumulator is isolated from
servo pilot pressure to enable the service spools the servo pilot system when the solenoid is de-
energised.
Figure 1297.
A
B
A Solenoid B Accumulator
C Servo pilot pressure supply valve
(For: 512-26 [T4F]) pressure. The oil at servo pilot pressure is supplied
to the main control valve inlet section.
from the fan section of the hydraulic pump. The pressure regulating valve incorporates the
accumulator. The accumulator traps and stores the
The pressure regulating valve maintains the servo servo pilot pressure to enable the service spools
pilot pressure by regulating the incoming supply to be operated for a limited period with a stopped
30 - 344 9813/9400-1 30 - 344

00 - General
engine. This allows for attachments to be lowered main control valve is diverted to the tank. The service
safely to the ground when the engine stops. spools are locked and services cannot be operated
Supply of pilot oil can be isolated from the main
control valve by de-energising the solenoid. The The oil stored in the accumulator is isolated from
solenoid is controlled by switch in the cab. When the servo pilot system when the solenoid is de-
the valve is de-energised, the trapped pilot oil in the energised.
Figure 1298.
A
B
A Solenoid B Pilot pressure supply valve

C Accumulator
30 - 345 9813/9400-1 30 - 345

00 - General
Check (Pressure)
(For: 506-23 [T4F], 509-23 [T4F]) 1. Turn the ignition key switch to on, but do not start
the engine.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 2. Discharge the hydraulic pressure from the
Before connecting or removing any hydraulic hose, system. Refer to (PIL 30-00).
residual hydraulic pressure trapped in the service 3. Separate the hose from the filter and install tee-
hose line must be vented. Make sure the hose piece between the them.
Figure 1299.
A Hose B Filter
C Tee-piece D Pressure gauge
30 - 346 9813/9400-1 30 - 346

00 - General
4. Connect a pressure gauge of the specified value

to the tee-piece.
up to the specified working temperature.
6. Gradually increase the engine speed to 2200
RPM (Revolutions Per Minute). while you check
the maximum gauge reading, it should be as
stated on specification.
7. Make sure that the pressure does not fall below
the lower limit at engine idle speed.
Clean the valve

The servo pilot pressure reducing valve is not
adjustable. The valve cartridge is not serviceable
beyond cleaning. A cartridge should be renewed
complete if wear or damage is visible.
30 - 347 9813/9400-1 30 - 347

00 - General
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], Agri-Xtra Figure 1300.

................................................. Page 30-348
For: 506-23 [T4F], 509-23 [T4F], Agri, Agri-
Plus, Agri-Super ...................... Page 30-349
For: 512-26 [T4F] .................... Page 30-350
(For: 506-23 [T4F], 509-23 [T4F], Agri-

Xtra)
Remove
A
B
3. Discharge the hydraulic pressure. Refer to (PIL A
30-00).
4. Disconnect the electrical harness at the solenoid
5. Put a label on each hose to help installation. E
6. Disconnect the hydraulic hoses. C

contamination.
8. Support the valve.
9. Remove the bolts, washers and remove the valve
and bracket from the machine.
G
D F
A Hoses
B Solenoid electrical connector
C Valve
D Accumulator
E Bracket
F Bolts
G Washers
Install
1. If a new accumulator is to be installed, it may
require charging. Refer to (PIL 30-00).
steps.
2.1. Make sure that the hoses are reconnected
to the correct ports.
2.2. After installation, check the servo pressure.
30 - 348 9813/9400-1 30 - 348

00 - General
The extent of permissible servicing is the renewal Figure 1301.

of the solenoid coil and the accumulator. Further
dismantling of the valve is not recommended. If the
A B C
valve is suspected as being faulty it must be renewed
(For: 506-23 [T4F], 509-23 [T4F], Agri,

Agri-Plus, Agri-Super)
Remove
A
2. Install the safety strut. Refer to (PIL 06-69). A
3. Discharge the hydraulic pressure. Refer to

(PIL30-00).
4. Disconnect the electrical harness from the
solenoid electrical connector. D

E
contamination.
8. Support the valve.
9. Remove the bolts and washers, remove the valve
from the bracket.
F
A Hoses
B Solenoid coil
C Accumulator
D Valve
E Washers
F Bracket
Install
steps.
The extent of permissible servicing is the renewal

30 - 349 9813/9400-1 30 - 349

00 - General
(For: 512-26 [T4F]) 4. Disconnect the electrical harness at the solenoid

Remove 5. Put a label on each hose to help installation.
1. Make the machine safe with the lift arm raised. 6. Disconnect the hydraulic hoses.
2. Install the safety strut. Refer to (PIL 06-69). contamination..
3. Discharge the hydraulic pressure. Refer to (PIL 8. Support the valve.
30-00).
9. Remove the bolts, washers and remove the valve
from the machine.
Figure 1302.
A Bolts and washers B Solenoid coil

C Valve D Accumulator
30 - 350 9813/9400-1 30 - 350

00 - General
Install
steps.
The extent of permissible servicing is the renewal

30 - 351 9813/9400-1 30 - 351

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-353

30-93-03 Lift Arm ......................................................................................................................... 30-361
30 - 352 9813/9400-1 30 - 352

93 - Hose
00 - General
Introduction .................................................. 30-353 Hydraulic hoses are used to connect different
Component Identification ............................. 30-354 components in the hydraulic circuit. The hoses
Disconnect and Connect ............................. 30-359 are graded by pressure, temperature, and fluid
Check (Condition) ........................................ 30-360 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 - 353 9813/9400-1 30 - 353

93 - Hose
00 - General
For: 506-23 [T4F], 509-23 [T4F]

................................................. Page 30-354
For: 506-23 [T4F], 509-23 [T4F]
................................................. Page 30-356
(For: 506-23 [T4F], 509-23 [T4F])
Figure 1303. Neutral Circuit Layout
30 - 354 9813/9400-1 30 - 354

93 - Hose
00 - General
Figure 1304.
Item Description
90 Hose 3/8 BSP
Table 559.
110 Tee adaptor M/F/M
Item Description
120 Hose 5/8 BSP480mm
10 Bolt M8 x 60 Grade 8.8
130 Hose 5/8 BSP2,590mm
20 Plain washer M8
140 Hose 1/4 BSP1,110mm
30 Accumulator 9/16" 18
160 BSP adaptor 5/8 x 5/8 x
UNF
1/4
40 Adaptor 3/8 BSP X
170 Grommet
3/8BSP X 3/8
180 Label- hydraulic trailer
brake speed
60 Trailer brake coupling
70 Hose 3/8 BSP (British
Standard Pipe)2,100mm
30 - 355 9813/9400-1 30 - 355

93 - Hose
00 - General
(For: 506-23 [T4F], 509-23 [T4F])
Figure 1305.
30 - 356 9813/9400-1 30 - 356

93 - Hose
00 - General
Figure 1306.
Item Description
Table 560. 200 Hose 1,645mm White
Item Description 210 Hose- 04 BSP HP
10 Plain washer M10 740mm
20 Spring washer M10 220 Hose 3/4 " BSP- 1"
SAE570mm
30 HMH tank return tem-
plate 230 Hose 1,350mm Green/
Yellow
40 Adaptor G1/2A x 3/4
SAE (Society of Auto- 240 Hose 1,550mm Red
motive Engineers) 250 Hose 3/8" 285LG
50 5/8 BSP cap 260 Hose 5/8 LP
60 CPV 270 Hose-06 BSP HP
70 Trailer brake 1,300mm A
90 BSP adaptor 5/8 x 5/8 x 280 Cap screw M10 x 65
1/4 G12.9
100 Hose 1,150mm Yellow 290 Low pressure hose
150mm
110 HOSE 5/8" BSP 1585
300 Clip worm drive 60/80
120 Hose 5/8 BSP980mm mm
130 Hose 3,560mm Orange 310 Tube suction HMH
150 Hose- 10 BSP HP 320 Plug 9/16 ring boss
680mm C
330 Port adaptor flange
170 Hose 1" BSP1,420mm
340 Pressure test point
180 Hose 1/2 BSP950mm
350 O-ring
190 Hose 1/4 BSP1,155mm
30 - 357 9813/9400-1 30 - 357

93 - Hose
00 - General
Item Description
360 Split flange
370 Plain washer M8
380 Set screw M10 x 25
G8.8
390 Bolt M8 x 50 G8.8
400 WA fan pipes
410 M8 locknut
420 Cable tie 300mm
430 Plain washer M10
30 - 358 9813/9400-1 30 - 358

93 - Hose
00 - General
Disconnect and Connect 4. Pull the hose to verify that the coupling is fully
engaged.
Special Tools
Description Part No. Qty. 4.1. If the connection is not good the coupling
will release very easily.
Quick Connect Hose 825/10053 1
Release Tool
WARNING Hydraulic fluid at system pressure

can injure you. Before connecting or removing
any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented.
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.
Disconnect
2. Push the hose. Refer to Figure 1307.
3. Insert the specified tool.
Special Tool: Quick Connect Hose Release Tool
(Qty.: 1)
4. Push on the hose, and at the same time use the
tool as a lever to release the coupling.
Figure 1307.
A
B
A Hose
B Quick connect hose release tool
Connect
1. Make sure that the hose coupling is clean and
the O-rings are not damaged.
1.1. Apply some clean hydraulic fluid to the O-
rings.
2. Align the coupling to the hydraulic port.
3. Push the coupling into the port as far as possible.
3.1. The coupling will click when it is fully
engaged.
30 - 359 9813/9400-1 30 - 359

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 - 360 9813/9400-1 30 - 360

93 - Hose
03 - Lift Arm
03 - Lift Arm
Technical Data
Refer to hydraulic system, hose, lift arm, component

identification (PIL 30-93-03).
30 - 361 9813/9400-1 30 - 361

96 - Pipe
96 - Pipe
Contents Page No.
30-96-03 Lift Arm ......................................................................................................................... 30-363
30 - 362 9813/9400-1 30 - 362

96 - Pipe
03 - Lift Arm
03 - Lift Arm
Refer to component identification, (PIL 30-93-03).
30 - 363 9813/9400-1 30 - 363

97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling .............................................................................................. 30-365

30-97-09 Adaptor ......................................................................................................................... 30-367
30-97-24 Push Lock Fitting ......................................................................................................... 30-369
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-370
30 - 364 9813/9400-1 30 - 364

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-365 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-366 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 1311.
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 - 365 9813/9400-1 30 - 365

97 - Connectors
03 - Quick Release Coupling
• Periodically lubricate the internal locking balls Disconnect and Connect

on the female half of the coupling with silicone
grease.
Some attachments are hydraulically powered. The
Essential Don'ts following procedures show how to connect and
disconnect the hydraulic hoses safely.
• Never try to reconnect using a damaged half
coupling as this will destroy the seals in the
mating half and necessitate replacement of Connect
both halves. 1. Make the machine safe.
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this Refer to: PIL 01-03.
will distort the sleeve and prevent connection
and disconnection. 2. Discharge the hydraulic pressure.
• Never try to turn the sleeve when the coupling is Refer to: PIL 30-00-00.
disconnected as this will cause the locking ball
to jam under the locking sleeve and damage the 3. Wipe the two faces of the male and female
coupling. couplings and make sure they are clean.
• Never try to strip the coupling down, there are
no user serviceable parts. If the coupling is 4. Make sure that the ball in the female coupling is
damaged it must be replaced with a new one. located in one of its slots.
• Never hit the centre poppet of the coupling to 5. Connect the male coupling into the female
try and release the locked in pressure. This can coupling.
cause irreparable damage to the coupling and
serious injury. 6. Where applicable, rotate the sleeve half a turn
• When connecting the couplings, never clamp and make sure that the locking ball does not align
on the sleeve of the female or nose of the male, with the slot.
this will cause distortion and/or damage.
• Never subject the couplings to external forces, Disconnect
especially side load. This can decrease the life
of the coupling or cause failure. 1. Make the machine safe.
• Never allow the torsional forces transmitted
from the hoses to unscrew/screw together the Refer to: PIL 01-03.
couplings.
2. Discharge the hydraulic pressure.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in Refer to: PIL 30-00-00.
the line unless the coupling type is specifically
designed to do so. 3. Where applicable, align the slot with the ball.
4. Pull back the sleeve to release the coupling.
Figure 1312.
C D E
C Ball
D Slot
E Sleeve
30 - 366 9813/9400-1 30 - 366

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-367 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-368 may utilise Positional Type SAE (Society of
Automotive Engineers) Hydraulic Adaptors. When
you install a Positional Type Hydraulic Adaptor,
it is important to adopt the Remove and Install
procedure. Refer to: PIL 30-97-09.
If this procedure is not followed correctly, damage to

the O-ring seal can occur which can result in oil leaks.
Figure 1313.
A O-ring seal
B Locknut
C Washer
30 - 367 9813/9400-1 30 - 367

97 - Connectors
09 - Adaptor
1. Make sure that the locknut is screwed back on to

the body of the adaptor as far as possible.
2. Check that the O-ring backing washer is a tight
fit on the adaptor. Note that the washer should
not move freely, if the washer is slack do not use
the adaptor.
3. Check that the O-ring seal is installed and
that it is free from damage or nicks. Before
you install the adaptor, smear the O-ring with
clean hydraulic fluid. The dimensions and shore
hardness of the O-ring seal is critical. Should it
become necessary to replace the O-ring seal,
make sure you use JCB Genuine Parts.
Figure 1314.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.

Item Nm
B 81
A O-ring seal
B Locknut
C Backing washer
4. Screw the adaptor into the port of the hydraulic
component as far as possible, so that all the
threads engage and the O-ring seal is correctly
seated against the sealing face.
5. Set the angular position of the adaptor as
required, then secure by tightening the locknut.
When installed correctly no more than one thread
should be visible at Z as shown.
30 - 368 9813/9400-1 30 - 368

97 - Connectors
24 - Push Lock Fitting
24 - Push Lock Fitting
Remove and Install
The fitting is installed and removed without the need

for tools, it is removable and reusable.
1. To release the tube push the collet and release

the tube. All tubes have an assembly mark to
assist installation.
Figure 1316.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 369 9813/9400-1 30 - 369

97 - Connectors
27 - Rapid Assembly Hose Fitting
27 - Rapid Assembly Hose Fitting
Remove and Install
The hose has a toolless installation. The hose is not

removable. The complete hose and fitting assembly
must be replaced.
1. To install the hose, push the tube into the fitting

body.
Figure 1317.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 370 9813/9400-1 30 - 370

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 ................................................................................................................... 33-314
33-03 Battery
33-03-00 General ......................................................................................................................... 33-319
33-03-03 Isolator Switch .............................................................................................................. 33-330
33-06 Battery Cable
33-06-00 General ......................................................................................................................... 33-333
33-06-12 Earth Strap ................................................................................................................... 33-335
33-09 Power Distribution
33-09-00 General ......................................................................................................................... 33-339
33-09-03 Fuse ............................................................................................................................. 33-341
33-09-06 Relay ............................................................................................................................ 33-347
33-12 Harness
33-12-00 General ......................................................................................................................... 33-351
33-12-04 Chassis ......................................................................................................................... 33-364
33-12-06 Lift Arm ......................................................................................................................... 33-376
33-12-09 Engine .......................................................................................................................... 33-393
33-12-12 Operator Station ........................................................................................................... 33-416
33-12-14 Sway ............................................................................................................................. 33-468
33-12-15 Front Console ............................................................................................................... 33-473
33-12-22 Armrest ......................................................................................................................... 33-498
33-12-30 Gearbox ........................................................................................................................ 33-510
33-12-34 Trailer Brake ................................................................................................................. 33-528
33-12-36 Work Lights .................................................................................................................. 33-530
33-12-39 Road Lights .................................................................................................................. 33-541
33-12-44 Battery .......................................................................................................................... 33-561
33-12-45 Power Distribution ........................................................................................................ 33-595
33-12-46 Immobiliser ................................................................................................................... 33-601
33-12-93 Selective Catalytic Reduction (SCR) ........................................................................... 33-607
33-15 Alarm
33-15-03 Reverse Warning .......................................................................................................... 33-615
33-21 Immobiliser
33-21-00 General ......................................................................................................................... 33-617
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-623
33-24-10 Hourmeter .................................................................................................................... 33-627
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................... 33-629
33-27-51 Hydraulic Flow .............................................................................................................. 33-631
33-33 Console Switch
9813/9400-1
2017-10-21
33-33-04 Direction Indicators ...................................................................................................... 33-637
33-33-15 Transmission Disconnect ............................................................................................. 33-648
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-651
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-655
33-45-06 Engine .......................................................................................................................... 33-682
33-45-09 Gearbox ........................................................................................................................ 33-685
33-45-24 Servo ............................................................................................................................ 33-700
33-45-36 Hydraulic ...................................................................................................................... 33-706
33-45-44 Nitrogen Oxide (NOx) Sensor ...................................................................................... 33-721
33-48 Entertainment
33-48-03 Radio ............................................................................................................................ 33-725
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-729
33-51-03 Socket .......................................................................................................................... 33-730
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-733
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-735
33-57-03 Servicemaster .............................................................................................................. 33-739
33-57-90 Fault Codes .................................................................................................................. 33-805
33-66 Load Motion Control System
33-66-00 General ......................................................................................................................... 33-885
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-899
33-84-15 Transmission Oil Temperature ..................................................................................... 33-900
33-84-41 Lift Arm ......................................................................................................................... 33-901
33-84-51 Rear Axle ..................................................................................................................... 33-904
33-84-72 Chassis ......................................................................................................................... 33-908
33-86 Solenoid
33-86-00 General ......................................................................................................................... 33-915
9813/9400-1
2017-10-21
Acronyms Glossary
2WD Two Wheel Drive

4WS Four Wheel Steer
AWS All Wheel Steer
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
DTVT Dual Technology Variable
Transmission
LCD Liquid Crystal Display
LED Light Emitting Diode
LLMC Longitudinal Load Moment Control
LLMI Longitudinal Load Moment Indicator
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
OEM Original Equipment Manufacturer
RAS Rear Axle Stabilization
TMAF Temperature and Mass Air Flow
USB Universal Serial Bus
VIN Vehicle Identification Number
9813/9400-1
2017-10-21
Notes:
9813/9400-1
2017-10-21
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................... 33-314
33 - 1 9813/9400-1 33 - 1
Notes:
33 - 2 9813/9400-1 33 - 2
00 - General
Introduction ...................................................... 33-3 It is important that the electrical system on the
Health and Safety ........................................... 33-4 machine is in a sound state of repair.
Fault-Finding .................................................... 33-5
Check (Condition) ............................................ 33-7 Make sure that all the health and safety warnings
in this section are followed. The machine must be
safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/9400-1 33 - 3
00 - General
Health and Safety

Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the
alternator before arc-welding on the machine or
attached implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
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
Always connect the welder earth (ground) cable to
the same component that is being welded to avoid
the welder earth (ground) cable a distance from the
part being welded no more than 0.6m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9813/9400-1 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 562. Page 33-5
General Relay Fault Table 563. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 564. Page 33-6
ECM Faults Table 565. Page 33-6
Table 562. 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 563. 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 9813/9400-1 33 - 5
00 - General
Cause Remedy
ECM Connection Fault Disconnect the harness from engine ECM and
necessary.
Check the continuity and electrical insulation, repair
or replace as necessary.
If a relay fault is found, raise Techweb Helpdesk Call.
Table 564. 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 565. 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 9813/9400-1 33 - 6
00 - General
Check (Condition)
Examine the electrical circuits regularly for:
• Damaged connectors.
• Loose connections.
• Chafing on the wiring harnesses.
• Corrosion.
• Missing insulation.
• Incorrect routing of the wiring harnesses.
Do not use the machine if one or more of these faults

are found. You must make sure that the electrical
circuit is repaired immediately.
33 - 7 9813/9400-1 33 - 7
50 - Schematic Circuit Introduction

Introduction ...................................................... 33-8 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 33-11 representation of the machines electrical circuit. It
shows the components of the circuit as simplified
electrical symbols, and the power and signal
connections between the devices. The wiring
diagram is used to troubleshoot problems and to
make sure that all the connections have been made
and that everything is present.
Use the schematics together with the correct

electrical harness drawings to reference the
connector pin details.
This section may contain more than one set of

electrical schematics for different machine variants.
Understanding Electrical Schematics

Use the applicable schematic set to trace wires
and connections between electrical devices. In most
cases it will be necessary to trace wires across more
than one schematic sheet.
The example identifies the information contained on

the diagrams. It also shows how to follow wires from
one diagram sheet to another.
The harness inter-connector codes and device

harness connector codes are the same as used on
the applicable harness drawings.
Splices are not normally accessible. Splices are

inside the harness sheath and not visible on the
outside. Wires are welded together at a splice, there
are no individual connector components.
33 - 8 9813/9400-1 33 - 8
Figure 1318.
/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 9813/9400-1 33 - 9
Figure 1319. 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 9813/9400-1 33 - 10
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................... Page 33-11
For: 512-26 [T4F] ...................... Page 33-92
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1320. Primary Fuses, Secondary Fuses, Ignition Relays 160/16000 Issue 1 (sheet 1 of
20)........................................................................................................................................... Page 33-13
Figure 1321. Engine Senders, Starting and Charging 160/16000 Issue 1 (sheet 2 of 20)......Page 33-17
Figure 1322. Instruments, Warning Lamps 160/16000 Issue 1 (sheet 3 of 20)......................Page 33-21
Figure 1323. Road light, Reverse Alarm, Trailer Electrics 160/16000 Issue 1 (sheet 4 of
20)........................................................................................................................................... Page 33-25
Figure 1324. Work lights, Rotating Beacon, Heated Seat, Interior light 160/16000 Issue 1 (sheet 5 of
20)........................................................................................................................................... Page 33-29
Figure 1325. Horn, Wipers, Heater, Air Conditioning, Low Beam, Main Beam and Indicator Switching
160/16000 Issue 1 (sheet 6 of 20)......................................................................................... Page 33-33
Figure 1326. 6 Speed Transmission Control Machine Interface 160/16000 Issue 1 (sheet 7 of
20)........................................................................................................................................... Page 33-37
Figure 1327. 6 Speed Transmission Control Gearbox Interface, Tow Mode Control 160/16000 Issue 1
(sheet 8 of 20)........................................................................................................................ Page 33-41
Figure 1328. Steer Mode Control 160/16000 Issue 1 (sheet 9 of 20).................................... Page 33-45
Figure 1329. LSP Hydraulic Control 160/16000 Issue 1 (sheet 10 of 20).............................. Page 33-49
Figure 1330. Smooth Ride System 160/16000 Issue 1 (sheet 11 of 20)................................Page 33-53
Figure 1331. Inloader Control, Reverse Fan, Hitch Control, LLMI, Sway Control 160/16000 Issue 1
(sheet 12 of 20)...................................................................................................................... Page 33-57
Figure 1332. Twin Auxiliary- Non LSP Hydraulics 160/16000 Issue 1 (sheet 13 of 20)..........Page 33-61
Figure 1333. Single Auxiliary- Non LSP Hydraulics 160/16000 Issue 1 (sheet 14 of 20)....... Page 33-65
Figure 1334. In Cab Entertainment 160/16000 Issue 1 (sheet 15 of 20)............................... Page 33-69
Figure 1335. Engine Splices, Chassis Splices 160/16000 Issue 1 (sheet 16 of 20)...............Page 33-73
Figure 1336. Cab Splices 160/16000 Issue 1 (sheet 17 of 20)..............................................Page 33-77
Figure 1339. Cab Splices, Rear Cab Ground 160/16000 Issue 1 (sheet 20 of 20)................ Page 33-89
33 - 11 9813/9400-1 33 - 11
Notes:
33 - 12 9813/9400-1 33 - 12
Figure 1320. Primary Fuses,
Page 33-14 Secondary Fuses, Ignition Relays

160/16000 Issue 1 (sheet 1 of 20) Page 33-15
33 - 13 9813/9400-1 33 - 13
33-14 33-15
Page 33-15
33 - 14 9813/9400-1 33 - 14
33-14 33-15
Page 33-14
33 - 15 9813/9400-1 33 - 15
33 - 16 9813/9400-1 33 - 16
Page 33-18 Figure 1321. Engine Senders, Starting and

Charging 160/16000 Issue 1 (sheet 2 of 20) Page 33-19
33 - 17 9813/9400-1 33 - 17
33-18 33-19
Page 33-19
33 - 18 9813/9400-1 33 - 18
33-18 33-19
Page 33-18
33 - 19 9813/9400-1 33 - 19
33 - 20 9813/9400-1 33 - 20
Page 33-22 Figure 1322. Instruments, Warning

Lamps 160/16000 Issue 1 (sheet 3 of 20) Page 33-23
33 - 21 9813/9400-1 33 - 21
33-22 33-23
Page 33-23
33 - 22 9813/9400-1 33 - 22
33-22 33-23
Page 33-22
33 - 23 9813/9400-1 33 - 23
33 - 24 9813/9400-1 33 - 24
Page 33-26 Figure 1323. Road light, Reverse Alarm, Trailer

Electrics 160/16000 Issue 1 (sheet 4 of 20) Page 33-27
33 - 25 9813/9400-1 33 - 25
33-26 33-27
Page 33-27
33 - 26 9813/9400-1 33 - 26
33-26 33-27
Page 33-26
33 - 27 9813/9400-1 33 - 27
33 - 28 9813/9400-1 33 - 28
Figure 1324. Work lights, Rotating
Page 33-30 Beacon, Heated Seat, Interior light

33 - 29 9813/9400-1 33 - 29
33-30 33-31
Page 33-31
33 - 30 9813/9400-1 33 - 30
33-30 33-31
Page 33-30
33 - 31 9813/9400-1 33 - 31
33 - 32 9813/9400-1 33 - 32
Figure 1325. Horn, Wipers, Heater,

Air Conditioning, Low Beam, Main
Page 33-34 Beam and Indicator Switching

33 - 33 9813/9400-1 33 - 33
33-34 33-35
Page 33-35
33 - 34 9813/9400-1 33 - 34
33-34 33-35
Page 33-34
33 - 35 9813/9400-1 33 - 35
33 - 36 9813/9400-1 33 - 36
Figure 1326. 6 Speed Transmission
Page 33-38 Control Machine Interface

33 - 37 9813/9400-1 33 - 37
33-38 33-39
Page 33-39
33 - 38 9813/9400-1 33 - 38
33-38 33-39
Page 33-38
33 - 39 9813/9400-1 33 - 39
33 - 40 9813/9400-1 33 - 40
Figure 1327. 6 Speed Transmission
Page 33-42 Control Gearbox Interface, Tow Mode

Control 160/16000 Issue 1 (sheet 8 of 20) Page 33-43
33 - 41 9813/9400-1 33 - 41
33-42 33-43
Page 33-43
33 - 42 9813/9400-1 33 - 42
33-42 33-43
Page 33-42
33 - 43 9813/9400-1 33 - 43
33 - 44 9813/9400-1 33 - 44
Page 33-46 Figure 1328. Steer Mode Control

33 - 45 9813/9400-1 33 - 45
33-46 33-47
Page 33-47
33 - 46 9813/9400-1 33 - 46
33-46 33-47
Page 33-46
33 - 47 9813/9400-1 33 - 47
33 - 48 9813/9400-1 33 - 48
Page 33-50 Figure 1329. LSP Hydraulic Control

33 - 49 9813/9400-1 33 - 49
33-50 33-51
Page 33-51
33 - 50 9813/9400-1 33 - 50
33-50 33-51
Page 33-50
33 - 51 9813/9400-1 33 - 51
33 - 52 9813/9400-1 33 - 52
Page 33-54 Figure 1330. Smooth Ride System

33 - 53 9813/9400-1 33 - 53
33-54 33-55
Page 33-55
33 - 54 9813/9400-1 33 - 54
33-54 33-55
Page 33-54
33 - 55 9813/9400-1 33 - 55
33 - 56 9813/9400-1 33 - 56
Figure 1331. Inloader Control, Reverse
Page 33-58 Fan, Hitch Control, LLMI, Sway Control

33 - 57 9813/9400-1 33 - 57
33-58 33-59
Page 33-59
33 - 58 9813/9400-1 33 - 58
33-58 33-59
Page 33-58
33 - 59 9813/9400-1 33 - 59
33 - 60 9813/9400-1 33 - 60
Page 33-62 Figure 1332. Twin Auxiliary- Non LSP

Hydraulics 160/16000 Issue 1 (sheet 13 of 20) Page 33-63
33 - 61 9813/9400-1 33 - 61
33-62 33-63
Page 33-63
33 - 62 9813/9400-1 33 - 62
33-62 33-63
Page 33-62
33 - 63 9813/9400-1 33 - 63
33 - 64 9813/9400-1 33 - 64
Page 33-66 Figure 1333. Single Auxiliary- Non LSP

Hydraulics 160/16000 Issue 1 (sheet 14 of 20) Page 33-67
33 - 65 9813/9400-1 33 - 65
33-66 33-67
Page 33-67
33 - 66 9813/9400-1 33 - 66
33-66 33-67
Page 33-66
33 - 67 9813/9400-1 33 - 67
33 - 68 9813/9400-1 33 - 68
Page 33-70 Figure 1334. In Cab Entertainment

33 - 69 9813/9400-1 33 - 69
33-70 33-71
Page 33-71
33 - 70 9813/9400-1 33 - 70
33-70 33-71
Page 33-70
33 - 71 9813/9400-1 33 - 71
33 - 72 9813/9400-1 33 - 72
Page 33-74 Figure 1335. Engine Splices, Chassis

Splices 160/16000 Issue 1 (sheet 16 of 20) Page 33-75
33 - 73 9813/9400-1 33 - 73
33-74 33-75
Page 33-75
33 - 74 9813/9400-1 33 - 74
33-74 33-75
Page 33-74
33 - 75 9813/9400-1 33 - 75
33 - 76 9813/9400-1 33 - 76
Page 33-78 Figure 1336. Cab Splices

33 - 77 9813/9400-1 33 - 77
33-78 33-79
Page 33-79
33 - 78 9813/9400-1 33 - 78
33-78 33-79
Page 33-78
33 - 79 9813/9400-1 33 - 79
33 - 80 9813/9400-1 33 - 80

33 - 81 9813/9400-1 33 - 81
33-82 33-83
Page 33-83
33 - 82 9813/9400-1 33 - 82
33-82 33-83
Page 33-82
33 - 83 9813/9400-1 33 - 83
33 - 84 9813/9400-1 33 - 84

33 - 85 9813/9400-1 33 - 85
33-86 33-87
Page 33-87
33 - 86 9813/9400-1 33 - 86
33-86 33-87
Page 33-86
33 - 87 9813/9400-1 33 - 87
33 - 88 9813/9400-1 33 - 88
Page 33-90 Figure 1339. Cab Splices, Rear Cab

Ground 160/16000 Issue 1 (sheet 20 of 20) Page 33-91
33 - 89 9813/9400-1 33 - 89
33-90 33-91
Page 33-91
33 - 90 9813/9400-1 33 - 90
33-90 33-91
Page 33-90
33 - 91 9813/9400-1 33 - 91
(For: 512-26 [T4F])

Figure 1340. 2 Speed Washer/Wiper (Agri Xtra (servo), Agri Super) 160/F3101- Issue 3 (sheet 2 of
57)........................................................................................................................................... Page 33-95
Figure 1341. Single Speed Washer/Wiper (Agri Plus) 160/F3101- Issue 3 (sheet 3 of
57)........................................................................................................................................... Page 33-99
Figure 1342. Roadlights Panel (Agri Xtra (servo), Agri Super) 160/F3101- Issue 3 (sheet 4 of
57)......................................................................................................................................... Page 33-103
Figure 1343. Roadlights Panel (Agri Plus) 160/F3101- Issue 3 (sheet 5 of 57)................... Page 33-107
Figure 1344. Roadlights- Chassis (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101- Issue 3 (sheet
6 of 57)..................................................................................................................................Page 33-111
Figure 1345. Work Lights and Beacon (Agri Xtra (servo), Agri Super, Agri Plus, 550-80) 160/F3101-
Issue 3 (sheet 7 of 57)......................................................................................................... Page 33-115
Figure 1346. Air Conditioning and Other Cab Functions (Agri Xtra (servo), Agri Super) 160/F3101-
Issue 3 (sheet 8 of 57)......................................................................................................... Page 33-119
Figure 1347. Air Conditioning and Other Cab Functions (Agri Plus) 160/F3101- Issue 3 (sheet 9 of
57)......................................................................................................................................... Page 33-123
Figure 1348. Park Brake (Agri Xtra (servo), Agri Super) 160/F3101- Issue 3 (sheet 10 of
57)......................................................................................................................................... Page 33-127
Figure 1349. Park Brake (Agri Plus) 160/F3101- Issue 3 (sheet 11 of 57)...........................Page 33-131
Figure 1350. Joystick (Agri Xtra (servo)) 160/F3101- Issue 3 (sheet 12 of 57)....................Page 33-135
Figure 1351. Joystick (Agri Xtra (servo)) 160/F3101- Issue 3 (sheet 13 of 57)....................Page 33-139
Figure 1352. Joystick (Agri Super) 160/F3101- Issue 3 (sheet 14 of 57).............................Page 33-143
Figure 1353. Joystick (Agri Plus) 160/F3101- Issue 3 (sheet 15 of 57)............................... Page 33-147
Figure 1354. Joystick (Agri Super, Agri Plus) 160/F3101- Issue 3 (sheet 16 of 57)............. Page 33-151
Figure 1355. Electro Hydraulic Control (LSV Plus) 160/F3101- Issue 3 (sheet 17 of 57).....Page 33-155
Figure 1356. Electro Hydraulic Control (Electro LSV Plus) 160/F3101- Issue 3 (sheet 18 of
57)......................................................................................................................................... Page 33-159
Figure 1357. Electro Hydraulic Control (Electro S LSV Plus) 160/F3101- Issue 3 (sheet 19 of
57)......................................................................................................................................... Page 33-163
Figure 1358. Electro Hydraulic Control (LSV Plus, Electro LSV Plus, Electro S LSV Plus) 160/F3101-
Issue 3 (sheet 20 of 57)....................................................................................................... Page 33-167
Figure 1359. Steer Mode (Agri Xtra (servo), Agri Super) 160/F3101- Issue 3 (sheet 21 of
57)......................................................................................................................................... Page 33-171
Figure 1360. Steer Mode (Agri Plus) 160/F3101- Issue 3 (sheet 22 of 57)..........................Page 33-175
Figure 1361. Machine Side Engine (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue 3 (sheet
23 of 57)................................................................................................................................Page 33-179
Figure 1363. Machine Side Engine (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue 3 (sheet
25 of 57)................................................................................................................................Page 33-183
Figure 1364. T3 Electronic Engine (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue 3 (sheet
26 of 57)................................................................................................................................Page 33-187
Figure 1365. SRS (Agri Xtra (servo)) 160/F3101 Issue 3 (sheet 27 of 57).......................... Page 33-191
Figure 1366. SRS (Agri Super, Agri Plus) 160/F3101 Issue 3 (sheet 28 of 57)................... Page 33-195
Figure 1367. Warning Lights (Agri Xtra (servo), Agri Super) 160/F3101 Issue 3 (sheet 29 of
57)......................................................................................................................................... Page 33-199
Figure 1368. Warning Lights (Agri Plus) 160/F3101 Issue 3 (sheet 30 of 57)......................Page 33-203
Figure 1369. Left Side Column Switch (Agri Xtra (servo), Agri Super) 160/F3101 Issue 3 (sheet 31 of
57)......................................................................................................................................... Page 33-207
Figure 1370. Left Side Column Switch (Agri Plus) 160/F3101 Issue 3 (sheet 32 of 57)....... Page 33-211
Figure 1371. Heated Screen, LMI and Radio (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue
3 (sheet 33 of 57)................................................................................................................. Page 33-215
Figure 1372. Auxiliary and Tow (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue 3 (sheet 34
of 57)..................................................................................................................................... Page 33-219
Figure 1373. Hitch (Agri Xtra (servo)) 160/F3101 Issue 3 (sheet 35 of 57)......................... Page 33-223
Figure 1374. Hitch (Agri Super, Agri Plus) 160/F3101 Issue 3 (sheet 36 of 57)...................Page 33-227
33 - 92 9813/9400-1 33 - 92
Figure 1375. Reverse Fan and Info (Agri Xtra (servo), Agri Super, Agri Plus, 550-80) 160/F3101 Issue
3 (sheet 37 of 57)................................................................................................................. Page 33-231
Figure 1376. Machine Side Transmission (Agri Xtra (servo)) 160/F3101 Issue 3 (sheet 38 of
57)......................................................................................................................................... Page 33-235
Figure 1377. Machine Side Transmission (Agri Super) 160/F3101 Issue 3 (sheet 39 of
57)......................................................................................................................................... Page 33-239
Figure 1378. Machine Side Transmission (Agri Plus) 160/F3101 Issue 3 (sheet 40 of
57)......................................................................................................................................... Page 33-243
Figure 1379. 6 Speed VP Transmission (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue 3
(sheet 41 of 57).................................................................................................................... Page 33-247
Figure 1380. 4 Speed VP Transmission (Agri Xtra (servo), Agri Super, Agri Plus) 160/F3101 Issue 3
(sheet 42 of 57).................................................................................................................... Page 33-251
Figure 1381. Transmission Drive Control (LSV Plus) 160/F3101 Issue 3 (sheet 43 of 57)...Page 33-255
Figure 1382. Transmission Drive Control (Electro LSV Plus) 160/F3101 Issue 3 (sheet 44 of
57)......................................................................................................................................... Page 33-259
Figure 1383. Transmission Drive Control (Electro S LSV Plus) 160/F3101 Issue 3 (sheet 45 of
57)......................................................................................................................................... Page 33-263
Figure 1384. CAN (Agri Xtra (servo), Agri Super) 160/F3101 Issue 3 (sheet 46 of 57)........Page 33-267
Figure 1385. CAN (Agri Plus) 160/F3101 Issue 3 (sheet 47 of 57)......................................Page 33-271
Figure 1386. CAN (LSV Plus) 160/F3101 Issue 3 (sheet 48 of 57)..................................... Page 33-275
Figure 1387. CAN (Electro LSV Plus) 160/F3101 Issue 3 (sheet 49 of 57)......................... Page 33-279
Figure 1388. CAN (Electro S LSV Plus) 160/F3101 Issue 3 (sheet 50 of 57)...................... Page 33-283
Figure 1389. Electro Hydraulic Control (550-80) 160/F3101 Issue 3 (sheet 51 of 57)......... Page 33-287
Figure 1390. Joystick Control (550-80) 160/F3101 Issue 3 (sheet 52 of 57)....................... Page 33-291
Figure 1391. Machine Side Transmission (550-80) 160/F3101 Issue 3 (sheet 53 of 57)..... Page 33-295
Figure 1392. Proportional Fan Control (550-80) 160/F3101 Issue 3 (sheet 54 of 57).......... Page 33-299
Figure 1393. Roadlights- Chassis (550-80) 160/F3101 Issue 3 (sheet 55 of 57)................. Page 33-303
Figure 1394. Steermode (550-80) 160/F3101 Issue 3 (sheet 56 of 57)............................... Page 33-307
Figure 1395. CAN (550-80) 160/F3101 Issue 3 (sheet 57 of 57).........................................Page 33-311
33 - 93 9813/9400-1 33 - 93
Notes:
33 - 94 9813/9400-1 33 - 94
Figure 1340. 2 Speed Washer/
Page 33-96 Wiper (Agri Xtra (servo), Agri Super)

160/F3101- Issue 3 (sheet 2 of 57) Page 33-97
33 - 95 9813/9400-1 33 - 95
33-96 33-97
Page 33-97
33 - 96 9813/9400-1 33 - 96
33-96 33-97
Page 33-96
33 - 97 9813/9400-1 33 - 97
33 - 98 9813/9400-1 33 - 98
Page 33-100 Figure 1341. Single Speed Washer/Wiper

(Agri Plus) 160/F3101- Issue 3 (sheet 3 of 57) Page 33-101
33 - 99 9813/9400-1 33 - 99
33-100 33-101
Page 33-101
33 - 100 9813/9400-1 33 - 100

33-100 33-101
Page 33-100
33 - 101 9813/9400-1 33 - 101

33 - 102 9813/9400-1 33 - 102

Figure 1342. Roadlights Panel
Page 33-104 (Agri Xtra (servo), Agri Super)

33 - 103 9813/9400-1 33 - 103

33-104 33-105
Page 33-105
33 - 104 9813/9400-1 33 - 104

33-104 33-105
Page 33-104
33 - 105 9813/9400-1 33 - 105

33 - 106 9813/9400-1 33 - 106

Page 33-108 Figure 1343. Roadlights Panel (Agri

Plus) 160/F3101- Issue 3 (sheet 5 of 57) Page 33-109
33 - 107 9813/9400-1 33 - 107

33-108 33-109
Page 33-109
33 - 108 9813/9400-1 33 - 108

33-108 33-109
Page 33-108
33 - 109 9813/9400-1 33 - 109

33 - 110 9813/9400-1 33 - 110

Figure 1344. Roadlights- Chassis (Agri
Page 33-112 Xtra (servo), Agri Super, Agri Plus)

33 - 111 9813/9400-1 33 - 111

33-112 33-113
Page 33-113
33 - 112 9813/9400-1 33 - 112

33-112 33-113
Page 33-112
33 - 113 9813/9400-1 33 - 113

33 - 114 9813/9400-1 33 - 114

Figure 1345. Work Lights and Beacon
Page 33-116 (Agri Xtra (servo), Agri Super, Agri Plus,

550-80) 160/F3101- Issue 3 (sheet 7 of 57) Page 33-117
33 - 115 9813/9400-1 33 - 115

33-116 33-117
Page 33-117
33 - 116 9813/9400-1 33 - 116

33-116 33-117
Page 33-116
33 - 117 9813/9400-1 33 - 117

33 - 118 9813/9400-1 33 - 118

Figure 1346. Air Conditioning and Other
Page 33-120 Cab Functions (Agri Xtra (servo), Agri

Super) 160/F3101- Issue 3 (sheet 8 of 57) Page 33-121
33 - 119 9813/9400-1 33 - 119

33-120 33-121
Page 33-121
33 - 120 9813/9400-1 33 - 120

33-120 33-121
Page 33-120
33 - 121 9813/9400-1 33 - 121

33 - 122 9813/9400-1 33 - 122

Figure 1347. Air Conditioning and
Page 33-124 Other Cab Functions (Agri Plus)

33 - 123 9813/9400-1 33 - 123

33-124 33-125
Page 33-125
33 - 124 9813/9400-1 33 - 124

33-124 33-125
Page 33-124
33 - 125 9813/9400-1 33 - 125

33 - 126 9813/9400-1 33 - 126

Page 33-128 Figure 1348. Park Brake (Agri Xtra (servo),

Agri Super) 160/F3101- Issue 3 (sheet 10 of 57) Page 33-129
33 - 127 9813/9400-1 33 - 127

33-128 33-129
Page 33-129
33 - 128 9813/9400-1 33 - 128

33-128 33-129
Page 33-128
33 - 129 9813/9400-1 33 - 129

33 - 130 9813/9400-1 33 - 130

Page 33-132 Figure 1349. Park Brake (Agri Plus)

33 - 131 9813/9400-1 33 - 131

33-132 33-133
Page 33-133
33 - 132 9813/9400-1 33 - 132

33-132 33-133
Page 33-132
33 - 133 9813/9400-1 33 - 133

33 - 134 9813/9400-1 33 - 134

Page 33-136 Figure 1350. Joystick (Agri Xtra (servo))

33 - 135 9813/9400-1 33 - 135

33-136 33-137
Page 33-137
33 - 136 9813/9400-1 33 - 136

33-136 33-137
Page 33-136
33 - 137 9813/9400-1 33 - 137

33 - 138 9813/9400-1 33 - 138

Page 33-140 Figure 1351. Joystick (Agri Xtra (servo))

33 - 139 9813/9400-1 33 - 139

33-140 33-141
Page 33-141
33 - 140 9813/9400-1 33 - 140

33-140 33-141
Page 33-140
33 - 141 9813/9400-1 33 - 141

33 - 142 9813/9400-1 33 - 142

Page 33-144 Figure 1352. Joystick (Agri Super)

33 - 143 9813/9400-1 33 - 143

33-144 33-145
Page 33-145
33 - 144 9813/9400-1 33 - 144

33-144 33-145
Page 33-144
33 - 145 9813/9400-1 33 - 145

33 - 146 9813/9400-1 33 - 146

Page 33-148 Figure 1353. Joystick (Agri Plus)

33 - 147 9813/9400-1 33 - 147

33-148 33-149
Page 33-149
33 - 148 9813/9400-1 33 - 148

33-148 33-149
Page 33-148
33 - 149 9813/9400-1 33 - 149

33 - 150 9813/9400-1 33 - 150

Page 33-152 Figure 1354. Joystick (Agri Super, Agri

33 - 151 9813/9400-1 33 - 151

33-152 33-153
Page 33-153
33 - 152 9813/9400-1 33 - 152

33-152 33-153
Page 33-152
33 - 153 9813/9400-1 33 - 153

33 - 154 9813/9400-1 33 - 154

Page 33-156 Figure 1355. Electro Hydraulic Control (LSV

33 - 155 9813/9400-1 33 - 155

33-156 33-157
Page 33-157
33 - 156 9813/9400-1 33 - 156

33-156 33-157
Page 33-156
33 - 157 9813/9400-1 33 - 157

33 - 158 9813/9400-1 33 - 158

Page 33-160 Figure 1356. Electro Hydraulic Control (Electro

LSV Plus) 160/F3101- Issue 3 (sheet 18 of 57) Page 33-161
33 - 159 9813/9400-1 33 - 159

33-160 33-161
Page 33-161
33 - 160 9813/9400-1 33 - 160

33-160 33-161
Page 33-160
33 - 161 9813/9400-1 33 - 161

33 - 162 9813/9400-1 33 - 162

Page 33-164 Figure 1357. Electro Hydraulic Control (Electro

S LSV Plus) 160/F3101- Issue 3 (sheet 19 of 57) Page 33-165
33 - 163 9813/9400-1 33 - 163

33-164 33-165
Page 33-165
33 - 164 9813/9400-1 33 - 164

33-164 33-165
Page 33-164
33 - 165 9813/9400-1 33 - 165

33 - 166 9813/9400-1 33 - 166

Figure 1358. Electro Hydraulic Control
Page 33-168 (LSV Plus, Electro LSV Plus, Electro S LSV

33 - 167 9813/9400-1 33 - 167

33-168 33-169
Page 33-169
33 - 168 9813/9400-1 33 - 168

33-168 33-169
Page 33-168
33 - 169 9813/9400-1 33 - 169

33 - 170 9813/9400-1 33 - 170

Page 33-172 Figure 1359. Steer Mode (Agri Xtra (servo),

Agri Super) 160/F3101- Issue 3 (sheet 21 of 57) Page 33-173
33 - 171 9813/9400-1 33 - 171

33-172 33-173
Page 33-173
33 - 172 9813/9400-1 33 - 172

33-172 33-173
Page 33-172
33 - 173 9813/9400-1 33 - 173

33 - 174 9813/9400-1 33 - 174

Page 33-176 Figure 1360. Steer Mode (Agri Plus)

33 - 175 9813/9400-1 33 - 175

33-176 33-177
Page 33-177
33 - 176 9813/9400-1 33 - 176

33-176 33-177
Page 33-176
33 - 177 9813/9400-1 33 - 177

33 - 178 9813/9400-1 33 - 178

Figure 1361. Machine Side Engine
Page 33-180 (Agri Xtra (servo), Agri Super, Agri

Plus) 160/F3101 Issue 3 (sheet 23 of 57) Page 33-181
33 - 179 9813/9400-1 33 - 179

33-180 33-181
Page 33-181
33 - 180 9813/9400-1 33 - 180

33-180 33-181
Page 33-180
33 - 181 9813/9400-1 33 - 181

Figure 1362. T3 Electronic Engine (Agri Xtra (servo),

Agri Super, Agri Plus) 160/F311 Issue 3 (sheet 24 of 57)
33 - 182 9813/9400-1 33 - 182

Figure 1363. Machine Side Engine

33 - 183 9813/9400-1 33 - 183

33-184 33-185
Page 33-185
33 - 184 9813/9400-1 33 - 184

33-184 33-185
Page 33-184
33 - 185 9813/9400-1 33 - 185

33 - 186 9813/9400-1 33 - 186

Figure 1364. T3 Electronic Engine (Agri

160/F3101 Issue 3 (sheet 26 of 57) Page 33-189
33 - 187 9813/9400-1 33 - 187

33-188 33-189
Page 33-189
33 - 188 9813/9400-1 33 - 188

33-188 33-189
Page 33-188
33 - 189 9813/9400-1 33 - 189

33 - 190 9813/9400-1 33 - 190

Page 33-192 Figure 1365. SRS (Agri Xtra (servo))

33 - 191 9813/9400-1 33 - 191

33-192 33-193
Page 33-193
33 - 192 9813/9400-1 33 - 192

33-192 33-193
Page 33-192
33 - 193 9813/9400-1 33 - 193

33 - 194 9813/9400-1 33 - 194

Page 33-196 Figure 1366. SRS (Agri Super, Agri

33 - 195 9813/9400-1 33 - 195

33-196 33-197
Page 33-197
33 - 196 9813/9400-1 33 - 196

33-196 33-197
Page 33-196
33 - 197 9813/9400-1 33 - 197

33 - 198 9813/9400-1 33 - 198

Page 33-200 Figure 1367. Warning Lights (Agri Xtra (servo),

Agri Super) 160/F3101 Issue 3 (sheet 29 of 57) Page 33-201
33 - 199 9813/9400-1 33 - 199

33-200 33-201
Page 33-201
33 - 200 9813/9400-1 33 - 200

33-200 33-201
Page 33-200
33 - 201 9813/9400-1 33 - 201

33 - 202 9813/9400-1 33 - 202

Page 33-204 Figure 1368. Warning Lights (Agri Plus)

33 - 203 9813/9400-1 33 - 203

33-204 33-205
Page 33-205
33 - 204 9813/9400-1 33 - 204

33-204 33-205
Page 33-204
33 - 205 9813/9400-1 33 - 205

33 - 206 9813/9400-1 33 - 206

Figure 1369. Left Side Column
Page 33-208 Switch (Agri Xtra (servo), Agri Super)

33 - 207 9813/9400-1 33 - 207

33-208 33-209
Page 33-209
33 - 208 9813/9400-1 33 - 208

33-208 33-209
Page 33-208
33 - 209 9813/9400-1 33 - 209

33 - 210 9813/9400-1 33 - 210

Page 33-212 Figure 1370. Left Side Column Switch (Agri

33 - 211 9813/9400-1 33 - 211

33-212 33-213
Page 33-213
33 - 212 9813/9400-1 33 - 212

33-212 33-213
Page 33-212
33 - 213 9813/9400-1 33 - 213

33 - 214 9813/9400-1 33 - 214

Figure 1371. Heated Screen, LMI and
Page 33-216 Radio (Agri Xtra (servo), Agri Super, Agri

33 - 215 9813/9400-1 33 - 215

33-216 33-217
Page 33-217
33 - 216 9813/9400-1 33 - 216

33-216 33-217
Page 33-216
33 - 217 9813/9400-1 33 - 217

33 - 218 9813/9400-1 33 - 218

Figure 1372. Auxiliary and Tow (Agri

33 - 219 9813/9400-1 33 - 219

33-220 33-221
Page 33-221
33 - 220 9813/9400-1 33 - 220

33-220 33-221
Page 33-220
33 - 221 9813/9400-1 33 - 221

33 - 222 9813/9400-1 33 - 222

Page 33-224 Figure 1373. Hitch (Agri Xtra (servo))

33 - 223 9813/9400-1 33 - 223

33-224 33-225
Page 33-225
33 - 224 9813/9400-1 33 - 224

33-224 33-225
Page 33-224
33 - 225 9813/9400-1 33 - 225

33 - 226 9813/9400-1 33 - 226

Page 33-228 Figure 1374. Hitch (Agri Super, Agri

33 - 227 9813/9400-1 33 - 227

33-228 33-229
Page 33-229
33 - 228 9813/9400-1 33 - 228

33-228 33-229
Page 33-228
33 - 229 9813/9400-1 33 - 229

33 - 230 9813/9400-1 33 - 230

Figure 1375. Reverse Fan and Info (Agri
Page 33-232 Xtra (servo), Agri Super, Agri Plus,

550-80) 160/F3101 Issue 3 (sheet 37 of 57) Page 33-233
33 - 231 9813/9400-1 33 - 231

33-232 33-233
Page 33-233
33 - 232 9813/9400-1 33 - 232

33-232 33-233
Page 33-232
33 - 233 9813/9400-1 33 - 233

33 - 234 9813/9400-1 33 - 234

Page 33-236 Figure 1376. Machine Side Transmission (Agri

Xtra (servo)) 160/F3101 Issue 3 (sheet 38 of 57) Page 33-237
33 - 235 9813/9400-1 33 - 235

33-236 33-237
Page 33-237
33 - 236 9813/9400-1 33 - 236

33-236 33-237
Page 33-236
33 - 237 9813/9400-1 33 - 237

33 - 238 9813/9400-1 33 - 238

Page 33-240 Figure 1377. Machine Side Transmission (Agri

Super) 160/F3101 Issue 3 (sheet 39 of 57) Page 33-241
33 - 239 9813/9400-1 33 - 239

33-240 33-241
Page 33-241
33 - 240 9813/9400-1 33 - 240

33-240 33-241
Page 33-240
33 - 241 9813/9400-1 33 - 241

33 - 242 9813/9400-1 33 - 242

Page 33-244 Figure 1378. Machine Side Transmission

(Agri Plus) 160/F3101 Issue 3 (sheet 40 of 57) Page 33-245
33 - 243 9813/9400-1 33 - 243

33-244 33-245
Page 33-245
33 - 244 9813/9400-1 33 - 244

33-244 33-245
Page 33-244
33 - 245 9813/9400-1 33 - 245

33 - 246 9813/9400-1 33 - 246

Figure 1379. 6 Speed VP Transmission

33 - 247 9813/9400-1 33 - 247

33-248 33-249
Page 33-249
33 - 248 9813/9400-1 33 - 248

33-248 33-249
Page 33-248
33 - 249 9813/9400-1 33 - 249

33 - 250 9813/9400-1 33 - 250

Figure 1380. 4 Speed VP Transmission

33 - 251 9813/9400-1 33 - 251

33-252 33-253
Page 33-253
33 - 252 9813/9400-1 33 - 252

33-252 33-253
Page 33-252
33 - 253 9813/9400-1 33 - 253

33 - 254 9813/9400-1 33 - 254

Page 33-256 Figure 1381. Transmission Drive Control

(LSV Plus) 160/F3101 Issue 3 (sheet 43 of 57) Page 33-257
33 - 255 9813/9400-1 33 - 255

33-256 33-257
Page 33-257
33 - 256 9813/9400-1 33 - 256

33-256 33-257
Page 33-256
33 - 257 9813/9400-1 33 - 257

33 - 258 9813/9400-1 33 - 258

Figure 1382. Transmission Drive
Page 33-260 Control (Electro LSV Plus) 160/

F3101 Issue 3 (sheet 44 of 57) Page 33-261
33 - 259 9813/9400-1 33 - 259

33-260 33-261
Page 33-261
33 - 260 9813/9400-1 33 - 260

33-260 33-261
Page 33-260
33 - 261 9813/9400-1 33 - 261

33 - 262 9813/9400-1 33 - 262

Figure 1383. Transmission Drive
Page 33-264 Control (Electro S LSV Plus) 160/

33 - 263 9813/9400-1 33 - 263

33-264 33-265
Page 33-265
33 - 264 9813/9400-1 33 - 264

33-264 33-265
Page 33-264
33 - 265 9813/9400-1 33 - 265

33 - 266 9813/9400-1 33 - 266

Page 33-268 Figure 1384. CAN (Agri Xtra (servo), Agri

Super) 160/F3101 Issue 3 (sheet 46 of 57) Page 33-269
33 - 267 9813/9400-1 33 - 267

33-268 33-269
Page 33-269
33 - 268 9813/9400-1 33 - 268

33-268 33-269
Page 33-268
33 - 269 9813/9400-1 33 - 269

33 - 270 9813/9400-1 33 - 270

Page 33-272 Figure 1385. CAN (Agri Plus) 160/

33 - 271 9813/9400-1 33 - 271

33-272 33-273
Page 33-273
33 - 272 9813/9400-1 33 - 272

33-272 33-273
Page 33-272
33 - 273 9813/9400-1 33 - 273

33 - 274 9813/9400-1 33 - 274

Page 33-276 Figure 1386. CAN (LSV Plus) 160/

33 - 275 9813/9400-1 33 - 275

33-276 33-277
Page 33-277
33 - 276 9813/9400-1 33 - 276

33-276 33-277
Page 33-276
33 - 277 9813/9400-1 33 - 277

33 - 278 9813/9400-1 33 - 278

Page 33-280 Figure 1387. CAN (Electro LSV Plus)

33 - 279 9813/9400-1 33 - 279

33-280 33-281
Page 33-281
33 - 280 9813/9400-1 33 - 280

33-280 33-281
Page 33-280
33 - 281 9813/9400-1 33 - 281

33 - 282 9813/9400-1 33 - 282

Page 33-284 Figure 1388. CAN (Electro S LSV Plus)

33 - 283 9813/9400-1 33 - 283

33-284 33-285
Page 33-285
33 - 284 9813/9400-1 33 - 284

33-284 33-285
Page 33-284
33 - 285 9813/9400-1 33 - 285

33 - 286 9813/9400-1 33 - 286

Page 33-288 Figure 1389. Electro Hydraulic Control

(550-80) 160/F3101 Issue 3 (sheet 51 of 57) Page 33-289
33 - 287 9813/9400-1 33 - 287

33-288 33-289
Page 33-289
33 - 288 9813/9400-1 33 - 288

33-288 33-289
Page 33-288
33 - 289 9813/9400-1 33 - 289

33 - 290 9813/9400-1 33 - 290

Page 33-292 Figure 1390. Joystick Control (550-80)

33 - 291 9813/9400-1 33 - 291

33-292 33-293
Page 33-293
33 - 292 9813/9400-1 33 - 292

33-292 33-293
Page 33-292
33 - 293 9813/9400-1 33 - 293

33 - 294 9813/9400-1 33 - 294

Page 33-296 Figure 1391. Machine Side Transmission

33 - 295 9813/9400-1 33 - 295

33-296 33-297
Page 33-297
33 - 296 9813/9400-1 33 - 296

33-296 33-297
Page 33-296
33 - 297 9813/9400-1 33 - 297

33 - 298 9813/9400-1 33 - 298

Page 33-300 Figure 1392. Proportional Fan Control

33 - 299 9813/9400-1 33 - 299

33-300 33-301
Page 33-301
33 - 300 9813/9400-1 33 - 300

33-300 33-301
Page 33-300
33 - 301 9813/9400-1 33 - 301

33 - 302 9813/9400-1 33 - 302

Page 33-304 Figure 1393. Roadlights- Chassis (550-80)

33 - 303 9813/9400-1 33 - 303

33-304 33-305
Page 33-305
33 - 304 9813/9400-1 33 - 304

33-304 33-305
Page 33-304
33 - 305 9813/9400-1 33 - 305

33 - 306 9813/9400-1 33 - 306

Page 33-308 Figure 1394. Steermode (550-80)

33 - 307 9813/9400-1 33 - 307

33-308 33-309
Page 33-309
33 - 308 9813/9400-1 33 - 308

33-308 33-309
Page 33-308
33 - 309 9813/9400-1 33 - 309

33 - 310 9813/9400-1 33 - 310

Page 33-312 Figure 1395. CAN (550-80) 160/

33 - 311 9813/9400-1 33 - 311

33-312 33-313
Page 33-313
33 - 312 9813/9400-1 33 - 312

33-312 33-313
Page 33-312
33 - 313 9813/9400-1 33 - 313

90 - Earth Point
90 - Earth Point Introduction

Introduction .................................................. 33-314 The ground or earth refers to the reference point in an
Component Identification ............................. 33-315 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 - 314 9813/9400-1 33 - 314

90 - Earth Point
Figure 1396.
D C
Table 566. Cables and straps

Item Description Location
A Earth cable, battery to chassis. Under cab, and battery compart-
ment
B Earth strap, cab to chassis. Inside the external lower front pan-
el of the cab.
33 - 315 9813/9400-1 33 - 315

90 - Earth Point
Item Description Location

C Earth cable, starter motor to chas- Inside engine compartment.
sis.
D Earth cable, engine block to chas- Inside engine compartment, cable
sis. bolted to engine at the rear of the
cylinder block.
Table 567. Harness earths

Item Wire number Description Location
E -001 Earth point, chassis har- Inside engine compart-
ness. ment.
F -003 Earth point, cab harness. Inside the cab instrument
-004 panels. Access required
to the cab frame on the
right side of the steering
column.
G -006 Earth point, cab rear har- Inside the cab roof lining
ness.
33 - 316 9813/9400-1 33 - 316

03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ......................................................................................................................... 33-319

33-03-03 Isolator Switch .............................................................................................................. 33-330
33 - 317 9813/9400-1 33 - 317

Notes:
33 - 318 9813/9400-1 33 - 318

03 - Battery
00 - General
Introduction .................................................. 33-319 Batteries used in normal temperate climate
Health and Safety ........................................ 33-320 applications should not need topping up. However,
Technical Data ............................................. 33-321 in certain conditions (such as prolonged operation
Fault-Finding ................................................ 33-322 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Disconnect and Connect ............................. 33-323 frequently and topped up as necessary.
Clean ........................................................... 33-326
Check (Condition) ........................................ 33-326 The electrolyte level should be checked in
Charge ......................................................... 33-327 accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
Remove and Install ..................................... 33-328 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 1397.
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
6mm 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 - 319 9813/9400-1 33 - 319

03 - Battery
00 - General
• Never charge a battery at a voltage in excess Health and Safety

of 15.8V.
• 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 5min 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 - 320 9813/9400-1 33 - 320

03 - Battery
00 - General
suitable closed receptacle and must be disposed Technical Data

of in accordance with local environmental waste
regulations.
Table 568.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to Voltage Cold Cranking Battery Type
protect the circuits and components. The battery Amps (CCA)
must still be disconnected even if a battery 12V 1000 1131XMF Main-
isolator is installed. tenance free
33 - 321 9813/9400-1 33 - 321

03 - Battery
00 - General
Fault-Finding
The most obvious sign of a battery problem is a
machine not being able to start. However, because
the battery is part of a larger electrical system
connected to other parts of the machine, a flat battery
may indicate another problem.
If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition.
33 - 322 9813/9400-1 33 - 322

03 - Battery
00 - General
Disconnect and Connect
Notice: Before you install a pair of batteries to Figure 1398. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.
Disconnect 12 V 24 V
1. Make the machine safe. D B D B
Refer to: PIL 01-03-27. Figure 1399. Twin Battery 12V Ma-
chines- Parallel Connection (Example)
2. Get access to the battery or batteries (depending
on the specification of your machine). The actual B
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key. C
4. Disconnect the battery negative lead first.
5. Disconnect the battery positive lead and store
away from the batteries.
A
A D
6. Disconnect and remove the battery link lead or
leads.
A Battery
B Positive lead
C Battery link lead
D Negative lead
33 - 323 9813/9400-1 33 - 323

03 - Battery
00 - General
Figure 1400. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 324 9813/9400-1 33 - 324

03 - Battery
00 - General
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 1401.
Figure 1401.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
33 - 325 9813/9400-1 33 - 325

03 - Battery
00 - General

WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the Battery Test
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it This test is to determine the electrical condition of
happens you can get burned. the battery and to give an indication of the remaining
useful life.
Before you test the battery, make sure that the
2. Get access to the battery. battery is at least 75% charged (Specific Gravity of
1.23 to 1.25 for ambient temperature up to 27°C).
3. If the terminal posts are corroded and covered
with white powder wash them with hot water. Make sure that the battery is completely
If there is considerable corrosion, clean the disconnected from the vehicle.
terminal posts with a wire brush or abrasive
paper. Refer to Figure 1402. Figure 1403.
Figure 1402.
4. Apply a thin layer of petroleum jelly to the

terminal posts.
A Battery voltage switch
B Check load switch
Connect up the battery tester as follows:
1. Set the Check Load switch to OFF.

2. Set the battery voltage switch to 12V.
3. Connect the red flying lead to the battery positive
(+) terminal and the black flying lead to the
battery negative (-) terminal.
4. Set the Check/Load switch to CHECK to read the
battery no-load voltage which should be at least
12.4 volts.
5. Set the Check/Load switch to LOAD and hold
down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 326 9813/9400-1 33 - 326

03 - Battery
00 - General
Table 569. Fault Diagnosis Charge

Battery Tester Read- Remedy
ings
CHECK: 0 -12.6 Volts: Renew battery Precautions before Charging
LOAD: less than 6 Volts
Follow all the precautions described below, to
CHECK: 6 -12.4 Volts: Recharge and re-test. If prevent damage to the alternator and battery.
LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery 1. Make the machine safe.
mains in yellow zone
CHECK: less than 10 Indicates battery has
Volts: LOAD: less than 3 been over-discharged 2. Make sure that the battery negative terminal is
Volts and unlikely to recover. connected to the earth cable.
Renew battery
CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover 3. Do not connect or disconnect the battery
steady or alternator connections, or any part of the
charging circuit while the engine is in operation.
Specific Gravity Test If you disregard this instruction, the regulator or
rectifying diodes will be damaged.
The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings 4. Main output cables are always in active state
should be taken using a hydrometer, when the of current flow even when the engine is not in
electrolyte temperature is 15°C (60°F). If the battery operation. If the alternator connector is removed,
has recently been on charge, wait approximately one do not earth the moulded plug.
hour (or slightly discharge the battery) to dissipate
the surface charge before testing. 5. When you do arc welding on the machine,
remove the moulded plug (or if the separate
Readings should be as tabulated and should not vary output cables are installed, remove the cables)
between cells by more than 0.04. A greater variation to protect the alternator.
indicates an internal fault on that particular cell.
6. If it is necessary to jump start the battery then do
If the electrolyte temperature is other than 15°C the steps below.
(60°F) a 'correction factor' must be applied to the 6.1. Connect the secondary battery in parallel
reading obtained. Add 0.07 per 10°C (18°F) if the without disconnecting the vehicle battery
temperature is higher than 15°C (60°F) and subtract from the charging circuit.
the same if the temperature is lower.
6.2. After the jump start, safely disconnect and
Table 570. Specific Gravity at 15°C (60°F)) remove the secondary battery.
Ambient Fully Half Dis- Fully Dis- 6.3. Make sure you connect the positive terminal
Temper- Charged charged charged to the positive terminal and the negative
ature de- terminal to the negative terminal of both the
grees C batteries.
(degrees
F)
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
(80)
Above 27 1.240-1.260 1.170-1.190 1.090-1.110
(80)
33 - 327 9813/9400-1 33 - 327

03 - Battery
00 - General
Remove and Install
(For: 506-23 [T4F], 509-23 [T4F]) 4. Disconnect the batteries. Refer to (PIL 33-03).
CAUTION This component is heavy. It must only 5. Make sure that all battery connection wires are
be removed or handled using a suitable lifting clear of the top of the batteries.
method and device.
6. Remove the wing nuts and disconnect the battery
clamps.
Your machine will differ from that shown below. The
illustration is for information only. 7. Lift the clamp clear of the batteries. Make sure
you do not touch the battery terminals with the
Remove clamps.
1. Make the machine safe. Refer to (PIL 01-03). 8. Remove the batteries from the compartment and
make sure that you do not use the access cover
2. Follow the hydraulic care and safety procedures. to support the weight of the battery.
3. Get access to the battery (or batteries). Refer to
(PIL 06-06-03).
Figure 1404.
B
A
A Wing nuts B Clamp
33 - 328 9813/9400-1 33 - 328

03 - Battery
00 - General
C Battery
Install
The machine has a 12 volt electrical system. If there
are 2 batteries, they are connected in parallel so that
they have a combined voltage of 12 volts.
Make sure the batteries are not connected in series

(24 volt) because the increased voltage will damage
the machines electrical system.

removal procedure.
33 - 329 9813/9400-1 33 - 329

03 - Battery
03 - Isolator Switch
03 - Isolator Switch
Introduction
The battery isolator switch is used to disconnect the

battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect. Refer to: PIL
33-03-00.
33 - 330 9813/9400-1 33 - 330

06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ......................................................................................................................... 33-333

33-06-12 Earth Strap ................................................................................................................... 33-335
33 - 331 9813/9400-1 33 - 331

Notes:
33 - 332 9813/9400-1 33 - 332

06 - Battery Cable
00 - General
Introduction .................................................. 33-333 The cables connect the battery positive and negative
Check (Condition) ........................................ 33-334 terminals to the machine electrical system.
33 - 333 9813/9400-1 33 - 333

06 - Battery Cable
00 - General
Check (Condition)
2. Make sure that all battery terminals and
connections are secure and tight.
3. Make sure that all earth connections are secure
and tight.
4. Check that the battery terminals or cables are not
corroded. Refer to clean, (PIL 33-03-00).
4.1. Remove any corrosion.
4.2. Apply petroleum jelly to battery
connections.
5. Check the cables are not damaged or chaffed.
6. Repair or replace as needed.
33 - 334 9813/9400-1 33 - 334

06 - Battery Cable
12 - Earth Strap
12 - Earth Strap
Figure 1405. Earth Points
CT
DE
AE
Table 571. Earth Points

Item Description Access
A Earth cable, battery to chassis. Under cab and battery compart-
ment.
B Earth strap, cab to chassis. Remove external lower front panel
from cab.
C Earth cable, motor to chassis. Inside engine compartment.
D Earth cable, engine block to chas- Inside engine compartment, cable
sis. bolted to engine at the rear of the
cylinder block.
33 - 335 9813/9400-1 33 - 335

06 - Battery Cable
12 - Earth Strap
Item Description Access

DE Earth point, cab harness. Remove cab instrument panels.
Access required to the cab frame
on the right side of the steering col-
umn.
AE Earth point, cab rear harness. Remove cab roof lining.
CT Earth point, chassis harness. Inside engine compartment.
33 - 336 9813/9400-1 33 - 336

09 - Power Distribution
Contents Page No.
33-09-00 General ......................................................................................................................... 33-339

33-09-03 Fuse ............................................................................................................................. 33-341
33-09-06 Relay ............................................................................................................................ 33-347
33 - 337 9813/9400-1 33 - 337

Notes:
33 - 338 9813/9400-1 33 - 338

00 - General
Introduction .................................................. 33-339 The electrical circuits are protected by fuses. If a
Health and Safety ........................................ 33-340 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 - 339 9813/9400-1 33 - 339

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 - 340 9813/9400-1 33 - 340

03 - Fuse
03 - Fuse Technical Data

Technical Data ............................................. 33-341
Secondary Fuses
Figure 1406.
1A 11B
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
21C 31D
22 32
23 33
24 34
25 35
26 36
27 37
28 38
29 39
30 40
41E 51
42 52
43 53
44 54
45
46
47
48
49
50
33 - 341 9813/9400-1 33 - 341

03 - Fuse
Table 572.
Fuse Circuit(s) Protected Rating
1A Ignition 5A
2 Crank 30A
3 Heated Glass 25A
4 Front/rear Auxiliary 15A
5 Heater Hose and SCR (Selective Catalytic Reduction)ECU (Electronic Control 5A
Unit)
6 Engine ECU 3A
7 Heater Blower 30A
8 Brake Lights 10A
9 Seat Pressure Switch and Park Brake 3A
10 Directional Indicators 3A
11B Roof Air Conditioning Fans 25A
12 Rear Wiper 20A
13 Front Wiper 15A
14 Air Conditioning 20A
15 12V Power Connection Auxiliary 15A
16 After Treatment 20A
17 Front Work lights 25A
18 Beacon 7.5A
19 Machine ECU 15A
20 Boom Worklights 25A
21C Reverse Alarm 10A
22 Auxiliary Connector 5A
23 Transmission Controller 10A
24 Radio 10A
25 Ignition 5A
26 Live Link 5A
27 Rear Work Lights 25A
28 Head Lights 10A
29 Head Lights 20A
30 Horn and Main Beam 25A
31D Hydraulic ECU 20A
32 SPARE 15A
33 NOx Sensor 10A
34 Hazard Lights 3A
35 Instruments V+ 15A
36 Machine ECU 3A
37 Live Link 5A
38 LLMI (Longitudinal Load Moment Indicator) 3A
39 Instruments 3A
40 Immobiliser 5A
41E Dipped Beam 15A
42 Main Beam 20A
43 Side Lights 7.5A
44 Side Lights 5A
45 Fog lights 5A
46 Live Link 5A
47 Seat Heater and Face Fan 20A
33 - 342 9813/9400-1 33 - 342

03 - Fuse

48 Trailer Directional Indicators 10A
49 DEF (Diesel Exhaust Fluid) Heated Hoses 20A
50 Interior Light and Radio 10A
51 Daily Checks (when fitted) 5A
52 Daily Checks (when fitted) 5A
53 Man Basket - Recovery Pump (when fitted) 10A
54 Man Basket - Radio (when fitted) 5A
Primary Fuses
Figure 1407.
A C
B D
E G
F H
Table 573.
A Starting circuit 50A
B Engine/DEFECU, Heater blower, Directional Indicators 50A
C Wipers, A/C Fluid Levels 50A
D Fluid Levels, Work Lights, Beacon, Radio, Interior Light 50A
E Reverse Lights/Alarm, DEF System, DEF Heated Lines 50A
F Road Lights, Worklights, Horn 50A
G Machine ECU, Hazards/DIR, RH Instruments 50A
H Engine 50A
33 - 343 9813/9400-1 33 - 343

03 - Fuse
Engine Fuses
Figure 1408.
K2 K3
K1
F1
F10 F2
F11 F3
F12 F4
F13 F5
F14 F6
F15 F7
F16 F8
F17 F9
Table 574.
Fuse Circuit(s)
F1 Power hold relay
F2 Fuel pump
F3 Starter solenoid
F4 Fuel Pump ECU- 40
F5 Spare
F6 Spare
F7 Spare
F8 ECU- 49
F9 ECU- 53
F10 HC-doser /spare
F11 Machine Isolation
F12 WF sensor
F13 Empty/spare
F14 Engine power supply
F15 Engine power supply
33 - 344 9813/9400-1 33 - 344

03 - Fuse
Fuse Circuit(s)
F16 ECU- 60
F17 ECU- 57
33 - 345 9813/9400-1 33 - 345

03 - Fuse
Figure 1409. Fuse Box Termi-
nal Pin Number Identification
A B
1 2 1 2
3 4 3 4
5 6 5 6
7 8 7 8
9 10 9 10
11 12 11 12
13 14 13 14
15 16 15 16
17 18 17 18
19 20 19 20
C D
1 2 1 2
3 4 3 4
5 6 5 6
7 8 7 8
9 10 9 10
11 12 11 12
13 14 13 14
15 16 15 16
17 18 17 18
19 20 19 20
E
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
33 - 346 9813/9400-1 33 - 346

06 - Relay
06 - Relay Technical Data

Technical Data ............................................. 33-347
Figure 1410.
A B C D
Table 575.
Relay Circuit(s)
A1 Ignition
A2 Ignition
A3 Ignition
A4 Right Trailer Flash
A5 Trailer Indicator
A6 DEF Heated Line 1
A7 DEF Heated Line 3
A8 Immobiliser
B1 Ignition
B2 Ignition
B4 Ignition
B4 Left Trailer Flash
B5 Engine Run
B6 DEF Heated Line All
B7 DEF Heated Line 2
B8 NOx Sensor
C1 Boom Worklight
C2 Roof Air Conditioning Fans
33 - 347 9813/9400-1 33 - 347

06 - Relay
Relay Circuit(s)
C3 Reverse Alarm and Lamp
C4 Rear Work Lights
C5 Roadlights
C6 Air Conditioning
C7 Man Basket - Recovery Pump
D1 Brake Lights
D2 Air Conditioning
D3 Crank
D4 Front Work Lights
D5 Machine Isolation
D5 Man Basket - Remote Start
Engine Relays
Figure 1411.
K2 K3
K1
F1
F10 F2
F11 F3
F12 F4
F13 F5
F14 F6
F15 F7
F16 F8
F17 F9
Table 576.
Relay Circuit(s)
K1 Power hold relay
K2 Starter inhibit
K3 Fuel pump
33 - 348 9813/9400-1 33 - 348

06 - Relay
The relay mounting bases are connected to the Each relay base can hold 2 relays. Pins 1-5 being
Panel Harness. used for relay position B and pins 6-10 being used
for relay position A. Therefore each relay could have
Specific location and connector number will change. alternative pin numbers due to its position in relay
base.
Figure 1412. Relay Base Pin Number Identification
A B
6
5 4 3
7
2
8 9 10
1
8 10 4
1
2
7
6
3
9 5
A B
A Relay A B Relay B
33 - 349 9813/9400-1 33 - 349

12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ......................................................................................................................... 33-351

33-12-04 Chassis ......................................................................................................................... 33-364
33-12-06 Lift Arm ......................................................................................................................... 33-376
33-12-09 Engine .......................................................................................................................... 33-393
33-12-12 Operator Station ........................................................................................................... 33-416
33-12-14 Sway ............................................................................................................................. 33-468
33-12-15 Front Console ............................................................................................................... 33-473
33-12-22 Armrest ......................................................................................................................... 33-498
33-12-30 Gearbox ........................................................................................................................ 33-510
33-12-34 Trailer Brake ................................................................................................................. 33-528
33-12-36 Work Lights .................................................................................................................. 33-530
33-12-39 Road Lights .................................................................................................................. 33-541
33-12-44 Battery .......................................................................................................................... 33-561
33-12-45 Power Distribution ........................................................................................................ 33-595
33-12-46 Immobiliser ................................................................................................................... 33-601
33 - 350 9813/9400-1 33 - 350

12 - Harness
00 - General
Introduction .................................................. 33-351
Health and Safety ........................................ 33-352
Harness Drawings
Component Identification ............................. 33-353 Drawings are reproduced from production electrical
Repair .......................................................... 33-358 harness drawings. Each harness drawing includes
Check (Condition) ........................................ 33-360 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 - 351 9813/9400-1 33 - 351

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 - 352 9813/9400-1 33 - 352

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 1413.
The illustration shows a typical connector and wires. it's length. The number stamped on the wire identifies
Each wire has an individual identification number the following:
permanently marked on it, at regular intervals along
Table 577. Wire and Harness Number Identification

Identification Number Description
# The # indicates the start of the identification num-
ber. It is always printed to the left of the identification
number.
B If applicable- The colour of the flying lead that the
harness wire should mate with. For instance, if wire
819 from harness 719/37100 mated with a flying lead
coloured black (colour code B) then the number print-
ed on the wire would be B-819 9/371.
819 The wire's unique identification number. The wire
functions and numbers allocated to them are consis-
tent through out the JCB range of products. Refer to
Wire Numbers and Functions.
9/371 If applicable- The part number of the harness that the
wire originates from. If the harness part number is
719/37100, the number printed on the harness wires
will be 9/371 (71 and 00 are common numbers and
therefore deleted).
Wire Numbers and Functions Table 579. Wires 200-399 (These

numbers are reserved for battery feeds)
Table 578. Wires 000-199 (These Wire Number Description
numbers are reserved for ignition feeds,
heater start circuits and start circuits) Wires 200 - 299 Unfused battery feeds
Wires 300 - 399 Fused battery feeds
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds
33 - 353 9813/9400-1 33 - 353

12 - Harness
00 - General
Table 580. Wires 400-599 Figure 1415.

Wires 400-599 These numbers are re-
served for instruments,
i.e. alternators to tachos,
temperature switches
to warning lights, etc.
and signal wires used in
electronic systems
Table 581. Wires 600-799

Wires 600-799 These numbers are
used for earth wires.
When the number is
printed on to a wire it General Points
is prefixed by the Earth
1. Wires continue to have the same number even
symbol. This symbol is
after passing through a connector block to
printed onto the wire, it
another harness.
may however be omitted
from harness drawings 2. If all the numbers in a category have been
allocated, then the category is re-used with an
additional prefix '1', i.e. 1832.
Figure 1414.
Electrical Connectors- RAS System
The RAS (Rear Axle Stabilization) system is not
600 installed on all Loadall machines.
The table shows the harness connectors that

connect to the electrical devices. The connectors
are shown looking at the mating face when
disconnected. Remember that the drawings show
Table 582. Wires 800-999 the harness connectors and not the device
Wire Number Description connectors.
Wires 800-999 These numbers are re- Use the table and the relevant electrical schematic
served for switched sup- to identify the pins in the harness connectors.
plies to electrical loads, Continuity checks on the harness wires can be
i.e. to lights, etc. carried out using a multimeter. Do not touch the ECU
(Electronic Control Unit) connector pins. Do not use
a multimeter on ECU connector pins.
Table 583. Wires In Splices
Various The main input wire is
allocated with a wire
number and a suitable
description, i.e. Wire 640
earth splice to earth.
The additional wires in
the splice are allocated
the same wire number
and a postfix, i.e. 640A,
640B, etc.
33 - 354 9813/9400-1 33 - 354

12 - Harness
00 - General
Table 584. Electrical Connectors- RAS System

Device Description Location Harness Con-
nector
1042A Stabiliser isolation switch Located on the instrument panel. Re-
move the switch to get access to the
connector.
1058 Sway spool switch Located on the parallel valve block

sway valve spool.
1062A Right stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1062B Left stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1063 Left stabiliser switch Located on the parallel valve block

left stabiliser valve spool.
1064 Right stabiliser switch Located on the parallel valve block

right stabiliser valve spool.
1065 Lift arm proximity switch- 60° Inside face of the right side chassis
(stabiliser isolation) near the lift arm pivot.
1066 Lift arm proximity switch- 60° Inside face of the left side chassis
near the lift arm pivot.
1067 Lift arm extend proximity TBA

switch
2000 Relays Refer to electrical system- fuse and

relay, refer to (PIL 33-09).
3054 Sway / stabiliser isolation Located on the parallel valve block.
valve solenoid
3055 Lift pilot pressure supply isola- Located on the pilot pressure supply
tion valve solenoid valve.
4013 LMS (Loadall Monitoring Sys- The ECU connectors are located be- 10 1
tem) display connector J2 hind the LMS display unit. Be sure to
identify the correct connector. Con- 20 11
nector J2 is coloured black.

4018A ECU connector1 (black) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
4018B ECU connector2 (white) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
33 - 355 9813/9400-1 33 - 355

12 - Harness
00 - General
Device Description Location Harness Con-

nector
8000 Harness interconnections Refer to electrical system- harness,
9000 Fuses Refer to electrical system- fuse and
relay, refer to (PIL 33-09).
Electrical Connectors- Gearbox Harness Use the table and the relevant electrical schematic
to identify the pins in the harness connectors.
The table shows the harness connectors that Continuity checks on the harness wires can be
connect to the electrical devices. The connectors carried out using a multimeter. Do not touch ECU
are shown looking at the mating face when connector pins. Do not use a multimeter on ECU
disconnected. The drawings show the harness connector pins.
connectors, not the device connectors.
Table 585. Gearbox Harness Electrical Connectors

Device Description Location Harness connector
1013 Column Switch L/H A cable and connector
connects to the panel har-
ness at the steering col-
umn below the steering
wheel. Refer to driveline-
semi-automatic gearbox,
1068 Transmission Dump The switch is installed
Switch to the hydraulic control
lever. A cable and con-
necter connects to the
chassis harness below
the hydraulic control
lever. Refer to driveline-
1057 Park Brake Switch The switch is installed to
the park brake lever. A
cable and connector con-
nects to the rear cab har-
ness at the park brake
lever. Refer to driveline-
2000 Relays Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
3021 Forward high solenoid Located on the gearbox.
3022 Forward low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
3029 Layshaft solenoid
fer to (PIL 27-06).
3033 Mainshaft solenoid
3040 Reverse high solenoid Located on the gearbox.
3041 Reverse low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
fer to (PIL 27-06).
7014 Diode Gate- Gearbox Connects to the panel
harness below the left
side instrument console.
33 - 356 9813/9400-1 33 - 356

12 - Harness
00 - General
Device Description Location Harness connector

8000 Harness interconnections Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
9000 Fuseboxes Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
-000 Earth Points Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
33 - 357 9813/9400-1 33 - 357

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 1417.
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 1418.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 1416.
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 - 358 9813/9400-1 33 - 358

12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 1421.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 1419.
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 1420. 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 1422.
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 - 359 9813/9400-1 33 - 359

12 - Harness
00 - General
Figure 1423. 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 1424.
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 - 360 9813/9400-1 33 - 360

12 - Harness
00 - General
Figure 1425. Fluke 85 Multimeter Figure 1426. 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 1427. 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 - 361 9813/9400-1 33 - 361

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 - 362 9813/9400-1 33 - 362

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 - 363 9813/9400-1 33 - 363

12 - Harness
04 - Chassis
04 - Chassis
Diagram
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1428. Chassis harness 721/Y1342-1 sheet 1........................................................... Page 33-365
Chassis harness Item Description
C029 Engine pod sensor
Table 586. Key to connectors C031 Fuel level sender
C035 Isolation solenoid
Item Description
C037 Chassis angle sensor
C001 Washer tank level
C039 Auxiliary changeover
C002 Starter motor solenoid valve
C003 Ground C043 Trailer socket
C004 Starter motor C044 Transmission speed
C005 Engine supply sensor
C006 Speed sensor 2 C045 Hydraulics ECU (Elec-
C007 Transmission connector tronic Control Unit) J1
C008 Front proximity switch C046 Hydraulics ECU J2
C009 Right side head light C047 Hydraulics ECU J3
C010 LLMI (Longitudinal Load C048 Hydraulics ECU J4
Moment Indicator) trans- C049 Hydraulics ECU J5
ducer C051 SRS (Smooth Ride Sys-
C011 Rear proximity switch tem) harness
C012 Lift arm retract harness C056 Throttle/ overrun
C012-A Lift arm retract 33K C061 Number plate light
C012-B Lift arm retract 5K6 C062 Left side rear lights
C012-C Lift arm retract 1K8 C063 Right side rear lights
C013 Lift arm work light C064 Number plate light
C014 Joystick pod C065 Reverse alarm
C015 Panel connector C066-A Blank
C016 2nd auxiliary valve C073 Drain solenoid (A)
C017 Horn C074 Lift arm angle sensor
C018 Foot brake transducer C075 Isolation solenoid (A)
C019 Two wheel steer C076 Rear hitch light
C020 Four wheel steer C077 Pin lock
C021 Crab steer C086 Tank harness
C022 All wheel steer C167 After treatment
C023 Additional wires C440-E CAN based quality sen-
C024 Valve block harness sor
C027 CAN (Controller Area
Network) interface
33 - 364 9813/9400-1 33 - 364

12 - Harness
04 - Chassis
Page 33-366 Figure 1428. Chassis

harness 721/Y1342-1 sheet 1 Page 33-367
33 - 365 9813/9400-1 33 - 365

12 - Harness
04 - Chassis
33-366 33-367
Page 33-367
33 - 366 9813/9400-1 33 - 366

12 - Harness
04 - Chassis
33-366 33-367
Page 33-366
33 - 367 9813/9400-1 33 - 367

12 - Harness
04 - Chassis
33 - 368 9813/9400-1 33 - 368

12 - Harness
04 - Chassis

33 - 369 9813/9400-1 33 - 369

12 - Harness
04 - Chassis
33-370 33-371
Page 33-371
33 - 370 9813/9400-1 33 - 370

12 - Harness
04 - Chassis
33-370 33-371
Page 33-370
33 - 371 9813/9400-1 33 - 371

12 - Harness
04 - Chassis
33 - 372 9813/9400-1 33 - 372

12 - Harness
04 - Chassis

33 - 373 9813/9400-1 33 - 373

12 - Harness
04 - Chassis
33-374 33-375
Page 33-375
33 - 374 9813/9400-1 33 - 374

12 - Harness
04 - Chassis
33-374 33-375
Page 33-374
33 - 375 9813/9400-1 33 - 375

12 - Harness
06 - Lift Arm
06 - Lift Arm
Diagram
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1431. Lift Ram Harness 721/C5996- Issue 1 (sheet 1 of 1)......................................Page 33-377
Figure 1432. Lift Ram Harness 721/C1943- Issue 2 (sheet 1 of 1)......................................Page 33-381
Figure 1433. Lift Arm Auxiliary 721/G3060- Issue 2 (sheet 1 of 1)...................................... Page 33-385
Figure 1434. Lift Arm 332/E3427- Issue 2 (sheet 1 of 1).....................................................Page 33-389
Lift Ram
SRS Machine
33 - 376 9813/9400-1 33 - 376

12 - Harness
06 - Lift Arm
Page 33-378 Figure 1431. Lift Ram Harness

721/C5996- Issue 1 (sheet 1 of 1) Page 33-379
33 - 377 9813/9400-1 33 - 377

12 - Harness
06 - Lift Arm
33-378 33-379
Page 33-379
33 - 378 9813/9400-1 33 - 378

12 - Harness
06 - Lift Arm
33-378 33-379
Page 33-378
33 - 379 9813/9400-1 33 - 379

12 - Harness
06 - Lift Arm
Table 587. Key to connectors

Item Description
SR01 Chassis connector
SR02 SRS (Smooth Ride Sys-
tem) transducer
SR03 Accumulator solenoid
Non SRS Machine
33 - 380 9813/9400-1 33 - 380

12 - Harness
06 - Lift Arm
Page 33-382 Figure 1432. Lift Ram Harness

33 - 381 9813/9400-1 33 - 381

12 - Harness
06 - Lift Arm
33-382 33-383
Page 33-383
33 - 382 9813/9400-1 33 - 382

12 - Harness
06 - Lift Arm
33-382 33-383
Page 33-382
33 - 383 9813/9400-1 33 - 383

12 - Harness
06 - Lift Arm

Item Description
SR01 Chassis connector
SR02 SRS transducer
Lift Arm Auxiliary Harness
33 - 384 9813/9400-1 33 - 384

12 - Harness
06 - Lift Arm
Page 33-386 Figure 1433. Lift Arm Auxiliary

721/G3060- Issue 2 (sheet 1 of 1) Page 33-387
33 - 385 9813/9400-1 33 - 385

12 - Harness
06 - Lift Arm
33-386 33-387
Page 33-387
33 - 386 9813/9400-1 33 - 386

12 - Harness
06 - Lift Arm
33-386 33-387
Page 33-386
33 - 387 9813/9400-1 33 - 387

12 - Harness
06 - Lift Arm

Item Description
B001 Main harness
B002 Change over solenoid
Lift Arm Harness
33 - 388 9813/9400-1 33 - 388

12 - Harness
06 - Lift Arm
Page 33-390 Figure 1434. Lift Arm 332/

E3427- Issue 2 (sheet 1 of 1) Page 33-391
33 - 389 9813/9400-1 33 - 389

12 - Harness
06 - Lift Arm
33-390 33-391
Page 33-391
33 - 390 9813/9400-1 33 - 390

12 - Harness
06 - Lift Arm
33-390 33-391
Page 33-390
33 - 391 9813/9400-1 33 - 391

12 - Harness
06 - Lift Arm

Item Description
L001 Work light connector
L002 Retract proximity switch
L003 Chassis connector
BW03 Chassis connector
33 - 392 9813/9400-1 33 - 392

12 - Harness
09 - Engine
09 - Engine
Diagram
Figure 1435. Engine Pod Harness 721/X1206- Issue 4 (sheet 1 of 3).................................Page 33-395
Figure 1436. Engine Pod Harness 721/X1206- Issue 4 (sheet 2 of 3).................................Page 33-399
Figure 1438. Starter Motor Harness 721/C7691- Issue 3 (sheet 1 of 1).............................. Page 33-403
Figure 1439. Grid Heater Fuse Link Lead 718/E0209- Issue 1 (sheet 1 of 1)......................Page 33-409
Figure 1440. Grid Heater Relay To Heater Power Lead 718/E0210- Issue 1 (sheet 1 of
1)........................................................................................................................................... Page 33-413
Engine harness Item Description
E013 Proportional fan
Table 591. Key to connectors E014 Speed sensor
E020 Grid heater
Item Description
E021 Coolant level
E001 Fuse / relay box
E024-1 Binary switch 1
E002 Agglomerator
E024-2 Binary switch 2
E003 Fuel pump
E025 Air conditioning com-
E004 Engine ECU (Electronic pressor
Control Unit)
E026 -
E005 Engine connector
E030 Engine oil level
E006 Vacuum switch
E035 NOx (Nitrogen
E008 TMAF (Temperature and Oxide)downstream /
Mass Air Flow) tailpipe
E009 Chassis connector E036 NOx upstream engine
E010 Powertrain CAN (Con- out
troller Area Network) E097 Dosing module
bus resistor
E109 Exhaust inlet tempera-
E011 Transmission oil temper- ture
ature
E012 Reverse fan
33 - 393 9813/9400-1 33 - 393

Notes:
33 - 394 9813/9400-1 33 - 394

12 - Harness
09 - Engine
Page 33-396 Figure 1435. Engine Pod Harness

721/X1206- Issue 4 (sheet 1 of 3) Page 33-397
721-X1206-4 Sheet 1
33 - 395 9813/9400-1 33 - 395

12 - Harness
09 - Engine
33-396 33-397
Page 33-397
33 - 396 9813/9400-1 33 - 396

12 - Harness
09 - Engine
33-396 33-397
Page 33-396
721-X1206-4 Sheet 1
33 - 397 9813/9400-1 33 - 397

12 - Harness
09 - Engine
33 - 398 9813/9400-1 33 - 398

12 - Harness
09 - Engine
Page 33-400 Figure 1436. Engine Pod Harness

721/X1206- Issue 4 (sheet 2 of 3) Page 33-401
721-X1206-4- Sheet 2
33 - 399 9813/9400-1 33 - 399

12 - Harness
09 - Engine
33-400 33-401
Page 33-401
721-X1206-4- Sheet 2
33 - 400 9813/9400-1 33 - 400

12 - Harness
09 - Engine
33-400 33-401
Page 33-400
33 - 401 9813/9400-1 33 - 401

12 - Harness
09 - Engine
Figure 1437. Engine Pod Harness 721/X1206- Issue 4 (sheet 3 of 3)
Starter Motor Harness
33 - 402 9813/9400-1 33 - 402

12 - Harness
09 - Engine
Page 33-404 Figure 1438. Starter Motor Harness

B,· A4k
Cp
33 - 403 9813/9400-1 33 - 403

12 - Harness
09 - Engine
33-404 33-405
B,· A4k
Cp
Page 33-405
33 - 404 9813/9400-1 33 - 404

12 - Harness
09 - Engine
33-404 33-405
Page 33-404
33 - 405 9813/9400-1 33 - 405

12 - Harness
09 - Engine
ST01 Chassis connector ST03 Charge lead

ST04 D Terminal ST05 Charge lead
ST06 W Terminal
33 - 406 9813/9400-1 33 - 406

12 - Harness
09 - Engine
Grid Heater Fuse Link Lead
33 - 407 9813/9400-1 33 - 407

Notes:
33 - 408 9813/9400-1 33 - 408

12 - Harness
09 - Engine
Page 33-410 Figure 1439. Grid Heater Fuse Link

Lead 718/E0209- Issue 1 (sheet 1 of 1) Page 33-411
33 - 409 9813/9400-1 33 - 409

12 - Harness
09 - Engine
33-410 33-411
Page 33-411
33 - 410 9813/9400-1 33 - 410

12 - Harness
09 - Engine
33-410 33-411
Page 33-410
33 - 411 9813/9400-1 33 - 411

12 - Harness
09 - Engine
Grid Heater Relay To Heater Power Lead
33 - 412 9813/9400-1 33 - 412

12 - Harness
09 - Engine
Page 33-414 Figure 1440. Grid Heater Relay To Heater

Power Lead 718/E0210- Issue 1 (sheet 1 of 1) Page 33-415
33 - 413 9813/9400-1 33 - 413

12 - Harness
09 - Engine
33-414 33-415
Page 33-415
33 - 414 9813/9400-1 33 - 414

12 - Harness
09 - Engine
33-414 33-415
Page 33-414
33 - 415 9813/9400-1 33 - 415

12 - Harness
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................. Page 33-416
For: 512-26 [T4F] .................... Page 33-437
For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F], Agri-Plus, Agri-Super, Agri-Xtra
................................................. Page 33-455
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1441. Rear Cab Harness 721/H4545-1 Sheet 1....................................................... Page 33-417
Figure 1443. Rear cab harness 721/H4646-1 sheet 1......................................................... Page 33-423
Figure 1445. SLC harness 721/G8008-2............................................................................. Page 33-429
Figure 1446. Sway panel harness 332/E7785-1.................................................................. Page 33-433
Rear cab harness

Rear cab harness (RAC) (If installed)
33 - 416 9813/9400-1 33 - 416

12 - Harness
Page 33-418 Figure 1441. Rear Cab

Harness 721/H4545-1 Sheet 1 Page 33-419
33 - 417 9813/9400-1 33 - 417

12 - Harness
33-418 33-419
Page 33-419
33 - 418 9813/9400-1 33 - 418

12 - Harness
33-418 33-419
Page 33-418
33 - 419 9813/9400-1 33 - 419

12 - Harness
Figure 1442. Rear Cab Harness 721/H4545-1 Sheet 2
33 - 420 9813/9400-1 33 - 420

12 - Harness

Item Description
RC01 Panel harness connector
RC02 Heated seat
R03 Air seat
RC04 Rear wiper
RC05 Left hand work light
RC06 Ground
RC07 Beacon
RC08 Right hand work light
RC09 Roof wiper
RC10 Interior light +ve
RC11 Interior light -ve
RC12 Park brake
RC13 Roof fan +ve
RC14 Roof fan +ve
RC15 Roof fan -ve
RC16 Roof fan -ve
RC17 Seat pressure
RC18 Basket E-stop
Rear cab harness (Non-RAC) (If installed)
33 - 421 9813/9400-1 33 - 421

Notes:
33 - 422 9813/9400-1 33 - 422

12 - Harness
Page 33-424 Figure 1443. Rear cab

harness 721/H4646-1 sheet 1 Page 33-425
33 - 423 9813/9400-1 33 - 423

12 - Harness
33-424 33-425
Page 33-425
33 - 424 9813/9400-1 33 - 424

12 - Harness
33-424 33-425
Page 33-424
33 - 425 9813/9400-1 33 - 425

12 - Harness
Figure 1444. Rear cab harness 721/H4646-1 sheet 2
Table 593. key to connectors

Item Description
AA Panel harness connector
AB Heated seat
AC Air seat
AD Rear wiper
AE Left hand work light
AF Ground
33 - 426 9813/9400-1 33 - 426

12 - Harness
Item Description
AG Beacon
AH Right hand work light
AJ Roof wiper
AK-1 Interior light +ve
AK-2 Interior light -ve
AL Park brake
AM Seat pressure
RC18 Basket E-stop
SLC harness
33 - 427 9813/9400-1 33 - 427

Notes:
33 - 428 9813/9400-1 33 - 428

12 - Harness
Page 33-430 Figure 1445. SLC harness 721/G8008-2 Page 33-431
721/G8008-2
33 - 429 9813/9400-1 33 - 429

12 - Harness
33-430 33-431
Page 33-431
33 - 430 9813/9400-1 33 - 430

12 - Harness
33-430 33-431
Page 33-430
721/G8008-2
33 - 431 9813/9400-1 33 - 431

12 - Harness

Item Description
SLC1 Chassis connector
SLC2 Single lever controller (Push button joystick connec-
tor)
SLC3 Auxiliary A solenoid
SLC4 Auxiliary B solenoid
SLC5 Retract solenoid
SLC6 Extend solenoid
SLC7 Resistor R1 909
SLC8 Resistor R2 1,043
SSLC1 Resistor R3
SSLC2 Resistor R6
SSLC3 Resistor R9
SSLC4 ECU (Electronic Control Unit)5
SSLC5 Extend / retract return
SSLC6 Auxiliary (A) / auxiliary (B) return
Sway panel additional harness
33 - 432 9813/9400-1 33 - 432

12 - Harness
Page 33-434 Figure 1446. Sway panel harness 332/E7785-1 Page 33-435
332/E7785-1
33 - 433 9813/9400-1 33 - 433

12 - Harness
33-434 33-435
Page 33-435
33 - 434 9813/9400-1 33 - 434

12 - Harness
33-434 33-435
Page 33-434
332/E7785-1
33 - 435 9813/9400-1 33 - 435

12 - Harness

Item Description
P001 Auxiliary connector
P002 Panel to chassis
P003 Ground
P004 Sway relay
P005 Sway switch
33 - 436 9813/9400-1 33 - 436

12 - Harness
(For: 512-26 [T4F])

Figure 1447. Rear cab harness 721/H4545-1 Sheet 1........................................................ Page 33-439
Figure 1451. Sway panel harness 332/E7785-1.................................................................. Page 33-451
Rear cab harness

33 - 437 9813/9400-1 33 - 437

Notes:
33 - 438 9813/9400-1 33 - 438

12 - Harness

harness 721/H4545-1 Sheet 1 Page 33-441
33 - 439 9813/9400-1 33 - 439

12 - Harness
33-440 33-441
Page 33-441
33 - 440 9813/9400-1 33 - 440

12 - Harness
33-440 33-441
Page 33-440
33 - 441 9813/9400-1 33 - 441

12 - Harness
Figure 1448. Rear cab harness 721/H4545-1 Sheet 2
33 - 442 9813/9400-1 33 - 442

12 - Harness

Item Description
RC02 Heated seat
R03 Air seat
RC04 Rear wiper
RC06 Ground
RC07 Beacon
RC09 Roof wiper
RC12 Park brake
RC13 Roof fan +ve
RC14 Roof fan +ve
RC15 Roof fan -ve
RC16 Roof fan -ve
RC17 Seat pressure
RC18 Basket E-stop
33 - 443 9813/9400-1 33 - 443

Notes:
33 - 444 9813/9400-1 33 - 444

12 - Harness

33 - 445 9813/9400-1 33 - 445

12 - Harness
33-446 33-447
Page 33-447
33 - 446 9813/9400-1 33 - 446

12 - Harness
33-446 33-447
Page 33-446
33 - 447 9813/9400-1 33 - 447

12 - Harness

Item Description
AA Panel harness connector
AB Heated seat
AC Air seat
AD Rear wiper
AF Ground
33 - 448 9813/9400-1 33 - 448

12 - Harness
Item Description
AG Beacon
AH Right hand work light
AJ Roof wiper
AK-1 Interior light +ve
AK-2 Interior light -ve
AL Park brake
AM Seat pressure
RC18 Basket E-stop
Sway panel additional harness
33 - 449 9813/9400-1 33 - 449

Notes:
33 - 450 9813/9400-1 33 - 450

12 - Harness
Page 33-452 Figure 1451. Sway panel harness 332/E7785-1 Page 33-453
332/E7785-1
33 - 451 9813/9400-1 33 - 451

12 - Harness
33-452 33-453
Page 33-453
33 - 452 9813/9400-1 33 - 452

12 - Harness
33-452 33-453
Page 33-452
332/E7785-1
33 - 453 9813/9400-1 33 - 453

12 - Harness

Item Description
P001 Auxiliary connector
P002 Panel to chassis
P003 Ground
P004 Sway relay
P005 Sway switch
33 - 454 9813/9400-1 33 - 454

12 - Harness
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F], Agri-Plus, Agri-Super, Agri-Xtra)
Figure 1452. Rear cab harness 721/H4545-1 Sheet 1........................................................ Page 33-457
33 - 455 9813/9400-1 33 - 455

Notes:
33 - 456 9813/9400-1 33 - 456

12 - Harness

harness 721/H4545-1 Sheet 1 Page 33-459
33 - 457 9813/9400-1 33 - 457

12 - Harness
33-458 33-459
Page 33-459
33 - 458 9813/9400-1 33 - 458

12 - Harness
33-458 33-459
Page 33-458
33 - 459 9813/9400-1 33 - 459

12 - Harness
Figure 1453. Rear cab harness 721/H4545-1 Sheet 2
33 - 460 9813/9400-1 33 - 460

12 - Harness

Item Description
RC02 Heated seat
R03 Air seat
RC04 Rear wiper
RC06 Ground
RC07 Beacon
RC09 Roof wiper
RC12 Park brake
RC13 Roof fan +ve
RC14 Roof fan +ve
RC15 Roof fan -ve
RC16 Roof fan -ve
RC17 Seat pressure
RC18 Basket E-stop
33 - 461 9813/9400-1 33 - 461

Notes:
33 - 462 9813/9400-1 33 - 462

12 - Harness

33 - 463 9813/9400-1 33 - 463

12 - Harness
33-464 33-465
Page 33-465
33 - 464 9813/9400-1 33 - 464

12 - Harness
33-464 33-465
Page 33-464
33 - 465 9813/9400-1 33 - 465

12 - Harness
Item Description
Table 600. key to connectors AF Ground
Item Description AG Beacon
AA Panel harness connec- AH Right hand work light
tor AJ Roof wiper
AB Heated seat AK-1 Interior light +ve
AC Air seat AK-2 Interior light -ve
AD Rear wiper AL Park brake
33 - 466 9813/9400-1 33 - 466

12 - Harness
Item Description
AM Seat pressure
RC18 Basket E-stop
33 - 467 9813/9400-1 33 - 467

12 - Harness
14 - Sway
14 - Sway
Diagram
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1456. 332/E7787-1.................................................................................................... Page 33-469
Sway chassis additional harness
33 - 468 9813/9400-1 33 - 468

12 - Harness
14 - Sway
Page 33-470 Figure 1456. 332/E7787-1 Page 33-471
33 - 469 9813/9400-1 33 - 469

12 - Harness
14 - Sway
33-470 33-471
Page 33-471
33 - 470 9813/9400-1 33 - 470

12 - Harness
14 - Sway
33-470 33-471
Page 33-470
33 - 471 9813/9400-1 33 - 471

12 - Harness
14 - Sway

Item Description
C001 -
C046 Sway connector
C047 Sway isolation proximity
switch
33 - 472 9813/9400-1 33 - 472

12 - Harness
15 - Front Console
15 - Front Console
Diagram
Figure 1457. Panel Harness Interconnections T4f 721/Y0042- Issue 2 (sheet 1 of 6)......... Page 33-475
Figure 1460. Panel Harness- Harness Interconnections T4f 721/Y0042- Issue 2 (sheet 4 of
6)........................................................................................................................................... Page 33-487
6)........................................................................................................................................... Page 33-491
6)........................................................................................................................................... Page 33-495
Table 602. Key to Connectors Item Description
Item Description P024 Headlights
P001 Fusebox A P025 After treatment ground
P002 Fusebox B P026 Work lights
P003 Fusebox C P027 4WD (Four Wheel Drive)
P004 Fusebox D P028 Bacon
P005 Fusebox E P029 Lift arm work light
P006 Ignition relay 1 P030 Ground
P006 Ignition relay 2 P031 Turn signal diode
P007 Ignition relay 3 P032 Turn signal diode
P007 Ignition relay 4 P033 Heater connector
P008 Ignition relay 5 P034 Heater control
P008 Ignition relay 6 P035 Ground
P009 Heated hose power re- P037 Left hand column switch
lay (Red) P038 Right hand column
P010 Neutral start switch
P010 Reverse alarm P039 Panel to chassis con-
P011 Brake lights relay nector
P011 Lift arm work light relay P040 Centre panel
P012 Front work lights P041 Left hand headlight
P012 Rear work lights P042-A LLMI (Longitudinal Load
Moment Indicator)
P013 Livelink ignition
P042-B LLMICAN (Controller
P013 Road lights Area Network)
P014 Engine running relay P043 Ignition switch
P014 Trailer sense P044 Ignition switch
P015 Roof air condition fans P045 Fuse link box grey
P016 Trailer left hand direc- P046 Fuse link box blue
tional
P047 Fuse link box grey 2
P016 Trailer right hand direc-
tional P048 Fuse link box blue 2
P017 Front / rear auxiliary P049 Rear cab connector
P018 Purge hold inhibit freeze P050 Foot brake switch
valve P051 Face fan +ve
P019 Foot brake dump P052 Face fan -ve
P020 Hazard switch P053 Washer pump
P021 Roof wiper P054 Heated glass
P022 Rear wash wipe P055 Front wiper motor
P023 Fog light P056 Mobile phone
33 - 473 9813/9400-1 33 - 473

12 - Harness
15 - Front Console

P057 Mobile phone illumina- P096 Manual / auto resistor
tion 1K 300R
P058 Radio P097 Manual / auto resistor
P059 A Left hand work light 5K 360R
P059 B Right hand work light P098 Manual / auto switch
P060 Manual / auto switch P098 Resistor 10K
P061 Reverse fan switch P099 Eco switch
P062 SRS (Smooth Ride Sys- P101 NOx sensor relay
tem) switch P101 Immobiliser ignition
P063 Information button P102 Hose heater 2 (White)
P064 A Diode P102 Hose heater 3 (Yellow)
P064 B Diode P109 33K park brake resistor
P065 Auxiliary connection P110 5K6 park brake resistor
P066 Immobiliser P111 1K8 park brake resistor
P067 Hitch harness P112 Heater resistor
P068 Livelink P113 Livelink
P069 07/11 connector 1 P113 Permanent ground
P070 07/11 connector 2 P114 Pin lock switch
P071 Instrument panel J1 P114 A Pin lock
P072 Instrument panel J2 P114 A 1K8R resistor
P073 Diagnostic connector P114 B Pin lock 5K6R
P074 Terminator P114 C Pin lock 33,000
P075 SRS 1K 300R P115 IFM transmission con-
P076 SRS 5K 360R troller
P077 SRS 10K P125 Terminator
P078 Foot brake 1K 300R P126 Italian headlights
P079 Foot brake 5K 360R P127 Italian headlights (re-
move for Italian option)
P080 Foot brake dump 10K
P128 Front work light diode
P087 2WD (Two Wheel Drive)
/ 4WD P129 Rear work light diode
P087 1K8R resistor P130 Lift arm work light diode
P088 2WD / 4WD 5K6R P131 Additional fuse 1
P089 2WD / 4WD33,000 P132 Additional fuse 2
P090 Foot brake 10K P135 Additional wires
P091 Foot brake 1K 300R P137 RDM
P092 Foot brake 5K 360R P199 Tank harness connec-
tion
P093 -
P095 Steer mode switch
33 - 474 9813/9400-1 33 - 474

12 - Harness
15 - Front Console
Page 33-476 Figure 1457. Panel Harness Interconnections

T4f 721/Y0042- Issue 2 (sheet 1 of 6) Page 33-477
33 - 475 9813/9400-1 33 - 475

12 - Harness
15 - Front Console
33-476 33-477
Page 33-477
33 - 476 9813/9400-1 33 - 476

12 - Harness
15 - Front Console
33-476 33-477
Page 33-476
33 - 477 9813/9400-1 33 - 477

12 - Harness
15 - Front Console
33 - 478 9813/9400-1 33 - 478

12 - Harness
15 - Front Console

33 - 479 9813/9400-1 33 - 479

12 - Harness
15 - Front Console
33-480 33-481
Page 33-481
33 - 480 9813/9400-1 33 - 480

12 - Harness
15 - Front Console
33-480 33-481
Page 33-480
33 - 481 9813/9400-1 33 - 481

12 - Harness
15 - Front Console
33 - 482 9813/9400-1 33 - 482

12 - Harness
15 - Front Console

33 - 483 9813/9400-1 33 - 483

12 - Harness
15 - Front Console
33-484 33-485
Page 33-485
33 - 484 9813/9400-1 33 - 484

12 - Harness
15 - Front Console
33-484 33-485
Page 33-484
33 - 485 9813/9400-1 33 - 485

12 - Harness
15 - Front Console
33 - 486 9813/9400-1 33 - 486

12 - Harness
15 - Front Console
Figure 1460. Panel Harness-
Page 33-488 Harness Interconnections T4f

721/Y0042- Issue 2 (sheet 4 of 6) Page 33-489
33 - 487 9813/9400-1 33 - 487

12 - Harness
15 - Front Console
33-488 33-489
Page 33-489
33 - 488 9813/9400-1 33 - 488

12 - Harness
15 - Front Console
33-488 33-489
Page 33-488
33 - 489 9813/9400-1 33 - 489

12 - Harness
15 - Front Console
33 - 490 9813/9400-1 33 - 490

12 - Harness
15 - Front Console

33 - 491 9813/9400-1 33 - 491

12 - Harness
15 - Front Console
33-492 33-493
Page 33-493
33 - 492 9813/9400-1 33 - 492

12 - Harness
15 - Front Console
33-492 33-493
Page 33-492
33 - 493 9813/9400-1 33 - 493

12 - Harness
15 - Front Console
33 - 494 9813/9400-1 33 - 494

12 - Harness
15 - Front Console

33 - 495 9813/9400-1 33 - 495

12 - Harness
15 - Front Console
33-496 33-497
Page 33-497
33 - 496 9813/9400-1 33 - 496

12 - Harness
15 - Front Console
33-496 33-497
Page 33-496
33 - 497 9813/9400-1 33 - 497

12 - Harness
22 - Armrest
22 - Armrest
Diagram
Figure 1463. 721/C1616-1 sheet 1.......................................................................................Page 33-499

Figure 1465. 721/C1617-1 sheet 1.......................................................................................Page 33-505
Machines with pod mounted joystick
33 - 498 9813/9400-1 33 - 498

12 - Harness
22 - Armrest
Page 33-500 Figure 1463. 721/C1616-1 sheet 1 Page 33-501
33 - 499 9813/9400-1 33 - 499

12 - Harness
22 - Armrest
33-500 33-501
Page 33-501
33 - 500 9813/9400-1 33 - 500

12 - Harness
22 - Armrest
33-500 33-501
Page 33-500
33 - 501 9813/9400-1 33 - 501

12 - Harness
22 - Armrest
Figure 1464. 721/C1616-1 sheet 2
33 - 502 9813/9400-1 33 - 502

12 - Harness
22 - Armrest
Item Description
C045-C Tilt lock resistor 5K360R
Table 603.
C046 Constant auxiliary switch
Item Description
C046-A Constant auxiliary resis-
C033 Joystick 2 connector tor 10K
C034 Joystick 1 connector C046-B Constant auxiliary resis-
C038 Joystick isolation switch tor 1K300R
C038-A Joystick isolation resis- C046-C Constant auxiliary resis-
tor 10K tor 5K360R
C038-B Joystick isolation resis- C047 Stop switch
tor 1K330R C052 Auxiliary venting switch
C038-C Joystick isolation resis- JS01 Chassis harness con-
tor 5K360R nector
C045 Tilt lock switch
C045-A Tilt lock resistor 10K
C045-B Tilt lock resistor 1K300R
Agri and Xtra machines with cab mounted joystick
33 - 503 9813/9400-1 33 - 503

Notes:
33 - 504 9813/9400-1 33 - 504

12 - Harness
22 - Armrest
Page 33-506 Figure 1465. 721/C1617-1 sheet 1 Page 33-507
33 - 505 9813/9400-1 33 - 505

12 - Harness
22 - Armrest
33-506 33-507
Page 33-507
33 - 506 9813/9400-1 33 - 506

12 - Harness
22 - Armrest
33-506 33-507
Page 33-506
33 - 507 9813/9400-1 33 - 507

12 - Harness
22 - Armrest
Figure 1466. 721/C1617-1 sheet 2
33 - 508 9813/9400-1 33 - 508

12 - Harness
22 - Armrest
Table 604.
Item Description
C033 Joystick 2 connector
C034 Joystick 1 connector
C038 Joystick isolation switch
C038-A Joystick isolation resis-
tor 10K
C038-B Joystick isolation resis-
tor 1K
C038-C Joystick isolation resis-
tor 5K
C045 Tilt lock switch
C045-A Tilt lock resistor 10K
C045-B Tilt lock resistor 1K
C045-C Tilt lock resistor 5K
C046 Constant auxiliary switch
C046-A Constant auxiliary resis-
tor 10K
C046-B Constant auxiliary resis-
tor 1K
C046-C Constant auxiliary resis-
tor 5K
C047 Stop switch
C052 Auxiliary vent
C052-A Auxiliary venting resistor
5K8
C052-B Auxiliary venting resistor
33K
C052-C Auxiliary venting resistor
1K8
JS01 Chassis harness con-
nector
33 - 509 9813/9400-1 33 - 509

12 - Harness
30 - Gearbox
30 - Gearbox
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................. Page 33-510
For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F] ........................................ Page 33-515
................................................. Page 33-521
For: Agri-Pro ........................... Page 33-527
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1467. .........................................................................................................................Page 33-511
33 - 510 9813/9400-1 33 - 510

12 - Harness
30 - Gearbox
Page 33-512 Figure 1467. Page 33-513
33 - 511 9813/9400-1 33 - 511

12 - Harness
30 - Gearbox
33-512 33-513
Page 33-513
33 - 512 9813/9400-1 33 - 512

12 - Harness
30 - Gearbox
33-512 33-513
Page 33-512
33 - 513 9813/9400-1 33 - 513

12 - Harness
30 - Gearbox
Item Description
T006 Main shaft solenoid
Table 605.
T007 Layshaft solenoid
Item Description
T008 Forward low solenoid
T001 Mainframe connector
T009 Forward high solenoid
T003 Transmission oil pres-
T010 4WD (Four Wheel Drive)
sure
T004 Reverse low solenoid
T005 Reverse high solenoid
33 - 514 9813/9400-1 33 - 514

12 - Harness
30 - Gearbox
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F])

Figure 1468. Transmission Harness T4f 721/D0289-2 ........................................................Page 33-517
33 - 515 9813/9400-1 33 - 515

Notes:
33 - 516 9813/9400-1 33 - 516

12 - Harness
30 - Gearbox
Page 33-518 Figure 1468. Transmission

Harness T4f 721/D0289-2 Page 33-519
33 - 517 9813/9400-1 33 - 517

12 - Harness
30 - Gearbox
33-518 33-519
Page 33-519
33 - 518 9813/9400-1 33 - 518

12 - Harness
30 - Gearbox
33-518 33-519
Page 33-518
33 - 519 9813/9400-1 33 - 519

12 - Harness
30 - Gearbox
Item Description
T009 Layshaft solenoid
Table 606.
T010 Mainshaft solenoid
Item Description
T011 6th gear solenoid
T001 Chassis connector
T014 Pump control valve
T002 Forward high solenoid
T015 Temperature sender
T003 Reverse high solenoid
T018 Temperature sensor 2
T004 4WD solenoid
T020 Torque converter lock up
T005 Transmission oil pres- (TCLU)
sure switch
T021 Temperature 2 (Non
T006 Transmission oil pres- TCLU)
sure switch
T007 Forward low solenoid
T008 Reverse low solenoid
33 - 520 9813/9400-1 33 - 520

12 - Harness
30 - Gearbox

Figure 1469. 721/T0830-2 Dual Tech Variable Transmission, Transmission Harness..........Page 33-523
33 - 521 9813/9400-1 33 - 521

Notes:
33 - 522 9813/9400-1 33 - 522

12 - Harness
30 - Gearbox
Page 33-524 Figure 1469. 721/T0830-2 Dual Tech Variable

Transmission, Transmission Harness Page 33-525
B
L
D
E
A
J
K
721-T0830-2
N
33 - 523 9813/9400-1 33 - 523

12 - Harness
30 - Gearbox
33-524 33-525
E
A
Page 33-525
G
J
K
33 - 524 9813/9400-1 33 - 524

12 - Harness
30 - Gearbox
33-524 33-525
L
Page 33-524
721-T0830-2
N
33 - 525 9813/9400-1 33 - 525

12 - Harness
30 - Gearbox
A TR01 Chassis connector B TR25 Ground speed

C TR08 Pressure sensor D TR03 H1
E TR04 4WD F TR05 M3
G TR06 M2 H TR07 M4
J TR13 Bosch Rexroth speed sensor 2 K TR09 Temperature sensor
L TR15 BR Motor solenoid M TR11 Reverse solenoid
N TR10 Forward solenoid
33 - 526 9813/9400-1 33 - 526

12 - Harness
30 - Gearbox
Figure 1470. 721/T0830-2 Transmission Harness
721-T0830-2
(For: Agri-Pro)
33 - 527 9813/9400-1 33 - 527

12 - Harness
34 - Trailer Brake
34 - Trailer Brake
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................. Page 33-528
For: Agri-Pro ........................... Page 33-529
(For: 506-23 [T4F], 509-23 [T4F])
Towing harness
Figure 1471. 721/11270-1
33 - 528 9813/9400-1 33 - 528

12 - Harness
34 - Trailer Brake

Item Description
TA Mainframe connector
TB Rear harness connector
TC Trailer connector
(For: Agri-Pro)
Figure 1472. Trailer Socket Multicore Link 721/M6579-2
-C2_EBS#1
4 1
7214/0024
3 2
TRAILER POWER BRAKES
S TRAILER POWER BRAKES

_EB
-C2_EBS
-C2
m ID Tag Size Colour Destination Cable Cavity Seal
50 m
1 7210/0030
2 7210/0030
3 CORE 2 1.50 mm² BLACK -C1_EBS:5 Wires
m 4 CORE 1 1.50 mm² BLACK -C1_EBS:3 Wires
1 2 30 m
7 3 50 mm 240 mm 30 mm 7214/0024 4 Way DT04 Pin Housing
6 4 Additional Components
5
30 m
-ID1 m 7214/0014;1 # 4 Way DT04 Wedge
ID Label 700
0/3
-C1_EBS#1 212
332/R5072
-C1_EBS 50 m
m
TRAILER POWER SOCKET
700
TRAILER POWER SOCKET 0/3
-C1_EBS 202
ID Tag Size Colour Destination Cable Cavity Seal
2
5 CORE 2 1.50 mm² BLACK -C2_EBS:3 Wires -C3_EBS#1
6 -C3 1 2 7212/0063
_E TRAILER POWER
7 BS
332/R5072 7 Way Trailer ABS Socket - Male Pins
Additional Components -C3_EBS TRAILER POWER
ID Tag Size Colour Destination Cable Cavity Seal
7212/0063 2 Way DTP04 Pin Housing

Additional Components
7212/0061;1 # 2 Way DTP04 Wedge
Table 608.
Item Description
C1 EBS Trailer power socket
C2 EBS Trailer power brakes
C3 EBS Trailer power
33 - 529 9813/9400-1 33 - 529

12 - Harness
36 - Work Lights
36 - Work Lights
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................. Page 33-530
For: 512-26 [T4F] .................... Page 33-536
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1473. Work Light Harness 332/D8729- Issue 1 (sheet 1 of 1).................................. Page 33-531
33 - 530 9813/9400-1 33 - 530

12 - Harness
36 - Work Lights
Page 33-532 Figure 1473. Work Light Harness

332/D8729- Issue 1 (sheet 1 of 1) Page 33-533
33 - 531 9813/9400-1 33 - 531

12 - Harness
36 - Work Lights
33-532 33-533
Page 33-533
33 - 532 9813/9400-1 33 - 532

12 - Harness
36 - Work Lights
33-532 33-533
Page 33-532
33 - 533 9813/9400-1 33 - 533

12 - Harness
36 - Work Lights

Item Description
WL001 Lift arm connector
WL002 Right side work light
WL003 Left side work light
Figure 1474. Front Work Light Harness 721/11276- Issue 2 (sheet 1 of 1)
33 - 534 9813/9400-1 33 - 534

12 - Harness
36 - Work Lights

Item Description
AA Work light
AB Work light
AC Panel harness connec-
tor
Figure 1475. Lift Arm Work Light Harness 332/E3428- Issue 1 (sheet 1 of 1)

Item Description
BW01 Right side lift arm work
light
BW02 Left side lift arm work
light
BW03 Lift arm harness connec-
tor
33 - 535 9813/9400-1 33 - 535

12 - Harness
36 - Work Lights
(For: 512-26 [T4F])

Figure 1477. 721/C5908-1....................................................................................................Page 33-537
Boom work light harness
Figure 1476. 721/C5905-1

Item Description
BW01 Right hand Work light
BW02 Left hand Work light
BW03 Lift arm harness connec-
tor
Tractor light cab link harness
33 - 536 9813/9400-1 33 - 536

12 - Harness
36 - Work Lights
Page 33-538 Figure 1477. 721/C5908-1 Page 33-539
33 - 537 9813/9400-1 33 - 537

12 - Harness
36 - Work Lights
33-538 33-539
Page 33-539
33 - 538 9813/9400-1 33 - 538

12 - Harness
36 - Work Lights
33-538 33-539
Page 33-538
33 - 539 9813/9400-1 33 - 539

12 - Harness
36 - Work Lights

Item Description
C001 Chassis connector
C002 Headlight
C005 TBA
33 - 540 9813/9400-1 33 - 540

12 - Harness
39 - Road Lights
39 - Road Lights
Diagram
For: 506-23 [T4F], 509-23 [T4F]

................................................. Page 33-541
For: 512-26 [T4F] .................... Page 33-547
(For: 506-23 [T4F], 509-23 [T4F])

Figure 1478. Rear light harness 721/11517-1...................................................................... Page 33-543
33 - 541 9813/9400-1 33 - 541

Notes:
33 - 542 9813/9400-1 33 - 542

12 - Harness
39 - Road Lights
Page 33-544 Figure 1478. Rear light harness 721/11517-1 Page 33-545
33 - 543 9813/9400-1 33 - 543

12 - Harness
39 - Road Lights
33-544 33-545
Page 33-545
33 - 544 9813/9400-1 33 - 544

12 - Harness
39 - Road Lights
33-544 33-545
Page 33-544
33 - 545 9813/9400-1 33 - 545

12 - Harness
39 - Road Lights
Item Description
LD Reverse alarm
LF Number plate light
Item Description
LG Number plate light
LA MF plug
LB Right hand rear light
LC Left hand rear light
33 - 546 9813/9400-1 33 - 546

12 - Harness
39 - Road Lights
(For: 512-26 [T4F])

Figure 1479. 721/C3689-1 ...................................................................................................Page 33-549
Figure 1480. 721/C3690-1....................................................................................................Page 33-553
Figure 1481. 721/C5907-2....................................................................................................Page 33-557
Front tractor light harness
33 - 547 9813/9400-1 33 - 547

Notes:
33 - 548 9813/9400-1 33 - 548

12 - Harness
39 - Road Lights
33 - 549 9813/9400-1 33 - 549

12 - Harness
39 - Road Lights
33-550 33-551
Page 33-551
33 - 550 9813/9400-1 33 - 550

12 - Harness
39 - Road Lights
33-550 33-551
Page 33-550
33 - 551 9813/9400-1 33 - 551

12 - Harness
39 - Road Lights

Item Description
C001 TBA
C002 TBA
R.H. rear tractor light harness
33 - 552 9813/9400-1 33 - 552

12 - Harness
39 - Road Lights
33 - 553 9813/9400-1 33 - 553

12 - Harness
39 - Road Lights
33-554 33-555
Page 33-555
33 - 554 9813/9400-1 33 - 554

12 - Harness
39 - Road Lights
33-554 33-555
Page 33-554
33 - 555 9813/9400-1 33 - 555

12 - Harness
39 - Road Lights
Item Description
C003 Ambient sensor
C004 Chassis connector2
Item Description
C005 TBA
C002 Headlight
R.H. headlight harness
33 - 556 9813/9400-1 33 - 556

12 - Harness
39 - Road Lights
33 - 557 9813/9400-1 33 - 557

12 - Harness
39 - Road Lights
33-558 33-559
Page 33-559
33 - 558 9813/9400-1 33 - 558

12 - Harness
39 - Road Lights
33-558 33-559
Page 33-558
33 - 559 9813/9400-1 33 - 559

12 - Harness
39 - Road Lights

Item Description
C002 Headlight
C003 Ambient sensor
33 - 560 9813/9400-1 33 - 560

12 - Harness
44 - Battery
44 - Battery
Diagram
Figure 1482. 718/X7575-1 Purge Hold Negative Lead........................................................ Page 33-563

Figure 1483. 718/X7474-1 Purge Hold Negative Lead (Fuse)............................................. Page 33-567
Figure 1484. 718/G4493-1 Negative Battery to Isolator.......................................................Page 33-571
Figure 1485. 718/G4495-1 Negative Isolator To Chassis.....................................................Page 33-575
Figure 1486. 718/G4492-1 Negative Battery Link................................................................ Page 33-579
Figure 1487. 718/X2345-1 Main Battery Positive Lead........................................................Page 33-583
Figure 1488. 718/G4490-2 Primary Fuse Splitter T4F......................................................... Page 33-587
Figure 1489. 718/G4491-1 Positive Battery Link..................................................................Page 33-591
Negative Leads
33 - 561 9813/9400-1 33 - 561

Notes:
33 - 562 9813/9400-1 33 - 562

12 - Harness
44 - Battery
Page 33-564 Figure 1482. 718/X7575-1

Purge Hold Negative Lead Page 33-565
33 - 563 9813/9400-1 33 - 563

12 - Harness
44 - Battery
33-564 33-565
Page 33-565
33 - 564 9813/9400-1 33 - 564

12 - Harness
44 - Battery
33-564 33-565
Page 33-564
33 - 565 9813/9400-1 33 - 565

12 - Harness
44 - Battery
Table 618.
Item Description
C002 Ring terminal M10
C003 Ring cable lug M6
33 - 566 9813/9400-1 33 - 566

12 - Harness
44 - Battery
Page 33-568 Figure 1483. 718/X7474-1 Purge

Hold Negative Lead (Fuse) Page 33-569
718/X7474-1
33 - 567 9813/9400-1 33 - 567

12 - Harness
44 - Battery
33-568 33-569
Page 33-569
33 - 568 9813/9400-1 33 - 568

12 - Harness
44 - Battery
33-568 33-569
718/X7474-1
Page 33-568
33 - 569 9813/9400-1 33 - 569

12 - Harness
44 - Battery
Table 619.
Item Description
C001 Single primary fusebox
with sec lock
C002 Ring terminal M10
C003 Ring cable lug M6
33 - 570 9813/9400-1 33 - 570

12 - Harness
44 - Battery
Page 33-572 Figure 1484. 718/G4493-1

Negative Battery to Isolator Page 33-573
718/G4493-1
33 - 571 9813/9400-1 33 - 571

12 - Harness
44 - Battery
33-572 33-573
Page 33-573
33 - 572 9813/9400-1 33 - 572

12 - Harness
44 - Battery
33-572 33-573
718/G4493-1
Page 33-572
33 - 573 9813/9400-1 33 - 573

12 - Harness
44 - Battery
Table 620.
Item Description
C001 M10 ring lug terminal
95mm90°
C002 Lead connector taper
pillar / ferrule 95mm
33 - 574 9813/9400-1 33 - 574

12 - Harness
44 - Battery
Page 33-576 Figure 1485. 718/G4495-1

Negative Isolator To Chassis Page 33-577
718-G4495-1
33 - 575 9813/9400-1 33 - 575

12 - Harness
44 - Battery
33-576 33-577
Page 33-577
33 - 576 9813/9400-1 33 - 576

12 - Harness
44 - Battery
33-576 33-577
718-G4495-1
Page 33-576
33 - 577 9813/9400-1 33 - 577

12 - Harness
44 - Battery
Table 621.
Item Description
95mm
95mm90°
33 - 578 9813/9400-1 33 - 578

12 - Harness
44 - Battery
Page 33-580 Figure 1486. 718/G4492-1 Negative Battery Link Page 33-581
718-G4492-1
33 - 579 9813/9400-1 33 - 579

12 - Harness
44 - Battery
33-580 33-581
Page 33-581
33 - 580 9813/9400-1 33 - 580

12 - Harness
44 - Battery
33-580 33-581
718-G4492-1
Page 33-580
33 - 581 9813/9400-1 33 - 581

12 - Harness
44 - Battery
Table 622.
Item Description
C001 Battery -ve lug crimp
70mm
C002 Lead connector taper
Positive Leads
33 - 582 9813/9400-1 33 - 582

12 - Harness
44 - Battery
Page 33-584 Figure 1487. 718/X2345-1

Main Battery Positive Lead Page 33-585
33 - 583 9813/9400-1 33 - 583

12 - Harness
44 - Battery
33-584 33-585
Page 33-585
33 - 584 9813/9400-1 33 - 584

12 - Harness
44 - Battery
33-584 33-585
Page 33-584
33 - 585 9813/9400-1 33 - 585

12 - Harness
44 - Battery
Table 623.
Item Description
B001 Lead connector taper
B002 M10 90° extended ring
term
33 - 586 9813/9400-1 33 - 586

12 - Harness
44 - Battery
Page 33-588 Figure 1488. 718/G4490-2

Primary Fuse Splitter T4F Page 33-589
718-G4490-1
33 - 587 9813/9400-1 33 - 587

12 - Harness
44 - Battery
33-588 33-589
Page 33-589
33 - 588 9813/9400-1 33 - 588

12 - Harness
44 - Battery
33-588 33-589
Page 33-588
718-G4490-1
33 - 589 9813/9400-1 33 - 589

12 - Harness
44 - Battery
Item Description
B003 M8 ring lug terminal
Table 624.
25mm
Item Description S1 In line ultrasonic splice
16mm
16mm
33 - 590 9813/9400-1 33 - 590

12 - Harness
44 - Battery
Page 33-592 Figure 1489. 718/G4491-1 Positive Battery Link Page 33-593
718-G4491-1
33 - 591 9813/9400-1 33 - 591

12 - Harness
44 - Battery
33-592 33-593
Page 33-593
33 - 592 9813/9400-1 33 - 592

12 - Harness
44 - Battery
33-592 33-593
718-G4491-1
Page 33-592
33 - 593 9813/9400-1 33 - 593

12 - Harness
44 - Battery
Table 625.
Item Description
C001 Battery +ve lug crimp
70mm
C002 Battery +ve lug crimp
70mm
33 - 594 9813/9400-1 33 - 594

12 - Harness
Diagram
Figure 1490. Primary fuse link 721/G4490-1........................................................................Page 33-597
33 - 595 9813/9400-1 33 - 595

Notes:
33 - 596 9813/9400-1 33 - 596

12 - Harness
Page 33-598 Figure 1490. Primary fuse link 721/G4490-1 Page 33-599
33 - 597 9813/9400-1 33 - 597

12 - Harness
33-598 33-599
Page 33-599
33 - 598 9813/9400-1 33 - 598

12 - Harness
33-598 33-599
Page 33-598
33 - 599 9813/9400-1 33 - 599

12 - Harness
Table 626.
Item Description
S1 In line ultrasonic splice
33 - 600 9813/9400-1 33 - 600

12 - Harness
46 - Immobiliser
46 - Immobiliser
Diagram
Figure 1491. 721/D6018-1 Immobiliser link..........................................................................Page 33-603
33 - 601 9813/9400-1 33 - 601

Notes:
33 - 602 9813/9400-1 33 - 602

12 - Harness
46 - Immobiliser
Page 33-604 Figure 1491. 721/D6018-1 Immobiliser link Page 33-605
33 - 603 9813/9400-1 33 - 603

12 - Harness
46 - Immobiliser
33-604 33-605
Page 33-605
33 - 604 9813/9400-1 33 - 604

12 - Harness
46 - Immobiliser
33-604 33-605
Page 33-604
33 - 605 9813/9400-1 33 - 605

12 - Harness
46 - Immobiliser
L001 Diagnostic Connector L002 CAN (Controller Area Network)bus

connector
33 - 606 9813/9400-1 33 - 606

12 - Harness
93 - Selective Catalytic Reduction

(SCR)
Diagram
Figure 1492. 721/Y1262-1 Sheet 1 After Treatment Harness.............................................. Page 33-609
Table 627. Key to Connectors

Item Description
C001 Adblue to chassis harness
C010E SCR (Selective Catalytic Reduction)ECU (Electronic
Control Unit)
C002 Isolation relay
C003 Ground
C007
C200E Tank heater Valve
C240E Hose heater valve 1 (Red)
C260E Hose heater 2 (White)
C280E Hose heater 3 (yellow)
C410LH Supply module
C006 Dieselmax terminating resistor
33 - 607 9813/9400-1 33 - 607

Notes:
33 - 608 9813/9400-1 33 - 608

12 - Harness
Page 33-610 Figure 1492. 721/Y1262-1 Sheet

1 After Treatment Harness Page 33-611
33 - 609 9813/9400-1 33 - 609

12 - Harness
33-610 33-611
Page 33-611
33 - 610 9813/9400-1 33 - 610

12 - Harness
33-610 33-611
Page 33-610
33 - 611 9813/9400-1 33 - 611

12 - Harness
Figure 1493. 721/Y1262-1 Sheet 2 After Treatment Harness
33 - 612 9813/9400-1 33 - 612

15 - Alarm
15 - Alarm
Contents Page No.
33-15-03 Reverse Warning .......................................................................................................... 33-615
33 - 613 9813/9400-1 33 - 613

Notes:
33 - 614 9813/9400-1 33 - 614

15 - Alarm
03 - Reverse Warning
03 - Reverse Warning
Introduction
The reverse alarm will sound when the machine is

moving in the reverse direction. The alarm will sound
anytime the drive control is moved into the reverse
position. In this position the drive control sends a
signal to the main ECU (Electronic Control Unit) to
sound the alarm.
33 - 615 9813/9400-1 33 - 615

21 - Immobiliser
21 - Immobiliser
Contents Page No.
33-21-00 General ......................................................................................................................... 33-617
33 - 616 9813/9400-1 33 - 616

21 - Immobiliser
00 - General
00 - General Preparation
Preparation .................................................. 33-617 The immobiliser set up tool is provided to setup/
Check (Operation) ....................................... 33-620 amend the immobiliser settings. Situations which
may require the immobiliser settings to be changed
may be:
• Transfer of machine ownership

• Replacement of immobiliser system
components
• Loss of keys/codes to deactivate the
immobiliser.
The tool is used to perform the following actions:
• Obtain an unlock ‘Response Code’ for security

authorisation to re-configure the immobiliser.
(The ‘Response Code’ is only available via JCB
Tech Web.)
• Configure a new immobiliser. (Change from
‘Factory Mode’ to key system or keypad system
mode as applicable).
• Configure new immobiliser keys. (Key systems
only).
• Configure new immobiliser codes. (Keypad
systems only).
• Delete existing keys/codes.
Installing Immobiliser Set Up

The setup tool is fully integrated within JCB Service
Master. To use the setup tool you must install
JCB ServiceMaster onto a suitable laptop computer.
For full instructions on how to install

JCB ServiceMaster software please refer to
the documentation which accompanies JCB
ServiceMaster.
Starting Immobiliser Set Up

1. Turn on the machine ignition.
2. Start JCB ServiceMaster on the laptop computer
and select the correct machine range. Refer to
(PIL 33-57-03).
3. Start the diagnostics tool running by clicking on
the Immobiliser Setup icon.
Figure 1494.
33 - 617 9813/9400-1 33 - 617

21 - Immobiliser
00 - General
Using The Immobiliser Set up Tool • Status of the immobiliser internal switches.
• Status of devices connected to the immobiliser
To use the immobiliser set up tool click on the “Help ECU. (includes key antenna and keypad
Menu” and select “Help”. The Help file will display devices).
and details the procedures to unlock and use the tool. • View active fault codes.
Installing Immobiliser Diagnostics
Figure 1495.
The diagnostics tool is fully integrated within JCB
Service Master. To use the setup tool you must install
JCB ServiceMaster onto a suitable laptop computer.
For full instructions on how to install

JCB ServiceMaster software please refer to
the documentation which accompanies JCB
ServiceMaster.
Connecting Immobiliser Diagnostics

To use the diagnostics tool the DLA and your
laptop computer must be connected to the machine
diagnostics connector. Refer to (PIL 33-57-03).
Starting Immobiliser Diagnostics

1. Turn ON the machine ignition.
and select the correct machine range.
the Immobiliser Diagnostics icon.
Figure 1496.
Immobiliser Diagnostic Tool

The immobiliser diagnostics tool has the following
status windows: Using the Immobiliser Diagnostics Tool
• System diagram.
To use the immobiliser diagnostics tool click on the
• Active Fault Codes
‘Help Menu’ and select ‘Help’. The Help file will
This tool is used to show the following: display and details the procedures for use of the tool.
33 - 618 9813/9400-1 33 - 618

21 - Immobiliser
00 - General
Figure 1497.
33 - 619 9813/9400-1 33 - 619

21 - Immobiliser
00 - General
Check (Operation)
tool to identify the faults.
2. Make sure that the applicable control interface
operates correctly. Rectify as required. Refer to
electrical system- electronic diagnostic, refer to
(PIL 33-57).
4. Do not use a multimeter at the pins on the ECU
(Electronic Control Unit). Only use the meter at
the pins on the harness connectors.
5. Without the use of sophisticated electronic test
equipment it is not possible to test the ECU. If the
ECU is returned under warranty it will be tested
at the factory to confirm possible faults.
33 - 620 9813/9400-1 33 - 620

24 - Instruments
24 - Instruments
Contents Page No.

33-24-10 Hourmeter .................................................................................................................... 33-627
33 - 621 9813/9400-1 33 - 621

Notes:
33 - 622 9813/9400-1 33 - 622

24 - Instruments
03 - Instrument Panel
03 - Instrument Panel Introduction

Introduction .................................................. 33-623 The instrument panel communicates information to
Fault-Finding ................................................ 33-624 the operator about the systems on the machine and
Remove and Install ..................................... 33-624 warns of any abnormal conditions that may occur.
The instrument panel houses all the gauges and
warning lights on the machine i.e. fuel gauge, coolant
warning, engine oil pressure warning light. For more
detailed information refer to the operator manual.
33 - 623 9813/9400-1 33 - 623

24 - Instruments
Fault-Finding Remove and Install

For the full list of fault codes, refer to (PIL 33-57).
Centre Warning Light Panel
Removal
3. Remove the screws (x2) that hold the centre
display panel in place.
4. Disconnect all connections and remove the
panel.
Figure 1498. Centre warning light panel
A A
00: 00: 05
A Retaining screws (x2)
Installation
removal procedure.
Heater Control Panel

Removal
Refer to (PIL 01-03)
3. Remove the screws (x2) that hold the heater
control panel in place, disconnect all connections
and remove the panel.
Depending on the specification of your machine, you

will have one of two types of heater control panel.
Refer to Figure 1499. and Refer to Figure 1500.
33 - 624 9813/9400-1 33 - 624

24 - Instruments
Installation 1.1. Make sure that the switch housing is aligned

correctly with the panel to make sure that
1. The installation procedure is the opposite of the the switch is in the correct position for all the
removal procedure. switch settings.
Figure 1499. Heater control panel (S1) Figure 1501. Left hand switch panel
A
A A
A
B
Figure 1500. Heater control panel (S2) B Left hand switch panel
Figure 1502. Left hand switch panel
C
Left Hand Switch Panel D

Removal
E
3. Remove the screws (x2) that hold the left
hand switch panel in place and disconnect all
connections. Remove the panel.
4. To remove the rotary switch:
F
4.1. Remove the knob from the front of the
panel. C Knob
4.2. Mark the position of the switch housing in D Panel
relation to the trim panel. E Switch
F Locknut
4.3. Unscrew the locknut and remove the switch
from the panel. Right Hand Instrument Panel
Installation Notice: Make sure you do not touch
the electrical connector pins on electronic
1. The installation procedure is the opposite of the instruments. Make sure you put protective caps
removal procedure. Additionally do the following on harness connectors and the connectors on the
step. instruments.
33 - 625 9813/9400-1 33 - 625

24 - Instruments
Removal
3. Remove the radio (if installed).
4. Remove the screws (x3) that hold the main
switch and instrument panel in place. Disconnect
all connections and remove the panel.
Installation
removal procedure.
Figure 1503. Right hand instrument panel
D
D
D
C Electronic instruments
D Retaining screws (x3)
33 - 626 9813/9400-1 33 - 626

24 - Instruments
10 - Hourmeter
10 - Hourmeter
Introduction
The hourmeter is a device that records the operating

time of an engine, machine, or mechanism, it is used
to monitor and log the service life of the engine. The
hours of operation are determined from the number
of revolutions of the engine.
33 - 627 9813/9400-1 33 - 627

27 - Interior Switch
Contents Page No.
33-27-03 Multi-Purpose ............................................................................................................... 33-629

33-27-51 Hydraulic Flow .............................................................................................................. 33-631
33 - 628 9813/9400-1 33 - 628

03 - Multi-Purpose
03 - Multi-Purpose Figure 1504.
Remove and Install
Remove
Refer to (PIL 01-03). A A
B
3. Remove the steering wheel. Refer to (PIL 09-36).
4. Remove the screws (x2) on the top of the
steering column upper surround.
5. Remove the button head screws (x2). 00:00:05
6. Remove the steering column lower surround.

7. Remove the button head screws (x2).
C
8. Remove the steering column upper surround.
9. Remove the steering column switch retaining
plate screw.
10. Remove the retaining plate (if installed).
A Steering upper column surround
11. Remove the switch covers. B Button head screw 1
C Button head screw 2
12. Disconnect the harness connectors.
Figure 1505.
13. Remove the retaining screw from the switch
collar. D
14. Pull the column switches away from the column.

E F
F
H
H G
J
J
K
D Retaining plate screw

E Switch retaining plate
F Switch cover
G Switch collar
H Column switch
J Harness connector
K Retaining screw
33 - 629 9813/9400-1 33 - 629

03 - Multi-Purpose
Install
steps.
1.1. Make sure that the transmission lever
securing bolt has 2 washers installed as
shown. Refer to Figure 1506.
Figure 1506.
L Transmission lever securing bolt
33 - 630 9813/9400-1 33 - 630

51 - Hydraulic Flow
51 - Hydraulic Flow
Remove and Install
For: 506-23 [T4F], 509-23 [T4F], 512-26 1. Remove the screw cover from the arm rest and
[T4F] ........................................ Page 33-631 then remove the screws and washers.
For: 506-23 [T4F], 509-23 [T4F]
................................................. Page 33-633 2. Lift away the armrest and the trim assembly.
(For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F]) 4. Remove the gaiter collar.
5. Remove the screws 2 then lift the control lever
Cab mounted control lever and powerbase assembly to access the electrical
connectors.
Remove
6. Disconnect the electrical connectors and remove
Control lever and the attached powerbase is a non control lever from the housing.
serviceable part. If it is faulty it must be replaced.
Figure 1507. Cab mounted control lever
A
B
J
C
H
D
E
G
Table 628.
Item Description
A Arm rest
B Screw cover
C Trim assembly
33 - 631 9813/9400-1 33 - 631

51 - Hydraulic Flow
Item Description
D Control lever
E Screws 1
F Housing
G Screws 2
H Gaiter collar
J Screws and washers
Install 3. Remove rear screws and washers.
1. The installation procedure is the opposite of the 4. Remove front screws and washers.
removal procedure.
5. Remove the gaiter collar.
Pod mounted control lever 6. Remove the pod top cover until you can gain
access to the switch electrical connectors.
Remove
7. Mark and disconnect the switch electrical
The control lever and the attached powerbase is a connectors.
non serviceable part. If it is faulty it must be replaced.
8. Disconnect the electrical connectors and remove
1. Remove the screw cover from the arm rest and the control lever from the pod.
then remove the screws and washers.
9. Remove the screws and remove the control lever
2. Lift away the armrest. then the powerbase assembly.
33 - 632 9813/9400-1 33 - 632

51 - Hydraulic Flow
Figure 1508. Pod mounted control lever
B
C
A
G
M
H
M
L
J K
D
Table 629.
Item Description
A Arm rest
B Screws
C Rear screws
D Front screws
E Gaiter collar
F Powerbase assembly
G Pod top cover
H Switch electrical connectors
J Electrical connector 1
K Electrical connector 2
L Electrical connector 3
Install (For: 506-23 [T4F], 509-23 [T4F])

removal procedure. Remove
33 - 633 9813/9400-1 33 - 633

51 - Hydraulic Flow
2. Lift up the gaiter. 7. Remove the wires from the connector.

3. Loosen the locknut. 7.1. Use a screwdriver to remove the wires and
pins from the connector.
4. Cut and discard the cable tie.
7.2. Alternatively cut the wires and re-solder on
5. Disconnect the lever electrical connector from assembly.
the chassis harness connector.
8. Remove the lever top from the control rod.
6. Make sure to label the control lever wires
according to their position in the electrical
connector to aid replacement.
Figure 1509.
F
B
D
C
G
1 2 3
4 5 6 7
8 9 10 11
12 13 14 H
33 - 634 9813/9400-1 33 - 634

51 - Hydraulic Flow
Table 630.
Item Description
A Gaiter
B Locknut
C Control rod
D Cable tie
E Connector
F Lever top
G Wires
H Pins
Install
steps.
1.1. If the wires and pins are removed from the
connector make sure to replace them in the
correct positions. For pin or wire numbers
Refer to Table 631.
1.2. Install a new cable tie to attach the lever
wires to the control rod.
Table 631. Pin/wire numbers

Pin number Wire number
(1)
1 931
2 932
3 120A
4 660AN
5 856
6 933
7 1208
8 930
9 120C
10 929
12 934
(1) Not all wires will be in use on a single auxiliary
control lever with four buttons.
33 - 635 9813/9400-1 33 - 635

33 - Console Switch
33 - Console Switch
Contents Page No.
33-33-04 Direction Indicators ...................................................................................................... 33-637

33-33-15 Transmission Disconnect ............................................................................................. 33-648
33 - 636 9813/9400-1 33 - 636

33 - Console Switch
04 - Direction Indicators
04 - Direction Indicators Component Identification

Component Identification ............................. 33-637 The colour and position of the turn signal units may
Diagram ....................................................... 33-638 vary according to territory.
Figure 1510.
A B
A Rear indicator light B Front indicator and headlight unit
33 - 637 9813/9400-1 33 - 637

33 - Console Switch
Diagram
Wires and Connectors • Front right side headlight- chassis harness.

• Left side and right side rear lights- chassis
The turn signal lights are connected to the machine harness.
harnesses as follows:
The 550-80 machines have additional link harnesses
• Front left side headlight- panel harness. for the lights. Refer to (PIL 33-12).
Figure 1511.
1 6 3 4
2 5 2 5
3 4 1 6
1 6 3 4
2 5 2 5
3 4 1 6
33 - 638 9813/9400-1 33 - 638

33 - Console Switch
Figure 1512. Right Side Indicators Enabled
6 6
8 10
6
3
9
5 4
2
RHF 1
RHR 5
10 J2-20
J2-4
1 ECU
14
11 J1-17
J2-10
3
2
4
6 6
1
2
5 3
4
5
2
1
LHF
5
LHR
3
-VE
+VE
6
1 Fuse 2 Right side column switch
33 - 639 9813/9400-1 33 - 639

33 - Console Switch
3 LMS (Loadall Monitoring System)/Right side 4 Trailer lights direction relay

instrument panel ECU (Electronic Control
Unit)
5 Diode 6 Centre warning cluster
LHF Left side front light connector LHR Left side rear light connector
RHF Right side front light connector RHR Right side rear light connector
33 - 640 9813/9400-1 33 - 640

33 - Console Switch
Figure 1513. Left Side Indicators Enabled
6 6
8 10
6
3
9
5 4
2
RHF 1
RHR 5
10 J2-20
J2-4
1 ECU
14
11 J1-17
J2-10
3
2
4
6 6
1
2
5 3
4
5
2
1
LHF
5
LHR
3
-VE
+VE
6
1 Fuse 2 Right side column switch
33 - 641 9813/9400-1 33 - 641

33 - Console Switch
3 LMS/Right side instrument panel ECU 4 Trailer lights direction relay

5 Diode 6 Centre warning cluster
LHF Left side front light connector LHR Left side rear light connector
RHF Right side front light connector RHR Right side rear light connector
33 - 642 9813/9400-1 33 - 642

33 - Console Switch
526-56 Machines
Table 632. Harness Connector Right hand Front

Connectors Pins Details
RHF 5 6
C010 1 Chassis Earth Point. Refer to (PIL
33-12).
i016 39 Refer to (PIL 33-12).
P15 20 Right side instrument panel connec-
tor J2.
Table 633. Harness Connector Left hand Front

LHF 5 6
P036 3 Panel Earth Point. Refer to (PIL
33-12).
tor J2.
Table 634. Harness Connector Right hand Rear

RHR 5 6
C010 1 Chassis earth point. Refer to (PIL
33-12).
i016 39 Refer to (PIL 33-12).
tor J2.
Table 635. Harness Connector Left hand Rear

LHR 5 6
33-12).
i016 40 Refer to (PIL 33-12).
tor J2.
Other Machines
Table 636. Harness Connector Right Side Front

RHF 5 6
33-12).
i016 39 Refer to (PIL 33-12).
tor J2.
33 - 643 9813/9400-1 33 - 643

33 - Console Switch
Table 637. Harness Connector Left Side Front

LHF 5 6
P035 1 Panel earth point. Refer to (PIL
33-12).
tor J2.
Table 638. Harness Connector Right hand Rear

RHR 5 6
33-12).
i016 39 Refer to (PIL 33-12).
tor J2.
Table 639. Harness Connector Left hand Rear

LHR 5 6
33-12).
i016 40 Refer to (PIL 33-12).
tor J2.
33 - 644 9813/9400-1 33 - 644

33 - Console Switch
Remove and Install
Front Indicator / Headlight Unit 3. Disconnect the electrical harness connector from
the light unit electrical connector.
Remove 4. Support the light unit.
5. Remove the nut.
6. Remove the light unit from the mounting arm.
Figure 1514.
C
C
A
B
D
A Electrical connector B Mounting arm

C Light unit D Nut
33 - 645 9813/9400-1 33 - 645

33 - Console Switch

removal procedure. 3. Disconnect the electrical harness connector from
the light unit electrical connector.
Rear Indicator Light Unit 4. Support the light unit.
Remove 5. Remove the securing nuts and washers.
1. Make the machine safe. Refer to (PIL 01-03). 6. Remove the light unit from the mounting bracket.
Figure 1515.
B C
A
A Nuts B Washers
C Light unit D Electrical connector
E Mounting bracket
33 - 646 9813/9400-1 33 - 646

33 - Console Switch
Install
removal procedure.
33 - 647 9813/9400-1 33 - 647

33 - Console Switch
15 - Transmission Disconnect
15 - Transmission Disconnect Component Identification

Operation ..................................................... 33-649
(For: 512-26 [T4F])
Figure 1516. Transmission Dump Components
1 Transmission disconnect mode switch 2 Brake pedal

3 0711 Transmission ECU (Electronic Control 4 Brake servo
Unit)
5 Brake pressure transducer
33 - 648 9813/9400-1 33 - 648

33 - Console Switch
15 - Transmission Disconnect
Operation
(For: 512-26 [T4F])

Refer to component identification, (PIL 33-33-15)
and service brake, general, (24-03).
The transmission disconnect (dump) mode can be

switched on and off using the switch.
Transmission Disconnect mode- On

When the brake pedal is applied the transmission is
disconnected from the axles to prevent the machine
driving against the resistance of the brakes. This
operates automatically when the mode is set to on.
Transmission Disconnect mode- Off

The transmission is not disconnected when the brake
pedal is applied.
Operation
A pressure sensor is located on the brake servo and
senses the brake system pressure.
When the foot brake is applied, the transducer

detects the change in brake system pressure. Input
from the transducer is connected to the 0711
Transmission ECU (Electronic Control Unit). The
transmission ECU (IFM) selects neutral even if
forward or reverse is selected.
The feature enables an increase in machine

efficiency.
33 - 649 9813/9400-1 33 - 649

40 - Bulb
40 - Bulb
Contents Page No.
33-40-00 General ......................................................................................................................... 33-651
33 - 650 9813/9400-1 33 - 650

40 - Bulb
00 - General
Introduction .................................................. 33-651 Make sure the bulbs are replaced with the same type
Technical Data ............................................. 33-652 and rating as the damaged bulb.
33 - 651 9813/9400-1 33 - 651

40 - Bulb
00 - General
Technical Data Remove and Install
Table 640. Remove

Application Rating Type
1. Before replacing any bulb, make the machine
Work lights 55W H3 safe with the lift arm lowered. Refer to (PIL
Headlights 55W H3 01-03).
Dip beam 55W H7
2. Stop the engine and isolate the battery. Refer to
Side lights 4W T4W
(PIL 33-03-03).
Direction indica- 21W
tor lights 3. If necessary, wait for the light to cool down.
Brake lights 21W
4. Wear protective gloves.
Interior light 10W
Warning lights 1.2W 5. Gain access to the defective bulb.
Beacon (if fit- 55W
6. Remove the defective bulb
ted)
Install
1. Replace the bulb with one of the correct type
and specification. Refer to technical data, (PIL
33-40-00).
2. Where applicable, make sure you follow the bulb
manufacturers installation instructions. Make
sure you do not touch halogen bulbs by the glass.
Use gloves if necessary.
3. Make sure that the bulb is correctly aligned as it
is installed. Some bulb caps have projections to
make sure they are fitted in the correct orientation
and/or application.
4. If necessary, make sure that the light lens is clean
and the electrical contacts are free of corrosion.
5. Make sure that any seals are in serviceable
condition and are installed correctly.
6. Install any items removed when removing the
bulb.
7. Connect the battery. Refer to (PIL 33-03-03).
8. Make sure that the light works. (It is good practice
to check that the other lights are working too).
9. If appropriate, check the alignment of any light
unit that has had a bulb replacement.
33 - 652 9813/9400-1 33 - 652

45 - Control Module
45 - Control Module
Contents Page No.
33-45-00 General ......................................................................................................................... 33-655

33-45-06 Engine .......................................................................................................................... 33-682
33-45-09 Gearbox ........................................................................................................................ 33-685
33-45-24 Servo ............................................................................................................................ 33-700
33-45-36 Hydraulic ...................................................................................................................... 33-706
33-45-44 Nitrogen Oxide (NOx) Sensor ...................................................................................... 33-721
33 - 653 9813/9400-1 33 - 653

Notes:
33 - 654 9813/9400-1 33 - 654

45 - Control Module
00 - General
Introduction .................................................. 33-655 Modern machines use ECU (Electronic Control Unit)
Health and Safety ........................................ 33-656 to control machine systems such as hydraulics,
Operation ..................................................... 33-656 transmission and engine. In much the same way as
office computers can be ‘networked’ to communicate
with each other the machine ECU’s can be
‘networked’. Some advantages of networking are:
• Improved more intelligent control systems

• More comprehensive and reliable in-cab
instrumentation
• Service software tools can be used for fault
finding and machine control set up
The ECM (Engine Control Module) can communicate

with other machine ECU using a CANbus network
system.
CANbus Communications System

CAN (Controller Area Network) is an electronic
communications system that connects all the
machine ECU to one pair of data wires, this is called
the CANbus. Coded data is sent to and from the
ECU on the CANbus. By connecting Servicemaster
diagnostic software to the CANbus, data is seen and
decoded for use by a service engineer.
CANbus System Schematic

A typical CANbus system architecture is shown for
illustration purposes only below: Refer to Figure
1517.
Figure 1517. Typical CANbus architecture
ECU ECU ECU ECU ECU
F B C E G
Hi
Lo
Hi H
ECU Lo
A D
The CAN architecture may differ on your machine.

33 - 655 9813/9400-1 33 - 655

45 - Control Module
00 - General
Health and Safety Operation

Arc Welding The machines use an ECU (Electronic Control
To prevent the possibility of damage to electronic Unit) to control machine operations. The ECU uses
components, disconnect the battery and the analogue and digital signals from machine sensors,
alternator before arc-welding on the machine or switches etc. and uses this data to supply a feed or
attached implements. a ground connection for other machine devices. The
If the machine is equipped with sensitive electrical machines can have one or more ECU’s depending
equipment, i.e. amplifier drivers, electronic control on the model variant. For information on each ECU,
units (ECUs), monitor displays, etc., then disconnect refer to the correct topic in the subsequent pages.
them before welding. Failure to disconnect the
The machine ECU's can be connected to JCB
servicemaster diagnostic software to check ECU
version and operation. Refer to electrical system-
Parts of the machine are made from cast iron, welds electronic diagnostic. Refer to: PIL 33-57.
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable ECU Inputs
Always connect the welder earth (ground) cable to There are two main types of input, digital and
the same component that is being welded to avoid analogue.
the welder earth (ground) cable a distance from the Digital inputs (On-Off switch type inputs)
part being welded no more than 0.6m.
Digital type inputs are on-off type inputs (i.e.
Notice: Do not disconnect the battery while the switches). The digital inputs can be low side inputs or
engine is running, otherwise the electrical circuits high side inputs. The low side inputs are inputs that
may be damaged. provide a ground to the ECU. The high side inputs
are the inputs that provide a positive feed to the ECU.
Low side input
The low side input is the most frequently used input

on an electrical system. The low side input can be in
the form of rocker switches or pressure switches.
Figure 1518.
C
12 v
B
A ECU
B Input
C Switch (rocker, pressure etc.)
High side input
The high side input is used on circuits that require a

positive feed when the ignition is switched off, e.g.
sidelights or hazard lights.
33 - 656 9813/9400-1 33 - 656

45 - Control Module
00 - General

A A
C
C
12 v 12 v
B B
A ECU A ECU
B Input B Output
C Switch (lights etc.) C Solenoid or relay coil
Analogue inputs (Sensor type switch inputs) High side output
Analogue inputs are sensor type inputs that provide In the high side output circuit, the solenoid or relay
a varying type input to the ECU. This input could be which is being driven already has a ground available.
a voltage, resistance or frequency type input. The ECU provides the positive side of the circuit.
A A C
E
B
5v 12 v
C B
D A ECU
B Output
C Solenoid or relay coil
A ECU
B Sensor ref voltage Modulated outputs
C Sensor ref 0 voltage
D Thumbwheel input (potentiometer type input) In the modulated output circuit, the ECU provides
E Thumbwheel position switch a PWM (Pulse Width Modulation) signal to a
proportional valve. As the ECU varies the duty cycle
ECU Outputs of the signal, the proportional valve will be selected
depending on the change in duty cycle.
There are three main types of outputs. Low side
output, High side output and Modulated output. Figure 1523.
Low side output A C
In the low side output circuit, the solenoid or relay

which is being driven already has a positive feed B
available. The ECU then provides ground to the
circuit.
A ECU
B Output
C Proportional solenoid
33 - 657 9813/9400-1 33 - 657

45 - Control Module
01 - Instrument Panel Component Identification

Operation ..................................................... 33-659
Diagram ....................................................... 33-676
Check (Operation) ....................................... 33-679
Location
Figure 1524.
F F
B
D C
A E E
A Analogue fuel level gauge B Analogue engine coolant temperature gauge

C Analogue tachometer D Colour VGA LCD (Liquid Crystal Display)
E Up and down user control buttons F ECU (Electronic Control Unit) connectors
33 - 658 9813/9400-1 33 - 658

45 - Control Module
Operation
The instrument panel, warning indicator and warning You can navigate to different screen shown on
lights are located in the dash panel at the front of the the LCD display screen using the up and down
cab in the line of sight from the operator's seat. navigation buttons and information switch.
It provides the interface with the machines electronic The control levers and switches may vary on
system. machines.
Figure 1525.
A
H G F E D
A Display screen B Warning indicator

C Tachometer D Navigation button - down
E Navigation button - up F Fuel level gauge
G Coolant temperature gauge H Information switch
Display Screen Navigation button (Down)

The LCD screen displays information such as current Used to navigate through the various options on the
machine status, machine setup, service information LCD Screen. Refer to Figure 1525.
and fault logs. Refer to Figure 1525.
Navigation button (Up)
Warning Indicator
Used to navigate through the various options on the
The warning indicator will light up amber whenever LCD Screen. Refer to Figure 1525.
there is a Warning Error. A buzzer shall sound for
1s when there is a service fault. This fault can be Fuel level gauge
cancelled via the Fault Log Screen. Refer to Figure
1525. Indicates the level of diesel fuel in the tank. Do
not let the tank run dry, or air will enter the fuel
The warning indicator will light up red whenever there system. When the Fuel level enters the red zone, an
is a critical Error. A buzzer will permanently sound alarm will sound and the Warning Indicator Lamp will
when there is a critical fault. This fault cannot be illuminate. Refer to Figure 1525.
cancelled and you should contact your dealer.
Coolant temperature gauge
Tachometer
Indicates the temperature of the engine coolant. The
Indicates the engine speed in revolutions per minute. gauge pointer will gradually swing upwards as the
Refer to Figure 1525. coolant temperature increases. When the coolant
33 - 659 9813/9400-1 33 - 659

45 - Control Module
temperature enters the red zone, an alarm will sound • Long Press - Press the information button
and the Warning Indicator Lamp will illuminate. Refer longer than 2s allows the operator to enter the
to Figure 1525. displayed screen.
Information Switch Main Display Screens

The information switch is used to perform different Start-Up Screen
actions: Refer to Figure 1525.
When the ignition switch is switched on the JCB
• Short Press - Press the information button for logo is displayed or on AGRIPRO models a different
less than 2s allows the operator to cycle through screen is shown. After 3s the display will show the
the main screens. normal operating mode screen.
Figure 1526.
Default Operating Screen Transmission FNR and gear information - Displays

the selected gear and direction of the machine. The
Displays the machine travel speed, transmission and current selected gear will be displayed in solid yellow.
gear information, steer mode, clock and machine When a gear change request is acknowledged by the
status. transmission, but has not yet been carried out, the
requested gear will be displayed in flashing yellow
Figure 1527. until the shift takes place. Requested shifts can be
B C D cancelled by shifting in the opposite direction.
Travel Speed
Normally displays the speed of the machine.

H
A Transmission FNR and Gear Information
G Figure 1528.
A B
F E D
A Travel speed
B Transmission FNR and gear information
C Transmission status and SCR (Selective C
Catalytic Reduction) status tray
D Steer mode tray
E Clock/machine hours
F Machine status tray (stabilisers, joystick
configuration) A Active gear information
G DEF (Diesel Exhaust Fluid) level B Forward arrow icon
H Brake system accumulator pressure C Reverse arrow icon
D Neutral
Travel speed - Normally displays the speed of
the machine. This section is also used when a Displays the gear and direction of the machine.
notification is activated.
33 - 660 9813/9400-1 33 - 660

45 - Control Module
The current selected gear will be displayed in solid The reverse arrow will be shown if a reverse gear is
yellow. selected.
When a gear change request is acknowledged by the If neutral is selected the icon N and the previously
transmission, but has not yet been carried out, the selected forward gear will be shown.
requested gear will be displayed in flashing yellow
until the shift takes place. Requested shifts can be Transmission Status Symbols
cancelled by shifting in the opposite direction. Both
multiple changes and downshift protection can delay Displays the current transmission status. There are
shifts. more icons than space in the Transmission Icons
Tray, you will always have a notification when a
The forward arrow will be shown if a forward gear is status changes, however only the most important
selected. status icons will be displayed.
Table 641.
ECO mode active
Park brake active
Foot brake dump active
Torque converter lock up engaged
2WD active/Auto 2WD active
Driver not in seat
Transmission auto mode active
Auto Steer Mode Symbols (if installed) If there is a fault a symbol will flash rapidly, and a
notification will be displayed.
Displays the active steer mode in the solid grey.
When changing between the steer modes the amber

icons will flash at 1s intervals.
Table 642.
2 Wheel steer mode active
4 Wheel steer mode active
33 - 661 9813/9400-1 33 - 661

45 - Control Module
Crab steer mode active
2WS to 4WS (symbol flashes during mode change)
2WS to crab steer (symbol flashes during mode change)
4WS to 2WS (symbol flashes during mode change)
Crab steer to 2WS (symbol flashes during mode change)
Indicated Manual Steer Mode Symbols (if If there is a fault a symbol will flash rapidly, and a
installed) notification will be displayed.
Displays when the wheels are aligned to straight

ahead position.
Table 643.
No wheels are aligned
Front wheels are aligned
Rear wheels are aligned
All wheels are aligned
Machine Status Symbols the Machine Status Tray. You will always have a
notification when a status changes, however only the
Displays the status of various hydraulic systems of most important status icons will be displayed.
the machine. There are more icons than space in
Table 644.
Auto SRS (Smooth Ride System) active (if installed)
Bucket control system active (if installed)
33 - 662 9813/9400-1 33 - 662

45 - Control Module
SRS active
Constant auxiliary mode active
Secondary auxiliary active
Auto fan reverse active
Tilt lock active
Full lock active or Hydraulic function isolation active
Left stabilizer deployed
Right stabilizer deployed
Joystick configuration - placing pattern
Joystick configuration - loader pattern
Notification Screens display screen and the notification is displayed on the

right side of the main display screen. A buzzer may
The notification screen displays temporary operator sound to notify the operator that a request has been
messages such as operator requested mode acknowledged.
changes, user input screens, etc.
If multiple operator notifications become active, only
When a request becomes active, the primary the latest active notification is displayed.
information is displayed on the left half of the main
33 - 663 9813/9400-1 33 - 663

45 - Control Module
Table 645.
Icon Event Buzzer
Audible/Visual. Steer mode change No
from 2WS to 4WS.

from 2WS to crab steer.

from 4WS to 2WS.

from crab steer to 2WS.
Audible/Visual. Cab heater fan No

speed setting. Number of yellow
bars corresponds to current fan
speed setting.
Audible/Visual. Constant auxiliary No

operational position.

stored position.

cancelled.
33 - 664 9813/9400-1 33 - 664

45 - Control Module
Icon Event Buzzer

Audible/Visual. 2nd auxiliary ac- No
tive.
Audible/Visual. 2nd auxiliary can- No

celled.
Audible/Visual. SRS active. No
Audible/Visual. SRS cancelled. No
Audible/Visual. Hydraulic lock ac- No

tive.
Audible/Visual. Hydraulic lock can- No

celled.
Audible/Visual. Tilt lock active. No
Audible/Visual. Tilt lock cancelled. No
33 - 665 9813/9400-1 33 - 665

45 - Control Module
Icon Event Buzzer

Audible/Visual. Transmission dis- No
connect active.
Audible/Visual. Transmission dis- No

connect cancelled.
Audible/Visual. LLMC (Longitudinal Yes

Load Moment Control) override ac-
tive.
Audible/Visual. Air conditioning No

system active.
Audible/Visual. Air conditioning No

system cancelled.
Audible/Visual. Auto reverse fan No

active.
Audible/Visual. Auto reverse fan No

cancelled.
Audible/Visual. Grid heater active. No
33 - 666 9813/9400-1 33 - 666

45 - Control Module
Icon Event Buzzer

Audible/Visual. 2WD active. No
Audible/Visual. 2WD cancelled. No
Audible/Visual. Stabilizer isolation No

active.
Audible/Visual. Stabilizer isolation No

cancelled.
Audible/Visual. Immobiliser active. No
Audible/Visual. Operator has left Yes

the seat, with transmission en-
gaged and park brake disengaged
(excludes 540-170).
Audible/Visual. Service/Aux vent- Yes

ing activated
Audible/Visual. Transmission auto No

mode active.
33 - 667 9813/9400-1 33 - 667

45 - Control Module
Icon Event Buzzer

Audible/Visual. Transmission auto No
mode cancelled.
Audible/Visuall. Transmission auto No

mode cancelled.
PWR
Audible/Visual. ECO mode mode No
active.
Audible/Visual. Snail mode active No

or, snail percent adjusted..
99%
Secondary Level Display Screens Figure 1531.
Pressing the information switch and navigation

arrows will take the operator to the secondary level
display screens.
Press the information switch for less than 2s to cycle

through the main screens.
Machine setup screen
Figure 1529.
Figure 1532.
Machine status screen

Fault log screen
Figure 1530.
Press the information switch for longer than 2s to
enter the displayed screen.
Press the arrows to navigate up and down within the

main screens.
Machine Status
Service information screen
To see the machine status information:
Go to the machine status screen.
33 - 668 9813/9400-1 33 - 668

45 - Control Module
Press the information switch for more than 2s to see Figure 1536.
the machine status.
A
Figure 1533. B
A C
B D
C
A Engine hours
D B Machine type
C Machine serial number
A Battery voltage D Next service interval
B Coolant temperature
C Not used Figure 1537.
D Engine RPM (Revolutions Per Minute)
E
Figure 1534. F
E G
F H
E Time to next service
F Right hand cluster hardware version number
G Right hand cluster software version number
E Not used H Tyre diameter
F Engine air intake temperature
Figure 1538.
Press the navigation arrows to switch between the
screens. J
Press the information switch again for less than 2s

to the exit screen.
Figure 1535.
J Axle ratio
The machine option screens allow the dealer to

identify the options installed and the status of each
option.
Figure 1539.
Exit screen K
Press the information switch again for more than
2s to return to the default operating screen (home
screen).
Service Information K Machine options screen 1

To see the service information: Figure 1540.
Go to the service information screen. L
Press the information switch for 20s to see the

service information.

screens. L Machine options screen 2
Press the information switch again for less than 2s to

display the last screen.
33 - 669 9813/9400-1 33 - 669

45 - Control Module
Exit screen Exit screen
Press the information switch again for more than Press the information switch again for more than
2s to return to the default operating screen (home 2s to return to the default operating screen (home
screen). screen).
Machine Setup Time Setup
The machine setup screen allows the operator to To setup/adjust the time:
configure the time, date, brightness, etc.
1. Go to the machine setup screen.
Press the information switch for less than 2s to
display the main screen. 2. Press the navigation arrows to select the clock.
Figure 1545.
Press the navigation arrows to scroll down to the
machine setup screen.
Press the information switch for more than 2s to

active the machine setup screen.

available options on the screen.
Figure 1542. 3. Press the information switch for more than 2

seconds.
10: 30 A
11/ 03/ 11 B 4. Press the navigation arrows to select the time
format.
km / l / bar C
D Figure 1546.
1/ 2
A Clock
B Date
C Units of measure
D Display screen brightness
Figure 1543.
E
gauge_bac
klight
trans_calib
F
dpf_inhibit
G
2/ 2
E Gauge backlight brightness

F DTVT (Dual Technology Variable Transmission) 5. Press the information switch for 2 seconds to
Transmission calibration adjust the clock.
G Automatic refresh inhibit
6. Press the information switch for 2 seconds to
Press the information switch again for less than 2s to switch between the hours and minutes. Use the
display the last screen. arrows to adjust the values.
33 - 670 9813/9400-1 33 - 670

45 - Control Module
7. Press the information switch for more than 2

seconds to confirm the setup.
Units of Measure
To setup the units of measure:

seconds to confirm the setup. 1. Go to the machine setup screen.
Date Setup 2. Press the information switch for more than 2

seconds
To setup the date:
3. Press the navigation arrows to select the units.
1. Go to the machine setup screen. 4. Press the information switch for more than 2
2. Press the navigation arrows to select the date. seconds to confirm the setup.
Figure 1548. Display Screen Brightness
To adjust the brightness of gauge backlight or display

screen:

2. Press the navigation arrows to select the
brightness.
3. Press the information switch for more than 2 Figure 1551.

seconds.
4. Press the navigation arrows to select the date
format.
Figure 1549.

seconds.
4. Press the navigation arrows to increase or
decrease the brightness.
Figure 1552.
5. Press the information switch for 2 seconds to

adjust the date.
6. Press the information switch for 2 seconds to 5. Press the information switch for more than 2
switch between the day, month and year values. seconds to confirm the setup.
Use the arrows to adjust the values.
33 - 671 9813/9400-1 33 - 671

45 - Control Module
DTVT Transmission Calibration specified temperature range. If one or more

of these conditions is not met then the hand
To calibrate the transmission: symbol remains grey. Once the conditions are all
met the hand symbol illuminates. The specified
1. Make sure the transmission oil level is correct. temperature range is:
2. Go to the machine setup screen. Temperature: 50–55°C (121.9–130.9°F)
3. Press the navigation arrows to select the 6. A short press initiates calibration a quick press
transmission calibration. reverts to previous screen.
4. Press the information switch for more than 2 7. If calibration is unsuccessful a red X is displayed.
seconds. If calibration is successful a green tick is
displayed.
5. For the calibration to initiate the foot brake
and park brake must be applied and the 8. A short press initiates calibration a quick press
transmission temperature must be in the reverts to previous screen.
Figure 1553.
Automatic Refresh Inhibit Figure 1554.
Use this menu item enable/disable the automatic

refresh.

2. Press the navigation arrows to select the inhibit
feature.
3. Auto refresh inhibit active (tick mark), auto If a service fault or critical acknowledgeable fault is
refresh inhibit not active (X mark). recognised by the machine electronic system a fault
icon and fault code is displayed on the right side of
4. Press the information switch for more than 2 the home screen. The fault indicator is illuminated
seconds to confirm the setup. amber or red. The buzzer sounds momentarily when
a fault is active. The code will remain until it is
Fault Log acknowledged by pressing the information button.
The fault log screen provides information on the Figure 1555.

active and previously active faults on the machine.
The fault log display screen shows the fault code,
time, date, engine hours and number of times that
the fault has been active. By default, the fault log
display shall only show the active faults. It shall be
possible to view active and historical faults by going
to the diagnostic menu. Faults shall be displayed in
the colour of their severity (critical = red, warning =
yellow, trivial = grey). When a critical non-acknowledgeable fault is active,
the left area of the main screen will show the fault
33 - 672 9813/9400-1 33 - 672

45 - Control Module
icon and right area of the main screen will show the Figure 1558.
fault code. The fault indicator is illuminated red. The
buzzer sounds when a critical fault is active. It sounds
until the critical fault is no longer active.
Figure 1556.
Warning/Fault Icons
There are three levels of warnings each is
represented by a different colour. Depending on
the level of severity it may or may not be
Figure 1557. acknowledgeable by the operator. Some icons are
available at all three levels but are not shown below:
• Yellow - acknowledgeable
• Critical red - not acknowledgeable
• Critical red (50% screen size)-
acknowledgeable
Table 646.
Transmission Stabilizer Transmission
pressure
Exhaust treat- Joystick

ment
Telematics Immobiliser Brake
DEF level Engine Engine oil pres-

sure
Coolant temper- Steer

ature
Hydraulics DEF acknowl-

edgeable
Transmission CAN (Controller Foot brake press

temperature Area Network)
Fuel level Indicator lamp Reverse alarm
Water in fuel Ground speed
Sway Air filter Battery
Coolant level Engine oil level
HVAC (Heating Brake light

Ventilation Air
Conditioning)
33 - 673 9813/9400-1 33 - 673

45 - Control Module
Warning Lights way to cancel the alarm is to set the ignition switch
to position '0'. The problem can then be rectified.
CAUTION If any of the audible/visual warnings
operate while the engine is running, stop the Do not use the machine if it has a fault condition, or
engine as soon as it is safe to do so and rectify you may damage the engine and/or the transmission.
the fault.
All instruments and indicators will be turned off when
The warning lights are grouped together on a panel the ignition switch is set to off (the hazard warning
located on the dash board. indicator will still operate if the hazard warning lights
are switched on).
When a warning light comes on an alarm will sound
(depending on security of the condition). The only
Figure 1559.
A B C D E F G H
J K L M N P Q R
A Low fuel indicator - Not used. Information B Boom work light - Visual (Amber Light).
displayed on instrument panel. Illuminates when the boom work lights are
switched on.
C Front work light - Visual (Amber Light). D Rear work light - Visual (Amber Light).
Illuminates when the front work lights are Illuminates when the rear work lights are
switched on. switched on.
E Trailer indicator - Visual Only (Green Light). F Direction indicators - Visual only (Green light).
Flashes with the trailer indicators. Flashes with the direction indicators.
G Main beam - Visual only (Blue light). Illuminates H Side lights - Visual only (Green light).
when the headlight main beams are switched Illuminates when the side lights are switched on.
on.
J Grid heater - Not used. Information displayed on K Engine oil pressure - Visual only (Red light).
instrument panel. Operates if the engine oil pressure drops below
the normal working pressure.
L Transmission oil pressure - Visual (Red M Transmission oil temperature - Not used.
light).Illuminates if the oil pressure drops below Information displayed on instrument panel.
the normal working pressure.
N Park brake engaged - Visual (Red light). P Not used.
Illuminates when the park brake is engaged.
Q Master warning - Not used. Information R Fog lights - Visual only (Amber light). Illuminates
displayed on instrument panel. when the fog lights are switched on.
33 - 674 9813/9400-1 33 - 674

45 - Control Module
SCR Exhaust After Treatment Figure 1564.
Notification Symbols
Table 647.
• Flashing red notification symbol. Second stage
Low DEF, derate warn- derate condition, fill up now.
ing - flashing/solid - am-
ber icon. Figure 1565.
Low DEF derate warn-

ing - flashing/solid - red
icon.
• Solid red notification symbol. Forced idle,
machine unusable, fill up now.
DEF Level
Figure 1566.
The LCD (Liquid Crystal Display) permanently
displays the DEF level bargraph. Each bar
represents approximately 10% of tank volume.
Figure 1560.
As the DEF level depletes to low, warning icons

and notification symbols and warning icons are
displayed. The intensity of the warnings symbols
and indicator changes as follows as the DEF level
depletes further:
• Amber warning icon. Operator warning, fill up

this shift.
Figure 1561.
• Flashing amber notification symbol. Operator

warning, fill up now.
Figure 1562.
• Red warning icon. 0%DEF, fill up now. Initial

derate starts.
Figure 1563.
• Solid amber icon. Derate condition, fill up now.
33 - 675 9813/9400-1 33 - 675

45 - Control Module
Diagram
Location
The right side instrument panel is connected to the
panel harness.
Figure 1567.
20 10 1 11
KEYING OPTION A
KEYING OPTION B
J2 J1
11 1 10 20
Table 648. Connector J1

Pin Num- Connected To: Type Refer to Device
ber
1 Side lights (wake up) TBA TBA
2 Power 12 battery Right side instrument panel
ECU (Electronic Control Unit)
power and earth connections
3 Air conditioning fan relay Digital output HVAC (Heating Ventilation Air
Conditioning) devices
33 - 676 9813/9400-1 33 - 676

45 - Control Module

ber
4 Centre instrument panel (Trail- Digital output Center instrument panel dis-
er direction indicators) play panel
5 Not used - -
6 Not used - -
7 CAN (Controller Area CANbus CANbus system
Network)bus low
8 CANbus high CANbus CANbus system
9 SCR (Selective Catalytic Re- CANbus screen CANbus system
duction) (If installed)
ECU power and earth connec-
tions
11 Engine run relay / Engine RPM Alternator
(Revolutions Per Minute)
12 Cooling fan solenoid Digital output Fan reverse solenoid
13 Hazard warning lights Digital input Hazard lights
14 Right side trailer present direc- Digital input Trailer turn signal light circuit
tion indicator
15 Earth (Sensors) Earth -
16 Left side trailer present direc- Digital input Trailer turn signal light circuit
tion indicator
17 Right side column switch (Left Digital input Right side column switch
side / Right side direction indi-
cators)
18 Cooling fan reverse switch Digital input Fan reverse switch
19 Eco switch - TBA
tions

ber
1 Air filter vacuum switch Digital input Vacuum switch
2 Not used - -
3 Information operator button Digital input Information operator switch
4 Right side column switch (Left Digital input Right side column switch
side / Right side direction indi-
cators)
5 Heater switch panel HVAC devices
6 Cooling fan reverse switch Digital input Fan reverse switch
7 Alternator excitation Output Alternator
8 Speed sensor Frequency input Fan speed sensor
9 HVAC blower fan motor Digital output HVAC blower fan
10 Left side direction indicator Digital output Direction indicators / Turn sig-
lights nal
11 Fuel level sender Analog input Fuel level sensor
12 Not used - -
13 Not used - -
14 Cab temperature sensor Analog input -
15 Hitch direction TBA -
33 - 677 9813/9400-1 33 - 677

45 - Control Module

ber
16 Not used - -
17 Earth Earth Right side instrument panel
tions
18 HVAC blower fan motor speed Digital input HVAC devices
controls
19 Cooling fan proportional sole- PWM (Pulse Width Modula- Fan proportional solenoid
noid tion) output
20 Right side direction indicator Digital output Direction indicators / Turn sig-
lamps nal lights
Right Side Instrument Panel ECU Power and Earth Connections
Figure 1568.
CONNECTOR J1
A 2
10
A
20
CONNECTOR J2
17
ECU
A Fuse B Right side instrument panel ECU
Table 650. Harness connector J1

J1 2 10 20
P005 18 10 10 Fusebox. Refer to (PIL 33-09).
Table 651. Harness connector J2

J2 17
P030 1 Panel earth point. Refer to (PIL 33-12).
33 - 678 9813/9400-1 33 - 678

45 - Control Module
Check (Operation)
tool to identify faults.
(PIL 33-57).
equipment, it is not possible to test the ECU. If the
33 - 679 9813/9400-1 33 - 679

45 - Control Module
Remove and Install
Remove 4. Do not touch the connector pins on the right side

instrument panel ECU (Electronic Control Unit).
5. Remove the three screws that hold the right side
2. Disconnect the battery. Refer to (PIL 33-03). switch panel in place.
3. Remove the radio (if installed). 6. Put label and disconnect all connections and
remove the panel.
Figure 1569.
A C
B C
F E D
A Screws B Right side instrument panel ECU

C Connector pins D Right side switch panel
E Radio F Switches
33 - 680 9813/9400-1 33 - 680

45 - Control Module
Install
steps.
1.1. The right side instrument panel is an
integral part of the right side switch panel. If
you replace the right side instrument panel,
transfer the switches also to the new switch
panel.
1.2. Put labels on the switches to install in the
correct locations.
1.3. Before you operate the machine, make
sure that the right side instrument panel
is configured correctly. Use the correct
Servicemaster setup tool. Refer to (PIL
33-57).
33 - 681 9813/9400-1 33 - 681

45 - Control Module
06 - Engine
06 - Engine Introduction
Introduction .................................................. 33-682 Central to the engine control system is the ECM
Operation ..................................................... 33-683 (Engine Control Module). The prime function of the
Remove and Install ..................................... 33-684 ECM is to initiate fuel injection. The engine cannot
run without the ECM.
Signals from electrical sensors are continually

monitored and processed by the ECM to determine
when, how much and to which cylinder fuel must be
injected.
The ECM controls fuel injection by energising

electrical actuators in the fuel injectors, high pressure
fuel pump and the common fuel rail.
Note: Other devices are connected to the ECM to

control other engine related systems, refer to (PIL
15-84).
Figure 1570.
TDC 2 3
5
4
C1 C2
D1 D2 6

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
33 - 682 9813/9400-1 33 - 682

45 - Control Module
06 - Engine
Operation Other operating parameters may initiate automatic

engine shut down by the ECM. For example low
engine oil pressure or sensor faults.
The ECM (Engine Control Module) achieves
effective fuel injection by controlling two main Engine Fault Diagnostics
systems:
Since the ECM continually scans for expected inputs
Pressure Control from all connected devices it is capable of detecting
related electrical faults. These faults are datalogged
Fuel pressure in the common rail is varied according in the ECM memory. By connecting diagnostics
to engine operating parameters. software any faults recorded can be displayed in
code form. This assists service personnel when
For example when the engine speed and load is tracing faults with the fuel injection system.
high, fuel can be injected at very high pressure to
achieve optimum combustion. When engine speed In addition to fault datalogging, the ECM will respond
and load is low, fuel pressure must be reduced. In to some faults by shutting the engine down, thus
these conditions injecting fuel at too high a pressure preventing serious engine damage.
would result in poor combustion.
The ECM also has the facility to drive cab mounted
Engine cold starts require special conditions. The warning devices such as coolant temperature and oil
ECM increases fuel pressure to facilitate cold starting pressure displays.
and cold running.
The ECM actuates the inlet metering valve and high

pressure rail fuel valve to control fuel pressure.
Injection Control
Injection control requires the ECM calculation of the
following:
• Engine phase - to determine which cylinder is

firing.
• Injection timing - to determine when injection
takes place in relation to crankshaft position.
• Fuel flow - to determine how much fuel and
therefore, the duration of injection. The ECM
uses data from the various engine sensors
to calculate the injection timing and fuel flow
requirements using a `data map' stored in its
memory. Refer to the Fuel Injection Cycle
Idle Speed Control

The ECM incorporates an engine idle speed control
module. When the operator closes the throttle the
ECM initiates the idle control. The minimum fuel is
calculated to maintain the programmed idle speed.
Engine Shut Down

The ECM initiates engine shut down in response to
inputs from an operator controlled stop ignition key
switch.
Engine shut down is achieved by ceasing fuel

injection. When an engine stop input is received by
the ECM no current is sent to the injector solenoid
coils.
33 - 683 9813/9400-1 33 - 683

45 - Control Module
06 - Engine
Remove and Install is a non serviceable item. If the ECM is defective

it must be replaced.
Before Removal Important: Do not install an ECM from another

engine. Although identical in appearance the internal
1. Ensure that the engine is safe to work on. If the configuration is unique to every ECM. If the ECM
engine has been running let it cool before you has been renewed it must be flashed with the correct
start the service work. set-up data files and programmed with the correct
injector codes.
Carefully inspect the ECM housing. If it is defective
Figure 1571. replace it.
Install
D steps.
2. Make sure that the earth strap is correctly
installed adjacent to the engine bedplate.
E,F Table 652. Torque Values

Item Nm
C
C 24
D
G
A Electrical connector (Grey) -ECM (Engine

Control Module)
B Electrical connector (Black) - ECM
C Fixing bolts
D ECM
E Washer
F Bush
G Earth strap
Remove
1. Disconnect the battery.
2. Disconnect the electrical connectors at theECM.
Do not touch the electrical connector pins on the
ECM.
3. Undo the fixing bolts and carefully lift off the ECM
together with the washers and mounting bushes.
Note the position of earth strap. Note: The ECM
33 - 684 9813/9400-1 33 - 684

45 - Control Module
09 - Gearbox
09 - Gearbox Introduction
Introduction .................................................. 33-685 The transmission ECU (Electronic Control Unit)
Component Identification ............................. 33-686 installed on the machine is dependent on the
Check (Operation) ....................................... 33-697 gearbox variant.
Calibrate ...................................................... 33-697
Machines with PS750 transmission use an 0711 ECU
Remove and Install ..................................... 33-698 with 2 connectors both with 18 pins.
Machines with PS764 or PS766 transmission use an

IFM ECU with 1 connector with 55 pins.
Figure 1572. PS750 0711 ECU
Figure 1573. PS764 PS766 IFM ECU
33 - 685 9813/9400-1 33 - 685

45 - Control Module
09 - Gearbox

................................................. Page 33-686
For: PS750 MK4 ..................... Page 33-687
For: PS764, PS766 ................. Page 33-693

Figure 1574. Dual Tech Variable Trans-
mission- Transmission ECU Location
C
D
A
A ECU (Electronic Control Unit) Cover
B Cab
C View from inside cab (under the seat)
D Dual Tech Variable Transmission- Transmission
control ECU
E ECU Mounting bracket
33 - 686 9813/9400-1 33 - 686

45 - Control Module
09 - Gearbox
(For: PS750 MK4)
Transmission ECU 0711

Location
Figure 1575.
1 Transmission ECU 0711 (526-56 Machines) 2 Transmission ECU 0711 (Other Machines)
33 - 687 9813/9400-1 33 - 687

45 - Control Module
09 - Gearbox
Power and Earth Connections
Figure 1576.
J1
J2
A
1
15
A
12
ECU 16
A Fuse B Transmission 0711 ECU
33 - 688 9813/9400-1 33 - 688

45 - Control Module
09 - Gearbox
Figure 1577.
1 2
6 5 4 3 2 1
12 11 10 9 8 7
18 17 16 15 14 13
1 Connector J1 (key C) 2 Connector J2 (key B)

3 Connector identification letter
33 - 689 9813/9400-1 33 - 689

45 - Control Module
09 - Gearbox
ECU Pin Outs

540-170, 550-170 machines
Connector Pin Number Connected to Type
1 Transmission oil temperature sen- Low side output
sor (Machines with PS760 trans-
mission only)
2 Neutral start relay - pin 5 Low side output
3 Left column multi function switch / Digital input
gear selection diodes
4 Steer mode ECU Digital input
5 Transmission Forward High sole- High side output
noid - power
6 Transmission Forward Low sole- High side output
noid - power
7 Steer mode relay 2 High side output
8 Transmission oil temperature sen- Resistive input
sor
9 Operator present seat switch Frequency input
10 Steer mode switch - pin 6 Frequency input
11 Left column multi function switch - Digital input
direction selection
12 Steer mode switch - pin 3 Digital input
13 6th gear solenoid (PS766 gear- Low side output
box) / Mainshaft and Layshaft sole-
noid earth (PS750 gearbox)
14 Steer mode relay 2 High side output
15 Transmission Layshaft solenoid High side output
power
16 Transmission Mainshaft solenoid High side output
power
17 Transmission Reverse low sole- High side output
noid power
18 Transmission Reverse high sole- High side output
noid power

1 Battery Wake up input
2 Not used
3 Not used
4 CAN (Controller Area Network)bus CAN - low
5 CANbus CAN - shield
6 Sensor voltage 5V reference voltage
7 Not used
8 Not used
9 Not used
10 CANbus CAN - high
11 Sensor earth Sensor earth
12 Power Feed from battery
13 Not used 3.3V reference voltage
33 - 690 9813/9400-1 33 - 690

45 - Control Module
09 - Gearbox

14 Park brake relay Voltage input
15 Earth Earth
16 Earth Low side driver supply input
17 Power High side driver supply input
18 Power High side driver supply input
Machines with Gearpump Hydraulic Pump

1 Transmission oil temperature sen- Low side output
sor (Machines with PS760 trans-
mission only) / Forward drive sole-
noid earth (526-56)
3 Left column multi function switch / Digital input
gear selection diodes
4 Transmission oil temperature Digital input
sensor (machines with PS750 or
SS700 transmission)
5 Transmission Forward High sole- High side output
noid - power
6 Transmission Forward Low sole- High side output
noid - power
7 Brake lights relay - pin 5 High side output
8 Foot brake dump switch (550-80 Resistive input
machines)
9 Foot brake pressure switch Frequency input
11 Left column multi function switch - Digital input
direction selection
12 Operator present seat switch Digital input
13 6th gear solenoid (PS766 gear- Low side output
box) / Mainshaft and Layshaft sole-
noid earth (PS750 gearbox)
14 Reverse alarm / lights relay High side output
15 Transmission Layshaft solenoid High side output
power
16 Transmission Mainshaft solenoid High side output
power
17 Transmission Reverse low sole- High side output
noid power
18 Transmission Reverse high sole- High side output
noid power

2 Not used
3 Not used
4 CANbus CAN - low
5 CANbus CAN - shield
33 - 691 9813/9400-1 33 - 691

45 - Control Module
09 - Gearbox

7 Not used
8 Not used
9 Not used
14 Transmission dump Voltage input
15 Earth Earth
17 0711 Transmission ECU Drive High side driver supply input
Shutdown Relay pin 9
Machines with Variable Hydraulic Pump

1 Variflow Pump Control Solenoid Low side output
Earth
3 Manual / auto switch - pin 2 Digital input
4 Transmission oil temperature sen- Digital input
sor
5 Not used High side output
6 Variflow Pump Control Solenoid High side output
Power
7 Brake lights relay - pin 5 High side output
8 Foot brake dump switch (550-80 Resistive input
machines)
9 Foot brake pressure switch Frequency input
11 Brake charge pressure transducer Digital input
(550-80 machines)
12 Operator present seat switch Digital input
13 Not used Low side output
14 Reverse alarm / lights relay High side output

2 Not used
3 Not used
4 CANbus CAN - low
5 Not used CAN - shield
33 - 692 9813/9400-1 33 - 692

45 - Control Module
09 - Gearbox

7 Not used
8 Not used
9 Not used
14 Not used Voltage input
15 Earth Earth
(For: PS764, PS766) Figure 1578.
Location
The IFM Transmission ECU is located below the
drivers seat.
1 IFM Transmission ECU
Power and Earth Connections
Figure 1579.
1
A 20
19
32 42
B
10 ECU
A Secondary fuse B Primary fuse

C IFM ECU
33 - 693 9813/9400-1 33 - 693

45 - Control Module
09 - Gearbox

The IFM transmission ECU is connected to the panel
harness.
Figure 1580.
38 55
20
37
1 19
ECU Pin Outs
Table 659.
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Transmission forward high sole- High side output
noid - power
7 Transmission reverse low solenoid High side output
- power
8 Transmission layshaft solenoid - High side output
power
9 Transmission 6th gear solenoid - High side output
power
11 Transmission 4WD (Four Wheel High side output
Drive) solenoid - pin 1
12 Transmission mainshaft solenoid - High side output
power
13 Transmission reverse high sole- High side output
noid - power
14 Transmission forward low solenoid High side output
- power
33 - 694 9813/9400-1 33 - 694

45 - Control Module
09 - Gearbox

15 Torque converter lock up solenoid - High side output
power
16 Not used
17 Transmission 4WD solenoid - pin 2 High side output
18 Not used
19 Ignition feed Ignition feed
20 Earth Earth
21 Left column multi function switch - Input
3rd gear manual selection
Neutral direction selection
direction selection switch power
pin 3 - not used
25 Not used
26 Not used
27 Not used
28 Not used
29 CANbus CAN - low
30 Not used
31 Not used
32 Ignition feed Ignition feed
33 Not used
34 Transmission speed sensor - sig- Input
nal output B
35 Not used
36 Transmission speed sensor - sig- Input
nal output A
37 Not used
38 Not used
39 Not used
40 Not used
forward direction selection
42 Earth Earth
43 Not used
44 Not used
45 Not used
46 Not used
48 Not used
49 Not used
50 Not used
52 Not used
53 Not used
33 - 695 9813/9400-1 33 - 695

45 - Control Module
09 - Gearbox

54 Transmission oil temperature sen- Input
sor 1 - power
55 Transmission oil temperature sen- Input
sor 2 - power
33 - 696 9813/9400-1 33 - 696

45 - Control Module
09 - Gearbox
Check (Operation) Calibrate

(For: 506-23 [T4F], 509-23 [T4F])
2. Make sure that the applicable control interface Refer to electrical system- electronic diagnostic, refer
operates correctly. Rectify as required. Refer to to (PIL 33-57).
(PIL 33-57).
33 - 697 9813/9400-1 33 - 697

45 - Control Module
09 - Gearbox
Remove and Install
For: HM560 Variable Transmission 5. Disconnect the electrical connectors from the
................................................. Page 33-698 ECU. Make sure you do not touch the connector
For: PS764, PS766 ................. Page 33-698 pins on the ECU.
For: PS750 MK4 ..................... Page 33-699 6. Remove the ECU mounting screws.
(For: HM560 Variable Transmission) 7. Remove the ECU from the machine.
Removal Install
Refer to electrical system, control module, gearbox, 1. The installation procedure is the opposite of the
remove and install, (PIL 33-45-09). removal procedure. Additionally do the following
steps.
1.1. Before you operate the machine, make sure
2. Follow the general health and safety procedures. the ECU is configured correctly. Use the
Refer to (PIL 01-03). correct Servicemaster set-up tool. Refer to
(PIL 33-57).
4. Remove the applicable trim panels / cover panels
to get access to the ECU (Electronic Control
Unit).
(For: PS764, PS766)
Removal
Figure 1581.
2
2 3
1 Drivers seat platform 2 Bolts (X4)

3 ECU
1. Make the machine safe. Refer to (PIL 01-03). 4. Remove the applicable trim panels / instrument
panels to get access to the ECU.
Refer to (PIL 01-03). 5. Disconnect the electrical connectors from the
ECU. Make sure you do not touch the connector
3. Isolate the battery. Refer to (PIL 33-03). pins on the ECU.
33 - 698 9813/9400-1 33 - 698

45 - Control Module
09 - Gearbox
6. Support the ECU and remove the four mounting Figure 1583. Other Machines
bolts which secure the ECU to the underside of
the drivers seat platform.
1
7. Remove the ECU from the machine.
Install 1
step.
1.1. Before you operate the machine, make sure 2
that the ECU is configured correctly. Use
the correct Servicemaster set-up tool. Refer
to (PIL 33-57).
(For: PS750 MK4)
Remove
A Mounting screws
1. Make the machine safe. Refer to (PIL 01-03). B ECU
Refer to (PIL 01-03). Install
3. Isolate the battery. Refer to (PIL 33-03). 1. The installation procedure is the opposite of the
4. Remove the applicable trim panels / instrument step.
panels to get access to the ECU.
2. Before you operate the machine, make sure that
5. Disconnect the electrical connectors from the the ECU is configured correctly. Use the correct
ECU. Make sure you do not touch the connector Servicemaster set-up tool. Refer to (PIL 33-57).
pins on the ECU.
6. Support the ECU and remove the mounting
screws.
Figure 1582. 526-56 Machines
1
2
A Mounting screws
B ECU
33 - 699 9813/9400-1 33 - 699

45 - Control Module
24 - Servo
24 - Servo Component Identification

Diagram ....................................................... 33-701
Check (Operation) ....................................... 33-704
Figure 1584. Joystick Powerbase ECU

1 2
1 Pod mounted joystick 2 Cab mounted joystick

3 Joystick handle assembly 4 Joystick powerbase ECU (Electronic Control
Unit)
The joystick powerbase ECU is located below the

joystick control handle assembly.
The joystick assembly must be removed to get

access to the powerbase ECU.
33 - 700 9813/9400-1 33 - 700

45 - Control Module
24 - Servo
Diagram
The joystick powerbase ECU (Electronic Control

Unit) is connected to the armrest / pod harness /
chassis harness and joystick handle assembly.
Figure 1585.
12 11 10 9 8 7
1 2 3 4 5 6
2
6 1 1 6
1 2 3 4 5 6 5 2 2 5
4 3 3 4
121110 9 8 7
1
1 Connector 1 2 Connector 2
Table 660. Connector 1

Pin Number Connected to Type Refer to device
1 Thumbwheel 5 reference Reference General control devices
2 Forward rocker switch po- Input General control devices
sition
3 Reverse rocker switch po- Input General control devices
sition
33 - 701 9813/9400-1 33 - 701

45 - Control Module
24 - Servo

4 Neutral rocker switch po- Input General control devices
sition
5 Earth Earth Refer to joystick power-
base power and earth
connections.
6 Extend / retract thumb- Input General control devices
wheel direction signal- ex-
tend
7 Auxiliary thumbwheel di- Input General control devices
rection signal- up
8 Extend / retract thumb- Input General control devices
wheel direction signal- re-
tract
9 Gear change up button Input General control devices
(+)
10 Gear change down button Input General control devices
(-)
11 2nd auxiliary button Input General control devices
12 Auxiliary thumbwheel di- Input General control devices
rection signal- down
Table 661. Connector 2

Pin Number Connected to: Type Refer to Device:
1 Power 12 battery
2 Earth Earth
3 Not used -
4 Not used -
5 CAN (Controller Area CANbus CANbus system
Network)bus high
6 CANbus low CANbus CANbus system
Joystick Powerbase ECU Power and Earth Connections (526-56 Machines)
Figure 1586. 526-56 Machines Only
CONNECTOR A
1
1 4
CONNECTOR B
ECU
1 Fuse 2 Powerbase ECU
33 - 702 9813/9400-1 33 - 702

45 - Control Module
24 - Servo
Table 662. Harness Connector 2

Connectors Pins Pins Details
2 1 2
i016 64 Refer to (PIL 33-00-50)
C010 1 Chassis earth isolator, re-
fer to (PIL 33-12)
P005 14 Fusebox D, refer to (PIL
33-09)
Joystick Powerbase ECU Power and Earth Connections (Other Machines)
Figure 1587. Other Machines
1
1 2
ECU
1 Fuse 2 Powerbase ECU
Table 663. Harness Connector 2

2 1 2
i005 11 10
C001 1 Chassis earth point, refer
to (PIL 33-00-50)
i016 69 Refer to (PIL 33-00-50)
P005 20 Fusebox E, refer to (PIL
33-09)
33 - 703 9813/9400-1 33 - 703

45 - Control Module
24 - Servo

Remove
Figure 1588.
(PIL 33-57).
continuity, shorts to battery and shorts to earth. 1
(Electronic Control Unit). Only use the meter at 2
5
1 Lever Top
2 Locknut
3 Powerbase
4 ECU (Electronic Control Unit) Connector
1. The Joystick handle assembly and powerbase
ECU must be removed from the machine to
getting access to the electrical connectors.
2. For Joystick removal refer to (PIL 09-27)
3. The Handle assembly can then be removed from
the powerbase ECU.
Remove the Powerbase from the Joystick

Handle
1. Slacken the locknut.
2. Cut any cable ties and discard.
3. Disconnect the handle assembly electrical
connector from the powerbase ECU connector.
33 - 704 9813/9400-1 33 - 704

45 - Control Module
24 - Servo
4. Unscrew the lever top from the powerbase.
Install
procedure.
33 - 705 9813/9400-1 33 - 705

45 - Control Module
36 - Hydraulic
36 - Hydraulic Component Identification

Component Identification ............................. 33-706 For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F] ........................................ Page 33-706
Diagram ....................................................... 33-708
Check (Operation) ....................................... 33-716 ................................................. Page 33-707
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F])
Figure 1589.
1 Hydraulic Control ECU - 526-56 Machines 2 Chaff Guard

3 Hydraulic Control ECU - Other Machines
1. On 525-56 machines the ECU (Electronic

Control Unit) is located under an access panel on
the side of the cab. Refer to (PIL 06-06).
2. On other machines the ECU is located in the
under boom cut out area under the chaff guard.
33 - 706 9813/9400-1 33 - 706

45 - Control Module
36 - Hydraulic

Figure 1590. Hydraulic ECU Location- Dual
Tech Variable Transmission Machines
B B
A Chassis (front end)

B Hydraulic ECU
33 - 707 9813/9400-1 33 - 707

45 - Control Module
36 - Hydraulic
Diagram

The hydraulic control ECU (Electronic Control Unit)
is connected to the chassis harness.
Figure 1591.
A Hydraulic control ECU connector J5 (Harness B Hydraulic control ECU connector J4 (Harness
connector key E) connector key D)
C Hydraulic control ECU connector J3 (Harness D Hydraulic control ECU connector J2 (Harness
connector key C) connector key B)
E Hydraulic control ECU connector J1 (Harness F Harness connector identification key letter
connector key A)
33 - 708 9813/9400-1 33 - 708

45 - Control Module
36 - Hydraulic
Hydraulic Control ECU Pin Outs
Table 664. Hydraulic Control ECU Pin Outs

1 Power 12 battery Refer to diagram, (PIL
33-45-36)
33-45-36)
33-45-36)
4 Left side column switch Input Operator left side column
pin 6 switch
5 Not used - -
6 Valve block extend / re- Output Main hydraulic control de-
tract solenoid returns vices
33-45-36)
33-45-36)
33-45-36)
10 Lift arm retract proximity Input Lift arm retract proximity
switch switch
11 Transmission speed sen- Input Gearbox speed sensors
sor signal output B
12 ECU earth Earth Refer to diagram, (PIL
33-45-36)
13 Valve block retract sole- Output Main hydraulic control de-
noid vices
14 Pin lock Output -
15 Park brake switch Input Park brake switch
16 Auxiliary venting switch Input -
17 Valve block lift / lower so- Output Main hydraulic control de-
lenoid returns vices
18 Valve block auxiliary A/B Output Main hydraulic control de-
solenoid returns vices

1 Crab steer solenoid D Output Mode valve solenoids
2 AWS (All Wheel Steer) Output Mode valve solenoids
solenoid C
3 Left side column switch- Input Operator left side column
pin 10 switch
4 Foot brake switch Input Foot brake switch
5 Transmission speed sen- Input Gearbox speed sensors
sor signal output A
6 Hydraulic isolation sole- Output Main hydraulic control de-
noid vices
7 2 Wheel steer solenoid A Output Mode valve solenoids
8 Pin lock Input Main hydraulic control de-
vices
33 - 709 9813/9400-1 33 - 709

45 - Control Module
36 - Hydraulic

9 Left side column switch Input Operator left side column
pin 4 switch
10 2WD (Two Wheel Drive) / Input 2WD / 4WD operator
4WD (Four Wheel Drive) switch
switch
11 ECU Earth Earth Refer to diagram, (PIL
33-45-36)
12 ECU Earth Earth Refer to diagram, (PIL
33-45-36)
13 4WS (Four Wheel Steer) Output Mode valve solenoids
solenoid B
14 Valve block lower sole- Output Main hydraulic control de-
noid vices
15 Not used - -
16 Emergency stop switch - Main hydraulic control de-
vices
17 SRS (Smooth Ride Sys- Input SRS pressure transducer
tem) pressure switch
18 Steer mode solenoid re- Output Mode valve solenoids
turns

1 Valve block lift solenoid Output Main hydraulic control de-
vices
2 Valve block extend sole- Output Main hydraulic control de-
noid vices
3 Lift arm angle sensor sig- Input Lift arm angle sensor
nal output 2
4 Chassis angle sensor sig- Input Chassis angle sensor
nal output 1
5 Chassis angle sensor sig- Input Chassis angle sensor
nal output 2
6 SRS drain / accumulator Output SRS control devices
solenoid returns
7 Not used - -
8 Not used - -
9 Not used - -
10 Not used - -
33-45-36)
12 Not used - -
13 Not used - -
14 SRS drain solenoid re- Output -
turns
15 Hydraulic isolation switch Input Hydraulic isolation sole-
noid
16 SRS operator switch pow- Input SRS control devices
er
17 Crowd / dump solenoid Output Main hydraulic control de-
returns vices
18 4WD solenoid earth Output Transmission devices
33 - 710 9813/9400-1 33 - 710

45 - Control Module
36 - Hydraulic

Pin Number Connected to: Type Refer to device:
1 Valve block crowd sole- Output Main hydraulic control de-
noid vices
2 SRS accumulator sole- Output SRS control devices
noid power
3 Not used - -
4 Not used - -
5 CAN (Controller Area CAN bus screen CAN bus system
Network) bus shield
6 CAN bus shield CAN bus screen CAN bus system
7 Rear steer proximity Input Proximity switches
switch signal output 2
8 Lift arm angle sensor sig- Input Lift arm angle sensor
nal output 1
9 Not used - -
10 Not used - -
11 CANbus low CAN bus CAN bus system
12 CANbus low CAN bus CAN bus system
13 Valve block dump sole- Output Main hydraulic control de-
noid vices
14 Valve block auxiliary A so- Output Main hydraulic control de-
lenoid vices
15 Not used - -
16 Not used - -
17 CANbus high CAN bus CAN bus system
18 CAN bus high CAN bus CAN bus system

1 Auxiliary changeover so- Output Main hydraulic control de-
lenoid power / second vices
auxiliary power
2 Valve block auxiliary B so- Output Main hydraulic control de-
lenoid vices
3 Rear steer proximity Input Proximity switches
4 Tilt lock switch power Input Main hydraulic control de-
vices
5 Constant auxiliary switch Input Main hydraulic control de-
power vices
6 Front steer proximity Input Proximity switches
7 Sensor earths Earth -
8 Joystick 4 pin connector- Input Joystick
gear minus button
9 Steer mode switch signal Input Mode operator switch
output 1
10 Steer mode switch signal Input Mode operator switch
output 2
11 Front steer proximity Input Proximity switches
33 - 711 9813/9400-1 33 - 711

45 - Control Module
36 - Hydraulic

33-45-36)
13 4WD solenoid power Output Main hydraulic control de-
vices
14 5 reference feed Ref -
15 Wake up Input -
16 SRS pressure switch pin Input SRS control devices
3
17 Joystick 4 pin connector- Input Joystick
gear plus button
33-45-36)
Hydraulic Control ECU Power and Earth Connections
Figure 1592. 526-56 Machines

1
2
3
A
2 12
7
8
9
CONNECTOR J1
11
12 C002
CONNECTOR J2
11
12
CONNECTOR J3
CONNECTOR J4
18
12
A 8 15
CONNECTOR J5
ECU
A Fuse B Hydraulic Control ECU
33 - 712 9813/9400-1 33 - 712

45 - Control Module
36 - Hydraulic
Table 669. Harness Connector J1 (Key A)

Connec- Pins Pins Pins Pins Pins Pins Pins Details
tors
J1 1 2 3 7 8 9 12
i016 62 62 62 62 62 62 Refer to
electrical
system,
general,
schemat-
ic cir-
cuit, (PIL
33-00-50)
P05 2 2 2 2 2 2 Fusebox
D, refer to
(PIL 33-09
C010 1 Chas-
sis earth
point, re-
fer to (PIL
33-00-90)
Table 670. Harness Connector J2 (Key B)

J2 11 12
C010 1 1 Chassis earth point, refer
to (PIL 33-00-90)
Table 671. Harness Connector J3 (Key C)

J3 11 12
C010 1 1 Chassis earth point, refer
to (PIL 33-00-90)
Table 672. Harness Connector J5 (Key E)

Connectors Pins Pins Pins Details
J5 12 15 18
i016 65 62 Refer to electrical
system, general,
schematic circuit,
(PIL 33-00-50)
P05 8 2 Fusebox D, refer to
(PIL 33-09
C010 1 Chassis earth
point, refer to (PIL
33-00-90)
33 - 713 9813/9400-1 33 - 713

45 - Control Module
36 - Hydraulic
Hydraulic Control ECU Power and Earth Connections
Figure 1593. Other Machines

1
2
A 3
2 12
7
8
9
CONNECTOR J1
11
12 C001
CONNECTOR J2
11
CONNECTOR J3
CONNECTOR J4
18
A
20 15
CONNECTOR J5
ECU
A Fuse B Hydraulic control ECU
Table 673. Harness Connector J1 (Key A)

Connec- Pins Pins Pins Pins Pins Pins Pins Details
tors
J1 1 2 3 7 8 9 12
i016 32 32 32 32 32 32 Refer to
electrical
system,
general,
schemat-
ic cir-
cuit, (PIL
33-00-50)
P05 2 2 2 2 2 2 Fusebox
E, refer
to (PIL
33-50)
C001 1 Chassis
earth iso-
lator
33 - 714 9813/9400-1 33 - 714

45 - Control Module
36 - Hydraulic
Table 674. Harness Connector J2 (Key B)

J2 11 12
C001 1 1 Chassis earth isolator
Table 675. Harness Connector J3 (Key C)

J3 11
C001 1 Chassis earth isolator
Table 676. Harness Connector J5 (Key E)

J5 15 18
i016 69 32 Refer to electrical system,
general, schematic circuit,
(PIL 33-00-50)
P05 20 2 Fusebox E, refer to (PIL
33-50)
33 - 715 9813/9400-1 33 - 715

45 - Control Module
36 - Hydraulic

For: 506-23 [T4F], 509-23 [T4F], 512-26
1. Use the applicable Servicemaster diagnostics [T4F] ........................................ Page 33-716
For: 506-23 [T4F] .................... Page 33-717
operates correctly. Rectify as required. Refer to (For: 506-23 [T4F], 509-23 [T4F], 512-26
electrical system- electronic diagnostic, refer to [T4F])
(PIL 33-57).
3. Test the applicable wires and connectors for Removal
Rectify as required. 1. Make the machine safe with the lift arm raised.
(Electronic Control Unit). Only use the meter at 2. Install the safety strut. Refer to (PIL 06-69).
the pins on the harness connectors. 3. Get access to the ECU (Electronic Control Unit).
5. Without the use of sophisticated electronic test 4. Disconnect the battery. Refer to (PIL 33-03).
ECU is returned under warranty it will be tested 5. Make sure you do not touch the connector pins
at the factory to confirm possible faults. of the ECU.
ECU.
7. Support the ECU and remove the mounting bolts
and nuts.
33 - 716 9813/9400-1 33 - 716

45 - Control Module
36 - Hydraulic
Figure 1594. 5. Remove the undershield. Refer to (PIL

06-30-30).
6. Get access to the ECU.
ECU.
8. Make sure you do not touch the connector pins
of the ECU.
9. Support the ECU and remove the mounting bolts
and nuts.
Install
step.
2. Before you operate the machine, make sure
the ECU is configured correctly. Use the correct
Servicemaster setup tool. Refer to (PIL 33-57).
1 Mounting bolts and nuts

2 ECU
Install
step.
2. Before you operate the machine, make sure
the ECU is configured correctly. Use the correct
Servicemaster set-up tool. Refer to (PIL 33-57).
(For: 506-23 [T4F])
Removal
Refer to Electrical System, Control Module,
Hydraulic, (PIL 33-45-36).

3. Securely block all the road wheels on both sides.
33 - 717 9813/9400-1 33 - 717

45 - Control Module
42 - Selective Catalytic Reduction Introduction

(SCR)
The DCU (Dosing Control Unit) controls the injection
Introduction .................................................. 33-718 of DEF (Diesel Exhaust Fluid) in to the exhaust
Operation ..................................................... 33-719 system. It uses information from the sensors in
Remove and Install ..................................... 33-720 the SCR (Selective Catalytic Reduction) as well
as communicating with the engine ECU (Electronic
Control Unit) to determine the optimum amount of
DEF to be injected. It also controls the heating of
DEF to prevent freezing when the machine is used
in temperatures below -8°C (17.6°F).
The DCU contains its own power hold relay to ensure

of a correct power down sequence after a machine
shutdown.
The DCU Is machine mounted, the location will

depend on the machine and its application.
Figure 1595.
33 - 718 9813/9400-1 33 - 718

45 - Control Module
Operation
DEF Injection
The primary function of the DCU (Dosing Control
Unit) is to control the Injection of DEF (Diesel
Exhaust Fluid) into the exhaust gasses.
By comparing the readings from the upstream NOx

(Nitrogen Oxide) sensor and the downstream NOx
sensor, the DCU is able to accurately control the
dosing module to inject the optimum amount of DEF
in order to reduce the NOx levels in the exhaust
gasses to the required level. It can also use this
information to estimate SCR (Selective Catalytic
Reduction) system efficiency.
Fault Diagnostics
The DCU monitors the SCR and will generate fault
codes if a reading or result is not within the expected
parameters.
These fault codes can be used to aid fault diagnosis

and repair. Certain faults will cause the DCU to
force an engine inducement. This is to protect the
engine and associated systems from damage or
to prevent machines being used without the SCR
system functioning which would cause unnecessary
exhaust emissions to be released.
33 - 719 9813/9400-1 33 - 719

45 - Control Module
Remove and Install
Figure 1596.
2
1 Electrical connector 2 Bolts
Before removal Install

1. Make sure that the engine is safe to work on. If 1. Installation is the reversal of the removal
the engine has been running, let it cool before procedure.
2. Get access to the DCU (Dosing Control Unit).
Removal Item Nm
1. Disconnect the electrical connector. 2 8

3. Remove the DCU from the machine.
33 - 720 9813/9400-1 33 - 720

45 - Control Module
44 - Nitrogen Oxide (NOx) Sensor
44 - Nitrogen Oxide (NOx) Sensor Introduction

Introduction .................................................. 33-721 The sensor control unit is permanently connected to
Remove and Install ..................................... 33-722 the NOx (Nitrogen Oxide) sensor. The sensor control
unit receives the signals from the NOx sensor and
sends them to the ECM (Engine Control Module)
using a CAN (Controller Area Network) Bus system.
The sensor control unit also controls the heating of
the NOx sensor.
Figure 1597.
33 - 721 9813/9400-1 33 - 721

45 - Control Module
44 - Nitrogen Oxide (NOx) Sensor
Remove and Install
For remove and install instructions refer to NOx

(Nitrogen Oxide) sensor remove and install (PIL
15-84-51).
33 - 722 9813/9400-1 33 - 722

48 - Entertainment
48 - Entertainment
Contents Page No.
33-48-03 Radio ............................................................................................................................ 33-725
33 - 723 9813/9400-1 33 - 723

Notes:
33 - 724 9813/9400-1 33 - 724

48 - Entertainment
03 - Radio
03 - Radio Introduction
Introduction .................................................. 33-725 The manufacturer is not responsible for any
Diagram ....................................................... 33-726 radio or TV interference caused by unauthorized
modifications to this equipment. Such modifications
could void the User's authority to operate the
equipment.This device complies with Part 15 of the
FCC rules. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference.

2. This device must accept any interference
received, including interference that may cause
undesired operation.
33 - 725 9813/9400-1 33 - 725

48 - Entertainment
03 - Radio
Diagram
The wiring diagram depicts all the wiring connections connection with switched power, such as IGN or
required for the correct operation of the unit. ACC.
Do not connect the red wire to a constant power

connection. It should be connected to a vehicle
Figure 1598.
6 4 5
2
3
17
16 8
9 7
15
14
13 12 11 10
1 Antenna connector (black wire) 2 PCB

3 Headphone output (1/4 inch) 4 Washer
5 Nut 6 Rubber cap
7 Vehicle panel or headphone mounting bracket 8 Heatshrink tubing
9 Fuse 3A 10 Accessory (red)
11 Ground (black) 12 Right speaker -ve (grey/black)
13 Right speaker +ve (grey) 14 Left speaker -ve (white/black)
15 Left speaker +ve (white) 16 Black wire
17 9 - Pin Connector (male)
33 - 726 9813/9400-1 33 - 726

51 - Beacon
51 - Beacon
Contents Page No.
33-51-00 General ......................................................................................................................... 33-729

33-51-03 Socket .......................................................................................................................... 33-730
33 - 727 9813/9400-1 33 - 727

Notes:
33 - 728 9813/9400-1 33 - 728

51 - Beacon
00 - General
00 - General
Introduction
Beacons are rotating or flashing lights affixed to

the top of a machine to attract the attention of
surrounding vehicles and pedestrians.
33 - 729 9813/9400-1 33 - 729

51 - Beacon
03 - Socket
03 - Socket Introduction
Introduction .................................................. 33-730 The machine has two separate beacon sockets
Component Identification ............................. 33-731 installed depending on variant.
• Socket A - is for the Green Beacon (if installed)

• Socket B - is for the standard beacon
The beacon is operated from a rocker switch in the

operator compartment.
Figure 1599.
A Green Beacon socket (if installed) B Standard beacon socket
33 - 730 9813/9400-1 33 - 730

51 - Beacon
03 - Socket
Figure 1600. Harness connector -
Beacon socket - RC07 / AG (stan-
dard beacon), C22-RC (Green Beacon)
1 Earth
2 Standard beacon : +24V from beacon switch
2 Green beacon : +24V from beacon ECU
(Electronic Control Unit)
33 - 731 9813/9400-1 33 - 731

54 - Window Washer/Wipe
Contents Page No.
33-54-00 General ......................................................................................................................... 33-733
33 - 732 9813/9400-1 33 - 732

00 - General
00 - General
Introduction
The wash/wipe system is used to remove rain and

debris from the front or rear window. The main
components of the system are:
• Wiper Arm.
• Wiper Blade.
• Nozzle (jet).
• Wiper Motor Mechanism.
• Tank (reservoir).
• Washer Pump.
• Wash/Wipe Switch.
• Multifunction Switch (intermittent speed
settings).
The wiper assembly consists of an arm, pivoting at

one end with a long rubber blade attached to the
other. The blade is swung back and forth over the
glass, pushing water from its surface. The speed is
normally adjustable, with several continuous speeds
and often one or more intermittent settings. Some
machines may use two wiper arms.
The wipers operate together with the washer system.

The washer pump supplies a mixture of water,
alcohol, and detergent (washer fluid) from a tank to
the windows through a hose. The fluid is dispensed
through small nozzles mounted below the screen. It
is essential the correct washer fluid is used as an
incorrect fluid could freeze in colder climates and
damage the pump. Although antifreeze is chemically
similar to windscreen wiper fluid, it should not be
used because it can damage the paintwork.
33 - 733 9813/9400-1 33 - 733

57 - Electronic Diagnostic
Contents Page No.
33-57-00 General ......................................................................................................................... 33-735

33-57-03 Servicemaster .............................................................................................................. 33-739
33-57-90 Fault Codes .................................................................................................................. 33-805
33 - 734 9813/9400-1 33 - 734

00 - General
Introduction .................................................. 33-735 JCB machines use the latest developments in
Health and Safety ........................................ 33-736 electronic management of machine systems. This
Check (Condition) ........................................ 33-737 means that machine systems such as service
Calibrate ...................................................... 33-738 hydraulics, engine, transmission and steering are
controlled using ECU (Electronic Control Unit)'s.
The ECU's process inputs from electrical sensors
and then send signals to electrical actuators on the
applicable devices. The ECU's are also connected
to the machine CAN (Controller Area Network) bus
electronic communication system.
Fault Finding
Faults with ECU controlled systems can be difficult
or impossible to trace using traditional methods. In
addition to the primary function of machine control
the ECU's are also able to detect possible faults
with sensors and actuators. The faults are logged
using a code system. Use Servicemaster to see and
understand these codes. In addition Servicemaster
has direct links to relevant on screen help information
about relevant devices. This information is designed
to help you identify, test, and if applicable, remove
and replace devices.
Poor Maintenance
System faults that are present, or have happened in
the past can be seen. This is not only useful when
fault finding but can also identify poor standards of
maintenance - for example a log showing a history
of water in fuel detected. Use Servicemaster to see
and understand these logs.
Machine Set-up Data

Machine parameters such as tyre sizes, gear shift
points and engine injector calibration codes are all
stored and used by the relevant control ECU's.
During the life of the machine it will be necessary
to change some of these parameters. Without the
correct data the machine will not operate correctly.
Re-Programming ECU's
The ECU's use pre-loaded data to compute
responses to inputs from sensors. If an ECU is
replaced the correct data files must be programmed
(`flashed') into the ECU memory. New data files may
also be issued by JCB Service to improve machine
operation. This will also require the ECU to be re-
programmed.
Summary
With the latest Servicemaster software loaded on
your laptop and you can:
33 - 735 9813/9400-1 33 - 735

00 - General
• Fault find. Health and Safety

• Check maintenance standards, to see if the
machine has been abused. WARNING Make sure you read and follow any
• View and change machine set-up data. on screen instructions. Failure to follow the
• Flash ECU's with the correct data files instructions could result in death or injury.
33 - 736 9813/9400-1 33 - 736

00 - General
Introduction
The datalogger tool is used to retrieve stored error
codes from the machine ECU (Electronic Control
Unit).
The tool will also allow the codes to be printed out

and the fault memory cleared.
3. The stored machine error logs will appear in the
The data logger tool will have the function of error log tab.
removing front screen errors from production built is
shown in the figure. E.g.: Low fuel count. Figure 1603.
The data logger will also have the ability to log:
• When the LLMI (Longitudinal Load Moment

Indicator) has been in the red.
• When the machine has been tripped 'Less than
800kg on rear axle'.
• LLMC (Longitudinal Load Moment Control)
override button has been used.
• Capture a 2 minute log when the above has
been logged.
Figure 1601.
4. To print the log file, select 'File' and 'Print'.

Figure 1604.
5. To clear the error log, select 'Reset' and 'Reset

error log'.
A Data logger tool
Figure 1605.
Reading Machine Data
1. Connect the laptop to the machine CAN
(Controller Area Network)bus.
2. Click on the 'File' menu and select 'Read data'.
33 - 737 9813/9400-1 33 - 737

00 - General
Calibrate
Lift Arm Angle Sensor Calibration

Calibration of the lift arm angle sensor must be
carried out after using the LMS (Loadall Monitoring
System) setup or machine setup tools and/or if a lift
arm angle sensor has been replaced.
To calibrate the angle sensors, park the machine on

safe level ground with the lift arm set horizontal.
Connect the DLA (Data Link Adaptor) to the machine

and select 'Connect'.
After you connect, select 'Click to calibrate the

sensors'.
Close down the calibration tool.
Figure 1606.
33 - 738 9813/9400-1 33 - 738

03 - Servicemaster
03 - Servicemaster Introduction
Introduction .................................................. 33-739 JCB Servicemaster is an application to allow
Component Identification ............................. 33-756 engineers to diagnose and setup the various
Operation ..................................................... 33-758 electronic control units within the JCB product range.
Disconnect and Connect ............................. 33-802 The tools comprise of a front end generic user
interface that allows the user to select the machine
which they wish to work on as well as a number of
various tools which allow:
• Programming electronic control units

• Diagnosing electronic issues
• Setup of various options
• Checking the service history of the machine
JCB Servicemaster is updated on a monthly basis by

incorporating Web Update. This is a program which
works alongside Servicemaster to let the user know
and allow them to download an update as and when
it becomes available.
JCB Servicemaster software is for use with Microsoft

Windows and a laptop personal computer. The
laptop computer is connected to the machine
diagnostic socket using special cables and an
adaptor.
Use Servicemaster software to:
• Display data from a machine ECU (Electronic

Control Unit)
• Change data stored in a ECU
Servicemaster software communicates with the

machine ECM (Engine Control Module) using the
CAN (Controller Area Network) bus, refer to Control
Modules (PIL 33-45).
Structure
Servicemaster software is supplied via DVD and
updated via the internet. A selector window is used
to choose the correct software tool set for each
machine range. Each tool is specific to the chosen
machine range. The tool icons are shortcuts to the
tool software files. Detailed information about how
to use the tools is given in the applicable machine
documentation.
Servicemaster Front Screen

The start-up page of Servicemaster is known as the
front screen. This interface allows the user to easily
and quickly navigate to the machine they are working
on to ensure that they have the applicable tools for
that machine.
33 - 739 9813/9400-1 33 - 739

03 - Servicemaster
Figure 1607. Typical Front Screen View engine operating parameters in real time.
Perform engine electrical actuator tests. View, save
or clear ECM fault code log.
Figure 1610. Flash Programmer tool
View ECM software file version. Upload and

Reprogramme software updates to the ECM
memory. Upload revisions to software.
Figure 1611. Data Logger tool
Once the user has clicked on the applicable machine

type they will be able to select the tool they require
from a list of the tools available for that machine
range. Below are screen-shots showing the different
machine tool sets.
Running Data Collection, Operating Data, Statistics,
Servicemaster Tools Device Error Log Recording.
Servicemaster tool sets are different for each Figure 1612. Service History
machine range. When you have navigated to the
correct machine type via the front end, you will be
greeted with the relevant tools for that particular
machine. These tools are accessed by a single click
on the icon of the tool you require. There are 6 main
tools within Servicemaster, these are:
Figure 1608. Machine/Engine Set-up tool

Engine Hour records, Service Dealership Codes.
Figure 1613. Help
View and change engine and machine specification

data stored in the engine ECU. Settings include: Comprehensive information about engine related
sensors, actuators and ECM fault codes.
• Parameter settings
• Option/Attachment control Additional Service Tool
• Alternative Language Support
• Model/Serial Number Identification As well as the tools stated above there are also third
party tools for some of the machine ranges which will
Figure 1609. Diagnostics tool need to be installed. These tools are denoted by the
following symbol:
33 - 740 9813/9400-1 33 - 740

03 - Servicemaster
Figure 1614. 2. Start JCB Servicemaster on the laptop computer.

Figure 1616.
To install these applications you need to take the

following steps:
1. On the front end, click the other tab.

2. Click on general.
3. Click onto "extra applications".
4. Choose the relevant tool which you require to be
installed and run the installer.
Once the installer has been run, the icon should have
changed within the machine tool page. e.g. the above
3. Make sure that the correct DLA (Data Link
icon has now become:
Adaptor) is selected in the chooser. Click on
Figure 1615. Utilities, DLA Setup. The DLA chooser window
opens. Check the button to match to the current
device. Click Apply.
Figure 1617.
Diagnostics Tool - User Guide

Introduction
The diagnostics software tool is part of the
JCB Servicemaster software suite. The diagnostics
software is designed to be an easy to use fault finding
tool.
Connecting the Diagnostics

Diagnostics Overview
To use Diagnostics your laptop computer must be
There are several key elements to the diagnostics
connected to the machine CAN bus.
tool. These can be seen labelled below. Each
element is explained in detail in later sections.
Starting the Diagnostics
1. Turn ON the machine ignition and additionally
start the engine if required (taking normal
precautions).
33 - 741 9813/9400-1 33 - 741

03 - Servicemaster
Figure 1618.
5 10 6 7 8
1
2
3
9
11
4 12
1 Menu bar 2 Start and stop buttons

3 Engine selection buttons 4 Main window
5 Engine connector page 6 Machine connector page
7 Actuator test page 8 Fault codes page
9 Page list 10 LED (Light Emitting Diode) status key
11 Status bar 12 CAN communication status LEDs
33 - 742 9813/9400-1 33 - 742

03 - Servicemaster
Navigating within Diagnostics Menu Bar-Options Menu
Navigation is designed to be via a mouse. On Laptop Figure 1620.

PCs this may take the form of a small joystick
or touch sensitive pad and some buttons, usually
located near to the keyboard.
As with most Windows based programs, it is possible

to navigate the diagnostics software using the
keyboard by pressing certain combinations of keys.
Note: This can be particularly useful for certain

Laptop computers where the mouse/joystick can be
oversensitive. Try out the following, it may come in
useful one day.
There are two main methods of navigation described • Start Diagnostics to commence
below: communications with the ECM.
• Stop Diagnostics to cease communications.
• Pressing the ALT key will cause the File option • Controller Status Click on the buttons to toggle
on the Menu Bar to be highlighted. You can then ON or OFF the diagnostics connection with the
use the arrow keys to navigate the menus. machine CAN system.
• Notice that all the menu items on the Menu
Bar have a letter that is underlined (e.g. the Figure 1621.
'F' in File). Holding down the ALT key and
pressing the required letter key will activate that
option (i.e. either open the menu or execute
a function). For example, if you wish to open
the Preferences Dialogue this can be done by
pressing ALT + O (to open the Options menu)
then ALT + P (to execute the Preferences
option).
Menu Bar-File Menu
The File Menu contains an Exit option to close down

the program.
• Preferences option opens up the Preference
Figure 1619. Dialogue.
• From the Preferences Dialogue there is support
for multiple languages. Use the drop-down
menu and scroll bar to chose the required
language. Languages available are:
• English (United Kingdom)
• French (France)
• German (Germany)
On exiting the program communications with both
• Spanish (International Sort)
ECU and DLA are shut down.
Note: The language option only effects text within the
Main Window (e.g. Page List, LED Status Key, etc).
Language support is not available for the text within
the page displays.
Once your preferences have been selected either:
Click on the OK button to apply them or click on the

Cancel button to leave them unchanged.
33 - 743 9813/9400-1 33 - 743

03 - Servicemaster
Menu Bar-Help Menu function keys, F2, F3 etc. can also be used to select
pages as required.
Figure 1622.
Status bar
There are 2 items of interest displayed on the

Status Bar, which is located along the bottom of the
Diagnostics main window.
Figure 1625.
• About: Opens a window showing the part

number and the version number of the installed
copy of the Diagnostics software Connected ECU: The type of ECU connected to the
• Help: Opens a help file about the software. Diagnostics tool is indicated on the far left side of the
• Engine Help: Opens a help file containing Status bar.
information about the engine sensor and
actuator devices for engine control. CAN communications: Two small LEDs indicate data
being transmitted (red) and received (green) over the
Start and Stop Buttons CAN communications link.
These offer the same function as the Start These LEDs can be seen to be flashing rapidly
Diagnostics and Stop Diagnostics options within as data is transported. This can be another useful
the Options Menu. To start the Diagnostics tool aid to determining the state of any established
communicating with the gearbox ECU simply click communications.
on the Start Button (large green LED) at the top of
the Main Window. Similarly, click on the Stop Button Connection Status: Indicates if the diagnostics
(large red LED) to cease communications. software is connected, connecting or not connected
to the ECM.
Figure 1623.
Information Window: Displays information about data
on the diagnostics pages when the mouse is rolled
over the fields.
LED Status Key
Displays a key for the colour status of the LEDs

shown on the diagnostics pages. The LEDs change
colour dependant on the electrical signal.
Page List
Figure 1626.
In the top left corner of the main window is displayed
a list of pages which can be displayed.
Figure 1624.
Table 678.
LED Colour Electrical signal status
Clicking in the box next to the required page will Red Off
make that page appear in the main window display
Green On/Active
area. (A tick will also appear in the box to show it
is being displayed.) At any time the user may swap Blue Open Circuit
between displayed pages simply by clicking in the Yellow Short Circuit
check box of the required page in the page list. The Grey No Data
33 - 744 9813/9400-1 33 - 744

03 - Servicemaster
Fault Codes Page
Figure 1627.
This page allows the engineer to access fault codes The Engine Setup tool can be used to view and
logged by the ECM. The ECM logs a fault code if change data stored the ECM. If the machine or
sensor or actuator signals are not valid. These codes engine specification is changed due to operational or
are useful when fault finding. maintenance requirements the relevant data must be
changed in the ECM.
• Active Fault Codes: Displays fault codes for
active faults in real time. To link to information Connecting Engine Setup
about the fault code click on the code. Note:
Start the engine to see all the active fault codes. To use Vehicle Setup your laptop computer must be
Note: To check if a fault code is no longer connected to the machine CANbus.
active set engine ignition system to OFF and
then restart the engine. The Servicemaster log Starting Engine Setup
display will not delete codes that are no longer
active until the engine ignition system is set to 1. Turn ON the machine ignition and additionally
OFF. start the engine if required (taking normal
• Previously Active Fault Codes: Displays fault precautions).
codes for faults that have occurred but are not 2. Start JCB Servicemaster on the laptop computer.
necessarily active. To link to information about
the fault code click on the code.
• Save Faults: Click the button to save the fault
code lists as a file to a computer location.
• Link to Fault Code List: Click to link to a
complete list of possible fault codes.
• Erase Fault Codes: Click the button to erase
logged fault codes from the ECM memory.
Engine Setup Data Tool-User Guide
Introduction
The Engine Setup software tool is part of the JCB

Servicemaster software suite.
33 - 745 9813/9400-1 33 - 745

03 - Servicemaster
4. Select Engine Tools from the drop down list

and then start the vehicle setup tool running by
clicking on the Engine Setup icon.
Figure 1630.
3. Make sure that the correct DLA is selected in
the chooser. Click on Utilities, DLA Setup. The
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply.
5. The Engine Setup tool will then open. There are

four groups of data to available shown by the
tabs:
• General
• Wheels
• Options
• Injector Calibration
33 - 746 9813/9400-1 33 - 746

03 - Servicemaster
General
Figure 1631.
33 - 747 9813/9400-1 33 - 747

03 - Servicemaster
Wheels
Figure 1632.
33 - 748 9813/9400-1 33 - 748

03 - Servicemaster
Options
Figure 1633.
33 - 749 9813/9400-1 33 - 749

03 - Servicemaster
Injector Calibration
Figure 1634.
Each injector is individually tested at the factory can be used to access the data file name currently
to record its operational characteristics. This loaded in the ECM memory and is necessary upload
information is written as a calibration code. The code a new data file to the ECM.
for each injector is loaded into the ECM. The ECM
uses this data to adjust control of the injector solenoid Connecting Flash Loader
and ensure correct injection.
To use Flashloader your laptop computer must be
The currently stored codes for each injector are connected to the machine CANbus.
displayed in the fields. If an injector or the ECM is
replaced the codes must be transferred or altered. Starting Flashloader
Flashloader Tool-User Guide 1. Turn ON the machine ignition but DO NOT start
the engine.
The Flashloader software tool is part of the JCB
Servicemaster software suite. If the ECM Engine 2. Start JCB Servicemaster on the laptop computer.
Control Module is replaced and the data file in its
flash memory is not applicable it will be necessary to
flash the ECM Engine Control Module memory with
the correct data file. The Flashloader software tool
33 - 750 9813/9400-1 33 - 750

03 - Servicemaster
Figure 1635. 3. Click on the Browse button and select the correct
data file. Click Open.
Figure 1638.
3. Make sure that the correct DLA is selected in

the chooser. Click on Utilities, DLA Setup. The
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply.
4. Select the required machine range. 4. Click on the Start button. A confirmation window
will appear. Click on the Yes to start the
Figure 1636.
reprogramming of the ECM. The progress bar is
displayed.
5. When the programming is complete switch
the machine ignition to the OFF position.
Important: Re-flashing the ECM changes the
base programme. Re-flashing the ECM does
not configure the machine settings such as fuel
injector calibration codes, and other machine
specific options.
Figure 1639.
5. The Flashloader tool will then open.

Figure 1637.
Using Flashloader
Important: Do not turn off the ignition or isolate the

system by accidentally engaging the operators seat
isolation switch when using the flashloader. This
will interrupt the flash signal to the ECM and will
irreparably damage the ECM.
1. Make sure that the machine ignition switch is set 6. Before starting the engine make sure that the
to ON but do not start the engine. machine setup data is correct. You must check
that all other relevant machine settings are
2. Click on the ECM icon. correctly configured. Use the setup software tool.
33 - 751 9813/9400-1 33 - 751

03 - Servicemaster
Re-Flashing Guide Figure 1641.
Load the Ecomax Engine Setup Tool for the correct

application. Make sure that the following is correct for
the application.
• Make
• Machine Type
• Power Rating
Figure 1640.
5. The Additional Info Tab should have the correct

Make, Model and Power Rating.
Figure 1642.
1. If the Make or Machine Type is incorrect please

change and then press Write.
2. If the Power Rating is incorrect please order a
replacement ECM of the correct power rating.
3. Close the Tool.
4. Load the JCB Flashloader.
6. Press the button highlighted to select the flash

file.
7. Navigate to the Machine SW folder. (C:
\JCB_Servicemaster_2\Machine SW).
33 - 752 9813/9400-1 33 - 752

03 - Servicemaster
8. Navigate to the relevant application folder.

9. Navigate to the ECM folder.
14. Before pressing start please ensure that:
10. Select and Open the relevant file that matches
the Make, Model and Power Rating. 14.1. All electrical connections between the
laptop and machine are secure.
11. If the file selected does not match the Make,
Model and Power Rating which is currently 14.2. The laptop battery is sufficient.
stored in the ECM it will cause an error. 14.3. You are familiar with any safety cut out
feature on the machine (seat switch) and
Figure 1644. do not invoke it during the flash.
15. Pressing Yes will flash the ECM.
Figure 1646.
12. Please make another selection or close the 16. Pressing No will abort the download.
Flashloader tool and use the Engine Setup tool 17. Ecomax Engine only - If the Engine Immobiliser
to correct the Make or Model. is active you can not flash the ECM. You will get
13. If no error occurs and the file information below this warning.
the file path populates you are ready to flash the Figure 1647.
engine.
18. Please refer to the immobiliser guide to disable

the immobiliser before proceeding.
19. Flashing process will then start and progress bar
will update.
33 - 753 9813/9400-1 33 - 753

03 - Servicemaster
23. If Cold Start Kit required, Set to “Function and

Diagnostics” and then press Write.
Figure 1651.
20. ECM Download will complete.

21. Load the Ecomax Engine Setup Tool for the
correct application. Note: Ecomax Only Software
Identification will contain the name of the flash
file you just downloaded to the ECM.
Figure 1649.
24. Ensure Injector Calibration is complete and

correct.
Figure 1652.
22. Both Ecomax and Dieselmax Press Restore

Default Press Yes.
33 - 754 9813/9400-1 33 - 754

03 - Servicemaster
25. Ecomax Press Write Injector Codes.

26. DieselMax Press Write.
33 - 755 9813/9400-1 33 - 755

03 - Servicemaster
Tool Suite
All tools available for the Loadall range of machines
are included in this section. The applicability of the
tool depends on the machine model/ variant.
Table 679.
Tool Machine Application Icon Description
JCB Ecomax engine set- Machines with SH, SL Configure the engine
up and DH engines ECU (Electronic Control
Unit) to match the engine
parameters.
IFM transmission diag- Machines with PS760, 4 View gearbox operating

nostics or 6 gearbox parameters in real time.
Perform gearbox electri-
cal actuator tests.
T4i cluster setup All machines Configure the LMS (Load-
all Monitoring System)
display ECU to match
machine parameters.
Loadall datalogger All machines Reads/ prints/ displays

and clears the machine
fault code logs.
JCB loadall machine di- All machines Comprehensive diagnos-

agnostics T4i tic information about ma-
chine related sensors, ac-
tuators and ECUs.
Lift arm angle sensor cali- Machines with LLMC Calibrates the lift arm an-
bration (Longitudinal Load Mo- gle sensors.
ment Control)
Loadall immobiliser setup Machines with immobilis-

er
Immobiliser diagnostics Machines with immobilis- View immobiliser oper-

er ating parameters in real
time. Applicable for key
system and keypad sys-
tem immobilisers.
Diagnostics Connector The main connection point is shown in the figure

Refer to Figure 1653. .
For the Servicemaster System connection
procedure, refer to electrical system- electronic
33 - 756 9813/9400-1 33 - 756

03 - Servicemaster
Figure 1653.
D
C E
B A F
J
H
G A
A Diagnostic connector location
Figure 1654.
B Diagnostic socket location
On the Agri/ Plus/ Super/ Xtra machines with SH, SL,

DH engine and PS760 transmission, an additional
diagnostic socket is located below the operator
seat. This is for flashing the software on the IFM
transmission ECU only.
33 - 757 9813/9400-1 33 - 757

03 - Servicemaster
Operation
For: 506-23 [T4F], 509-23 [T4F], 512-26 For transmission diagnostics for machines with
[T4F], PS750 MK4, PS764 ...... Page 33-758 JCB SH, SL, DH Ecomax engines and PS766
For: 506-23 [T4F], 509-23 [T4F], 512-26 transmission, refer to electrical system- electronic
[T4F] ........................................ Page 33-781 diagnostic, refer to (PIL 33-57).
For: 506-23 [T4F], 509-23 [T4F], 512-26
[T4F] ........................................ Page 33-788 Machine Applications
(For: 506-23 [T4F], 509-23 [T4F], 512-26 The diagnostics software is not applicable to all
machine variants.
[T4F], PS750 MK4, PS764)
The diagnostics software contains more than one
This tool set is for machines with JCB SH, SL, diagnostics tool. The different tools are selected by
DH Ecomax engines with PS764 and PS750 clicking on the applicable tab. Refer to the table to
transmissions. select the correct tool.
Table 680.
Machine System Tab Machine Applications
Hydraulics ECU (Electronic Control Unit) Agri, Agri Plus, Agri Super. Nov. 2009 on
Powershift transmission Machines with PS764 and PS750 transmission
Hydraulic pump control Machines with variflow hydraulic Pump
RAS (Rear Axle Stabilization) For Machines with Manplatform System
Vehicle CAN (Controller Area Network) To view the status of all machine ECUs
Care and Safety Figure 1655.

WARNING Make sure you read and follow any A B
on screen instructions. Failure to follow the
instructions could result in death or injury.
Install
The Loadall Machine Diagnostics tool is fully
integrated within JCB Servicemaster 4. To use the
program, you must install JCB Servicemaster 4 onto
a suitable laptop computer. C
For instructions on how to install JCB Servicemaster

software, refer to electrical system- electronic
Connection
To use the program, the laptop computer must
be connected to the machine CANbus. For A 'Construction' tab
Servicemaster installation, refer to electrical system- B 'Agricultural' tab
electronic diagnostic, refer to (PIL 33-57). C 'Telescopic handlers' icon
4. Select the applicable machine model:
Starting Loadall Machine Diagnostics
1. Open the ServiceMaster. Refer to electrical
system- electronic diagnostic, refer to (PIL
33-57).
2. Click on the 'Construction' tab or 'Agriculture' tab.
3. Click on the 'Telescopic Handlers' icon.
33 - 758 9813/9400-1 33 - 758

03 - Servicemaster
4.1. 2007 - (Machines built before 2007)

4.2. 2007 + (Machines built after 2007)
5. Make sure that the correct DLA (Data Link
Adaptor) is selected in the chooser. Click on
'Other'. Select 'General' then 'DLA'. The DLA
Chooser window opens. Check the button to
match to the current device. Click 'Apply'.
Figure 1657. 8. Enable the connection between the PC/Laptop
by pressing the 'Start Diagnostics' button or
select 'Start Diagnostics' from the 'File' menu.
Figure 1660.
6. Start the diagnostic tool running by clicking on

the Loadall Machine Diagnostics icon.
Figure 1658.
7. The Loadall Machine Diagnostic tool will then

open up displaying the main window.
33 - 759 9813/9400-1 33 - 759

03 - Servicemaster
Menu bar- 'Options' menu

Navigation within the Loadall Machine
Diagnostics Figure 1663.
Navigation is designed to be via a mouse. On Laptop


to navigate the cluster setup software using the
This can be particularly useful for certain laptop

computers where the mouse/joystick can be
oversensitive. Try the following as it might be useful.
There are two main methods of navigation described

below:
• Pressing the 'ALT' key will cause the 'File' option

on the menu bar to be highlighted. You can then
use the arrow keys to navigate the menus.
• Notice that all the menu items on the menu • Start Diagnostics: to connect the PC/laptop to
bar have a letter that is underlined (e.g. the the ECU to enable communication and the
'F' in File). Holding down the 'ALT' key and tracking of machine sensors and actuators.
pressing the required letter key will activate that • Stop Diagnostics: to disconnect the PC/laptop
option (i.e. either open the menu or execute and the ECU and cease communication.
a function). For example, if you wish to open • Controller Status: to show that the ECU is
the 'Preferences' dialogue, this can be done by online. When the ECU is online, the machine
pressing 'ALT + O' (to open the Options menu) codes are displayed. This diagram shows the
and then 'ALT + P' (to execute the 'Preferences' actual settings read from a test machine.
option). • Preferences: to select the language of the
machine diagnostic program.
Menu bar- 'File' menu • Unlock. Refer to the 'Unlock' procedure.
• Exit: to close down the program. On exiting the
program communications with both ECU and
DLA are shut down.
33 - 760 9813/9400-1 33 - 760

03 - Servicemaster
Figure 1665.
1. Select 'Unlock'.
2. This will produce a security unlock screen
displaying a 'Challenge Value'.
3. No further connection-set up can be made until
the engineer either emails this value or contacts
JCB Service.
4. JCB Service will apply your 'Challenge Code' and
through a special Dongle Tool and set up exe
file, JCB Service will then receive a 'Response
Unlock Procedure Value'.
5. This value will be passed back to the dealer/
To access the ECU a new access code must be
engineer to use this into the unlock screen.
requested.
6. When all numbers/letters have been completed,
This can only be requested from Loadall Technical the ECU will self unlock.
Service, and the following procedure must be
followed. Figure 1667.
7. Set up can then be completed.
This is a one off response code only. So if the

dealer/engineer types this incorrectly, they will have
to restart the complete procedure again.
33 - 761 9813/9400-1 33 - 761

03 - Servicemaster
Menu bar- 'Help' menu Menu bar- 'Data Capture'

• Capture Open Diagrams: allows the current

display to be saved.
• Stop: Stop the capture operation.
LED Status Key

• Help: opens the help program.
• About: Opens a window showing the version Displays a key for the colour status of the LED (Light
number of the installed copy of the software. Emitting Diode)s shown on the diagnostics pages.
Figure 1669. The LEDs change colour dependant on the electrical
signal.
Figure 1671.
Table 681.
LED Colour Electrical Signal Status
Dark green Input/Output off
Light green Input/Output on
Blue Open circuit
Red Short to ground
33 - 762 9813/9400-1 33 - 762

03 - Servicemaster
LED Colour Electrical Signal Status

Magneta Short to battery
Grey No data
Status bar 'NO' (Normally Open) and 'NC' (Normally closed)

inputs are shown. The status is displayed using the
There are 3 items displayed on the status bar, which simulated LEDs.
is located along the bottom of the diagnostics main
window. Variable inputs
Figure 1672. The voltage of the variable inputs is shown. The
voltages can be observed during operation and their
values compared to expected readings.
Digital outputs
• CAN Communications: Two small LEDs The status of the digital outputs from ECU are
indicate data being transmitted (red) and displayed using the simulated LEDs.
received (green) over the CAN communications
link. These LEDs can be seen to be flashing Valve outputs
rapidly as data is transported. This can be
another useful aid to determine the state of any The status of the digital outputs from the ECU to
established communications. the hydraulic solenoid valves is displayed using the
• Connection Status: Indicates if the diagnostics simulated LEDs. The current value of the solenoid
software is connected, connecting or not outputs can be monitored to make sure they both
connected to the ECU. meet specifications.
• Data Identification: When the mouse pointer is
put on a data field or 'LED' in the diagnostics Diagnostic procedure
page, its description is shown in the status bar.
Use of the diagnostics pages requires operation
Hydraulics ECU Diagnostic Pages of the relevant machine system at the same time.
If necessary get the help of an assistant. In the
The information on the diagnostic pages is constantly event of a system fault, the applicable diagnostic
updated in real-time. The status of the ECU electrical page can be used to check the operation of all the
inputs and outputs is displayed using: relevant electronic and electrical devices. Operate
the system and view the diagnostics page to see
• Simulated LEDs: The LEDs change colour if the system devices respond as expected. For
depending on the status of the inputs and example: There is no voltage change shown when
outputs. the servo control lever is operated in the relevant
• Numerical values: i.e. Volts, PWM (Pulse Width axis. This may indicate a fault with the servo lever or
Modulation) output, current. its wire interconnection.
Switches
The status of each of the switch inputs to the
ECU is shown. Where there are two switch inputs,
33 - 763 9813/9400-1 33 - 763

03 - Servicemaster
Figure 1673. Hydraulics ECU Power Supply
33 - 764 9813/9400-1 33 - 764

03 - Servicemaster
Figure 1674. Engine Speed
33 - 765 9813/9400-1 33 - 765

03 - Servicemaster
Figure 1675. Extend/Retract/Auxiliaries
Figure 1676. Raise/Lower
33 - 766 9813/9400-1 33 - 766

03 - Servicemaster
Figure 1677. Crowd/Dump
Figure 1678. Smooth Ride System
33 - 767 9813/9400-1 33 - 767

03 - Servicemaster
Figure 1679. Second Auxiliary
Figure 1680. Constant Auxiliary
33 - 768 9813/9400-1 33 - 768

03 - Servicemaster
Figure 1681. Hydraulic Isolation
Figure 1682. Tilt Isolation
33 - 769 9813/9400-1 33 - 769

03 - Servicemaster
Figure 1683. Load Control
Figure 1684. Auto Steer Mode Control
33 - 770 9813/9400-1 33 - 770

03 - Servicemaster
LLMI/LLMC ECU Diagnostic Pages Digital outputs
Information on the diagnostic pages is constantly The status of the digital outputs from ECU are
updated in real-time. The status of the ECU electrical displayed using the simulated LEDs.
inputs and outputs is displayed using:
Valve outputs
• Simulated LEDs. The LEDs change colour
depending on the status of the inputs and The status of the digital outputs from the ECU to
outputs. the hydraulic solenoid valves is displayed using the
• Numerical values i.e. Volts, PWM output, simulated LEDs. The current value of the solenoid
current. outputs can be monitored to make sure they both
meet specifications.
The following is a brief explanation of each feature.
Diagnostic procedure
Switches
The use of the diagnostics pages requires operation
The status of each of the switch inputs to the of the relevant machine system at the same time. If
ECU is shown. Where there are two switch inputs, necessary, get the help of an assistant. In the event
'NO' (Normally Open) and 'NC' (Normally closed) of a system fault, the applicable diagnostic page can
inputs are shown. The status is displayed using the be used to check the operation of all the relevant
simulated LEDs. electronic and electrical devices. Operate the system
and view the diagnostics page to see if the system
Variable inputs devices respond as expected.
The voltage of the variable inputs is shown. The

33 - 771 9813/9400-1 33 - 771

03 - Servicemaster
Figure 1685. System Diagram
33 - 772 9813/9400-1 33 - 772

03 - Servicemaster
Figure 1686. LED Health
33 - 773 9813/9400-1 33 - 773

03 - Servicemaster
Figure 1687. Active Fault Codes
33 - 774 9813/9400-1 33 - 774

03 - Servicemaster
Figure 1688. Calibration Settings
33 - 775 9813/9400-1 33 - 775

03 - Servicemaster
Figure 1689. Calibration Status
Powershift Transmission Diagnostic inputs are shown. The status is displayed using the
Pages simulated LEDs.
Information on the diagnostic pages is constantly Variable inputs

updated in real-time. The status of the ECU electrical
inputs and outputs is displayed using: The voltage of the variable inputs is shown. The
• Simulated LEDs. The LEDs change colour values compared to expected readings.
depending on the status of the inputs and
outputs. Digital outputs
• Numerical values i.e. Volts, PWM output,
current. The status of the digital outputs from ECU are
displayed using the simulated LEDs.
Valve outputs
Switches
The status of the digital outputs from the ECU to
The status of each of the switch inputs to the the hydraulic solenoid valves is displayed using the
ECU is shown. Where there are two switch inputs, simulated LEDs. The current value of the solenoid
'NO' (Normally Open) and 'NC' (Normally closed)
33 - 776 9813/9400-1 33 - 776

03 - Servicemaster
outputs can be monitored to make sure they both necessary, get the help of an assistant. In the event
meet specifications. of a system fault, the applicable diagnostic page can
be used to check the operation of all the relevant
Diagnostic procedure electronic and electrical devices. Operate the system
The use of the diagnostics pages requires operation devices respond as expected.
of the relevant machine system at the same time. If
Figure 1690. System Status
Variflow Hydraulic Pump Control Switches

Diagnostic Pages
Information on the diagnostic pages is constantly ECU is shown. Where there are two switch inputs,
updated in real-time. The status of the ECU electrical 'NO' (Normally Open) and 'NC' (Normally closed)
inputs and outputs is displayed using: inputs are shown. The status is displayed using the
simulated LEDs.
• Simulated LEDs. The LEDs change colour
depending on the status of the inputs and Variable inputs
outputs.
• Numerical values i.e. Volts, PWM output, The voltage of the variable inputs is shown. The
current. voltages can be observed during operation and their
Digital outputs
The status of the digital outputs from ECU are
displayed using the simulated LEDs.
33 - 777 9813/9400-1 33 - 777

03 - Servicemaster
Valve outputs Diagnostic procedure

The status of the digital outputs from the ECU to The use of the diagnostics pages requires operation
the hydraulic solenoid valves is displayed using the of the relevant machine system at the same time. If
simulated LEDs. The current value of the solenoid necessary, get the help of an assistant. In the event
outputs can be monitored to make sure they both of a system fault, the applicable diagnostic page can
meet specifications. be used to check the operation of all the relevant
electronic and electrical devices. Operate the system
devices respond as expected.
Figure 1691. System Status
Rear Axle Stabilisation (RAS) Diagnostic Switches

Pages
Information on the diagnostic pages is constantly ECU is shown. Where there are two switch inputs,
updated in real-time. The status of the ECU electrical 'NO' (Normally Open) and 'NC' (Normally closed)
inputs and outputs is displayed using: inputs are shown. The ECU switch power output
status is shown in the third column as 'COM'. The
• Simulated LEDs. The LEDs change colour status is displayed using the simulated LEDs.
depending on the status of the inputs and
outputs. Transmission
• Numerical values i.e. Volts, PWM output,
current. The status of the transmission gear and direction
inputs to the ECU are shown using the simulated
LEDs.
33 - 778 9813/9400-1 33 - 778

03 - Servicemaster
Ignition switch can be monitored to make sure they both meet

specifications.
The ignition switch input to the ECU status is shown
using the simulated LEDs. The battery voltage is also RAS mode
displayed to make sure it meets specifications.
The current mode of the RAS system is displayed.
Digital outputs
Diagnostic procedure
The status of the digital outputs from ECU are
displayed using the simulated LEDs. The use of the diagnostics pages requires operation
of the relevant machine system at the same time. If
Valve outputs necessary, get the help of an assistant. In the event
of a system fault, the applicable diagnostic page can
The status of the digital outputs from the ECU to the be used to check the operation of all the relevant
LS (low side) and HS (high side) of the hydraulic electronic and electrical devices. Operate the system
solenoid valves is displayed using the simulated and view the diagnostics page to see if the system
LEDs. The current value of the solenoid outputs devices respond as expected.
Figure 1692. RAS System Status
Vehicle CAN- Diagnostic Pages CANbus is shown. Data is displayed in the fields on
the page when CAN messages are transmitted.
Information on the diagnostic page is constantly
updated in real-time. Each ECU connected to the
33 - 779 9813/9400-1 33 - 779

03 - Servicemaster
Figure 1693. Vehicle Can - Machines with PS760 Transmission and Variflow Hydraulic Pump
Figure 1694. Vehicle Can - Machines with PS760/PS750 Transmission and Gearpump Hydraulic Pump
Connection Problems The setup program must use the authorised DLA
contained in the Electronic Service Tool Kit. The
In general, whenever there are problems latest versions of both the hardware and software
communicating with the DLA there will be an error can be obtained through authorised suppliers.
message displayed. The following section although
not exhaustive attempts to identify the more common A number of reasons can generate software
ECU communication problems. problems and assistance from an information
33 - 780 9813/9400-1 33 - 780

03 - Servicemaster
technology engineer is advised. In particular, laptop • Authorised machine dealer or agent.

PCs can suffer serial communications conflicts, • Machine OEM (Original Equipment
where the PC hardware does not allow the software Manufacturer). The OEM will make the relevant
access to the communication ports. In the majority of enquires.
cases conflicts are caused by either software already
running on the PC, or by certain 'driver' files not (For: 506-23 [T4F], 509-23 [T4F], 512-26
releasing the COM port(s). [T4F])
An error is generated when no communications
can be established with the DLA and the ECU Introduction
usually through a hardware problem. Another source
could be related to resistance of the two data The Loadall cluster setup software tool is part of
communication wires making up the machine’s the JCB service master software suite. The software
harness for the ECU's CAN connection to the is designed to allow software updates and to
Deutsch 9 way round diagnostic connector. configure the electronic instrument cluster to match
the machine parameters.
Figure 1695.
This software guide is universal and some functions
may not be available on particular machine variants.
Clicking on the boxes marked with a question mark

(?) will open a screen to assist in the interpretation of
the data displayed or choice of option required.
Figure 1696.
The ECU must be powered for communications to

work. i.e the machine ignition must be ON (but engine
need not be running).
If a problem is experienced, it can take one A

of three forms, a constant failure to establish
communications, drop out during communications or
intermittent communication connection. Contributory
factors to communication errors could be related to
the following items:
• DLA Drivers: The DLA and PC are

programmed with software 'drivers' which
handle communications. Make sure that the A Boxes marked with question mark
latest drivers are installed on the PC and
DLA (contained in the latest version of Service Care and Safety
Master).
• PC Power Management: Previous experiences WARNING Make sure you read and follow any
have shown that some laptops’ power on screen instructions. Failure to follow the
management software can disrupt the COM instructions could result in death or injury.
ports. Turning off the power management
software may resolve the problem. Install
• IR Drivers: If the PC has an InfraRed (IR)
communications port then disabling the driver The Loadall cluster setup tool is fully integrated within
may help. JCB service master 4. To use the setup program, you
• Modem Drivers: Modem drivers could cause must install JCB Service Master 4 onto a suitable
communication conflicts and temporarily laptop computer.
prevent establishing a connection. This may be
because, the software is conflicting with the For information about installing the JCB service
port. master software, refer to electrical system- electronic
If the aforementioned information fails to resolve the
situation then the following contacts may be able to
provide further assistance:
• Information Technology (IT) engineer.
33 - 781 9813/9400-1 33 - 781

03 - Servicemaster
Connection 4.2. 2007+ (Machines built after 2007)
To use the setup program, connect your laptop 5. Make sure that the correct DLA is selected in
computer to the machine CANbus. Refer to electrical the chooser. Click on "Other". Select "General",
system- electronic diagnostic, refer to (PIL 33-57). and then "DLA".The DLA chooser window opens.
Check the button to match the current device.
Click "Apply". Refer to Figure 1699.
Starting Loadall Cluster Setup
Figure 1699.
1. Open Servicemaster. Refer to electrical system-
electronic diagnostic, refer to (PIL 33-57).
2. Click on the construction tab or the agricultural
tab.
3. Click on "Telescopic Handlers" icon.
Figure 1697.
A B
6. Start the setup tool by clicking on the Loadall T4i

Cluster Setup icon. Refer to Figure 1700.
Figure 1700.
7. The Loadall Cluster Setup tool will then open

up displaying the build option window. Refer to
Figure 1701.
A Construction tab Figure 1701.

B Agricultural tab
C Telescopic handlers icon
4. Select the applicable machine model:
Figure 1698.
4.1. 2007- (Machines built before 2007)
33 - 782 9813/9400-1 33 - 782

03 - Servicemaster
8. Enable the connection between the PC/ Laptop • Connect- To connect the PC/ laptop to the
by pressing the connect button. Refer to Figure instrument cluster to enable communication.
1702. • Disconnect- To disconnect the PC/ laptop
and the instrument cluster and cease
Figure 1702. communication.
• Read- To read the existing configuration of the
instrument cluster.
• Write- Used to update the instrument cluster
configuration.
• Exit- To close down the program. On exiting, the
program communications with both ECU and
DLA are shut down.
Navigating within Loadall Cluster Setup
Navigation is designed to be via a mouse. On laptop Menu bar- Utilities menu
PCs this may take the form of a small joystick Figure 1704.

to navigate the cluster setup software using the

computers where the mouse/ joystick have a
complaint.
There are two methods of navigation described

below:
• Pressing the ALT key will cause the File option

on the Menu Bar to be highlighted. You can then
• Notice that all the menu items on the Menu
Bar have a letter that is underlined (e.g. the
'F' in File). Holding down the ALT key and
option (i.e. either open the menu or execute Figure 1705.
the Preferences Dialogue this can be done by
pressing ALT + O (to open the Options menu)
then ALT + P (to execute the Preferences
option).
Menu bar- File menu

Figure 1703.
33 - 783 9813/9400-1 33 - 783

03 - Servicemaster
Figure 1706. 2. This will produce a security unlock screen

displaying a 'Challenge Value'. Refer to Figure
1708.
3. No further connection setup can be made until
the engineer either emails this value or contacts
JCB Service.
4. JCB service will apply your 'Challenge Code' and
through a special dongle tool and set up exe file.
JCB service will then receive a 'Response Value'.
5. This value will be passed back to the dealer/
engineer to use this into the unlock screen.
6. When all the numbers/ letters have been
completed, the ECU will self unlock.
7. The setup can then be completed.
This is a ONE OFF response code. So if the dealer/

• Select language- To select the language of the engineer types this incorrectly they will need to
setup program. Refer to Figure 1705. restart the complete procedure again.
• Unlock field- Refer to unlock procedure.
• Controller status- To show that the ECU is Figure 1708.
online. When the ECU is online, the machine
codes are displayed. The figure shows the
actual settings read from a test machine. Refer
to Figure 1706.
Unlock procedure
To access the ECU a new access code must be

requested.
This can only be requested from loadall technical

service and the following must be followed.
Figure 1707.
Menu bar- Help menu
Figure 1709.
• Help- Opens the help program. Refer to Figure

1710.
1. Select unlock. Refer to Figure 1707.
33 - 784 9813/9400-1 33 - 784

03 - Servicemaster
• About- opens a window showing the version

number of the installed copy of the software.
Figure 1711.
Configure electronic instrument cluster

build options
1. Click “Connect” to begin communication with the
ECU.
2. Enter the machine VIN (Vehicle Identification
Build Options Number) number into the VIN box.
This screen is used to configure the instrument 3. The available build options will be represented
cluster ECU machine build options. The options with white check boxes next to the text.
available will vary depending on machine model
selected. 4. Click on the relevant check boxes to inform the
ECU that the machine has that option installed.
5. Click "Next" button to be taken to the powertrain
screen.
Powertrain Options
This screen is used to configure the instrument
cluster ECU powertrain options. The options
available will vary depending on machine model
selected.
33 - 785 9813/9400-1 33 - 785

03 - Servicemaster
Configure electronic instrument cluster Configure electronic instrument cluster

powertrain options hydraulic options
1. Using the “Tyre Type and Manufacturer” drop 1. The available hydraulic build options will be
down menu, select the tyres that are installed on represented with white check boxes next to the
the machine. text.
2. Type the wheel circumference size into the 2. Click on the relevant check boxes to inform the
"Wheel Circumference" box. ECU that the machine has that option installed.
3. Using the “Axle Ratio” drop down box select the 3. Click "Next" to be taken to the service hours
axle ratio of the machine. screen.
4. Select the engine type by clicking on the check Service Hours

button next to the engine type installed.
5. Select the transmission type by clicking on cluster ECU service interval options. The options
the check button next to the transmission type available will vary depending on machine model
installed. selected.
6. Make sure the ‘Transmission Output Gear Teeth’
setting is set to ‘Standard Machine (47 Teeth)’.
7. Click “Next” to be taken to the hydraulic screen.
Hydraulic Options
cluster ECU hydraulic options. The options available
will vary depending on machine model selected.
33 - 786 9813/9400-1 33 - 786

03 - Servicemaster
If the “Write” function is disabled, make sure the

communication connection is enabled by pressing
the “Connect” button Refer to Figure 1718. or select
“Connect” from the “File” Menu Refer to Figure 1717.
Figure 1718.
Configure electronic instrument cluster

service options
1. Using the "Service Hours Schedule" drop down Read
menu, select the applicable service interval for
the machine. On occasion, it may be necessary for the software
2. Click "Next" to be taken to the languages screen. and setup information to be read back from the ECU
to check the settings or preload the current settings
ready for updating because of new options being
Write fitted to the vehicle.
The user can program the machine electronic Press the "Read" button Refer to Figure 1719. or
instrument cluster connected using the write select "Read" from the "File" menu Refer to Figure
function. 1720.
Several programming checks are made to make sure Figure 1719.
that all the required values are made (Model Type,
Languages etc.). It is to make sure that the data
written will not make any invalid conditions in the
vehicle system.
Press the "Write" button Refer to Figure 1716. or

select "Write" from the "File" menu Refer to Figure
1717.
Figure 1716.
33 - 787 9813/9400-1 33 - 787

03 - Servicemaster
Figure 1720. The ECU must be powered for communications to

work, i.e. the machine ignition must be ON (but the
engine need not be running).
If a problem is experienced, it can take one

of three forms, a constant failure to establish
communications, drop out during communications or
intermittent communication connection. Contributory
factors to communication errors could be related to
the following items:
• DLA Drivers- The DLA and PC are

programmed with software drivers which
handle communications. Make sure that the
latest drivers are installed on the PC and
DLA (contained in the latest version of service
master).
The progress of the read operation is shown in the • PC Power Management- Previous experiences
status window. When the data has been read from have shown that some laptop's power
the ECU, the data is stored back into the data entry management software can disrupt the COM
boxes on the options screen. ports. Turning off the power management
software may resolve the problem.
Connection Problems • IR Drivers- If the PC has an Infrared(IR)
communications port, then disabling the driver
In general, whenever there are problems may help.
communicating with the DLA, an error message will • Modem Drivers- Modem drivers could cause
be displayed. The following section although not communication conflicts and temporarily
exhaustive attempts to identify the more common prevent establishing a connection. This may be
ECU communication problems. because, the software is conflicting with the
port.
The setup program must use the authorised DLA
contained in the electronic service tool kit. The latest If the aforementioned information fails to resolve the
versions of both the hardware and the software can situation, then the following contacts may be able to
be obtained through authorised suppliers. provide further assistance:
A number of reasons can generate software • Information Technology (IT) engineer.

problems and assistance from an Information • Authorised machine dealer or agent.
Technology engineer is advised. In particular, laptop • Machine OEM. The OEM will make the relevant
PC's can suffer serial communications conflicts enquiries.
where the PC hardware does not allow the software
access to the communication ports. In the majority (For: 506-23 [T4F], 509-23 [T4F], 512-26
of cases, the conflicts are caused by either software [T4F])
already running on the PC, or by certain 'driver' files
not releasing the COM port(s). This tool set is for machines with JCB SH, SL, DH
Ecomax engines with PS766 transmission.
An error is generated when no communications
can be established with the DLA and the ECU For transmission diagnostics for machines with JCB
usually through a hardware problem. Another source SH, SL, DH Ecomax engines with Powershift PS764
could be related to resistance of the two data and PS 750 transmission, refer to electrical system-
communication wires making up the machine’s electronic diagnostic, refer to (PIL 33-57).
harness for the ECU’s CAN connection to the
Deutsch 9 way round diagnostic connector. Care and Safety
Figure 1721. WARNING Make sure you read and follow any
on screen instructions. Failure to follow the
instructions could result in death or injury.
33 - 788 9813/9400-1 33 - 788

03 - Servicemaster
Figure 1722. electrical system- electronic diagnostic, refer to

(PIL 33-57).
the IFM Transmission Diagnostics icon.Refer to
Figure 1723.
Figure 1723.
4. The IFM Transmission Diagnostics tool will then

open up displaying the main window. Refer to
Figure 1724.
Installing the IFM Transmission Figure 1724.
Diagnostic Tool
The diagnostics tool is fully integrated within JCB
ServiceMaster. To use the diagnostics tool, you must
install JCB ServiceMaster onto a suitable laptop
computer. For instructions on how to install JCB
ServiceMaster software, refer to electrical system-
Connecting the IFM Transmission

Diagnostic Tool
To use the diagnostics tool, the DLA and your
laptop computer must be connected to the machine
diagnostics connector. Refer to electrical system-
Starting the IFM transmission Diagnostic IFM Transmission Diagnostic Tool

Tool Overview
1. Turn ON the machine ignition and additionally There are several key elements to the Diagnostics
start the engine if required. tool. These can be seen labelled below. Each
element is explained in detail in later sections.
and select the correct machine range. refer to
33 - 789 9813/9400-1 33 - 789

03 - Servicemaster
Figure 1725.
A B C D D D D
E F
A Menu bar B Start and stop buttons

C Main window D LED status key
E Status bar F Page display area
33 - 790 9813/9400-1 33 - 790

03 - Servicemaster
Navigating within the IFM Transmission Menu Bar - File Menu

Diagnostic Tool Figure 1726.
Navigation is designed to be via mouse. On laptop

to navigate the Diagnostics software using the

computers where the mouse/joystick can be
oversensitive. Try the following as it might be useful.
There are two main methods of navigation described

below:
• Pressing the 'ALT' key will cause the 'File' option

on the menu bar to be highlighted. You can then
• Notice that all the menu items on the menu
bar have a letter that is underlined (e.g. the
'F' in File). Holding down the 'ALT' key and
option (i.e. either open the menu or execute
the 'Preferences' dialogue, this can be done by
pressing 'ALT + O' (to open the Options menu)
and then 'ALT + P' (to execute the 'Preferences'
option).
The File Menu contains an Exit option to close down

the program. Refer to Figure 1726.
On exiting the program communications with

bothECU and DLA are shut down.
33 - 791 9813/9400-1 33 - 791

03 - Servicemaster
Menu Bar - Options Menu Figure 1728.
Figure 1727.
Figure 1729.
Once your preferences have been selected, either

click on the 'OK' button to apply them or click on the
• Start Diagnostics: to commence 'Cancel' button to leave them unchanged.
communications with the IFM ECU. Refer to
Figure 1727. • Unlock. Refer to the 'Unlock' Procedure
• Stop Diagnostics: to cease communication.
Refer to Figure 1727. Unlock procedure
• Controller Status: to show that the ECU is
online. When the ECU is online the machine This feature is not used on this diagnostic tool.
codes are displayed. This diagram shows the
actual settings read from a test machine. Refer
to Figure 1729.
• Preferences: option opens up the preference
dialogue. Refer to Figure 1728.
From the preferences dialogue there is support for

multiple languages. Use the drop-down menu and
scroll bar to chose the required language.
The language option only effects text within the

main window (e.g. page list, LED status key, etc.).
Language support is not available for the text within
the page displays.
33 - 792 9813/9400-1 33 - 792

03 - Servicemaster
Menu Bar - Help Menu Figure 1731.
Figure 1730. A B
A Start button
B Stop button
A Status Bar
The Status Bar is located along the bottom of the
diagnostics main window.
CAN communications: Two small LEDs indicate data

being transmitted (red) and received (green) over the
CAN communications link. Refer to Figure 1732.
Figure 1732.
These LEDs can be seen to be flashing rapidly

A 'ABOUT' window as data is transported. This can be another useful
aid to determining the state of any established
• Help: Opens the applicable help files for the communications.
ServiceMaster tool being used.
• About: Opens a window showing the part
number and the version number of the installed
ECU Setup Page
copy of the diagnostics software. Figure 1733.
Start and Stop Buttons

These offer the same function as the Start
Diagnostics and Stop Diagnostics options within
the Options Menu. To start the diagnostics tool
communicating with the gearbox ECU, simply click
on the Start Button at the top of the main
window. Similarly, click on the Stop Button to cease
communications. Refer to Figure 1731.
This page displays crucial information about the ECU

configuration. Refer to Figure 1733.
It is always useful to confirm that this is the correct

configuration for the machine before commencing
any fault finding.
33 - 793 9813/9400-1 33 - 793

03 - Servicemaster
The ECU Setup Page displays the following are communications errors present, then this will
information: contain either:
ECU Setup Description: As well as its' operating • 'NO DLA COMMS' if there are problems in
software, the ECU also stores a group of setup data communication with the DLA, or
(or settings). This setup data is used to tailor how • 'NO ECU COMMS' if the DLA is working but the
a certain ECU part number functions. The setup Shiftmaster ECU is not responding.
data is loaded during the manufacturing process
and has been approved for use in the intended For help to resolve the communication problems,
application. Contained as part of the setup data is refer to connection problems section.
a description. This description is what is displayed
here. The engineer can use this description to verify • Hardware Version: The hardware version is a
that the correct setup data is being used. The Setup reference to the build level of the electronics.
software tool is designed to view and update current Future developments may mean that hardware
setup data. upgrades are required. This may effect which
software can be used.
Application code part number: During normal • Software Version: The software version refers
operation, the application code is displayed. If there to the issue level of the ECU operating software.
Future developments may require software
revisions.
TCEU Diagnostics Page
Figure 1734.
Figure 1735.
This section gives a detailed picture of how the ECU Information in this display is constantly updated in
is operating. real-time. The status of the ECU electrical inputs
33 - 794 9813/9400-1 33 - 794

03 - Servicemaster
and outputs is displayed using simulated LEDs. The LEDs change colour depending on the status of the
inputs and outputs. Refer to Figure 1735.
TECU System Status Page
Figure 1736.
This page gives a detailed picture of how the system • Selected Gear: This is the actual gear being
is operating. selected by the ECU.
Information in this display is constantly updated in The operator requested gear is not always the same
real-time. The applicable figures will be displayed in as the selected gear, e.g. when the ECU blocks shifts
the dialogue boxes. when offering protection.
• Direction Selection: This is the F/N/R selection • Clutch Current: The electrical current at each of
(Forward/Neutral/Reverse) the transmission clutch solenoids is displayed.
• Requested Gear: This is the demand from the
operator.
33 - 795 9813/9400-1 33 - 795

03 - Servicemaster
Torque Converter Lock Up (TCLU) Page
Figure 1737.
B
C
D F
A Driveline status B Lock up in process

C Lock up clutch solenoid status D Engine speed RPM (Revolutions Per Minute)
(real time)
E Reference value- engine, transmission speed F Transmission input speed RPM (real time)
differential
G Torque converter and elements
Figure 1738. The TCLU control page displays information relating

L to the torque converter lock up operation.
J K For operation of the lock up clutch two speed

references are required by the ECU.
Engine speed is read from the engine ECU via the

CANbus.
Transmission input speed is taken from the

transmission input speed sensor.
The circular graphic represents the torque converter

and its elements. Refer to Figure 1738.
H
H Stator
J Turbine
K Impeller
L Lock up clutch
33 - 796 9813/9400-1 33 - 796

03 - Servicemaster
Solenoid Test Mode page
Figure 1739.
Information in this display is constantly updated in • Initial Conditions: To enable Test Mode, the
real-time. The applicable figures will be displayed in handbrake must be 'ON', the 'FNR' lever set
the dialogue boxes. to 'NEUTRAL' and the road speed must be
'ZERO'. The conditions are displayed in the
The Solenoid Test Mode page allows testing of Initial Conditions panel.
each transmission solenoid individually. Since gear • Start/Stop Button: Press the button to toggle the
selection always requires two solenoid valves to test mode either on or off as required. 'TEST
be energised the tests can be carried out with the MODE READY' or 'TEST MODE ACTIVE' is
transmission in neutral. For electrical tests the engine displayed as applicable. If the initial conditions
does not have to be running. For hydraulic clutch are not compatible with the test mode the Start/
pressure testing the engine must be running, before Stop button is disabled and 'NOT ALLOWED' is
using the Test Mode facility disconnect the drive displayed.
shafts at the gearbox. • To test a solenoid: If tests are being carried
out with the engine running, make sure that the
It is possible that the gearbox may have developed drive shafts are disconnected at the gearbox.
a fault causing a clutch to be permanently engaged. Click the appropriate button using the mouse.
If a second clutch is engaged (by using the Test
Mode facility for instance) the gearbox will engage Solenoid Identification Page
a gear unexpectedly. Before using the Test Mode
facility disconnect the drive shafts at the gearbox. The solenoid identification page is for reference only.
33 - 797 9813/9400-1 33 - 797

03 - Servicemaster
Figure 1740.
ECU Block Diagram Page

The ECU block diagram page is for reference only.
33 - 798 9813/9400-1 33 - 798

03 - Servicemaster
Figure 1741.
Connection Problems the PC hardware does not allow the Diagnostic

software access to the communication ports. In most
In general, whenever there are problems of the cases, conflicts are caused by either software
communicating with the DLA, there will be an error already running on the PC, or by certain 'driver' files
message displayed. The following section although not releasing the COM port(s).
not exhaustive attempts to identify the more common
ECU communication problems. The first message is generated when the problem
exists between the PC and DLA then the 'Error
ServiceMaster Tools must use the authorised DLA Connecting to DLA' will be displayed. Refer to Figure
contained in the Electronic Service Tool Kit. The 1742.
latest versions of both the hardware and software
can be obtained through authorised suppliers.
A number of reasons can generate software

problems and assistance from an Information
Technology engineer is advised. In particular, laptop
PCs can suffer serial communications conflicts were
33 - 799 9813/9400-1 33 - 799

03 - Servicemaster
Confirmation of this error can be found in the 'ECU

Setup Page' with 'NO DLA COMMS' being displayed
in the 'ECU Part Number' box. Refer to Figure 1743.
Figure 1743.
The ECU must be powered for communications to

work, i.e. the machine ignition must be ON (but the
engine need not be running).
If a problem is experienced, it can take one of

the three forms; a constant failure to establish
communications, drop out during communications
or intermittent communication connection. However,
the source has a tendency to be of the 'NO DLA
COMMS' type and thus related to the user's PC.
Contributory factors to communication errors could
be related to the following items:
The second is generated when no communications
can be established with the DLA and the ECU usually • DLA Drivers. The DLA and PC are
through a hardware problem. No power supply from programmed with software 'drivers' which
the machine, indicated by the DLAs power LED handle communications. Make sure that the
will display the 'NO ECU COMMS' message. Refer latest drivers are installed on the PC and
to Figure 1744. Another source could be related DLA (contained in the latest version of
to resistance of the two data communication wires ServiceMaster).
making up the machine's harness for the ECU's CAN • PC power management. Previous experiences
connection to the Deutsch 9 way round diagnostic have shown that some laptops’ power
connector. The wiring must have two 120Ω resistors management software can disrupt the COM
fitted to either end of this run of cable to give a ports. Turning off the power management
60Ω impedance. If the impedance is incorrect, then software may resolve the problem.
'NO ECU COMMS' message will displayed. Refer to • IR Drivers. If the PC has an InfraRed (IR)
Figure 1744. communications port, then disabling the driver
may help.
• Modem Drivers. Modem drivers could
cause communication conflicts and temporary
disabling to establish if the software is
conflicting with the port may establish this
source.
If the aforementioned information fails to resolve the

situation then the following contacts may be able to
provide further assistance:
• Information Technology (IT) engineer.
33 - 800 9813/9400-1 33 - 800

03 - Servicemaster
• Authorised machine dealer or agent.

• Machine OEM. The OEM will make the relevant
enquires.
General Information
For all enquiries about the ServiceMaster tools,
please follow your normal channels of enquiry. This
makes sure that useful information can filter through
to JCB personnel at all levels.
33 - 801 9813/9400-1 33 - 801

03 - Servicemaster
Disconnect and Connect a Connect the USB cable directly to the laptop
computer. Do not connect the cable through a
Special Tools USB hub.
Description Part No. Qty. b The older DLA and laptop computers may not
Machine Cable 718/20237 1 be compatible with the USB ports. Use the
serial PC cable to connect the DLA to the laptop
Data Link Adaptor 892/01174 1 serial port.
(DLA) Kit
Do the steps below to connect your laptop computer
Connect your laptop computer to the machine to the machine.
through the diagnostic CAN (Controller Area
Network) bus connection, to use Servicemaster. Use 1. Make the machine safe. Refer to (PIL 01-03).
the DLA (Data Link Adaptor) and the applicable
cables to make the CAN bus connection. Refer to 2. Follow the general health and safety procedures.
Figure 1745. Refer to (PIL 01-03).
Figure 1745. 3. Turn the ignition switch to the off position.

4. Get access to the fusebox cover in the cab.
5. Remove the thumb screws that are attached to
the fuse box cover. Refer to Figure 1746. and
D Figure 1746. All Machines
Except 526-56 and 527-58
E
B
C
A Fuse box cover

B Thumb screws
Figure 1747. 526-56 and 527-58 Machines
A B
A
A USB (Universal Serial Bus) PC (Personal

Computer) cable (718/20235)
B Serial PC cable (718/20236)
C USBDLA (728/26500) A Fusebox cover
D Machine cable (718/20237) B Thumb screws
E DLA kit (892/01174)
6. Remove the fusebox cover to get access to the
Make a note of the following: machine DLA port.
33 - 802 9813/9400-1 33 - 802

03 - Servicemaster
7. Find both the Deutsch connectors phased behind Figure 1750.

the panel. Refer to Refer to Figure 1748. and
Figure 1748.
D C
F
C Vehicle decal connector

C F Cab harness connector
10. In order to connect the Powertrain CAN bus
connection, the connector with the Powertrain
E
decal must be connected to the cab harness.
Figure 1751.
C Vehicle connector
D Powertrain connector
E DLA port
Figure 1749.
D
F
E
D Powertrain decal connector
D F Cab harness connector
11. The vehicle connector must be connected, when
the Servicemaster diagnostic work has been
completed.
12. Install the fusebox cover.
13. Use the DLA to connect the laptop computer to
C the machine.
C Vehicle connector Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
D Powertrain connector 1)
E DLA port
13.1. Connect the USB PC cable between the
8. Pull both Deutsch connectors through the slot in DLA and the laptop computer USB port.
the panel.
14. Connect the machine cable to the DLA.
9. In order to connect the Vehicle CAN bus Special Tool: Machine Cable (Qty.: 1)
connection, the connector with the Vehicle decal
must be connected to the cab harness. Refer to 14.1. The machine cable has a 15-way D-type
Figure 1750. connector on one end and a 9-way CAN
connector on the other end.
14.2. Connect the 15-way D-type connector end
of the machine cable into the DLA and
tighten the thumb screws to attach it.
15. Connect the 9-way CAN connector end of the
machine cable to the machines diagnostics
connector. Refer to Figure 1752.
15.1. Put the CAN connector to align the
centre pin location tab with the diagnostics
connector.
33 - 803 9813/9400-1 33 - 803

03 - Servicemaster
15.2. Couple the connectors. Turn the locking

ring clockwise to secure the connectors.
Figure 1752.
C
D
A USB PC Cable
B Serial PC cable
C Centre pin location tab
D Locking ring
33 - 804 9813/9400-1 33 - 804

90 - Fault Codes
90 - Fault Codes Introduction

Introduction .................................................. 33-805 Should faults occur related to an ECU (Electronic
Technical Data ............................................. 33-808 Control Unit) or devices connected to it, the
electronic system will generate the applicable fault
codes. A complete list of fault codes is stored within
the applicable Servicemaster tools set.
Fault Code Structure

The structure of fault codes, otherwise known
as DTC (Diagnostic Trouble Code)'s has been
standardised to a 7 digit code for all on and off-
highway machine and vehicle applications. The
standard (referred to as J2012) requires all fault
codes to conform to the following structure.
• 1st character - defines the system on the

vehicle (e.g. P = Powertrain, C= Chassis, U =
Network).
• 2nd and 3rd characters - defines the sub-
system (e.g. transmission, CAN (Controller
Area Network) network, brakes etc).
• 4th and 5th characters - specifies the particular
component, circuit or fault (e.g. starter relay).
• 6th and 7th characters - referred to as the
'Failure Type Byte' (FTB) which indicates the
particular failure (e.g. 11 = short circuit to
ground). See FTB Numbers below for a full list.
Some specific fault codes are defined by

international standard, while other codes may be
defined by individual vehicle manufacturers.
Fault Code Display Systems

Depending on the machine specification fault codes
recorded by the engine ECU can be accessed and
displayed in several ways:
CAN Enabled Display

The machine may be equipped with a CAN enabled
display. Such a display will be capable of displaying
all recorded codes, for example P0047. All logged
codes will be displayed. The operator may also
have a facility to erase the fault code log. See
the applicable machine documentation for further
information.
CAN BUS Connected Computer

Fault codes logged can be accessed via a
suitable laptop computer running the applicable
diagnostics software, JCB 444 Engine Diagnostics
for example. The computer must be connected to the
machine CAN BUS socket using a DLA (Data Link
Adaptor). Once connected all recorded codes can be
displayed. The engineer also has a facility to erase
the fault code log.
33 - 805 9813/9400-1 33 - 805

90 - Fault Codes
Failure Type Byte (FTB) Numbers Number Failure Type Byte (FTB) De-
scription
92 Performance or incorrect opera-
Table 682. tion.
Number Failure Type Byte (FTB) De- 98 Component or system over tem-
scription perature.
0 No sub-type information.
2 General signal failure. Malfunction Indicator Light (MIL)
4 System internal failure.
Figure 1753.
5 System programming failure.
7 Mechanical failure.
9 Component failure.
11 Short Circuit To Ground (SC2G).
12 Short Circuit To Battery
(SC2VBAT). Amber/Red light. The MIL (Malfunction Indicator
13 Open Circuit (OC). Lamp) light comes on to show that a system error
16 Circuit voltage below threshold. has been detected. Refer to Figure 1753.
17 Circuit voltage above threshold. - Red light. The light comes ON (and a continuous
18 Circuit current below threshold. audible alarm sounds) to indicate faults that may
19 Circuit current above threshold. result in serious damage to the machine or make the
1A Circuit resistance above thresh- machine dangerous to operate. This is known as a
old. ‘STOP NOW’ fault.
1B Circuit resistance below thresh- - Amber light. The light comes ON (and an audible
old. alarm sounds for one second) to indicate faults that
1C Circuit voltage out of range. may result in reduced machine performance but are
1F Circuit intermittent. not dangerous. They are unlikely to damage the
23 Signal stuck low. machine. This is known as a ‘SERVICE’ fault.
24 Signal stuck high. When the MIL light comes ON another applicable
26 Signal rate of change below system warning may display. These lights can show
threshold. a blink code. Refer to Electronic Diagnostic, Fault
27 Signal rate of change above Codes, Introduction, Blink Codes (PIL 33-57-90).
threshold.
29 Signal invalid. Blink Codes
2F Signal erratic.
Some machine systems are equipped with a
31 No Signal (lost/missing).
dedicated indicator light. If there is a system fault the
36 Signal frequency too low. light can display fault codes as a series of blinks.
37 Signal frequency too high.
38 Signal frequency incorrect. For example code E127 can be displayed as a series
of blinks as follows:
45 Program memory failure.
46 Calibration / Parameter memory Table 683.
failure.
1 Blink
47 Watchdog / micro-controller / mi-
croprocessor failure. 2 Second delay
4B Over temperature. 2 Blink Blink
62 Signal compare failure. 2 Second delay
64 Signal plausibility failure. 7 Blink Blink Blink Blink Blink Blink Blink
71 Actuator stuck. The light will be ON for approximately 1s and OFF
72 Actuator stuck open. for approximately 0.5s. There is an OFF time of
73 Actuator stuck closed. approximately 2s between error code digits.
85 Signal above allowable range.
When a blink code is displayed the MIL light can
86 CAN signal invalid. also come ON. Refer to Electronic Diagnostic,
33 - 806 9813/9400-1 33 - 806

90 - Fault Codes
Fault Codes, Introduction, Malfunction Indicator Light

(MIL) (PIL 33-57-90).
Fault Code log

The fault code log can be read on the instrument
panel LCD (Liquid Crystal Display). Alternatively use
the JCB Servicemaster diagnostics tool.
Read the fault code log on the instrument panel LCD

via the service menu. Use JCB Servicemaster and
a laptop computer connected to machine CANbus to
see the codes. Refer to: PIL 33-57-03.
33 - 807 9813/9400-1 33 - 807

90 - Fault Codes
Technical Data
For: 506-23 [T4F], 509-23 [T4F], 512-26

[T4F] ........................................ Page 33-808
................................................. Page 33-845
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F])
Table 684.
Fault Code Fault Description Fault Severity
P046D-2F Trivial
7F0E6-3 Extend Boost Solenoid STB Operator
7F0E6-4 Extend Boost Solenoid STG Operator
7F0E6-5 Extend Boost Solenoid Open Operator
7F0E8-3 Extend Boost Solenoid Return STB Operator
7F0E8-4 Extend Boost Solenoid Return Operator
STG
Open
7F296-2 Left Stabiliser Lever Disagreement Operator
7F296-3 Left Stabiliser Lever 1 OORH Operator
7F296-4 Left Stabiliser Lever 1 OORL Operator
7F297-2 Right Stabiliser Lever Disagree- Operator
ment
7F297-3 Right Stabiliser Lever 1 OORH Operator
7F297-4 Right Stabiliser Lever 1 OORL Operator
7F2B3-3 Left Stabiliser Lower Solenoid STB Operator
7F2B3-4 Left Stabiliser Lower Solenoid STG Operator
7F2B3-5 Left Stabiliser Lower Solenoid Operator
Open
7F2B4-3 Left Stabiliser Raise Solenoid STB Operator
7F2B4-4 Left Stabiliser Raise Solenoid STG Operator
7F2B4-5 Left Stabiliser Raise Solenoid Operator
Open
7F2B5-3 Right Stabiliser Lower Solenoid Operator
STB
STG
Open
7F2B6-3 Right Stabiliser Raise Solenoid Operator
STB
STG
Open
7F2BE-3 Left Stabiliser Solenoid Return Operator
STB
STG
Open
33 - 808 9813/9400-1 33 - 808

90 - Fault Codes

7F2BF-3 Right Stabiliser Solenoid Return Operator
STB
STG
Open
7F34F-3 Left Stabiliser Lever 2 OORH Operator
7F34F-4 Left Stabiliser Lever 2 OORL Operator
7F350-3 Right Stabiliser Lever 2 OORH Operator
7F350-4 Right Stabiliser Lever 2 OORL Operator
7F58A-2 Extend Boost Proximity Switch Operator
OOR
Short
Open
Stuck
B104C-67 LLMI (Longitudinal Load Moment Operator
Indicator) Calibration Tip Point
B104D-67 LLMI Calibration Travel Point Operator
B104E-54 LLMI Calibration Required Operator
B104F-49 LLMILED (Light Emitting Diode)'S Operator
Connection Error
B1050-29 LLMI Calibration Error Operator
B1051-46 LLMI Eeprom Store Error Operator
B1052-46 LLMI Eeprom Read Error Operator
B1053-0 LLMI Valve Application Error Operator
B1054-87 LLMICAN (Controller Area Net- Operator
work) No Response Error
B1055-16 LLMI Low Voltage Error Operator
B1056-17 LLMI High Voltage Error Operator
B1057-47 LLMI Pic Comms Error Operator
B1058-24 LLMI Override Mode Error Operator
B1059-62 LLMI Cross Checking Error Operator
B1500-64 SRS (Smooth Ride System) Switch Trivial
Short
B1501-1C SRS Switch OOR Trivial
B1502-13 Hydraulic Lock Switch Open Trivial
B1503-64 Hydraulic Lock Switch Short Trivial
B1504-1C Hydraulic Lock Switch OOR Trivial
B1505-1C Sway Switch OOR Trivial
B1506-64 Sway Switch Short Trivial
B1507-13 Stabiliser Isolation Switch Open Trivial
B1508-64 Stabiliser Isolation Switch Short Trivial
B1509-1C Stabiliser Isolation Switch OOR Trivial
B150A-1C Ext_Aux2B_Sw_OOR Trivial
B150B-1C Auxa_Auxb_Sw_OOR Trivial
B150C-1C Ret_Aux2A_Sw_OOR Trivial
B150D-13 Column Fnr Open Trivial
B150E-64 Column Fnr Short Trivial
33 - 809 9813/9400-1 33 - 809

90 - Fault Codes

B150F-64 Steer Mode Sensor Disagreement Trivial
B1510-18 Steer Mode Sensor 1 OORL Trivial
B1511-17 Steer Mode Sensor 1 OORH Trivial
B1514-64 Fnr Transmission Monitor Rational- Trivial
ity Fault
B1515-13 Brake Light Switch Open Trivial
B1516-64 Brake Light Switch Short Trivial
B1517-1C Brake Light Switch OOR Trivial
B1518-13 Park Brake Switch Open Trivial
B1519-64 Park Brake Switch Short Trivial
B151A-1C Park Brake Switch OOR Trivial
B151B-13 2WD (Two Wheel Drive) Switch Trivial
Open
B151C-64 2WD Switch Short Trivial
B151D-1C 2WD Switch OOR Trivial
B151E-13 Drive Control Shutdown Open Trivial
B151F-11 Drive Control Shutdown STG Trivial
B1520-12 Drive Control Shutdown STB Trivial
B1521-1C Footbrake Dump Switch OOR Operator
B1521-1C Footbrake Dump Switch OOR Trivial
B1522-13 Auto Trans Switch Open Trivial
B1523-64 Auto Trans Switch Short Trivial
B1524-1C Auto Trans Switch OOR Trivial
B1525-13 Seat Switch Open Operator
B1525-13 Seat Switch Open Trivial
B1526-64 Seat Switch Short Operator
B1526-64 Seat Switch Short Trivial
B1527-13 Neutral Start Relay Open Operator
B1527-13 Neutral Start Relay Open Trivial
B1528-11 Neutral Start Relay STG Operator
B1528-11 Neutral Start Relay STG Trivial
B1529-12 Neutral Start Relay STB Operator
B1529-12 Neutral Start Relay STB Trivial
B152A-13 Brake Lamp Open Operator
B152B-11 Brake Lamp STG Operator
B152C-12 Brake Lamp STB Operator
B152D-13 Reverse Lamp Open Operator
B152E-11 Reverse Lamp STG Operator
B152F-12 Reverse Lamp STB Operator
B1530-18 Footbrake Pressure OORL Operator
33 - 810 9813/9400-1 33 - 810

90 - Fault Codes

B1531-17 Footbrake Pressure OORH Operator
B1532-18 5V Supply STG Operator
B1532-18 5V Supply STG Trivial
B1533-17 5V Supply STB Operator
B1533-17 5V Supply STB Trivial
B1534-13 Tilt Lock Switch Open Trivial
B1535-64 Tilt Lock Switch Short Trivial
B1536-1C Tilt Lock Switch OOR Trivial
B1537-64 Constant Auxiliary Set Switch Dis- Trivial
agreement
B1539-13 Constant Auxiliary Enable Switch Trivial
Open
B153A-64 Constant Auxiliary Enable Switch Trivial
Short
B153B-1C Constant Auxiliary Enable Switch Trivial
OOR
B153C-13 Joystick FNR Open Trivial
B153D-64 Joystick FNR Short Trivial
B153F-13 Fuel Level Sensor Open Circuit Trivial
B1541-68 Engine Oil Low When Engine Trivial
Started -
B1542-68 Air Filter Blocked Operator
B1543-4B Coolant Temperature High (Critical Critical
Level)
B1544-14 Coolant Temperature Sensor Short Trivial
B1545-13 Coolant Temperature Sensor Open Trivial
B1546-68 Coolant Temperature High (Opera- Trivial
tor Level)
B1547-68 Coolant Level Low, Engine Run- Trivial
ning
B1548-21 Coolant Level Low, Engine Not Trivial
Started
B1549-21 Ambient Temperature Sensor – Service
OORL
B154B-12 Left Indicator – Short To Battery Trivial
B154C-11 Left Indicator – Short To Ground Trivial
B154D-13 Left Indicator - Bulb Out / Open Trivial
B154E-12 Right Indicator – Short To Battery Trivial
B154F-11 Right Indicator – Short To Ground Trivial
B1550-13 Right Indicator - Bulb Out / Open Trivial
B1551-13 Right Trailer Indicator – Bulb Out / Trivial
Open
B1552-13 Left Trailer Indicator – Bulb Out / Trivial
Open
B1558-12 Reversing Fan Output – Short To Trivial
Battery
Ground
B155A-13 Reversing Fan Output - Open Trivial
B155E-12 Proportional Fan Output – Short To Trivial
Battery
33 - 811 9813/9400-1 33 - 811

90 - Fault Codes

B155F-11 Proportional Fan Output – Short To Trivial
Ground
B1560-13 Proportional Fan Output - Open Trivial
B1561-02 Hvac Switch – OOR Trivial
B1562-12 Hvac Fan Output – Short To Bat- Trivial
tery
B1563-11 Hvac Fan Output – Short To Trivial
Ground
B1564-13 Hvac Fan Output – Open Trivial
B1565-12 A/C Output – Short To Battery Trivial
B1566-11 A/C Output – Short To Ground Trivial
B1567-13 A/C Output – Open Trivial
B1568-12 Wading Output – Short To Battery Trivial
B1569-11 Wading Output – Short To Ground Trivial
B156A-13 Wading Output – Open Trivial
B1578-15 Engine Crank Relay STB Trivial
B1579-14 Engine Crank Relay STG Trivial
B157A-13 Engine Crank Relay Open Trivial
B1583-13 RAL Solenoid Open Operator
B1583-14 RAL Solenoid STG Operator
B1583-15 RAL Solenoid STB Operator
B1583-68 Isolation Valve Stuck Critical
B1584-64 Extend Dump Valve STB Operator
B1585-64 Pin Lock Solenoid Short Operator
B1586-64 Recovery Valve Short Operator
BAD CODE Keypad - Invalid Keypad Code En- Operator
tered
BATTERY Battery Voltage Monitoring Signal Operator
Low Fault
BRAKES Brake Charge Pressure Low, En- Critical
gine Running
BRAKES Brake Charge Pressure Low Trivial
C1019-38 LLMI Transducer 1 Pwm Signal Er- Operator
ror
C101A-29 LLMI Transducer 1 Range Eror Operator
C1500-13 Boom Retracted Switch Open Trivial
C1501-64 Boom Retracted Switch Short Trivial
C1502-1C Boom Retracted Switch OOR Trivial
C1503-07 Boom Retracted Switch Stuck Trivial
C1504-62 Load Moment Indicator Disagree- Operator
ment Fault
C1505-13 Accumulator Solenoid Open Trivial
C1506-11 Accumulator Solenoid STG Trivial
C1507-12 Accumulator Solenoid STB Trivial
C1508-13 Drain Solenoid Open Trivial
C1509-11 Drain Solenoid STG Trivial
C150A-12 Drain Solenoid STB Trivial
C150B-13 Extend Solenoid Open Trivial
C150C-11 Extend Solenoid STG Trivial
C150D-12 Extend Solenoid STB Operator
33 - 812 9813/9400-1 33 - 812

90 - Fault Codes

C150E-13 Retract Solenoid Open Trivial
C150F-11 Retract Solenoid STG Trivial
C1510-12 Retract Solenoid STB Trivial
C1511-13 Extend/Retract Solenoid Return Trivial
Open
STG
STB
C1514-13 Auxiliary A Solenoid Open Trivial
C1515-11 Auxiliary A Solenoid STG Trivial
C1516-12 Auxiliary A Solenoid STB Trivial
C1517-13 Auxiliary B Solenoid Open Trivial
C1518-11 Auxiliary B Solenoid STG Trivial
C1519-12 Auxiliary B Solenoid STB Trivial
C151A-13 Auxiliary Changeover Solenoid Trivial
Open
C151B-11 Auxiliary Changeover Solenoid Trivial
STG
C151C-12 Auxiliary Changeover Solenoid Trivial
STB
C151D-46 Eeprom Fault Trivial
C151E-62 Boom Angle Sensor Disagreement Trivial
C151F-23 Boom Angle Sensor 1 OORL Trivial
C1520-24 Boom Angle Sensor 1 OORH Trivial
C1521-23 Boom Angle Sensor 2 OORL Trivial
C1523-13 Hyd Isolate Solenoid Open Trivial
C1524-11 Hyd Isolate Solenoid STG Trivial
C1525-12 Hyd Isolate Solenoid STB Trivial
C1526-23 SRS Pressure Switch OORL Trivial
C1527-24 SRS Pressure Switch OORH Trivial
C1528-62 SRS Pressure Switch Disagree- Trivial
ment
C1529-62 Chassis Angle Sensor Disagree- Trivial
ment
C152A-23 Chassis Angle Sensor 1 OORL Trivial
C152B-24 Chassis Angle Sensor 1 OORH Trivial
C152C-23 Chassis Angle Sensor 2 OORL Trivial
C152D-24 Chassis Angle Sensor 2 OORH Trivial
C152E-62 Lift / Lower Spool Disagreement Trivial
C152F-23 Lift / Lower Spool 1 OORL Trivial
C1530-24 Lift / Lower Spool 1 OORH Trivial
C1531-62 Lift / Lower Spool 2 OORL Trivial
C1533-24 Ext / Retract Spool Disagreement Trivial
C1534-62 Ext / Retract Spool 1 OORL Trivial
C1535-23 Ext / Retract Spool 1 OORH Trivial
33 - 813 9813/9400-1 33 - 813

90 - Fault Codes

C1538-23 Crowd / Dump Spool Disagree- Trivial
ment
C1539-24 Crowd / Dump Spool 1 OORL Trivial
C153A-62 Crowd / Dump Spool 1 OORH Trivial
C153B-23 Crowd / Dump Spool 2 OORL Trivial
C153C-24 Crowd / Dump Spool 2 OORH Trivial
C153D-62 Aux A/B Spool Disagreement Trivial
C153E-23 Aux A/B Spool 1 OORL Trivial
C153F-24 Aux A/B Spool 1 OORH Trivial
C1540-62 Aux A/B Spool 2 OORL Trivial
C1541-23 Aux A/B Spool 2 OORH Trivial
C1542-24 Left Stabiliser Spool Disagreement Trivial
C1543-62 Left Stabiliser Spool 1 OORL Trivial
C1544-23 Left Stabiliser Spool 1 OORH Trivial
C1545-24 Left Stabiliser Spool 2 OORL Trivial
C1546-62 Left Stabiliser Spool 2 OORH Trivial
C1547-23 Right Stabiliser Spool Disagree- Trivial
ment
C1548-24 Right Stabiliser Spool 1 OORL Trivial
C1549-62 Right Stabiliser Spool 1 OORH Trivial
C154A-23 Right Stabiliser Spool 2 OORL Trivial
C154B-24 Right Stabiliser Spool 2 OORH Trivial
C154C-13 Sway Isolation Solenoid Open Trivial
C154D-11 Sway Isolation Solenoid STG Trivial
C154E-12 Sway Isolation Solenoid STB Trivial
C154F-13 Stab Isolation Solenoid Open Trivial
C1550-11 Stab Isolation Solenoid STG Trivial
C1551-12 Stab Isolation Solenoid STB Trivial
C1552-13 Stab Isolation Solenoid Return Trivial
Open
STG
STB
C1555-13 Sway Right Solenoid Open Trivial
C1556-11 Sway Right Solenoid STG Trivial
C1557-12 Sway Right Solenoid STB Trivial
C1558-13 Sway Left Solenoid Open Trivial
C1559-11 Sway Left Solenoid STG Trivial
C155A-12 Sway Left Solenoid STB Trivial
C155B-13 Motion Cut Valve Ls Open Trivial
C155C-11 Motion Cut Valve Ls STG Trivial
C155D-12 Motion Cut Valve Ls STB Trivial
C155E-62 Left Stabiliser Deployed Sensor Trivial
Disagreement
C155F-23 Left Stabiliser Deployed Sensor Trivial
OORL
C1560-24 Left Stabiliser Deployed Sensor Trivial
OORH
C1561-62 Right Stabiliser Deployed Sensor Trivial
Disagreement
33 - 814 9813/9400-1 33 - 814

90 - Fault Codes

OORL
OORH
C1564-23 Front Steer Alignment Sensor 1 Trivial
OORL
OORH
OORL
OORH
C1568-23 Rear Steer Alignment Sensor 1 Trivial
OORL
OORH
C156A-23 Rear Steer Alignment Sensor 2 Trivial
OORL
C156B-24 Rear Steer Alignment Sensor 2 Trivial
OORH
C156C-13 Steer A Solenoid Open Trivial
C156D-11 Steer A Solenoid STG Trivial
C156E-12 Steer A Solenoid STB Trivial
C156F-13 Steer B Solenoid Open Trivial
C1570-11 Steer B Solenoid STG Trivial
C1571-12 Steer B Solenoid STB Trivial
C1572-13 Steer C Solenoid Open Trivial
C1573-11 Steer C Solenoid STG Trivial
C1574-12 Steer C Solenoid STB Trivial
C1575-13 Steer D Solenoid Open Trivial
C1576-11 Steer D Solenoid STG Trivial
C1577-12 Steer D Solenoid STB Trivial
C1578-13 Drain / Accumulator Solenoid Re- Trivial
turn Open
turn STG
C157A-12 Drain / Accumulator Solenoid Re- Trivial
turn STB
C157B-13 Steer Solenoid Return Open Trivial
C157C-11 Steer Solenoid Return STG Trivial
C157D-12 Steer Solenoid Return STB Trivial
C157E-11 5V Supply STG Trivial
C157F-12 5V Supply STB Trivial
C1580-07 Boom Movement When Joystick Is Trivial
Neutral (Stuck Spool)
C1581-07 Boom Movement When Lmi Is > Trivial
115%
C1582-87 ECU (Electronic Control Unit) Pair- Trivial
ing Fault
C1583-68 Tipover Detected Trivial
C1584-56 Drive Control Options Fault Trivial
C1585-22 Hydraulic Temp High Trivial
33 - 815 9813/9400-1 33 - 815

90 - Fault Codes

C1587-16 Brake Charge Pressure OORL Operator
C1588-17 Brake Charge Pressure OORH Operator
C158A-13 Pump Control Solenoid Open Trivial
C158B-11 Pump Control Solenoid STG Trivial
C158C-12 Pump Control Solenoid STB Trivial
C158D-13 Pump Control Solenoid Return Trivial
Open
C158E-18 Pump Control Solenoid Return Trivial
STG
C158F-19 Pump Control Solenoid Return Trivial
STB
C1590-1B Hydraulic Temp OORH Trivial
C1591-1A Hydraulic Temp OORL Trivial
C1592-13 Auxiliary A/B Solenoid Return Trivial
Open
C1593-18 Auxiliary A/B Solenoid Return STG Trivial
C1594-19 Auxiliary A/B Solenoid Return STB Trivial
C1595-13 Raise Solenoid Open Trivial
C1596-11 Raise Solenoid STG Trivial
C1597-12 Raise Solenoid STB Trivial
C1598-13 Lower Solenoid Open Trivial
C1599-11 Lower Solenoid STG Trivial
C159A-12 Lower Solenoid STB Trivial
C159B-13 Crowd Solenoid Open Trivial
C159C-11 Crowd Solenoid STG Trivial
C159D-12 Crowd Solenoid STB Trivial
C159E-13 Dump Solenoid Open Trivial
C159F-11 Dump Solenoid STG Trivial
C15A0-12 Dump Solenoid STB Trivial
C15A1-13 Raise/Lower Solenoid Return Trivial
Open
C15A2-18 Raise/Lower Solenoid Return STG Trivial
C15A3-19 Raise/Lower Solenoid Return STB Trivial
C15A4-13 Crowd/Dump Solenoid Return Trivial
Open
C15A5-18 Crowd/Dump Solenoid Return STG Trivial
C15A6-19 Crowd/Dump Solenoid Return STB Trivial
C15A7-64 Emergency Stop Switch Short Trivial
C15A8-13 Fourth Extension Switch Open Operator
C15A9-64 Fourth Extension Switch Short Operator
C15AA-1E Fourth Extension Switch OOR Operator
C15AB-13 Hydraulic Pin Lock Switch Open Operator
C15AC-64 Hydraulic Pin Lock Switch Short Operator
C15AD-1E Hydraulic Pin Lock Switch OOR Operator
C15AE-13 Hydraulic Venting Switch Open Operator
C15AF-64 Hydraulic Venting Switch Short Operator
C15B0-1C Hydraulic Venting Switch OOR Operator
C15B1-13 Hydraulic Pin Lock Solenoid Open Operator
C15B2-14 Hydraulic Pin Lock Solenoid STG Operator
C15B3-15 Hydraulic Pin Lock Solenoid STB Operator
33 - 816 9813/9400-1 33 - 816

90 - Fault Codes

C15B4-13 Fourth Extension Solenoid Open Operator
C15B5-14 Fourth Extension Solenoid STG Operator
C15B6-15 Fourth Extension Solenoid STB Operator
C15BD-64 Invalid Vin Received Trivial
CLUTCH Service
DEF Level Warning Requested Operator
ENG Lock Engine - Engine ECU Lockout Trivial
ENG OIL Oil Level Sensor Signal Global Operator
Fault
Fault
IMM Lock Immobiliser Lockout Trivial
LOW DEF Ad-Blue Level Low - Most Severe Critical
LOW DEF Ad-Blue Level Low - Moderately Operator
Severe
LOW FUEL Low Fuel Level (Operator Level) Operator
LOW FUEL Low Fuel Level (Service Level) Operator
P0001-13 IMV Driver Fault Is Detected Service
P0002-00 Rail Pressure Positive Control Er- Critical
ror During 'IMV-Only' Control. Pid
Controller Not Able To Stabilise
The RPC Value
P0002-00 Rail Pressure Negative Control Er- Service
ror During 'IMV-Only' Control. Pid
The RPC Value
P0002-1A Rail Pressure Control Error (Pres- Service
sure Error Too Low).
P0002-1B Rail Pressure Control Error (Pres- Service
sure Error Too High).
P0003-18 Rail Pressure Control Feedback Critical
Low Error
P0004-19 Rail Pressure Control Feedback Service
High Error
P0070-81 CAN Bus Message Error From En- Operator
gine ECU
P0070-87 CAN bus Off Error From Engine Operator
ECU
P0071-87 CAN Bus Message Error For En- Operator
vironment Temperature From En-
gine ECU
P007A-00 TMAP (Temperature Manifold Air Service
Pressure) (Intake Manifold 1 Temp)
Temperature Element Sensor Fault
(ADC)
P007C-23 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor Low
Fault
P007D-24 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor High
Fault
33 - 817 9813/9400-1 33 - 817

90 - Fault Codes

P007E-2F TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor
Noise Fault
P0087-00 Rail Pressure Control Error Posi- Service
tive
P0087-00 Pressure Limiter Open Critical
P0087-00 Common Rail Pressure Fall (No Critical
Feed)
P0087-00 RPC Variable Limit Capacity Service
(Vlc) Torque Reduction Above Its
Threshold
P0087-00 RPC Variable Limit Capacity (Vlc) Critical
Torque Reduction Clamped
P0087-23 Rail Pressure Build Low Fault Critical
P0088-00 Rail Pressure Control Error During Service
HPV Control (Over Max Calibrated
System Pressure)
P0089-00 Rail Pressure Control Error Critical
P0090-13 HPV Driver In ECU Fault Detected Service
P0091-11 PCV 1 Drive System Open Circuit Service
Or Grand Short Circuit
P0091-23 Check HPV Regulation Control Service
Trim Low
P0092-12 HPV Driver In ECU Fault Detected Critical
P0092-24 Check HPV Regulation Control Service
Trim High.
P0095-00 Intake Manifold Temperature (M2) Service
Signal Sensor ADC Fault (Intake
Manifold 2 Temp)
P0096-2F Intake Manifold Temperature Sen- Service
sor (M2) Signal Noise Fault (Intake
Manifold 2 Temp)
P0096-64 Intake Manifold Temperature Sen- Service
sor (M2) Signal Plausibility Fault
(Intake Manifold 2 Temp)
sor (M2) Signal Low Fault (Intake
Manifold 2 Temp)
sor (M2) Signal High Signal Fault
P00B7-87 CAN Bus Message Error For Operator
Coolant Sensor From Engine
EECU
P0100-00 MAF (Mass Air Flow) Fault (Glob- Service
al). Set If Plausibility Error, Gra-
dient Error Or Electrical Flt Is
Present
P0100-11 MAF High Side Driver Fault Short Service
Circuit To Ground (SC2G)
P0102-23 MAF Low Voltage Fault Service
P0102-23 MAF Electrical Sensor Low Fault Service
P0103-24 MAF High Voltage Fault Service
P0103-24 MAF Electrical Sensor High Fault Service
33 - 818 9813/9400-1 33 - 818

90 - Fault Codes

P0105-00 MAP (Manifold Absolute Pressure) Service
Sensor Global Fault
P0106-23 MAP Sensor Signal Drift Low Fault Service
P0106-24 MAP Sensor Signal Drift High Fault Service
P0106-64 MAP Sensor Signal Plausibility Service
Fault
P0110-00 Inlet Air Temperature (IAT) Sensor Service
Signal ADC Fault Detected
Signal Low Fault Detected
Signal High Fault Detected
P0115-00 Coolant Sensor Signal Fault Service
P0116-64 Coolant Sensor Fault (Plausibility) Trivial
P0117-23 Coolant Sensor Signal Low Fault Trivial
P0118-24 Coolant Sensor Signal High Fault Trivial
P0120-00 Foot Pedal Signal Track 1 Fault Service
vironment Pressure From Engine
ECU
P0180-00 Fuel Temperature ADC Fault Service
P0181-27 Fuel Temperature Sensor Fault Service
P0181-27 Fuel Temperature Sensor Gradient Service
Fault
P0181-87 CAN Bus Message Error For Fuel Operator
Temperature From Engine ECU
P0182-23 Fuel Temperature Sensor Low Service
Fault
P0183-24 Fuel Temperature Sensor High Service
Fault
P0190-27 Rail Pressure Sensor Signal Grad Service
Fault
P0191-23 Rail Pressure Sensor Fault. Below Service
Minimum Threshold (Out Of Range
At Key-On)
P0191-24 Rail Pressure Sensor Fault. Above Service
Maximum Threshold (Out Of
Range At Key-On)
P0192-23 Rail Pressure Sensor Signal Low Service
Fault
P0193-24 Rail Pressure Sensor Signal High Service
Fault
P0194-00 Rail Pressure Sensor Signal Drop Critical
Fault
P0195-00 Oil Temperature Sensor Signal Service
Global Fault
Gradient Fault
Plausability Fault
P0196-87 CAN Bus Message Error For Oil Operator
33 - 819 9813/9400-1 33 - 819

90 - Fault Codes

Low Fault
High Fault
P0201-00 Injector In Cylinder 1 Short Circuit Critical
HSD To LSD
P0201-11 Injector 2 Open Circuit Fault (OC) Critical
HSD To LSD
P0202-11 Injection Nozzle #2Drive System Critical
Open Circuit Fault
HSD To LSD
Open Circuit Fault
HSD To LSD
Open Circuit Fault
P0218-22 Transmission Fluid Over Tempera- Operator
ture
ture
P0235-00 Boosted Air Pressure Sensor Service
Fault: ADC
P0237-23 Boosted Air Pressure Sensor Low Service
Fault
P0238-24 Boosted Air Pressure Sensor High Service
Fault
P0252-00 Rail Pressure Control Error (IMV Service
Current Trim Drift).
P0253-00 Rail Pressure Control By The IMV. Critical
Occurs At High Fuel Delivery For
Low (Negative) Current Trim
P0254-00 Rail Pressure Control Fault By The Critical
IMV. Occurs At High Fuel Delivery
For High (Positive) Current Trim
P0261-1A Injector And Wiring Harness Resis- Service
tance Too High/Low (Inj 2)
P0261-1B Injector And Wiring Harness Resis- Service
tance Drop (Inj 2)
tance Drop (Inj 2)
P0263-00 Cylinder Balancing Fault Injector 2 Service
Stuck Closed
tance Drop (Inj 1)
33 - 820 9813/9400-1 33 - 820

90 - Fault Codes

tance Drop (Inj 1)
Stuck Closed
tance Drop (Inj 3)
tance Drop (Inj 3)
Stuck Closed
P0270-1A Injector Drift Fault Detection On In- Service
jector 2. Fault Which Is Set When
Injector 2 MDP Trim Exceeds The
Maximum Calibrated Threshold
Limit. Max Apc Raw Trim At Medi-
um Rail Pressure
P0270-1B Injector Drift Fault Detection On In- Service
The Injector 2 MDP Trim Exceeds
The Maximum Calibrated Thresh-
old Limit. Max Apc Raw Trim At
Low Rail Pressure
tance Drop (Inj 0)
tance Drop (Inj 0)
Stuck Closed
P029A-00 Injector Drift Fault Detection On In- Critical
old Limit. Maximum Apc Raw Trim
At High Rail Pressure
P029B-00 Fault Which Is Set When The In- Critical
jector 3 Absolute MDP Value Is
Below A Calibrated Threshold
P029E-00 Injector Drift Fault Detection On In- Critical
P029F-00 Fault Which Is Set When The In- Critical
P02A2-00 Injector Drift Fault Detection On In- Critical
33 - 821 9813/9400-1 33 - 821

90 - Fault Codes

P02A3-00 Fault Which Is Set When The In- Critical
gine Speed From Engine ECU
P0325-00 Accelerometer Fault (Signal/Noise Trivial
Ratio Too Low In Idle)
P0330-00 Trivial
P0335-31 Trivial
P0340-54 Cam Signal Last Learnt Value Is Service
Outside Of Limits
P0341-00 Cam Signal Drift Higher Than Service
Threshold
P0341-2F Trivial
P0341-31 Cam Signal Lost (No Cam Signal Service
Seen In 2 Crank Rotations)
P0341-31 Cam Signal Fault (Missing Event Service
Within The Expected Window)
P0341-85 Cam Signal Fault (Overspeed De- Critical
tected)
P0350-02 Error Monitoring For System Pro- Operator
tection Based On Ignition Switch
Input
P0371-00 Crank Signal Is Too Close To The Service
Previous One
P0372-31 Elapsed Time Between Cps Service
Events Is Too High
P0374-31 Crank Signal Lost (No Cps Signal Service
Seen In 1 Cam Rotation)
P0380-00 Trivial
P0380-13 Trivial
P0383-11 Trivial
P0384-12 Trivial
P0400-00 EGR (Exhaust Gas Recirculation) Service
Flow Reached Its Limit
P0404-00 EGR Valve Control Fault Trivial
P0404-23 Trivial
P0406-23 Trivial
P0470-00 Exhaust Manifold Pressure (P3) Service
Signal ADC Fault
Signal Low Fault
Signal High Fault
P0504-08 Park Brake Switch Plausibly Error Operator
33 - 822 9813/9400-1 33 - 822

90 - Fault Codes

P0504-08 Foot Brake Switch Plausibly Error Operator
P0520-00 Low Oil Pressure Lamp/Gauge Dri- Trivial
ve Short Circuit (SC)
P0520-11 Low Oil Pressure Lamp/Gauge Trivial
Drive Short Circuit To Ground
(SC2Gnd)
ve Short Circuit To Battery Voltage
(SC2Vbatt)
ve Open Circuit (OC)
P0521-00 Oil Pressure Sensor Signal Global Critical
Fault
P0522-23 High Oil Pressure During Engine Critical
Running
P0523-23 Engine Oil Pressure Low - Critical
P0523-24 Engine Oil Pressure Sensor Fault Critical
(High Voltage Fault)
P0523-24 Low Oil Pressure During Engine Critical
Running
P0544-00 Turbo In Temperature Fault Service
P0545-23 Turbo In Temperature Count Low Service
Fault
P0546-24 Turbo In Temperature Count High Service
Fault
P0562-02 Fault Due To Low Or High Battery Operator
Voltage Supply To DCU
P0562-16 Low Battery Voltage Operator
P0563-17 High Battery Voltage Operator
P0563-24 Battery Voltage Monitoring Signal Service
High Fault
P0566-00 Cruise Switch Off Function Fault Trivial
Detected
P0567-00 Cruise Switch Resume Function Trivial
Fault Detected
P0569-00 Cruise Switch Decelerate Function Trivial
Fault Detected
P0570-00 Cruise Switch Accelerate Function Trivial
Fault Detected
P0575-00 Cruise Switch ADC Fault Detected Trivial
P0602-00 Trivial
P0602-45 Trivial
P0602-47 Trivial
P0602-56 Functional Safety Fault Critical
P0603-00 ECU Memory Integrity Fault (Data / Critical
Cal Integrity)
P0604-00 ECU Memory Integrity Fault (Ram Critical
Integrity)
33 - 823 9813/9400-1 33 - 823

90 - Fault Codes

P0605-00 ECU Memory Integrity Fault (Code Critical
Integrity)
P0606-02 Peripheral Monitoring Error On Operator
DCU
P0607-4B Throttle H-Bridge Driver In ECU Service
Fault: Over Temperature
P060A-00 Functional Safety Fault Critical
P060A-00 Monitoring Error On DCU Operator
P060B-00 ADC Circuit Fault (Global) Critical
P060B-16 Functional Safety Fault Critical
P060C-00 Functional Safety Fault Critical
P060C-00 DCU Software Reset Performed Operator
P060C-41 Monitoring Error On DCU Operator
P060C-F0 Functional Safety Fault Critical
P060D-00 Functional Safety Fault Critical
P060E-00 Functional Safety Fault Critical
P0612-11 Trivial
P0612-12 Trivial
P0612-13 Charge Circuit Fault ?Bank 2? Trivial
P0612-31 Trivial
P0615-13 Trivial
P0616-11 Trivial
P0617-12 Trivial
P0627-13 Lift Pump Global Fault Service
P062D-11 Injector Bank 0 Fault Shorted To Critical
Ground (SC2Gnd)
33 - 824 9813/9400-1 33 - 824

90 - Fault Codes

Ground (SC2Vbat)
P062E-11 Injector Bank 1 Fault Shorted To Critical
Ground (SC2Gnd)
Ground (SC2Vbat)
P062F-00 ECU Non Volatile Memory Fault Service
P0630-00 Trivial
P0641-00 ECU Internal 5V Supply 1 Fault Critical
P0641-4B ECU Internal 5V Supply 1 Fault Critical
P064F-13 Check Engine Lamp Fault Trivial
P0650-00 Trivial
P0650-11 Trivial
P0650-13 Check Engine Lamp Fault Trivial
P0658-14 Short Circuit To Ground Of Actua- Operator
tor Relay 1
P0659-12 Short Circuit To Battery Of Actuator Operator
Relay 1
P0668-23 ECU Internal Temperature Sensor Service
Low Fault
High Fault
P0685-00 Main ECU Relay Stuck Critical
P0686-72 Main Relay System Fault (Open) Trivial
P0697-00 Trivial
P0697-4B ECU Internal 5V Supply 2 Auxillary Critical
Fault
P06A7-00 Sensor Supply Monitoring Error Operator
Through DCU
P0711-21 Transmission Fluid Temperature Operator
Sensor Electrical Fault
P0712-13 Transmission Temp OORL Operator
P0713-17 Transmission Temp OORH Operator
P0714-1F Transmission Fluid Temperature Operator
P0716-16 Out Of Range. Shorted To Low Operator
Source
P0716-17 Short Circuit To Supply Operator
P0716-29 Change In Speed Greater Than Operator
Plausible (Possible Trans Lock)
P0716-64 Trans Input Speed Plausibility Operator
Check Failure, High Value Error In
Range
Check Failure, Low Value Error In
Range
33 - 825 9813/9400-1 33 - 825

90 - Fault Codes

P0716-64 Speed Sensor Fault. Operator
P0717-13 Trans Input Speed Sensor Input Operator
Open Circuit. Sensor Not Present,
Failure In Supply Or Short To
Ground.
P0718-1F Intermittent Wiring Fault Or Noisy Operator
Speed Signal
P0720-13 Sensor Not Present, Failure In Operator
Supply Or Short To Ground.
Source
P0721-16 Speed Sensor OORL Trivial
P0721-17 Speed Sensor OORH Trivial
P0721-64 Trans Output Speed Plausibility Operator
Range
Range
Speed Signal
Source
Plausible (Possible Engine Stall)
P0726-64 Engine Speed Plausibility Check Operator
Failure, High Value Error In Range
Failure, Low Value Error In Range
P0727-13 Engine Speed Sensor Input Open Operator
Circuit. Sensor Not Present, Fail-
ure In Supply Or Short To Ground.
P0727-87 Engine CAN Data Not Available Operator
Or In Error / Implausible (Engine
Speed)
Speed Signal
P0729-17 Speed Sensor 2 OORH Trivial
P072A-16 Speed Sensor 2 OORL Trivial
P072B-64 Speed Sensor Disagreement Trivial
P0741-00 Luc Control Error Operator
P0746-13 Forward Low Solenoid Open Operator
P0746-13 T Solenoid Open Circuit. Solenoid Operator
Not Present Or Short To Ground.
P0747-15 Forward Low Solenoid STB Operator
P0747-15 T Solenoid Short Circuit To Supply Operator
33 - 826 9813/9400-1 33 - 826

90 - Fault Codes

P0748-14 Forward Low Solenoid STG Operator
P0748-14 T Solenoid Out Of Range. Shorted Operator
To Low Source
P0748-18 T Solenoid Current Feedback Be- Operator
low Current Demand
P0748-19 T Solenoid Current Feedback Operator
Above Current Demand
P0749-1F T Solenoid Check Wiring Integrity, Operator
Possible Intermittent Fault
P0776-13 Forward High Solenoid Open Operator
P0776-13 U Solenoid Open Circuit. Solenoid Operator
P0777-15 Forward High Solenoid STB Operator
P0777-15 U Solenoid Short Circuit To Supply Operator
P0778-14 Forward High Solenoid STG Operator
P0778-14 U Solenoid Out Of Range. Shorted Operator
To Low Source
P0778-18 U Solenoid Current Feedback Be- Operator
low Current Demand
P0778-19 U Solenoid Current Feedback Operator
P0779-1F U Solenoid Check Wiring Integrity, Operator
P0792-16 Trans Intermediate Speed Plausi- Operator
bility Check Failure, Low Value Er-
ror In Range
bility Check Failure, High Value Er-
ror In Range
ror In Range
ror In Range
P0793-13 Intermediate Shaft Speed Sensor Operator
"A" Circuit No Signal
Speed Signal
P0796-13 Reverse High Solenoid Open Operator
P0796-13 V Solenoid Open Circuit. Solenoid Operator
P0797-15 Reverse High Solenoid STB Operator
P0797-15 V Solenoid Short Circuit To Supply Operator
P0798-14 Reverse High Solenoid STG Operator
P0798-14 V Solenoid Out Of Range. Shorted Operator
To Low Source
P0798-18 V Solenoid Current Feedback Be- Operator
low Current Demand
33 - 827 9813/9400-1 33 - 827

90 - Fault Codes

P0798-19 V Solenoid Current Feedback Operator
P0799-1F V Solenoid Check Wiring Integrity, Operator
P0868-21 Transmission Fluid Pressure Low Operator
P0955-87 Auto Mode Request CAN Data Not Operator
Available Or In Error
P0956-87 Accelerator Pedal Position CAN Operator
Data Not Available Or In Error
P1101-00 Rail Pressure Control Error Posi- Critical
tive Fault
P1102-00 Rail Pressure Control Error Nega- Critical
tive Fault
P1103-00 Rail Pressure Fault Detected - Not Trivial
Able To Maintain Pressure After A
Stop And Start Request
P1104-00 Fault Which Is Set When No MDP Service
Updates Occur On Injector 3 Due
To Environmental Conditions (As
Defined By The Update Strategy)
To A Fault Within The Update
Strategy
Strategy
Strategy
P110A-00 Fault Which Is Set When No MDP Service
P110B-00 Fault Which Is Set When No MDP Service
Strategy
P1400-00 Errorneous Signal From Override Operator
Switch
P1401-00 CAN Bus Message Error From Operator
Override Switch
P1402-00 CAN Bus Off Error From Override Operator
Switch
P1500-00 Foot Pedal Signal Fault Set (Trig- Service
gers Limp Home Mode)
33 - 828 9813/9400-1 33 - 828

90 - Fault Codes

gers Reduced Torque Mode)
P1503-00 Hand Pedal Signal Fault Set (Trig- Service
P1506-00 Pedal Global Limp Home Mode Service
Triggered
P1509-00 CAN Communication Error On Trivial
TSC
P150A-00 Trivial
P1713-87 Kickdown Request CAN Message Operator
Missing Or In Error
P1714-05 Set Up Data Invalid Operator
P1715-07 Transmission Temp High Critical
P1719-13 4WD (Four Wheel Drive) Solenoid Operator
Open Circuit. Solenoid Not Present
Or Short To Ground.
P1719-13 2WD Solenoid Open Trivial
P171A-15 4WD Solenoid Short Circuit To Operator
Supply
P171A-15 2WD Solenoid STB Trivial
P171B-14 4WD Solenoid Out Of Range. Operator
Shorted To Low Source
P171B-14 2WD Solenoid STG Trivial
P171B-14 2WD Solenoid Return STG Trivial
P171B-15 2WD Solenoid Return STB Trivial
P171B-18 4WD Solenoid Current Feedback Operator
Below Current Demand
P171B-18 2WD Solenoid Return Open Trivial
P171C-1F 4WD Solenoid Check Wiring In- Operator
tegrity, Possible Intermittent Fault
P171F-64 Brake Pressure Sensor Electrical Operator
Fault
P1720-64 Brake Pressure Sensor Electrical Operator
Fault
P1721-1F Brake Pressure Sensor Electrical Operator
Fault
Fault
Fault
Fault
Fault
33 - 829 9813/9400-1 33 - 829

90 - Fault Codes

P1726-19 Reverse Alarm Open Circuit. So- Operator
lenoid Not Present Or Short To
Ground.
P1727-18 Reverse Alarm Solenoid Short Cir- Operator
cuit To Supply
P1728-1F Reverse Alarm Solenoid Current Operator
Feedback Above Current Demand
P1729-15 Reverse Alarm Solenoid Current Operator
Feedback Below Current Demand
P172A-14 Reverse Alarm Solenoid Out Of Operator
Range. Shorted To Low Source
P172B-13 Reverse Alarm Solenoid Check Operator
Wiring Integrity, Possible Intermit-
tent Fault
P172C-00 Transmission Control Fault Operator
P172D-00 Transmission Control Fault Operator
P172E-00 Transmission Control Fault Operator
P172F-00 Transmission Control Fault Operator
P1730-00 Transmission Control Fault Operator
P1731-87 Driver OCcupancy CAN Message Operator
Missing Or In Error
P2000-00 Actual Average Conversion Effi- Operator
ciency Is Below The Threshold
P202A-13 Open Load Error Of Urea Tank Operator
Heater Actuator Powerstage
P202B-14 Error For Short To Ground Of Urea Operator
Tank Heater Actuator Powerstage
P202C-15 Error For Short To Battery Of Urea Operator
P202E-00 Error On Dosing Valve Short Cir- Operator
cuit
P202E-02 Error On Dosing Valve Plausibility Operator
cuit To Battery
cuit To Battery On High Side Or
Open Load
P202E-14 Error On Dosing Valve Short To Operator
Ground Or Open Circuit
At Low Voltage
P202E-4B Error On Dosing Valve Driver Operator
Overtemperature
P203B-00 Tank Level Signal Error. Operator
P203B-14 Urea Tank Level Signal Is Below Operator
Minimum Voltage Limit
P203B-15 Urea Tank Level Signal Is Above Operator
Maximum Voltage Limit
33 - 830 9813/9400-1 33 - 830

90 - Fault Codes

P203B-16 Error On Tank Level Plausibility Operator
P203B-22 Tank Head Unit Level Physical Sig- Operator
nal Above Maximum Limit
P203B-81 CAN Bus Message Error From Operator
Headunit
P203B-86 CAN Bus Message Error For Tank Operator
Level From Head Unit
P203B-87 CAN bus Off Error From Headunit Operator
P203F-21 Tank Head Unit Level Physical Sig- Operator
nal Below Minimum Limit
P203F-68 Reagent Tank Level Low And Be- Operator
low Warning Threshold
P203F-7B Reagent Tank Level Low And Operator
Empty
Headunit
P2043-86 Adblue Temperature Message Er- Operator
ror From Headunit
P2043-87 CAN bus Off Error From Headunit Operator
P204B-00 Error While Monitoring The Stabili- Operator
sation Of Pressure
P204B-02 Error On Pressure Line & Dosing Operator
Valve While Monitoring For BLock-
age
P204B-16 Measured Value Of Pressure Sen- Operator
sor Below The Tolerable Limit
sor Above The Tolerable Limit
P204B-26 Error On Rate Of Pressure Reduc- Operator
tion
P204B-29 Error On Pressure Line While Mon- Operator
itoring For BLockage
P204B-61 Error While Monitoring Of Pressure Operator
Buildup
P204C-16 Pump Pressure Signal Below The Operator
P204C-21 Error For Pump Pressure Physical Operator
Signal Below Lower Limit
P204D-17 Pump Pressure Signal Above The Operator
P204F-06 Error To Detect The Clogged Filter Operator
P204F-7A Error To Detect Leakage During No Operator
Dose
P204F-9A Inducement Repeat Offence Active Critical
P205B-00 Error To Indicate Overheating Of Operator
Adblue Tank
P205B-06 Error In Increase Of Urea Tank Operator
Temperature
P205B-16 Tank Head Unit Temperature Operator
Physical Signal Below Minimum
Limit
Physical Signal Above Maximum
Limit
33 - 831 9813/9400-1 33 - 831

90 - Fault Codes

P205B-23 Error On Tank Temperature Sen- Operator
sor Plausibility Below Minimum
Threshold
sor Plausibility Exceeds Maximum
Threshold
P205C-16 Tank Temperature Signal Voltage Operator
Below Minimum Limit
P205D-17 Tank Temperature Signal Voltage Operator
Above Maximum Limit
P205E-81 Tank Temperature Signal Error On Operator
CAN
P205E-87 CAN Bus Message Error For Tank Operator
Temperature From Head Unit
P207F-00 Ad Blue Quality Error During Refill Operator
Conditiion
P207F-86 Adblue Concentration Message Er- Operator
ror From Headunit
P207F-87 Adblue Quality Message Error Operator
From Headunit
P2080-2F Turbo In Temperature Count Noise Service
Fault
P208A-13 Open Load Error Of Supply Mod- Operator
ule Pump Motor
P208A-31 Supply Module Pump Feedback Operator
Error
P208B-02 Error On Supply Module Pump Operator
Speed Permanent Deviation
P208B-21 Supply Module Internal Dutycycle Operator
Below Min Range
In Invalid Range
P208B-4B Overtemperature Error Of Supply Operator
Module Pump Motor
Speed Deviation
P208B-84 Supply Module Motor Speed Duty Operator
Cycle Below Minimum Range
Cycle Above Maximum Range
P208C-14 Short Circuit To Ground Error Of Operator
Supply Module Pump Motor
P208D-13 Short Circuit To Battery Error Of Operator
P209F-4B Error For Overtemperature Of Urea Operator
P20A0-13 Open Load Error Of Backflow Operator
Pump Actuator Powerstage
P20A1-4B Error For Overtemperature Of Operator
Backflow Pump Actuator Power-
stage
P20A2-14 Error For Short To Ground Of Operator
stage
33 - 832 9813/9400-1 33 - 832

90 - Fault Codes

P20A3-13 Error For Short To Battery Of Back- Operator
flow Pump Actuator Powerstage
P20AD-06 Error On Supply Module Tempera- Operator
ture
P20AD-21 Supply Module Temperature Duty Operator
ture Cold Start
P20B5-13 Open Load Error Of Supply Mod- Operator
ule Heater Actuator Powerstage
P20B6-21 Supply Module Heater Tempera- Operator
ture Duty Cycle Below Minimum
Range
ture Duty Cycle Above Maximum
Range
P20B6-4B Error For Overtemperature Of Sup- Operator
ply Module Heater Actuator Power-
stage
P20B7-14 Error For Short To Ground Of Sup- Operator
stage
P20B8-15 Error For Short To Battery Of Sup- Operator
stage
P20B9-00 Error For Open Load On Heater Operator
Relay Of Backflow Line
P20B9-13 Open Load Error Of Urea Back- Operator
flowline Heater Actuator Power-
stage
P20BA-4B Error For Overtemperature Of Urea Operator
Backflowline Heater Actuator Pow-
erstage
P20BB-00 Error For Short To Ground Or Operator
Open Load On Heater Relay Of
Backflow Line
P20BB-14 Error For Short To Ground Of Urea Operator
erstage
P20BC-15 Error For Short To Battery Of Urea Operator
erstage
P20BD-00 Error For Open Load On Heater Operator
Relay Of Pressure Line
P20BE-00 Error On Supply Module Heater Operator
Temperature Sensor
Temperature Cold Start
P20BE-13 Error On Realys For Short To Bat- Operator
tery
33 - 833 9813/9400-1 33 - 833

90 - Fault Codes

P20BE-4B Error For Overtemperature Of Urea Operator
Pressureline Heater Actuator Pow-
erstage
P20BE-93 Error On Pressure Line To Perform Operator
Afterrun
P20BF-00 Error For Short To Ground Or Operator
Pressure Line
P20BF-14 Error For Short To Ground Of Urea Operator
erstage
P20C0-15 Error For Short To Battery Of Urea Operator
erstage
P20C1-00 Error For Open Load On Heater Operator
Relay Of Suction Line
P20C1-13 Open Load Error Of Urea Suction- Operator
line Heater Actuator Powerstage
P20C2-4B Error For Overtemperature Of Urea Operator
Suctionline Heater Actuator Power-
stage
P20C3-00 Error For Short To Ground Or Operator
Suction Line
P20C3-14 Error For Short To Ground Of Urea Operator
stage
stage
P20E8-84 Underpressure Error In Metering Operator
Control State
P20E9-00 Overpressure Error Regardless Of Operator
Supply Module State
P20E9-85 Overpressure Error In Metering Operator
Control State
P20EA-72 DCU Relay Early Opening Operator
P20EB-71 DCU Relay Stuck Operator
P2100-02 Throttle H-Bridge Driver In ECU Service
Fault: Undervoltage
Fault: OC
Fault: Current Limited
Fault: SC
Fault: SC2G
Fault: SC2Vbatt
P2119-00 Throttle Learning Position Fault S0 Service
P2120-00 Hand Pedal Signal Track 1 Fault Service
33 - 834 9813/9400-1 33 - 834

90 - Fault Codes

P2135-00 Foot Pedal Corrolation Track 1 Service
Over Track 2 Fault Detected
P2138-00 Hand Pedal Signal Corrolation Service
Fault
P2146-00 Injector Supply Voltage Faulty Trivial
P219D-13 Open Load Error Of Urea Heater Operator
Relay Actuator Powerstage
P219D-4B Error For Overtemperature Of Urea Operator
Heater Relay Actuator Powerstage
P219E-13 Error For Short To Battery Of Urea Operator
P219F-14 Error For Short To Ground Of Urea Operator
P21A9-12 Short Circuit To Battery Of Actuator Operator
Relay 4
P21AB-14 Short Circuit To Ground Of Actua- Operator
tor Relay 4
P2200-00 Upstream NOx (Nitrogen Oxide) Operator
Sensor Wire Diagnosis-Error In
Voltage Supply
P2200-02 Upstream NOx Sensor Short Cir- Operator
cuit To Gnd Or Batt
P2200-05 Upstream NOx Sensor Self Diag- Operator
nostic
P2200-11 Lambda Signal Below Minimum Operator
For Upstream NOx Sensor
P2200-12 Lambda Signal Above Maximum Operator
Limit For Upstream NOx Sensor
P2200-13 Upstream NOx Sensor Open Cir- Operator
cuit
P2200-61 Invalid Signal From Upstream NOx Operator
Sensor After Heater Release
nostic Timeout
nostic Abort
P2201-00 Downstream NOx Sensor Wire Di- Operator
agnosis-Error In Voltage Supply
P2201-06 Downstream NOxSensor Self Di- Operator
agnostic
Limit For Downstream NOx Sensor
Limit For Downstream NOx Sensor
P2201-13 Downstream NOx Sensor Open Operator
Circuit
P2201-16 Downstream NOx Offset Min Error Operator
Detection
P2201-17 Downstream NOx Offset Max Error Operator
Detection
P2201-1C Downstream NOx Sensor Short Operator
Circuit To GND Or Batt
33 - 835 9813/9400-1 33 - 835

90 - Fault Codes

P2201-61 Invalid Signal From Downstream Operator
NOx Sensor After Heater Release
P2201-63 Downstream NOx Sensor Self Di- Operator
agnostic Timeout
agnostic Abort
P2202-00 Upstream NOx Sensor Reading Operator
Below Minimum Threshold
P2202-16 Downstream NOx Sensor Reading Operator
Exceeds Above Maximum Thresh-
old
P2203-17 Downstream NOx Sensor Read- Operator
ing Exceeds Abbove Maximum
Threshold
P2208-00 Downstream NOx Sensor Heater Operator
Not Available
Not Heated Quickly
P2209-00 Upstream NOx Sensor Heater Not Operator
Available
Heated Quickly
P2228-23 Atmosp Sensor Low Fault Service
P2229-24 Atmosp Sensor High Fault Service
P2264-00 Water In Fuel Sensor Feedback Service
Signal ADC Fault
Signal 1 Plausability Fault
Signal Low Fault
Signal High Fault
P2275-87 Joystick CAN Data Not Available Operator
Or In Error
P2413-81 CAN Bus Message Error For EGR Operator
Faults From Engine E
gine ECU
P2413-87 Impeded EGR Fault Data Or Bus Operator
Off For EGR Faults From Engine
ECU
P2428-00 Trivial
P2428-17 Exhaust Catalyst Temperature T4 Operator
Limit
P242B-00 Error On SCR Catalyst Upstream Operator
Temperature Sensor Static Plausi-
bility
P242B-16 Error On Catalyst Temperature Operator
Sensor Plausibility Below Min
Threshold
33 - 836 9813/9400-1 33 - 836

90 - Fault Codes

Sensor Plausibility Above Max
Threshold
P242B-23 Exhaust Catalyst Temperature T4 Operator
Limit
P242C-16 Exhaust Catalyst Temperature T4 Operator
Voltage Signal Below Minimum
Limit
P242D-17 Exhaust Catalyst Temperature T4 Operator
Voltage Signal Above Maximum
Limit
P2502-87 CAN Bus Message Error For Pow- Operator
er Management From Engine ECU
P256A-13 Trivial
P256B-00 Trivial
P256B-23 Trivial
P256B-24 Trivial
P256B-2A Trivial
P256B-64 Trivial
P256C-11 Trivial
P256D-12 Trivial
P2620-00 Throttle Position Feedback ADC Service
Fault
P2620-2F Throttle Position Feedback Signal Service
Noisy Fault
P2621-23 Throttle Position Feedback Signal Service
Low Fault
High Fault
tor Relay 2
Relay 2
tor Relay 3
Relay 3
P2714-13 Reverse Low Solenoid Open Operator
P2714-13 W Solenoid Open Circuit. Solenoid Operator
P2715-15 Reverse Low Solenoid STB Operator
P2715-15 W Solenoid Short Circuit To Supply Operator
P2716-14 Reverse Low Solenoid STG Operator
P2716-14 W Solenoid Out Of Range. Shorted Operator
To Low Source
P2716-18 W Solenoid Current Feedback Be- Operator
low Current Demand
P2716-19 W Solenoid Current Feedback Operator
P2717-1F W Solenoid Check Wiring Integrity, Operator
33 - 837 9813/9400-1 33 - 837

90 - Fault Codes

P2723-13 X Solenoid Open Circuit. Solenoid Operator
P2724-15 X Solenoid Short Circuit To Supply Operator
P2725-14 X Solenoid Out Of Range. Shorted Operator
To Low Source
P2725-18 X Solenoid Current Feedback Be- Operator
low Current Demand
P2725-19 X Solenoid Current Feedback Operator
P2726-1F X Solenoid Check Wiring Integrity, Operator
P2732-13 Mainshaft Solenoid Open Operator
P2732-13 Y Solenoid Open Circuit. Solenoid Operator
P2733-15 Mainshaft Solenoid STB Operator
P2733-15 Y Solenoid Short Circuit To Supply Operator
P2734-14 Mainshaft Solenoid STG Operator
P2734-14 Y Solenoid Out Of Range. Shorted Operator
To Low Source
P2734-18 Y Solenoid Current Feedback Be- Operator
low Current Demand
P2734-19 Y Solenoid Current Feedback Operator
P2735-1F Y Solenoid Check Wiring Integrity, Operator
P2757-13 Luc Solenoid Open Circuit. So- Operator
Ground.
P2758-15 Luc Solenoid Short Circuit To Sup- Operator
ply
P2759-14 Luc Solenoid Out Of Range. Short- Operator
ed To Low Source
P2759-18 Luc Solenoid Current Feedback Operator
P2760-1F Luc Solenoid Check Wiring Integri- Operator
ty, Possible Intermittent Fault
P2779-87 Joystick CANData Not Available Or Operator
In Error
33 - 838 9813/9400-1 33 - 838

90 - Fault Codes

P2793-64 Requested Gear CAN Data Not Operator
P2793-64 Joystick N Switch Fault Operator
P2793-64 Joystick R Switch Fault Operator
P2793-64 Joystick F Switch Fault Operator
P2793-64 Column Lever Forward Switch Operator
Fault
P2793-64 Column Lever Neutral Switch Fault Operator
P2793-64 Column Lever Reverse Switch Operator
Fault
P2793-64 Gear Selection OOR Operator
P2793-87 Requested Gear CAN Data Not Operator
Fault
Fault
Fault
Fault
P2807-13 Layshaft Solenoid Open Operator
P2808-13 Z Solenoid Open Circuit. Solenoid Operator
P2808-15 Layshaft Solenoid STB Operator
P2809-15 Z Solenoid Short Circuit To Supply Operator
P280F-14 Layshaft Solenoid STG Operator
P2810-14 Z Solenoid Out Of Range. Shorted Operator
To Low Source
P2810-18 Z Solenoid Current Feedback Be- Operator
low Current Demand
P2810-19 Z Solenoid Current Feedback Operator
P2811-13 Forward Reverse Solenoid Return Operator
Open
P2811-1F Z Solenoid Check Wiring Integrity, Operator
STG
STB
P2814-13 Mainshaft Layshaft Solenoid Re- Operator
turn Open
33 - 839 9813/9400-1 33 - 839

90 - Fault Codes

turn STG
turn STB
P2A00-00 Upstream NOx Sensor Not Mount- Operator
ed Or Loose
P2A01-00 Downstream NOx Sensor Not Operator
Mounted Or Loose
P2BA7-68 Level Level 2 Enacted Critical
P2BA7-92 Level Level 1 Enacted Service
P2BA7-94 Level Level 1 Requested Service
P2BA7-9A Level Level 3 Enacted Critical
P2BA7-F0 Level Level 2 Requested Critical
P2BA8-00 Interruption Warning Requested Operator
P2BA8-68 Interruption Level 2 Enacted Critical
P2BA8-92 Interruption Level 1 Enacted Service
P2BA8-94 Interruption Level 1 Requested Service
P2BA8-9A Interruption Level 3 Enacted Critical
P2BA8-F0 Interruption Level 2 Requested Critical
P2BA9-00 Quality Warning Requested Operator
P2BA9-68 Quality Level 2 Enacted Critical
P2BA9-92 Quality Level 1 Enacted Service
P2BA9-94 Quality Level 1 Requested Service
P2BA9-9A Quality Level 3 Enacted Critical
P2BA9-F0 Quality Level 2 Requested Critical
P2BAA-00 Consumption Warning Requested Operator
P2BAA-68 Consumption Level 2 Enacted Critical
P2BAA-92 Consumption Level 1 Enacted Service
P2BAA-94 Consumption Level 1 Requested Service
P2BAA-9A Consumption Level 3 Enacted Critical
P2BAA-F0 Consumption Level 2 Requested Critical
P2BAB-00 EGR Warning Requested Operator
P2BAB-68 EGR Level 2 Enacted Critical
P2BAB-92 EGR Level 1 Enacted Service
P2BAB-94 EGR Level 1 Requested Service
P2BAB-9A EGR Level 3 Enacted Critical
P2BAB-F0 EGR Level 2 Requested Critical
P2BAD-00 Inducement Override Active Operator
P2BAD-16 Undershoot The Limit Value Of Operator
Long Term Adaptation Factor
P2BAD-17 Exceeded The Limit Value Of Long Operator
Term Adaptation Factor
P2BAD-68 Inducement Level 2 Is Active Due Operator
To Repeat Offense Error
33 - 840 9813/9400-1 33 - 840

90 - Fault Codes

P2BAD-9A Inducement Level 3 Is Active Due Operator
P2BAE-00 Driver Warning For System Tam- Operator
pering
P2BAE-68 System Tampering Level 2 Enact- Critical
ed
P2BAE-92 System Tampering Level 1 Enact- Service
ed
P2BAE-94 System Tampering Level 1 Re- Service
quested
P2BAE-9A System Tampering Level 3 Enact- Critical
ed
P2BAE-F0 System Tampering Level 2 Re- Critical
quested
quested
P3401-87 Excessive Ambient/Operating Operator
Temperature Error For Aftertreat-
ment 1 SCR Catalyst Reagent
Property
P3402-87 Concentration Too High For Af- Operator
tertreatment 1 SCR Catalyst
Reagent Properties
P3403-87 Concentration Too Low For Af- Operator
Reagent Properties
Property
P3405-87 Temperature Too High For Af- Operator
Reagent Properties
P3406-87 Temperature Too Low For Af- Operator
Reagent Properties
P3407-87 Sensor Open Circuit Error Af- Operator
Reagent Temperature
P3408-87 Sensor Short Circuit Error Af- Operator
Reagent Temperature
P3409-87 Excessive Ambient/Operating Lev- Operator
el Error For Aftertreatment 1 SCR
Catalyst Reagent Property
P3410-87 Level Too High For Aftertreatment Operator
1 SCR Catalyst Reagent Proper-
ties
P3411-87 Level Too Low For Aftertreatment 1 Operator
SCR Catalyst Reagent Properties
P3412-87 Tank Level Open Circuit Error Operator
Aftertreatment 1 SCR Catalyst
Reagent Temperature
33 - 841 9813/9400-1 33 - 841

90 - Fault Codes

P3413-87 Tank Level Short Circuit Error Operator
Reagent Temperature
P3414-87 Errorneous Signal For Engine Operator
Boost Pressure
P3415-87 Data Length Error For Ic1 Frame Operator
P3416-87 Time Out Error For Ic1 Frame Operator
P3417-87 Erroneous Signal For Intake Mani- Operator
fold Temperature
P3418-87 Erroneous Signal For Operating Operator
Mode Request
P3419-87 Error For Particulate Inlet Pressure Operator
P3420-87 Data Length Error For ProSCR3 Operator
Frame Received For Regeneration
P3421-87 Timeout Error For ProSCR3 Frame Operator
Received For Regeneration
P3422-87 Erroneous Signal For Soot Load Operator
Message
P3423-87 Erroneous Signal For Engine Ex- Operator
haust Gas Temperature.
P3424-85 SCR Partially Blocked (Over- Trivial
loaded)
P3425-85 SCR Fully Blocked (Plugged) Operator
RECOVERY Manplatform Rapid Recovery Ac- Critical
tive
RPM Crank Signal Overspeed Fault Operator
SERVICE Service Interval Elapsed Service
SERVICE Vehicle Serviced - Trivial
U0029-87 CAN bus Off Error 250Kbps Operator
U0029-88 CAN bus Off Error 250Kbps Operator
U0105-87 CAN Bus Message Error For Fuel Operator
Qnty From Engine ECU
U010A-08 CAN Communication Error: EGR- Service
CAN Fault
U010C-88 Trivial
U010E-08 Engine Rating To Service
U010E-87 Inducement Bam To Service
U0140-87 Cm1 Message Timeout Operator
U0401-61 CAN Bus Message Error For Mod- Operator
elled NOx From Engine ECU
U0401-81 CAN Bus Message Error From En- Operator
gine ECU
U0401-86 CAN Bus Message Error From En- Operator
gine ECU
U0401-87 CAN bus Off Error From Engine Operator
ECU
U040B-00 Trivial
U040B-4B CAN Communication Error: EGR Service
Overtemperature
U040B-96 Trivial
U040B-97 CAN Communication Error: EGR Service
Obstruction
33 - 842 9813/9400-1 33 - 842

90 - Fault Codes

U040B-98 CAN Communication Error: EGR Service
Overtemperature
U040D-00 Trivial
U040D-54 CAN Communication Error: Vgt Service
Spanlearn
Hardware
U040D-97 Trivial
Overtemperature
U040D-9A Trivial
U040F-81 Engine Rating Mismatch Service
U059E-00 CAN Bus Message Error For Temp Operator
Signal Status From Downstream
NOx Sensor
U059E-02 CAN Bus Message Error For No2 Operator
Level From Upstream NOx Sensor
U059E-08 CAN Bus Message Error For O2 Operator
Signal Status From Upstream NOx
Sensor
U059E-29 CAN Bus Message Error From Up- Operator
stream NOx Sensor
U059E-62 CAN Bus Message Error For Nh3 Operator
U059E-81 CAN Bus Message Error From Up- Operator
stream NOx Sensor
U059E-84 CAN Bus Message Error For Pow- Operator
er Signal Status From Upstream
NOx Sensor
U059E-86 CANBus Message Error From Up- Operator
stream NOx Sensor
U059E-87 CAN bus Off Error From Upstream Operator
NOx Sensor
U059E-93 CAN Bus Message Error For NOx Operator
U059E-94 CAN Bus Message Error For O2 Operator
U059E-97 CAN Bus Message Error For NOx Operator
Sensor
U059E-9A CAN Bus Message Error For Operator
Heater Ratio From Upstream NOx
Sensor
U059F-00 CAN Bus Message Error For Temp Operator
Sensor
U059F-02 CAN Bus Message Error For No2 Operator
Level From Downstream NOx Sen-
sor
U059F-08 CAN Bus Message Error For O2 Operator
NOx Sensor
U059F-29 CAN Bus Message Error From Operator
Downstream NOxSensor
33 - 843 9813/9400-1 33 - 843

90 - Fault Codes

U059F-62 CAN Bus Message Error For Operator
Nh3Level From Downstream NOx
Sensor
Downstream NOx Sensor
U059F-84 CAN Bus Message Error For Pow- Operator
er Signal Status From Downstream
NOx Sensor
U059F-87 CAN bus Off Error From Down- Operator
stream NOx Sensor
U059F-93 Can Bus Message Error For NOx Operator
sor
U059F-94 CAN Bus Message Error For O2 Operator
sor
U059F-97 CAN Bus Message Error For NOx Operator
NOx Sensor
U059F-9A CAN Bus Message Error For Operator
Heater Ratio From Downstream
NOx Sensor
U1501-88 Engine CAN Fault Trivial
U1501-88 Engine CAN Fault Trivial
U1502-88 Transmission CAN Fault Trivial
U1502-88 Transmission CAN Fault Trivial
U1503-88 Joystick CAN Fault Trivial
U1503-88 Joystick CAN Fault Trivial
U1504-88 Hydraulics Controller CAN Fault Critical
U1505-88 Machine Controller CAN Fault Trivial
U1506-88 Telematics CAN Fault Trivial
U1507-88 Immobilizer CAN Fault Trivial
U1508-88 Auxiliary Hydraulics Controller Operator
CAN Fault
U1900-16 Livelink - Vehicle Battery Voltage Trivial
Below Normal
U1901-16 Livelink - Internal Voltage Below Trivial
Normal
U1902-18 Livelink - Telematics Output For Trivial
Relay 0 Current Below Normal Or
Open Circuit
Open Circuit
U1904-85 Livelink - ECU Above Temperature Trivial
Threshold
U1905-84 Livelink - ECU Below Temperature Trivial
Threshold
U1906-96 Livelink - Accelerometer Internal Trivial
Failure
U1907-09 Livelink - Modem Jammed Trivial
U1908-09 Livelink - GPS Antenna Not Ok Trivial
33 - 844 9813/9400-1 33 - 844

90 - Fault Codes

U1909-96 Livelink - No Comms With GPS Trivial
Module
U190A-09 Livelink - Sim Card Failure Trivial
U190B-96 Livelink - No Comms With GSM Trivial
Module
U190C-86 Livelink - GSM Network Registra- Trivial
tion Failure
U1910 -16 Relay 1 Failure - No Voltage De- Trivial
tected When Relay On
U1910 -17 Relay 1 Failure - Voltage Detected Trivial
When Relay Off
When Relay Off
When Relay Off
U1913 -84 Supply Voltage Below Normal Trivial
U1913 -85 Supply Voltage Above Normal (? Trivial
32V)
U1915 -56 Transponder Key - Invalid Key De- Trivial
tected
U1915 -9 Transponder Key - Antenna Fault Trivial
U1916 -85 Key / Keypad Code - Memory Full Trivial
U1917 -2f Engine - Communications Fault Trivial
U1917 -4 Engine - Error State Trivial
U1917 -87 Engine - No Communication Trivial
U1917 -96 Engine - Disarm Failure Trivial
U1918 -96 Immobiliser Internal Fault Trivial
WARNING Abuse Level 2 Operator
WIF Water In Fuel Sensor Feedback Operator
Signal Setting Fault
Z111 Error Logs Full - Trivial
Z200 Errors Logs Erased - Trivial
Table 685. DTVT Transmission Machines

Fault Code Description Severity
P0404-23 Trivial
7F0E6-3 Extend Boost Solenoid STB Operator
7F0E6-4 Extend Boost Solenoid STG Operator
7F0E6-5 Extend Boost Solenoid Open Operator
7F0E8-3 Extend Boost Solenoid Return STB Operator
STG
Open
33 - 845 9813/9400-1 33 - 845

90 - Fault Codes

OOR
Short
Open
Stuck
B104C-67 LLMI Calibration Tip Point Operator
B104D-67 LLMI Calibration Travel Point Operator
B104E-54 LLMI Calibration Required Operator
B104F-49 LLMILED'S Connection Error Operator
B1050-29 LLMI Calibration Error Operator
B1051-46 LLMI Eeprom Store Error Operator
B1052-46 LLMI Eeprom Read Error Operator
B1053-0 LLMI Valve Application Error Operator
B1054-87 LLMICAN No Response Error Operator
B1055-16 LLMI Low Voltage Error Operator
B1056-17 LLMI High Voltage Error Operator
B1057-47 LLMI Pic Comms Error Operator
B1058-24 LLMI Override Mode Error Operator
B1059-62 LLMI Cross Checking Error Operator
B1500-64 SRS Switch Short Trivial
B1501-1C SRS Switch OOR Trivial
B1502-13 Hydraulic Lock Switch Open Trivial
B1503-64 Hydraulic Lock Switch Short Trivial
B1504-1C Hydraulic Lock Switch OOR Trivial
B1505-1C Sway Switch OOR Trivial
B1506-64 Sway Switch Short Trivial
B1507-13 Stabilizer Isolation Switch Open Trivial
B1508-64 Stabilizer Isolation Switch Short Trivial
B1509-1C Stabilizer Isolation Switch OOR Trivial
B150A-1C Ext_Aux2B_Sw_OOR Trivial
B150B-1C Auxa_Auxb_Sw_OOR Trivial
B150C-1C Ret_Aux2A_Sw_OOR Trivial
B150D-13 Column FNR Open Trivial
B150E-64 Column FNR Short Trivial
B150F-64 Steer Mode Sensor Disagreement Trivial
B1514-64 FNR Transmission Monitor Ratio- Trivial
nality Fault
B1515-13 Brake Light Switch Open Trivial
B1516-64 Brake Light Switch Short Trivial
B1517-1C Brake Light Switch OOR Trivial
B1518-13 Park Brake Switch Open Trivial
B1519-64 Park Brake Switch Short Trivial
B151A-1C Park Brake Switch OOR Trivial
33 - 846 9813/9400-1 33 - 846

90 - Fault Codes

B151B-13 2Wd Switch Open Trivial
B151C-64 2Wd Switch Short Trivial
B151D-1C 2Wd Switch OOR Trivial
B151E-13 Drive Control Shutdown Open Trivial
B151F-11 Drive Control Shutdown STG Trivial
B1520-12 Drive Control Shutdown STB Trivial
B1521-1C Footbrake Dump Switch OOR Operator
B1521-1C Footbrake Dump Switch OOR Trivial
B1522-13 Auto Trans Switch Open Trivial
B1523-64 Auto Trans Switch Short Trivial
B1524-1C Auto Trans Switch OOR Trivial
B1525-13 Seat Switch Open Operator
B1525-13 Seat Switch Open Trivial
B1526-64 Seat Switch Short Operator
B1526-64 Seat Switch Short Trivial
B1527-13 Neutral Start Relay Open Operator
B1527-13 Neutral Start Relay Open Trivial
B1528-11 Neutral Start Relay STG Operator
B1528-11 Neutral Start Relay STG Trivial
B1529-12 Neutral Start Relay STB Operator
B1529-12 Neutral Start Relay STB Trivial
B1532-18 5V Supply STG Operator
B1532-18 5V Supply STG Trivial
B1533-17 5V Supply STB Operator
B1533-17 5V Supply STB Trivial
B1534-13 Tilt Lock Switch Open Trivial
B1535-64 Tilt Lock Switch Short Trivial
B1536-1C Tilt Lock Switch OOR Trivial
B1537-64 Constant Auxiliary Set Switch Dis- Trivial
agreement
B1539-13 Constant Auxiliary Enable Switch Trivial
Open
33 - 847 9813/9400-1 33 - 847

90 - Fault Codes

B153A-64 Constant Auxiliary Enable Switch Trivial
Short
B153B-1C Constant Auxiliary Enable Switch Trivial
OOR
B153C-13 Joystick FNR Open Trivial
B153D-64 Joystick FNR Short Trivial
B153F-13 Fuel Level Sensor Open Circuit Trivial
B1541-68 Engine Oil Low When Engine Trivial
Started -
B1542-68 Air Filter Blocked Operator
B1543-4B Coolant Temperature High (Critical Critical
Level)
B1544-14 Coolant Temperature Sensor Short Trivial
B1545-13 Coolant Temperature Sensor Open Trivial
B1546-68 Coolant Temperature High (Opera- Trivial
tor Level)
B1547-68 Coolant Level Low, Engine Run- Trivial
ning
B1548-21 Coolant Level Low, Engine Not Trivial
Started
B1549-21 Ambient Temperature Sensor – Service
OORL
B154B-12 Left Indicator – Short To Battery Trivial
B154C-11 Left Indicator – Short To Ground Trivial
B154D-13 Left Indicator - Bulb Out / Open Trivial
B154E-12 Right Indicator – Short To Battery Trivial
B154F-11 Right Indicator – Short To Ground Trivial
B1550-13 Right Indicator - Bulb Out / Open Trivial
B1551-13 Right Trailer Indicator – Bulb Out / Trivial
Open
B1552-13 Left Trailer Indicator – Bulb Out / Trivial
Open
Battery
Ground
B155A-13 Reversing Fan Output - Open Trivial
B155E-12 Proportional Fan Output – Short To Trivial
Battery
B155F-11 Proportional Fan Output – Short To Trivial
Ground
B1560-13 Proportional Fan Output - Open Trivial
B1561-02 Hvac Switch – OOR Trivial
B1562-12 Hvac Fan Output – Short To Bat- Trivial
tery
B1563-11 Hvac Fan Output – Short To Trivial
Ground
B1564-13 Hvac Fan Output – Open Trivial
B1565-12 A/C Output – Short To Battery Trivial
B1566-11 A/C Output – Short To Ground Trivial
B1567-13 A/C Output – Open Trivial
B1568-12 Wading Output – Short To Battery Trivial
33 - 848 9813/9400-1 33 - 848

90 - Fault Codes

B1569-11 Wading Output – Short To Ground Trivial
B156A-13 Wading Output – Open Trivial
B1578-15 Engine Crank Relay STB Trivial
B1579-14 Engine Crank Relay STG Trivial
B157A-13 Engine Crank Relay Open Trivial
B1583-13 RAL Solenoid Open Operator
B1583-14 RAL Solenoid STG Operator
B1583-15 RAL Solenoid STB Operator
B1583-68 Isolation Valve Stuck Critical
BAD CODE Keypad - Invalid Keypad Code En- Operator
tered
BATTERY Battery Voltage Monitoring Signal Operator
Low Fault
BATTERY Alternator Not Charging Operator
BRAKES Brake Charge Pressure Low, En- Critical
gine Running
BRAKES Brake Charge Pressure Low Trivial
C1019-38 LLMI Transducer 1 Pwm Signal Er- Operator
ror
C101A-29 LLMI Transducer 1 Range Eror Operator
C1500-13 Boom Retracted Switch Open Trivial
C1501-64 Boom Retracted Switch Short Trivial
C1502-1C Boom Retracted Switch OOR Trivial
C1503-07 Boom Retracted Switch Stuck Trivial
C1504-62 Load Moment Indicator Disagree- Operator
ment Fault
C1505-13 Accumulator Solenoid Open Trivial
C1506-11 Accumulator Solenoid STG Trivial
C1507-12 Accumulator Solenoid STB Trivial
C1508-13 Drain Solenoid Open Trivial
C1509-11 Drain Solenoid STG Trivial
C150A-12 Drain Solenoid STB Trivial
C150B-13 Extend Solenoid Open Trivial
C150C-11 Extend Solenoid STG Trivial
C150D-12 Extend Solenoid STB Operator
C150E-13 Retract Solenoid Open Trivial
C150F-11 Retract Solenoid STG Trivial
C1510-12 Retract Solenoid STB Trivial
Open
STG
STB
C1514-13 Auxiliary A Solenoid Open Trivial
C1515-11 Auxiliary A Solenoid STG Trivial
C1516-12 Auxiliary A Solenoid STB Trivial
C1517-13 Auxiliary B Solenoid Open Trivial
C1518-11 Auxiliary B Solenoid STG Trivial
C1519-12 Auxiliary B Solenoid STB Trivial
33 - 849 9813/9400-1 33 - 849

90 - Fault Codes

C151A-13 Auxiliary Changeover Solenoid Trivial
Open
C151B-11 Auxiliary Changeover Solenoid Trivial
STG
C151C-12 Auxiliary Changeover Solenoid Trivial
STB
C151D-46 Eeprom Fault Trivial
C151E-62 Boom Angle Sensor Disagreement Trivial
C151F-23 Boom Angle Sensor 1 OORL Trivial
C1521-23 Boom Angle Sensor 2 OORL Trivial
C1523-13 Hyd Isolate Solenoid Open Trivial
C1524-11 Hyd Isolate Solenoid STG Trivial
C1525-12 Hyd Isolate Solenoid STB Trivial
C1526-23 SRS Pressure Switch OORL Trivial
C1527-24 SRS Pressure Switch OORH Trivial
C1528-62 SRS Pressure Switch Disagree- Trivial
ment
C1529-62 Chassis Angle Sensor Disagree- Trivial
ment
C152A-23 Chassis Angle Sensor 1 OORL Trivial
C152B-24 Chassis Angle Sensor 1 OORH Trivial
C152C-23 Chassis Angle Sensor 2 OORL Trivial
C152D-24 Chassis Angle Sensor 2 OORH Trivial
C152E-62 Lift / Lower Spool Disagreement Trivial
C152F-23 Lift / Lower Spool 1 OORL Trivial
C1531-62 Lift / Lower Spool 2 OORL Trivial
C1533-24 Ext / Retract Spool Disagreement Trivial
C1538-23 Crowd / Dump Spool Disagree- Trivial
ment
C1539-24 Crowd / Dump Spool 1 OORL Trivial
C153A-62 Crowd / Dump Spool 1 OORH Trivial
C153B-23 Crowd / Dump Spool 2 OORL Trivial
C153C-24 Crowd / Dump Spool 2 OORH Trivial
C153D-62 Aux A/B Spool Disagreement Trivial
C153E-23 Aux A/B Spool 1 OORL Trivial
C153F-24 Aux A/B Spool 1 OORH Trivial
C1540-62 Aux A/B Spool 2 OORL Trivial
C1541-23 Aux A/B Spool 2 OORH Trivial
C1542-24 Left Stabilizer Spool Disagreement Trivial
C1543-62 Left Stabilizer Spool 1 OORL Trivial
C1544-23 Left Stabilizer Spool 1 OORH Trivial
33 - 850 9813/9400-1 33 - 850

90 - Fault Codes

C1547-23 Right Stabilizer Spool Disagree- Trivial
ment
C1548-24 Right Stabilizer Spool 1 OORL Trivial
C1549-62 Right Stabilizer Spool 1 OORH Trivial
C154C-13 Sway Isolation Solenoid Open Trivial
C154D-11 Sway Isolation Solenoid STG Trivial
C154E-12 Sway Isolation Solenoid STB Trivial
C154F-13 Stab Isolation Solenoid Open Trivial
C1550-11 Stab Isolation Solenoid STG Trivial
C1551-12 Stab Isolation Solenoid STB Trivial
Open
STG
STB
C1555-13 Sway Right Solenoid Open Trivial
C1556-11 Sway Right Solenoid STG Trivial
C1557-12 Sway Right Solenoid STB Trivial
C1558-13 Sway Left Solenoid Open Trivial
C1559-11 Sway Left Solenoid STG Trivial
C155A-12 Sway Left Solenoid STB Trivial
C155B-13 Motion Cut Valve Ls Open Trivial
C155C-11 Motion Cut Valve Ls STG Trivial
C155D-12 Motion Cut Valve Ls STB Trivial
C155E-62 Left Stabilizer Deployed Sensor Trivial
Disagreement
C155F-23 Left Stabilizer Deployed Sensor Trivial
OORL
C1560-24 Left Stabilizer Deployed Sensor Trivial
OORH
C1561-62 Right Stabilizer Deployed Sensor Trivial
Disagreement
OORL
OORH
OORL
OORH
OORL
OORH
OORL
OORH
C156A-23 Rear Steer Alignment Sensor 2 Trivial
OORL
33 - 851 9813/9400-1 33 - 851

90 - Fault Codes

C156B-24 Rear Steer Alignment Sensor 2 Trivial
OORH
C156C-13 Steer A Solenoid Open Trivial
C156D-11 Steer A Solenoid STG Trivial
C156E-12 Steer A Solenoid STB Trivial
C156F-13 Steer B Solenoid Open Trivial
C1570-11 Steer B Solenoid STG Trivial
C1571-12 Steer B Solenoid STB Trivial
C1572-13 Steer C Solenoid Open Trivial
C1573-11 Steer C Solenoid STG Trivial
C1574-12 Steer C Solenoid STB Trivial
C1575-13 Steer D Solenoid Open Trivial
C1576-11 Steer D Solenoid STG Trivial
C1577-12 Steer D Solenoid STB Trivial
turn Open
turn STG
C157A-12 Drain / Accumulator Solenoid Re- Trivial
turn STB
C157B-13 Steer Solenoid Return Open Trivial
C157C-11 Steer Solenoid Return STG Trivial
C157D-12 Steer Solenoid Return STB Trivial
C157E-11 5V Supply STG Trivial
C157F-12 5V Supply STB Trivial
C1580-07 Boom Movement When Joystick Is Trivial
Neutral (Stuck Spool)
C1581-07 Boom Movement When Lmi Is > Trivial
115%
C1582-87 ECU Pairing Fault Trivial
C1583-68 Tipover Detected Trivial
C1584-56 Drive Control Options Fault Trivial
C1587-16 Brake Charge Pressure OORL Operator
C1588-17 Brake Charge Pressure OORH Operator
C158A-13 Pump Control Solenoid Open Trivial
C158B-11 Pump Control Solenoid STG Trivial
C158C-12 Pump Control Solenoid STB Trivial
C158D-13 Pump Control Solenoid Return Trivial
Open
C158E-18 Pump Control Solenoid Return Trivial
STG
C158F-19 Pump Control Solenoid Return Trivial
STB
C1590-1B Hydraulic Temp OORH Trivial
C1591-1A Hydraulic Temp OORL Trivial
C1592-13 Auxiliary A/B Solenoid Return Trivial
Open
C1593-18 Auxiliary A/B Solenoid Return STG Trivial
C1594-19 Auxiliary A/B Solenoid Return STB Trivial
C1595-13 Raise Solenoid Open Trivial
C1596-11 Raise Solenoid STG Trivial
33 - 852 9813/9400-1 33 - 852

90 - Fault Codes

C1597-12 Raise Solenoid STB Trivial
C1598-13 Lower Solenoid Open Trivial
C1599-11 Lower Solenoid STG Trivial
C159A-12 Lower Solenoid STB Trivial
C159B-13 Crowd Solenoid Open Trivial
C159C-11 Crowd Solenoid STG Trivial
C159D-12 Crowd Solenoid STB Trivial
C159E-13 Dump Solenoid Open Trivial
C159F-11 Dump Solenoid STG Trivial
C15A0-12 Dump Solenoid STB Trivial
C15A1-13 Raise/Lower Solenoid Return Trivial
Open
C15A2-18 Raise/Lower Solenoid Return STG Trivial
C15A3-19 Raise/Lower Solenoid Return STB Trivial
C15A4-13 Crowd/Dump Solenoid Return Trivial
Open
C15A5-18 Crowd/Dump Solenoid Return STG Trivial
C15A6-19 Crowd/Dump Solenoid Return STB Trivial
C15A7-64 Emergency Stop Switch Short Trivial
C15A8-13 Fourth Extension Switch Open Operator
C15A9-64 Fourth Extension Switch Short Operator
C15AA-1E Fourth Extension Switch OOR Operator
C15AB-13 Hydraulic Pin Lock Switch Open Operator
C15AC-64 Hydraulic Pin Lock Switch Short Operator
C15AD-1E Hydraulic Pin Lock Switch OOR Operator
C15AE-13 Hydraulic Venting Switch Open Operator
C15AF-64 Hydraulic Venting Switch Short Operator
C15B0-1C Hydraulic Venting Switch OOR Operator
C15B1-13 Hydraulic Pin Lock Solenoid Open Operator
C15B2-14 Hydraulic Pin Lock Solenoid STG Operator
C15B3-15 Hydraulic Pin Lock Solenoid STB Operator
C15B4-13 Fourth Extension Solenoid Open Operator
C15B5-14 Fourth Extension Solenoid STG Operator
C15B6-15 Fourth Extension Solenoid STB Operator
C15BD-64 Invalid Vin Received Trivial
CLUTCH Service
DEF Level Warning Requested Operator
ENG Lock Engine - Engine ECU LOCkout Trivial
Fault
Fault
HYD TEMP Hydraulic Temp High Critical
IMM Lock Immobiliser LOCkout Trivial
LOW DEF Ad-Blue Level Low - Most Severe Critical
LOW DEF Ad-Blue Level Low - Moderately Operator
Severe
LOW FUEL Low Fuel Level (Operator Level) Operator
LOW FUEL Low Fuel Level (Service Level) Operator
P0001-13 Imv Driver Fault Is Detected Service
33 - 853 9813/9400-1 33 - 853

90 - Fault Codes

P0002-00 Rail Pressure Positive Control Er- Critical
ror During 'Imv-Only' Control. Pid
The Rpc Value
P0002-00 Rail Pressure Negative Control Er- Service
ror During 'Imv-Only' Control. Pid
The Rpc Value
P0002-1A Rail Pressure Control Error (Pres- Service
sure Error Too Low).
P0002-1B Rail Pressure Control Error (Pres- Service
sure Error Too High).
P0003-18 Rail Pressure Control Feedback Critical
Low Error
P0004-19 Rail Pressure Control Feedback Service
High Error
gine ECU
P0070-87 CAN bus Off Error From Engine Operator
ECU
vironment Temperature From En-
gine ECU
P007A-00 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor Fault
(ADC)
P007C-23 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor Low
Fault
P007D-24 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor High
Fault
P007E-2F TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor
Noise Fault
P0087-00 Pressure Limiter Open Critical
P0087-00 Common Rail Pressure Fall (No Critical
Feed)
P0087-00 Rpc Variable Limit Capacity (Vlc) Critical
Torque Reduction Clamped
P0087-00 Rail Pressure Control Error Posi- Service
tive
P0087-00 Rpc Variable Limit Capacity (Vlc) Service
Torque Reduction Above Its
Threshold
P0087-23 Rail Pressure Build Low Fault Critical
P0088-00 Rail Pressure Control Error During Service
Hpv Control (Over Max Calibrated
System Pressure)
P0089-00 Rail Pressure Control Error Critical
P0090-13 Hpv Driver In ECU Fault Detected Service
33 - 854 9813/9400-1 33 - 854

90 - Fault Codes

P0091-11 Pcv 1 Drive System Open Circuit Service
Or Grand Short Circuit
P0091-23 Check Hpv Regulation Control Service
Trim Low
P0092-12 Hpv Driver In ECU Fault Detected Critical
P0092-24 Check Hpv Regulation Control Service
Trim High.
P0095-00 Intake Manifold Temperature (M2) Service
Signal Sensor ADC Fault (Intake
Manifold 2 Temp)
P0096-2F Intake Manifold Temperature Sen- Service
sor (M2) Signal Noise Fault (Intake
Manifold 2 Temp)
sor (M2) Signal Plausibility Fault
sor (M2) Signal Low Fault (Intake
Manifold 2 Temp)
sor (M2) Signal High Signal Fault
P00B7-87 CAN Bus Message Error For Operator
Coolant Sensor From Engine ECU
P0100-00 Amf Fault (Global). Set If Plau, Service
Grad Or Electrical Flt Is Present
P0100-11 Amf High Side Driver Fault Short Service
Circuit To Ground (SC2G)
P0102-23 Maf Low Voltage Fault Service
P0102-23 Amf Electrical Sensor Low Fault Service
P0103-24 Maf High Voltage Fault Service
P0103-24 Amf Electrical Sensor High Fault Service
P0105-00 MAP Sensor Global Fault Service
P0106-23 MAP Sensor Signal Drift Low Fault Service
P0106-24 MAP Sensor Signal Drift High Fault Service
P0106-64 MAP Sensor signal Plausibility Service
Fault
P0110-00 Inlet Air Temperature (Iat) Sensor Service
Signal ADC Fault Detected
Signal Low Fault Detected
Signal High Fault Detected
P0115-00 Coolant Sensor Signal Fault Service
P0116-64 Coolant Sensor Fault (Plausibility) Trivial
P0117-23 Coolant Sensor Signal Low Fault Trivial
P0118-24 Coolant Sensor Signal High Fault Trivial
vironment Pressure From Engine
ECU
P0180-00 Fuel Temperature ADC Fault Service
P0181-27 Fuel Temperature Sensor Fault Service
33 - 855 9813/9400-1 33 - 855

90 - Fault Codes

P0181-27 Fuel Temperature Sensor Gradient Service
Fault
P0181-87 CAN Bus Message Error For Fuel Operator
P0182-23 Fuel Temperature Sensor Low Service
Fault
P0183-24 Fuel Temperature Sensor High Service
Fault
P0190-27 Rail Pressure Sensor Signal Grad Service
Fault
P0191-23 Rail Pressure Sensor Fault. Below Service
Minimum Threshold (Out Of Range
At Key-On)
P0191-24 Rail Pressure Sensor Fault. Above Service
Maximum Threshold (Out Of
Range At Key-On)
P0192-23 Rail Pressure Sensor Signal Low Service
Fault
P0193-24 Rail Pressure Sensor Signal High Service
Fault
P0194-00 Rail Pressure Sensor Signal Drop Critical
Fault
Global Fault
Gradient Fault
Plausability Fault
P0196-87 CAN Bus Message Error For Oil Operator
Low Fault
High Fault
HSD To LSD
P0201-11 Injector 2 Open Circuit Fault (OC) Critical
HSD To LSD
Open Circuit Fault
HSD To LSD
Open Circuit Fault
HSD To LSD
Open Circuit Fault
ture
ture
33 - 856 9813/9400-1 33 - 856

90 - Fault Codes

P0235-00 Boosted Air Pressure Sensor Service
Fault: ADC
P0237-23 Boosted Air Pressure Sensor Low Service
Fault
P0238-24 Boosted Air Pressure Sensor High Service
Fault
P0252-00 Rail Pressure Control Error (Imv Service
Current Trim Drift).
P0253-00 Rail Pressure Control By The Imv. Critical
OCcurs At High Fuel Delivery For
Low (Negative) Current Trim
P0254-00 Rail Pressure Control Fault By The Critical
Imv. OCcurs At High Fuel Delivery
For High (Positive) Current Trim
tance Drop (Inj 2)
tance Drop (Inj 2)
Stuck Closed
tance Drop (Inj 1)
tance Drop (Inj 1)
Stuck Closed
tance Drop (Inj 3)
tance Drop (Inj 3)
Stuck Closed
P0270-1A Injector Drift Fault Detection On In- Service
Injector 2 MDP Trim Exceeds The
Maximum Calibrated Threshold
Limit. Max Apc Raw Trim At Medi-
um Rail Pressure
33 - 857 9813/9400-1 33 - 857

90 - Fault Codes

P0270-1B Injector Drift Fault Detection On In- Service
old Limit. Max Apc Raw Trim At
Low Rail Pressure
tance Drop (Inj 0)
tance Drop (Inj 0)
Stuck Closed
P029A-00 Injector Drift Fault Detection On In- Critical
P029B-00 Fault Which Is Set When The In- Critical
P029E-00 Injector Drift Fault Detection On In- Critical
P029F-00 Fault Which Is Set When The In- Critical
gine Speed From Engine ECU
P0325-00 Accelerometer Fault (Signal/Noise Trivial
Ratio Too Low In Idle)
P0330-00 Trivial
P0335-31 Trivial
P0340-54 Cam Signal Last Learnt Value Is Service
Outside Of Limits
33 - 858 9813/9400-1 33 - 858

90 - Fault Codes

P0341-00 Cam Signal Drift Higher Than Service
Threshold
P0341-2F Trivial
P0341-31 Cam Signal Lost (No Cam Signal Service
Seen In 2 Crank Rotations)
P0341-31 Cam Signal Fault (Missing Event Service
Within The Expected Window)
P0341-85 Cam Signal Fault (Overspeed De- Critical
tected)
P0350-02 Error Monitoring For System Pro- Operator
tection Based On Ignition Switch
Input
P0371-00 Crank Signal Is Too Close To The Service
Previous One
P0372-31 Elapsed Time Between CPS Service
Events Is Too High
P0374-31 Crank Signal Lost (No CPS Signal Service
Seen In 1 Cam Rotation)
P0380-00 Trivial
P0380-13 Trivial
P0383-11 Trivial
P0384-12 Trivial
P0400-00 EGR Flow Reached Its Limit Service
P0404-00 EGR Valve Control Fault Trivial
P0406-23 Trivial
Signal ADC Fault
Signal Low Fault
Signal High Fault
ve Short Circuit (SC)
P0520-11 Low Oil Pressure Lamp/Gauge Trivial
Drive Short Circuit To Ground
(SC2Gnd)
ve Short Circuit To Battery Voltage
(SC2Vbatt)
ve Open Circuit (OC)
P0521-00 Oil Pressure Sensor Signal Global Critical
Fault
P0522-23 High Oil Pressure During Engine Critical
Running
P0523-23 Engine Oil Pressure Low - Critical
33 - 859 9813/9400-1 33 - 859

90 - Fault Codes

P0523-24 Low Oil Pressure During Engine Critical
Running
P0544-00 Turbo In Temperature Fault Service
P0545-23 Turbo In Temperature Count Low Service
Fault
P0546-24 Turbo In Temperature Count High Service
Fault
P0562-02 Fault Due To Low Or High Battery Operator
Voltage Supply To DCU
P0562-16 Low Battery Voltage Operator
P0563-17 High Battery Voltage Operator
P0563-24 Battery Voltage Monitoring Signal Service
High Fault
P0566-00 Cruise Switch Off Function Fault Trivial
Detected
P0567-00 Cruise Switch Resume Function Trivial
Fault Detected
P0569-00 Cruise Switch Decelerate Function Trivial
Fault Detected
P0570-00 Cruise Switch Accelerate Function Trivial
Fault Detected
P0571-29 Brake Switch "A" Circuit Operator
P0572-11 Brake Switch "A" Circuit Low Operator
P0572-13 Brake Switch "A" Circuit Low Operator
P0573 -12 Brake Switch "A" Circuit High Operator
P0575-00 Cruise Switch ADC Fault Detected Trivial
P0602-00 Trivial
P0602-45 Trivial
P0602-47 Trivial
P0603-00 ECU Memory Integrity Fault (Data / Critical
Cal Integrity)
P0604-00 ECU Memory Integrity Fault (Ram Critical
Integrity)
P0605-00 ECU Memory Integrity Fault (Code Critical
Integrity)
P0606-02 Peripheral Monitoring Error On Operator
DCU
P0607-4B Throttle H-Bridge Driver In ECU Service
Fault: Over Temperature
P060A-00 Monitoring Error On DCU Operator
33 - 860 9813/9400-1 33 - 860

90 - Fault Codes

P060B-00 ADC Circuit Fault (Global) Critical
P060C-41 Monitoring Error On DCU Operator
P0612-11 Trivial
P0612-12 Trivial
P0612-13 Charge Circuit Fault ?Bank 2? Trivial
P0612-31 Trivial
P0615-13 Trivial
P0616-11 Trivial
P0617-12 Trivial
Ground (SC2Gnd)
Ground (SC2Vbat)
Ground (SC2Gnd)
Ground (SC2Vbat)
P062F-00 ECU Non Volatile Memory Fault Service
P0630-00 Trivial
P064F-13 Check Engine Lamp Fault Trivial
P0650-00 Trivial
P0650-11 Trivial
P0650-13 Check Engine Lamp Fault Trivial
33 - 861 9813/9400-1 33 - 861

90 - Fault Codes

tor Relay 1
Relay 1
Low Fault
High Fault
P0685-00 Main ECU Relay Stuck Critical
P0686-72 Main Relay System Fault (Open) Trivial
P0697-00 Trivial
P0697-4B ECU Internal 5V Supply 2 Auxillary Critical
Fault
P06A7-00 Sensor Supply Monitoring Error Operator
Through DCU
Sensor "A" Circuit Range/Perfor-
mance
Sensor "A" Circuit Range/Perfor-
mance
P0712-13 Transmission Temp OORL Operator
P0713-17 Transmission Temp OORH Operator
Source
Range
Range
P0717-13 Trans Input Speed Sensor Input Operator
Open Circuit. Sensor Not Present,
Failure In Supply Or Short To
Ground.
Speed Signal
P0720-13 Sensor Not Present, Failure In Operator
Supply Or Short To Ground.
Source
P0721-16 Speed Sensor OORL Trivial
33 - 862 9813/9400-1 33 - 862

90 - Fault Codes

P0721-17 Speed Sensor OORH Trivial
Range
Range
P0721-64 Output Speed Sensor Circuit Operator
Range/Performance
Speed Signal
Source
Plausible (Possible Engine Stall)
Failure, High Value Error In Range
Failure, Low Value Error In Range
P0727-13 Engine Speed Sensor Input Open Operator
Circuit. Sensor Not Present, Fail-
ure In Supply Or Short To Ground.
P0727-87 Engine CAN Data Not Available Operator
Or In Error / Implausible (Engine
Speed)
P0729-17 Speed Sensor 2 OORH Trivial
P072A-16 Speed Sensor 2 OORL Trivial
P072B-64 Speed Sensor Disagreement Trivial
P0745-14 Pressure Control Solenoid "A" Operator
P0746-13 Forward Low Solenoid Open Operator
P0746-13 Pressure Control Solenoid "A" Per- Operator
formance / Stuck Off
P0747-15 Forward Low Solenoid STB Operator
Stuck On
P0748-14 Forward Low Solenoid STG Operator
Electrical
P0748-18 T Solenoid Current Feedback Be- Operator
low Current Demand
P0748-19 T Solenoid Current Feedback Operator
P0749-1F T Solenoid Check Wiring Integrity, Operator
P0775-14 Pressure Control Solenoid "B" Operator
P0776-13 Forward High Solenoid Open Operator
P0776-13 Pressure Control Solenoid "B" Per- Operator
33 - 863 9813/9400-1 33 - 863

90 - Fault Codes

P0777-15 Forward High Solenoid STB Operator
Stuck On
P0778-14 Forward High Solenoid STG Operator
Electrical
P0778-18 U Solenoid Current Feedback Be- Operator
low Current Demand
P0778-19 U Solenoid Current Feedback Operator
P0779-1F U Solenoid Check Wiring Integrity, Operator
ror In Range
ror In Range
ror In Range
ror In Range
P0793-13 Intermediate Shaft Speed Sensor Operator
"A" Circuit No Signal
Speed Signal
P0795-14 Pressure Control Solenoid "C" Operator
P0796-13 Reverse High Solenoid Open Operator
P0796-13 Pressure Control Solenoid "C" Per- Operator
P0797-15 Reverse High Solenoid STB Operator
Stuck On
P0798-14 Reverse High Solenoid STG Operator
Electrical
P0798-18 V Solenoid Current Feedback Be- Operator
low Current Demand
P0798-19 V Solenoid Current Feedback Operator
P0799-1F V Solenoid Check Wiring Integrity, Operator
P0868-21 Transmission Fluid Pressure Low Operator
P0955-87 Auto Mode Request CAN Data Not Operator
P0956-87 Accelerator Pedal Position CAN Operator
Data Not Available Or In Error
P1101-00 Rail Pressure Control Error Posi- Critical
tive Fault
33 - 864 9813/9400-1 33 - 864

90 - Fault Codes

P1102-00 Rail Pressure Control Error Nega- Critical
tive Fault
P1103-00 Rail Pressure Fault Detected - Not Trivial
Able To Maintain Pressure After A
Stop And Start Request
Strategy
Strategy
Strategy
P110A-00 Fault Which Is Set When No MDP Service
P110B-00 Fault Which Is Set When No MDP Service
Strategy
P1400-00 Erroneous Signal From Override Operator
Switch
Override Switch
P1402-00 CAN Bus Off Error From Override Operator
Switch
P1506-00 Pedal Global Limp Home Mode Service
Triggered
P1509-00 CAN Communication Error On Trivial
TSC
P150A-00 Trivial
33 - 865 9813/9400-1 33 - 865

90 - Fault Codes

P1713-87 Kickdown Request CAN Message Operator
Missing Or In Error
P1714-05 Set Up Data Invalid Operator
P1715-07 Transmission Temp High Critical
P1719-13 4WD Solenoid Open Circuit. So- Operator
Ground.
P1719-13 2WD Solenoid Open Trivial
P171A-15 4WD Solenoid Short Circuit To Operator
Supply
P171A-15 2WD Solenoid STB Trivial
P171B-14 4WD Solenoid Out Of Range. Operator
Shorted To Low Source
P171B-14 2WD Solenoid STG Trivial
P171B-14 2WD Solenoid Return STG Trivial
P171B-15 2WD Solenoid Return STB Trivial
P171B-18 2WD Solenoid Return Open Trivial
P171C-1F 4WD Solenoid Check Wiring In- Operator
tegrity, Possible Intermittent Fault
P171F-64 Brake Pressure Sensor Electrical Operator
Fault
Fault
P1721-1F Brake Pressure Sensor Electrical Operator
Fault
Fault
Fault
Fault
Fault
P1726-19 Reverse Alarm Open Circuit. So- Operator
Ground.
P1727-18 Reverse Alarm Solenoid Short Cir- Operator
cuit To Supply
P1728-1F Reverse Alarm Solenoid Current Operator
Feedback Above Current Demand
P1729-15 Reverse Alarm Solenoid Current Operator
Feedback Below Current Demand
P172A-14 Reverse Alarm Solenoid Out Of Operator
Range. Shorted To Low Source
33 - 866 9813/9400-1 33 - 866

90 - Fault Codes

P172B-13 Reverse Alarm Solenoid Check Operator
Wiring Integrity, Possible Intermit-
tent Fault
P172C-00 Transmission Control Fault Operator
P172D-00 Transmission Control Fault Operator
P172E-00 Transmission Control Fault Operator
P172F-00 Transmission Control Fault Operator
P1730-00 Transmission Control Fault Operator
P1731-87 Driver Occupancy CAN Message Operator
Missing Or In Error
P1736-11 Speed Limit Potentiometer Circuit Operator
P1738-29 Hydrostatic Dsm Speed Sensor Operator
Circuit
P1738-64 Hydrostatic Dsm Speed Sensor Operator
Circuit
P17C5-85 Transmission Caused The Engine Operator
To Overspeed The Value Set In
The TECU
P17C6-17 Na Operator
P17CA-1 Na Operator
P17CB-13 Inhibit Pin Open Circuit On Start Operator
Up
P202A-13 Open Load Error Of Urea Tank Operator
Heater Actuator Powerstage
P202B-14 Error For Short To Ground Of Urea Operator
P202C-15 Error For Short To Battery Of Urea Operator
cuit
cuit To Battery
cuit To Battery On High Side Or
Open Load
P202E-14 Error On Dosing Valve Short To Operator
Ground Or Open Circuit
33 - 867 9813/9400-1 33 - 867

90 - Fault Codes

At Low Voltage
P202E-4B Error On Dosing Valve Driver Operator
Overtemperature
P203B-00 Tank Level Signal Error. Operator
P203B-14 Urea Tank Level Signal Is Below Operator
P203B-15 Urea Tank Level Signal Is Above Operator
P203B-16 Error On Tank Level Plausibility Operator
P203B-22 Tank Head Unit Level Physical Sig- Operator
nal Above Maximum Limit
P203B-81 CAN Bus Message Error From Operator
Headunit
P203B-86 CAN Bus Message Error For Tank Operator
Level From Head Unit
P203B-87 CAN bus Off Error From Headunit Operator
P203F-21 Tank Head Unit Level Physical Sig- Operator
nal Below Minimum Limit
P203F-68 Reagent Tank Level Low And Be- Operator
low Warning Threshold
P203F-7B Reagent Tank Level Low And Operator
Empty
Headunit
P2043-86 Adblue Temperature Message Er- Operator
ror From Headunit
P2043-87 CAN bus Off Error From Headunit Operator
P204B-00 Error While Monitoring The Stabili- Operator
sation Of Pressure
P204B-02 Error On Pressure Line & Dosing Operator
Valve While Monitoring For Block-
age
sor Below The Tolerable Limit
sor Above The Tolerable Limit
P204B-26 Error On Rate Of Pressure Reduc- Operator
tion
P204B-29 Error On Pressure Line While Mon- Operator
itoring For Blockage
P204B-61 Error While Monitoring Of Pressure Operator
Buildup
P204C-16 Pump Pressure Signal Below The Operator
P204C-21 Error For Pump Pressure Physical Operator
Signal Below Lower Limit
P204D-17 Pump Pressure Signal Above The Operator
P204F-06 Error To Detect The Clogged Filter Operator
P204F-7A Error To Detect Leakage During No Operator
Dose
P204F-9A Inducement Repeat Offence Active Critical
33 - 868 9813/9400-1 33 - 868

90 - Fault Codes

P205B-00 Error To Indicate Overheating Of Operator
Adblue Tank
P205B-06 Error In Increase Of Urea Tank Operator
Temperature
Limit
Limit
sor Plausibility Below Minimum
Threshold
sor Plausibility Exceeds Maximum
Threshold
P205C-16 Tank Temperature Signal Voltage Operator
Below Minimum Limit
P205D-17 Tank Temperature Signal Voltage Operator
Above Maximum Limit
P205E-81 Tank Temperature Signal Error On Operator
CAN
P205E-87 Can Bus Message Error For Tank Operator
Temperature From Head Unit
P207F-00 Ad Blue Quality Error During Refill Operator
Condition
P207F-86 Adblue Concentration Message Er- Operator
ror From Headunit
P207F-87 Adblue Quality Message Error Operator
From Headunit
P2080-2F Turbo In Temperature Count Noise Service
Fault
P208A-13 Open Load Error Of Supply Mod- Operator
ule Pump Motor
P208A-31 Supply Module Pump Feedback Operator
Error
Speed Permanent Deviation
Below Min Range
In Invalid Range
P208B-4B Overtemperature Error Of Supply Operator
Module Pump Motor
Speed Deviation
P208C-14 Short Circuit To Ground Error Of Operator
P208D-13 Short Circuit To Battery Error Of Operator
33 - 869 9813/9400-1 33 - 869

90 - Fault Codes

P209F-4B Error For Overtemperature Of Urea Operator
P20A0-13 Open Load Error Of Backflow Operator
Pump Actuator Powerstage
P20A1-4B Error For Overtemperature Of Operator
stage
P20A2-14 Error For Short To Ground Of Operator
stage
P20A3-13 Error For Short To Battery Of Back- Operator
flow Pump Actuator Powerstage
ture
ture Cold Start
P20B5-13 Open Load Error Of Supply Mod- Operator
ule Heater Actuator Powerstage
ture Duty Cycle Below Minimum
Range
ture Duty Cycle Above Maximum
Range
P20B6-4B Error For Overtemperature Of Sup- Operator
stage
P20B7-14 Error For Short To Ground Of Sup- Operator
stage
P20B8-15 Error For Short To Battery Of Sup- Operator
stage
P20B9-00 Error For Open Load On Heater Operator
Relay Of Backflow Line
P20B9-13 Open Load Error Of Urea Back- Operator
flowline Heater Actuator Power-
stage
P20BA-4B Error For Overtemperature Of Urea Operator
erstage
P20BB-00 Error For Short To Ground Or Operator
Backflow Line
P20BB-14 Error For Short To Ground Of Urea Operator
erstage
P20BC-15 Error For Short To Battery Of Urea Operator
erstage
33 - 870 9813/9400-1 33 - 870

90 - Fault Codes

Temperature Sensor
Temperature Cold Start
P20BE-13 Error On Realys For Short To Bat- Operator
tery
P20BE-4B Error For Overtemperature Of Urea Operator
erstage
P20BE-93 Error On Pressure Line To Perform Operator
Afterrun
P20BF-00 Error For Short To Ground Or Operator
Pressure Line
P20BF-14 Error For Short To Ground Of Urea Operator
erstage
erstage
P20C1-00 Error For Open Load On Heater Operator
Relay Of Suction Line
P20C1-13 Open Load Error Of Urea Suction- Operator
line Heater Actuator Powerstage
P20C2-4B Error For Overtemperature Of Urea Operator
stage
P20C3-00 Error For Short To Ground Or Operator
Suction Line
P20C3-14 Error For Short To Ground Of Urea Operator
stage
stage
P20E8-84 Underpressure Error In Metering Operator
Control State
P20E9-00 Overpressure Error Regardless Of Operator
Supply Module State
P20E9-85 Overpressure Error In Metering Operator
Control State
P20EA-72 DCU Relay Early Opening Operator
P20EB-71 DCU Relay Stuck Operator
Fault: Undervoltage
Fault: OC
33 - 871 9813/9400-1 33 - 871

90 - Fault Codes

Fault: Current Limited
Fault: SC
Fault: SC2G
Fault: SC2Vbatt
P2119-00 Throttle Learning Position Fault S0 Service
P212A-13 Throttle Position Sensor/Switch Operator
"G" Circuit
P212B-29 Throttle Position Sensor/Switch Operator
"G" Circuit Range/Performance
P212C-11 Throttle Position Sensor/Switch Operator
"G" Circuit Low
P212D-12 Throttle Position Sensor/Switch Operator
"G" Circuit High
P2130-13 Throttle/Pedal Position Sen- Operator
sor/Switch "F" Circuit
sor/Switch "F" Circuit Range/Per-
formance
sor/Switch "F" Circuit Low
sor/Switch "F" Circuit High
P2135-00 Foot Pedal Corrolation Track 1 Service
Over Track 2 Fault Detected
P2138-00 Hand Pedal Signal Corrolation Service
Fault
P219D-13 Open Load Error Of Urea Heater Operator
Relay Actuator Powerstage
P219D-4B Error For Overtemperature Of Urea Operator
P219E-13 Error For Short To Battery Of Urea Operator
P219F-14 Error For Short To Ground Of Urea Operator
P21A9-12 Short Circuit To Battery Of Actuator Operator
Relay 4
P21AB-14 Short Circuit To Ground Of Actua- Operator
tor Relay 4
P2200-00 Upstream NOx Sensor Wire Diag- Operator
nosis-Error In Voltage Supply
P2200-02 Upstream NOx Sensor Short Cir- Operator
cuit To Gnd Or Batt
nostic
For Upstream NOx Sensor
33 - 872 9813/9400-1 33 - 872

90 - Fault Codes

Limit For Upstream NOx Sensor
P2200-13 Upstream NOx Sensor Open Cir- Operator
cuit
P2200-61 Invalid Signal From Upstream NOx Operator
Sensor After Heater Release
nostic Timeout
nostic Abort
P2201-00 Downstream NOx Sensor Wire Di- Operator
agnosis-Error In Voltage Supply
agnostic
Limit For Downstream Nox Sensor
Limit For Downstream Nox Sensor
P2201-13 Downstream NOx Sensor Open Operator
Circuit
P2201-16 Downstream NOx Offset Min Error Operator
Detection
P2201-17 Downstream NOx Offset Max Error Operator
Detection
P2201-1C Downstream NOx Sensor Short Operator
Circuit To Gnd Or Batt
P2201-61 Invalid Signal From Downstream Operator
NOx Sensor After Heater Release
agnostic Timeout
agnostic Abort
P2202-16 Downstream NOx Sensor Reading Operator
Exceeds Above Maximum Thresh-
old
P2203-17 Downstream NOx Sensor Read- Operator
ing Exceeds Abbove Maximum
Threshold
Not Available
Not Heated Quickly
Available
Heated Quickly
P2228-23 Atmosp Sensor Low Fault Service
P2229-24 Atmosp Sensor High Fault Service
Signal ADC Fault
33 - 873 9813/9400-1 33 - 873

90 - Fault Codes

Signal 1 Plausability Fault
Signal Low Fault
Signal High Fault
P2275-87 Upshift Switch Circuit Range / Per- Operator
formance
P2413-81 Can Bus Message Error For EGR Operator
Faults From Engine E
P2413-86 Can Bus Message Error From En- Operator
gine ECU
P2413-87 Impeded EGR Fault Data Or Bus Operator
Off For EGR Faults From Engine
ECU
P2428-00 Trivial
P2428-17 Exhaust Catalyst Temperature T4 Operator
Limit
P242B-00 Error On SCR Catalyst Upstream Operator
Temperature Sensor Static Plausi-
bility
Sensor Plausibility Below Min
Threshold
Sensor Plausibility Above Max
Threshold
P242B-23 Exhaust Catalyst Temperature T4 Operator
Limit
P242C-16 Exhaust Catalyst Temperature T4 Operator
Voltage Signal Below Minimum
Limit
P242D-17 Exhaust Catalyst Temperature T4 Operator
Voltage Signal Above Maximum
Limit
P2502-87 Can Bus Message Error For Power Operator
Management From Engine ECU
P256A-13 Trivial
P256B-00 Trivial
P256B-23 Trivial
P256B-24 Trivial
P256B-2A Trivial
P256B-64 Trivial
P256C-11 Trivial
P256D-12 Trivial
P2620-00 Throttle Position Feedback ADC Service
Fault
P2620-2F Throttle Position Feedback Signal Service
Noisy Fault
Low Fault
33 - 874 9813/9400-1 33 - 874

90 - Fault Codes

High Fault
tor Relay 2
Relay 2
tor Relay 3
Relay 3
P2713-14 Pressure Control Solenoid "D" Operator
P2714-13 Reverse Low Solenoid Open Operator
P2714-13 Pressure Control Solenoid "D" Per- Operator
P2715-15 Reverse Low Solenoid STB Operator
Stuck On
P2716-14 Reverse Low Solenoid STG Operator
Electrical
P2716-18 W Solenoid Current Feedback Be- Operator
low Current Demand
P2716-19 W Solenoid Current Feedback Operator
P2717-1F W Solenoid Check Wiring Integrity, Operator
P2722-14 Pressure Control Solenoid "E" Operator
P2723-13 Pressure Control Solenoid "E" Per- Operator
Stuck On
Electrical
P2725-18 X Solenoid Current Feedback Be- Operator
low Current Demand
P2725-19 X Solenoid Current Feedback Operator
P2726-1F X Solenoid Check Wiring Integrity, Operator
P2731-14 Pressure Control Solenoid "F" Operator
P2732-13 Mainshaft Solenoid Open Operator
P2732-13 Pressure Control Solenoid "F" Per- Operator
P2733-15 Mainshaft Solenoid STB Operator
Stuck On
P2734-14 Mainshaft Solenoid STG Operator
Electrical
P2734-18 Y Solenoid Current Feedback Be- Operator
low Current Demand
P2734-19 Y Solenoid Current Feedback Operator
33 - 875 9813/9400-1 33 - 875

90 - Fault Codes

P2735-1F Y Solenoid Check Wiring Integrity, Operator
P2757-13 Luc Solenoid Open Circuit. So- Operator
Ground.
P2758-15 Luc Solenoid Short Circuit To Sup- Operator
ply
P2759-14 Luc Solenoid Out Of Range. Short- Operator
ed To Low Source
P2760-1F Luc Solenoid Check Wiring Integri- Operator
ty, Possible Intermittent Fault
P2779-87 Downshift Switch Circuit Range / Operator
Performance
P2781-87 Invalid Data Received From Ecm Operator
P2781-87 Invalid Data Received From Ecm Operator
P2783-87 Vehicle Speed Can Data Not Avail- Operator
able
Fault
Fault
P2793-87 Gear Shift Direction Circuit Operator
P2793-87 Gear Shift Direction Circuit Operator
Fault
Fault
33 - 876 9813/9400-1 33 - 876

90 - Fault Codes

Fault
Fault
P2807-13 Layshaft Solenoid Open Operator
P2807-14 Pressure Control Solenoid "G" Operator
P2808-13 Pressure Control Solenoid "G" Per- Operator
P2808-15 Layshaft Solenoid STB Operator
Stuck On
P280F-14 Layshaft Solenoid STG Operator
Electrical
P2810-18 Z Solenoid Current Feedback Be- Operator
low Current Demand
P2810-19 Z Solenoid Current Feedback Operator
Open
P2811-1F Z Solenoid Check Wiring Integrity, Operator
STG
STB
turn Open
turn STG
turn STB
P2A00-00 Upstream NOx Sensor Not Mount- Operator
ed Or Loose
P2A01-00 Downstream NOx Sensor Not Operator
Mounted Or Loose
P2BA7-68 Level Level 2 Enacted Critical
P2BA7-92 Level Level 1 Enacted Service
P2BA7-94 Level Level 1 Requested Service
P2BA7-9A Level Level 3 Enacted Critical
P2BA8-00 Interruption Warning Requested Operator
P2BA8-68 Interruption Level 2 Enacted Critical
P2BA8-92 Interruption Level 1 Enacted Service
P2BA8-94 Interruption Level 1 Requested Service
P2BA8-9A Interruption Level 3 Enacted Critical
33 - 877 9813/9400-1 33 - 877

90 - Fault Codes

P2BA9-00 Quality Warning Requested Operator
P2BA9-68 Quality Level 2 Enacted Critical
P2BA9-92 Quality Level 1 Enacted Service
P2BA9-94 Quality Level 1 Requested Service
P2BA9-9A Quality Level 3 Enacted Critical
P2BAA-00 Consumption Warning Requested Operator
P2BAA-68 Consumption Level 2 Enacted Critical
P2BAA-92 Consumption Level 1 Enacted Service
P2BAA-94 Consumption Level 1 Requested Service
P2BAA-9A Consumption Level 3 Enacted Critical
P2BAB-00 EGR Warning Requested Operator
P2BAB-68 EGR Level 2 Enacted Critical
P2BAB-92 EGR Level 1 Enacted Service
P2BAB-94 EGR Level 1 Requested Service
P2BAB-9A EGR Level 3 Enacted Critical
P2BAD-00 Inducement Override Active Operator
P2BAD-16 Undershoot The Limit Value Of Operator
Long Term Adaptation Factor
P2BAD-17 Exceeded The Limit Value Of Long Operator
Term Adaptation Factor
P2BAD-9A Inducement Level 3 Is Active Due Operator
P2BAE-00 Driver Warning For System Tam- Operator
pering
P2BAE-68 System Tampering Level 2 Enact- Critical
ed
P2BAE-92 System Tampering Level 1 Enact- Service
ed
P2BAE-94 System Tampering Level 1 Re- Service
quested
P2BAE-9A System Tampering Level 3 Enact- Critical
ed
quested
quested
Property
33 - 878 9813/9400-1 33 - 878

90 - Fault Codes

P3402-87 Concentration Too High For Af- Operator
Reagent Properties
P3403-87 Concentration Too Low For Af- Operator
Reagent Properties
Property
P3405-87 Temperature Too High For Af- Operator
Reagent Properties
P3406-87 Temperature Too Low For Af- Operator
Reagent Properties
P3407-87 Sensor Open Circuit Error Af- Operator
Reagent Temperature
P3408-87 Sensor Short Circuit Error Af- Operator
Reagent Temperature
P3409-87 Excessive Ambient/Operating Lev- Operator
el Error For Aftertreatment 1 SCR
Catalyst Reagent Property
P3410-87 Level Too High For Aftertreatment Operator
1 SCR Catalyst Reagent Proper-
ties
P3411-87 Level Too Low For Aftertreatment 1 Operator
SCR Catalyst Reagent Properties
P3412-87 Tank Level Open Circuit Error Operator
Reagent Temperature
P3413-87 Tank Level Short Circuit Error Operator
Reagent Temperature
P3414-87 Erroneous Signal For Engine Operator
Boost Pressure
P3415-87 Data Length Error For Ic1 Frame Operator
P3416-87 Time Out Error For Ic1 Frame Operator
P3417-87 Erroneous Signal For Intake Mani- Operator
fold Temperature
P3418-87 Erroneous Signal For Operating Operator
Mode Request
P3419-87 Error For Particulate Inlet Pressure Operator
P3420-87 Data Length Error For ProSCR3 Operator
Frame Received For Regeneration
P3421-87 Timeout Error For ProSCR3 Frame Operator
Received For Regeneration
P3422-87 Erroneous Signal For Soot Load Operator
Message
P3423-87 Erroneous Signal For Engine Ex- Operator
haust Gas Temperature.
P3424-85 SCR Partially Blocked (Over- Trivial
loaded)
33 - 879 9813/9400-1 33 - 879

90 - Fault Codes

P3425-85 SCR Fully Blocked (Plugged) Operator
RECOVERY Manplatform Rapid Recovery Ac- Critical
tive
RESTRICT Transmission Limp Mode Active Operator
RPM Crank Signal Overspeed Fault Operator
SERVICE Service Interval Elapsed Service
SERVICE Vehicle Serviced - Trivial
U0029-87 Canbus Off Error 250KBPS Operator
U0029-88 Canbus Off Error 250KBPS Operator
U0105-87 Can Bus Message Error For Fuel Operator
Qnty From Engine ECU
U010A-08 Can Communication Error: EGR Service
Can Fault
U010C-88 Trivial
U010E-08 Engine Rating To Service
U010E-87 Inducement Bam To Service
U0140-87 Cm1 Message Timeout Operator
U0401-61 Can Bus Message Error For Mod- Operator
elled NOx From Engine ECU
U0401-81 Can Bus Message Error From En- Operator
gine ECU
U0401-86 Can Bus Message Error From En- Operator
gine ECU
U0401-87 Canbus Off Error From Engine Operator
ECU
U040B-00 Trivial
U040B-4B Can Communication Error: EGR Service
Overtemperature
U040B-96 Trivial
U040B-97 Can Communication Error: EGR Service
Obstruction
U040B-98 Can Communication Error: EGR Service
Overtemperature
U040D-00 Trivial
U040D-54 Can Communication Error: VGT Service
Spanlearn
Hardware
U040D-97 Trivial
Overtemperature
U040D-9A Trivial
U040F-81 Engine Rating Mismatch Service
U059E-00 Can Bus Message Error For Temp Operator
NOx Sensor
U059E-02 Can Bus Message Error For No2 Operator
U059E-08 Can Bus Message Error For O2 Operator
Sensor
33 - 880 9813/9400-1 33 - 880

90 - Fault Codes

U059E-29 Can Bus Message Error From Up- Operator
stream NOx Sensor
U059E-62 Can Bus Message Error For Nh3 Operator
stream NOx Sensor
U059E-84 Can Bus Message Error For Power Operator
Sensor
stream NOx Sensor
U059E-87 Canbus Off Error From Upstream Operator
NOx Sensor
U059E-93 Can Bus Message Error For NOx Operator
U059E-94 Can Bus Message Error For O2 Operator
U059E-97 Can Bus Message Error For NOx Operator
Signal Status From Upstream Nox
Sensor
U059E-9A Can Bus Message Error For Operator
Heater Ratio From Upstream NOx
Sensor
U059F-00 Can Bus Message Error For Temp Operator
Sensor
U059F-02 Can Bus Message Error For No2 Operator
sor
U059F-08 Can Bus Message Error For O2 Operator
NOx Sensor
U059F-29 Can Bus Message Error From Operator
U059F-62 Can Bus Message Error For Operator
Nh3Level From Downstream NOx
Sensor
U059F-84 Can Bus Message Error For Pow- Operator
er Signal Status From Downstream
NOx Sensor
U059F-87 Canbus Off Error From Down- Operator
stream NOx Sensor
U059F-93 Can Bus Message Error For NOx Operator
Level From Downstream Nox Sen-
sor
U059F-94 Can Bus Message Error For O2 Operator
sor
U059F-97 Can Bus Message Error For Nox Operator
NOx Sensor
33 - 881 9813/9400-1 33 - 881

90 - Fault Codes

U059F-9A Can Bus Message Error For Operator
Heater Ratio From Downstream
NOx Sensor
U1501-88 Engine Can Fault Trivial
U1501-88 Engine Can Fault Trivial
U1502-88 Transmission Can Fault Trivial
U1502-88 Transmission Can Fault Trivial
U1503-88 Joystick Can Fault Trivial
U1503-88 Joystick Can Fault Trivial
U1504-88 Hydraulics Controller Can Fault Critical
U1505-88 Machine Controller Can Fault Trivial
U1506-88 Telematics Can Fault Trivial
U1507-88 Immobilizer Can Fault Trivial
U1508-88 Auxiliary Hydraulics Controller Can Operator
Fault
U1900-16 Livelink - Vehicle Battery Voltage Trivial
Below Normal
U1901-16 Livelink - Internal Voltage Below Trivial
Normal
Open Circuit
Open Circuit
U1904-85 Livelink - ECU Above Temperature Trivial
Threshold
U1905-84 Livelink - ECU Below Temperature Trivial
Threshold
U1906-96 Livelink - Accelerometer Internal Trivial
Failure
U1907-09 Livelink - Modem Jammed Trivial
U1908-09 Livelink - GPS Antenna Not OK Trivial
U1909-96 Livelink - No Comms With GPS Trivial
Module
U190A-09 Livelink - Sim Card Failure Trivial
U190B-96 Livelink - No Comms With GSM Trivial
Module
U190C-86 Livelink - GSM Network Registra- Trivial
tion Failure
When Relay Off
When Relay Off
When Relay Off
U1913 -84 Supply Voltage Below Normal Trivial
33 - 882 9813/9400-1 33 - 882

90 - Fault Codes

U1913 -85 Supply Voltage Above Normal (? Trivial
32V)
U1915 -56 Transponder Key - Invalid Key De- Trivial
tected
U1915 -9 Transponder Key - Antenna Fault Trivial
U1916 -85 Key / Keypad Code - Memory Full Trivial
U1917 -2f Engine - Communications Fault Trivial
U1917 -4 Engine - Error State Trivial
U1917 -87 Engine - No Communication Trivial
U1917 -96 Engine - Disarm Failure Trivial
U1918 -96 Immobiliser Internal Fault Trivial
WIF Water In Fuel Sensor Feedback Operator
Signal Setting Fault
Z111 Error Logs Full - Trivial
Z200 Errors Logs Erased - Trivial
33 - 883 9813/9400-1 33 - 883

66 - Load Motion Control System
Contents Page No.
33-66-00 General ......................................................................................................................... 33-885
33 - 884 9813/9400-1 33 - 884

00 - General
Introduction .................................................. 33-885 The LLMI (Longitudinal Load Moment Indicator) and
Component Identification ............................. 33-886 LLMC (Longitudinal Load Moment Control) systems
Operation (Hydraulic) .................................. 33-890 are both described in (PIL 33-66-00) for ease of
Diagram ....................................................... 33-893 explanation. Your machine may be installed with
either or no system.
Check (Operation) ....................................... 33-895
Calibrate ...................................................... 33-895
33 - 885 9813/9400-1 33 - 885

00 - General
For: 506-23 [T4F], 509-23 [T4F], 512-26

[T4F] ........................................ Page 33-886
For: Agri, Agri-Plus, Agri-Super, Agri-Xtra
................................................. Page 33-888
(For: 506-23 [T4F], 509-23 [T4F], 512-26 [T4F])
Display Location
Figure 1754.
1 LLMI Display 2 LLMC DIsplay
The LLMI (Longitudinal Load Moment Indicator) and 2. LLMC (Displays Longitudinal Load Moment
LLMC (Longitudinal Load Moment Control) display is Information and communicates with the machine
located in the pillar to the right side of the windscreen hydraulic ECU (Electronic Control Unit) to enable
control of the hydraulic systems when the LLMI
There are two types of display: limits are reached).
1. LLMI (Displays longitudinal load moment Refer to Electrical System, Sensor (PIL 33-84) for
information). sensors used in the system.
33 - 886 9813/9400-1 33 - 886

00 - General
Figure 1755. LLMC System Component Location

1 4
3
2
5
8 7
1 Control valve spool sensors 2 Proportional solenoid

3 Main control valve 4 Axle transducer
5 Electric inclinometer 6 Electric inclinometer
7 Transmission speed sensor 8 Boom retracted proximity switch
9 Hydraulic control ECU
33 - 887 9813/9400-1 33 - 887

00 - General
(For: Agri, Agri-Plus, Agri-Super, Agri-Xtra)
ECU Location
Figure 1756.
1 LLMI ECU 2 LLMC ECU
The LLMI and LLMCECU is located in the pillar to the 2. LLMCECU (Displays Longitudinal Load Moment
right side of the windscreen Information and communicates with the machine
ECU to enable control of the hydraulic systems
There are two types of ECU: when LLMI limits are reached).
1. LLMIECU (Displays longitudinal load moment Refer to Electrical System, Sensor (PIL 33-84) for
information). sensors used in the system.
33 - 888 9813/9400-1 33 - 888

00 - General
Figure 1757. LLMC System (Agri)
2 7 8
3 1
5
6
4
1 Axle transducer 2 Machine hydraulic control ECU

3 Chassis mounted electric inclinometer 4 Boom mounted electric inclinometer
5 Boom retracted proximity switch 6 Transmission speed sensor
7 Cut out solenoid valve
33 - 889 9813/9400-1 33 - 889

00 - General
Operation (Hydraulic)
LLMI System solenoid valve coil is not energised, pilot oil pressure
on the end of the steer priority valve is normal. The
The LLMI system does not interface with the valve works in the normal way with oil allowed to flow
hydraulic system. to the main hydraulic control valve and the machine
steer control valve.
LLMC System
System Pump Shut Off
When the LLMC (Longitudinal Load Moment Control)
system slows or stops the hydraulic services the Oil from the hydraulic pump flows to the main control
hydraulic ECU (Electronic Control Unit) automatically valve block in the normal way. The hydraulic control
controls the proportional solenoids on the main ECU energises the shut off solenoid valve coil. The
control valve. The main hydraulic system works in the valve now allows oil from the pilot end of the steer
normal way. priority valve to flow back to tank. The priority valve
spool now moves to its steer priority position. Flow to
the main control valve is shut off.
Pump Shut Off
The flushing valve is connected directly to the pump
Normal Operation outlet via a separate port on the main valve block. Oil
flows from the pump and back to tank via the flushing
Oil from the hydraulic pump flows to the main control valve in the normal way.
valve block in the normal way. When the shut off
33 - 890 9813/9400-1 33 - 890

00 - General
Figure 1758. Pump Shut Off- Normal Operation
T T DD P DLS 8
4 LS
1 D
B1
B
A1
T
B2
B
A2
A
T
T
B3
B
A3
T
B4
2
B
A4
A
T
PR
T PR
P1
5
6
1 Machine steer control valve 2 Hydraulic pump

3 Tank 4 Steer priority valve
5 Flushing valve 6 Shut off solenoid valve
33 - 891 9813/9400-1 33 - 891

00 - General
Figure 1759. Pump Shut Off- System Shut Off
T T DD P DLS 8
4 LS
1 D
B1
B
A1
T
B2
B
A2
A
T
T
B3
B
A3
T
B4
2
B
A4
A
T
PR
T PR
P1
5
6
1 Machine steer control valve 2 Hydraulic pump

3 Tank 4 Steer priority valve
5 Flushing valve 6 Shut off solenoid valve
33 - 892 9813/9400-1 33 - 892

00 - General
Diagram
Wires and Connectors (Electronic Control Unit) ECU is connected to the

panel harness.
The LLMI (Longitudinal Load Moment Indicator)
and LLMC (Longitudinal Load Moment Control)ECU
Figure 1760.
A B
2 1
A B
1 2 B A
4 3
C
3 4
C
A Connector A B Connector B
Table 686. Connector A

Pin Number Connected To: Type: Refer to Device:
1 Power 12 V Battery -
2 LLMI Axle Transducer Input Boom/Chassis Sensor
Signal 1 Output Devices
3 LLMC Axle Transducer Input Boom/Chassis Sensor
Signal 2 Output Devices
4 Earth Earth -
Table 687. Connector B

Pin Number Connected To: Type: Refer to Device:
1 CANbus High CANbus CANbus System
2 CANbus Low CANbus CANbus System
3 CANbus Shield CANbus Screen CANbus System
33 - 893 9813/9400-1 33 - 893

00 - General
LLMI/LLMC ECU Power and Earth Connections (526-56 Machines)
Figure 1761.
CONNECTOR A
1
1 4
CONNECTOR B
ECU
1 Fuse 2 LLMI/LLMCECU

A 1 4
P05 6 Fusebox D
P036 1 Panel Earth Point
LLMI/LLMC ECU Power and Earth Connections (Other Machines)
Figure 1762.
CONNECTOR A
1
1 4
CONNECTOR B
ECU
1 Fuse 2 LLMI/LLMCECU

A 1 4
P05 16 Fusebox E
P036 1 Panel Earth Point
33 - 894 9813/9400-1 33 - 894

00 - General
Check (Operation) Calibrate

WARNING There are different LLMI calibration
1. Use the applicable Servicemaster diagnostics procedures. The following procedure is for a
tool to identify faults. Ensure that the applicable CAN enabled LLMI system (machines with ECU
control interface operates correctly. Rectify as controlled hydraulic systems). Make sure you use
required. Refer to (PIL 33-57). the correct procedure.
2. Test the applicable wires and connectors for WARNING New LLMI units are not calibrated.
continuity, shorts to battery and shorts to earth. After installation of a new unit, make sure you
Rectify as required. carry out the correct calibration procedure.
3. Do not use a multimeter at the pins on the ECU. WARNING The LLMI system must be correctly
Only use the meter at the pins on the harness calibrated for the LLMC system (if installed) to
connectors. function correctly.
WARNING If a new LLMI/LLMC component is
4. Without the use of sophisticated electronic test installed make sure that it is configured correctly
equipment it is not possible to test the ECU. If the in Servicemaster using the LMS/Machine Setup
ECU is returned under warranty it will be tested and Boom Angle Sensor Calibration tools.
LLMI- Calibration
The display unit must be calibrated by setting the tip
point and machine calibration point.
The tip point is the point at which the machine starts

to tip forward due to the load moment.
The machine calibration point is a function of the

machine chassis and boom type.
Storing the tip and calibration values in the LLM

unit memory enables the unit to drive the LLMI
(Longitudinal Load Moment Indicator)LED (Light
Emitting Diode) warning display using the correct
load moment data.
Figure 1763.
E
D
B
A
A Button
B Green LED
D Amber LED
E Red LED
WARNING! During the following procedure, make
sure you do not raise the load more than 600 mm
above ground level otherwise the machine may be
able to tip forward at a dangerous angle. Keep all
personnel clear of the front and rear of the machine.
33 - 895 9813/9400-1 33 - 895

00 - General
1. Park the machine on firm level ground with the 8. Retract the boom and position it so that the top of
wheels in the straight ahead position. Drive the the boom structure is horizontal.Refer to Figure
machine backwards and forward for the specified 1764.
distance, three times. Make sure that the boom
is fully retracted, horizontal and the pallet forks (if 9. Press and release the button. The display unit
installed) are level. will revert to normal operation. The setting of
calibration point is now complete and the LLMI
Distance: 10m unit is calibrated.
2. If the following actions are not completed within 10. The calibration procedure causes the system to
a five minute period, the display unit will log a fault code (L071). This does not indicate a
automatically leave the `Calibration Mode' and system fault. Use JCB Servicemaster to clear the
the memory will revert to the previous settings. code from the fault code log.
If there is a system fault the unit will indicate the
appropriate fault code. The calibration procedure Figure 1764.
cannot continue until the fault is rectified.
2.1. Set the display unit to `Calibration Mode'.
2.2. Turn the ignition key to the OFF position.
Press and hold the button.
2.3. Start the engine with the button held down.
All the display LEDs will illuminate. Keep
the button held down for approximately the
specified time.
Duration: 30s
2.4. (After a specified time a ‘Stop Now’ warning
will display on the instrument panel, this
does not indicate a fault).
Duration: 15s
2.5. Continue holding the button until the display
shows the red LED and green LED only.
The alarm will emit short intermittent
bleeps.
2.6. (If the button is released too soon, the
process must be repeated).
2.7. Release the button.
3. With the boom fully retracted, pick up a load
of the specified weight. Use either pallet forks
loaded with a test weight or a shovel filled with a
high density material. Tilt carriage fully back.
Weight/Force: 1,800–2,000kg
4. Make sure that the machine is standing level with
its wheels in the straight ahead position.
5. Slowly extend the boom, keeping the load close
to the ground, until the machine is balanced
about the front axle with the rear wheels off the
ground. The display will show the red LED and
bottom green LED.
6. (If the transducer signal is out of range the LLMI
display will show an error state).
7. Remove the load. Remove the forks or
attachment as applicable. Leave the Q-fit
attached.
33 - 896 9813/9400-1 33 - 896

00 - General
Disassemble and Assemble 2.1. During assembly renew the seal 1, seal 2
and the seal 3.
3. Make sure that all components are tightened to
Disassemble the correct torque.
1. Remove the LLMC (Longitudinal Load Moment
Control) valve block. Refer to electrical system- Table 690. Torque Values
load motion control system, refer to (PIL 33-66). Item Nm
1A 27
2. Before you remove the solenoid assemblies or
coils, put a label on them for correct installation. 1B 27
1C 27
3. Loosen and remove the securing nut on the coil 4 4.1
on the valve you wish to remove.
5 4.1
4. Remove the solenoid. 6 4.1
5. Loosen and remove the cartridge.
6. Remove and discard the seal.
7. Repeat steps for the removal of the other valves.
3 to 6
Figure 1765.
2B 3B
5 6
3A
1B
1 3
4 1A 2 2A
1 Solenoid valve assembly 1
1A Cartridge 1
2A Cartridge 2
3A Cartridge 3
1B Seal 1
2B Seal 2
3B Seal 3
4 Securing nut
5 Securing nut
6 Securing nut
Assemble
Although the solenoid assemblies look very similar,
they have different flow characteristics.

removal procedure.
2. When you install, do the following step also:
33 - 897 9813/9400-1 33 - 897

84 - Sensor
84 - Sensor
Contents Page No.
33-84-09 Speed Sensor .............................................................................................................. 33-899

33-84-15 Transmission Oil Temperature ..................................................................................... 33-900
33-84-41 Lift Arm ......................................................................................................................... 33-901
33-84-51 Rear Axle ..................................................................................................................... 33-904
33-84-72 Chassis ......................................................................................................................... 33-908
33 - 898 9813/9400-1 33 - 898

84 - Sensor
09 - Speed Sensor
09 - Speed Sensor
Introduction
For details of the speed sensors - refer to (PIL

27-06-27).
33 - 899 9813/9400-1 33 - 899

84 - Sensor
15 - Transmission Oil Temperature
15 - Transmission Oil Temperature
Introduction
For details of the transmission oil temperature sensor

refer to (PIL 27-06-33).
33 - 900 9813/9400-1 33 - 900

84 - Sensor
41 - Lift Arm
41 - Lift Arm Check (Operation)

Check (Operation) ....................................... 33-901
Test procedures
1. Use the applicable servicemaster diagnostics
tool to identify the faults. Make sure that the
applicable control interface operates correctly.
Refer to electrical system- electronic diagnostic,
33 - 901 9813/9400-1 33 - 901

84 - Sensor
41 - Lift Arm
Remove and Install
(For: 512-26 [T4F], Rear) 2. Follow the general safety precautions. Refer to
(PIL 01-03).
Remove 3. Raise the lift arm and install the lift arm
WARNING You could be killed or injured if the maintenance strut, refer to body and framework-
boom drops while you are working under it. Install maintenance strut, refer to (PIL 06-69).
the boom maintenance strut as instructed before
4. Disconnect the sensor harness connector from
doing any maintenance work with the boom
the lift arm harness connector.
you install or remove the boom maintenance strut. 5. Remove the bolts.
1. Park the machine and make it safe. Refer to (PIL 6. Remove the sensor from the machines.
01-03).
Figure 1766.
B
A
A Sensor B Bolts
33 - 902 9813/9400-1 33 - 902

84 - Sensor
41 - Lift Arm
Install
removal procedure.
2. When you install, do the following steps also:
2.1. Make sure to route the harness correctly
and replace the harness securing clips.
2.2. Calibrate the LLMC (Longitudinal Load
Moment Control) system. Refer to electrical
system- load motion
33 - 903 9813/9400-1 33 - 903

84 - Sensor
51 - Rear Axle
51 - Rear Axle Component Identification

Operation (Electrical) ................................... 33-905
Check (Operation) ....................................... 33-907
Figure 1767.
A LLMI (Longitudinal Load Moment Indicator) axle

transducer
33 - 904 9813/9400-1 33 - 904

84 - Sensor
51 - Rear Axle
Operation (Electrical)

The axle transducer is connected to the chassis
harness.
Figure 1768.
1 6 6 1
2 5
5 2
3 4
4 3
526-56 Machines
Figure 1769.
J5-7 1
6
ECU 2 A-2 ECU
J1-16 5 3 A-3
1 4
2 3
1 Hydraulic control ECU (Electronic Control Unit) 2 Axle transducer

3 LLMI (Longitudinal Load Moment 4 Fuse
Indicator)ECU
33 - 905 9813/9400-1 33 - 905

84 - Sensor
51 - Rear Axle
A LLMIECU connector J1 Hydraulic control ECU connector

Connec- Pins Details
tors
C025 1 2 3 4 5 6
C049 7 7 Hydraulic control ECU connector J5.
i016 15 16 22 i016. Refer to electrical system- harness, refer to
(PIL 33-12).
P27 2 3 LLMIECU connector.
P02 20 Fusebox A. Refer to electrical system- power dis-
tribution, refer to (PIL 33-09).
C045 16 Hydraulic control ECU.
Other Machines
Figure 1770.
J5-7 1
ECU
6 2 A-2 ECU
J5-15 4 3 A-3
1 J5-16 5
3
2
1 Hydraulic control ECU 2 Axle transducer

3 LLMIECU A LLMIECU connector
J1 Hydraulic control ECU connector

Connec- Pins Details
tors
C010 1 2 3 4 5 6
C049 7 15 7 Hydraulic control ECU connector J5.
i016 15 16 i016. Refer to electrical system- harness, refer to
(PIL 33-12).
P042A 2 3 LLMIECU connector A.
C045 16 Hydraulic control ECU J1.
33 - 906 9813/9400-1 33 - 906

84 - Sensor
51 - Rear Axle
Check (Operation)
Test Procedures
tool to identify faults. Make sure that the
applicable control interface operates correctly.
Rectify as required. Refer to electrical system-
33 - 907 9813/9400-1 33 - 907

84 - Sensor
72 - Chassis
72 - Chassis Component Identification

Component Identification ............................. 33-908 For: Parallel System ................ Page 33-908
Remove and Install ..................................... 33-910 For: Closed Centre System ..... Page 33-909
(For: Parallel System)
Figure 1771. All machines excluding 550-80, 526-56, 535-125 HiViz, 535-140 HiViz
A Chassis angle sensor
33 - 908 9813/9400-1 33 - 908

84 - Sensor
72 - Chassis
(For: Closed Centre System)
Figure 1772. 550-80, 535-125 HiViz and 535-140 HiViz Machines
A Chassis angle sensor
33 - 909 9813/9400-1 33 - 909

84 - Sensor
72 - Chassis
Remove and Install
(For: 506-23 [T4F], 509-23 [T4F]) 2. Follow the general safety precautions. Refer to
(PIL 01-03).
Remove 3. Raise the lift arm and install the lift arm
WARNING You could be killed or injured if the lift maintenance strut. Refer to body and framework-
arm drops while you are working under it. Install maintenance strut, refer to (PIL 06-69).
the lift arm maintenance strut as instructed before
4. Release the hydraulic pressure. Refer to
doing any maintenance work with the lift arm
hydraulic system- general, refer to (PIL 30-00).
you install or remove the lift arm maintenance 5. Remove the chaff guard as applicable.
strut.
1. Park the machine and make it safe. Refer to (PIL chassis harness.
01-03).
7. Remove the bolts 2 and remove the sensor from
the machine.
Figure 1773.
A
G
33 - 910 9813/9400-1 33 - 910

84 - Sensor
72 - Chassis
A Chaff guard F Bolts 2

G Sensor H Connector
Chaff Guard 2. Raise the lift arm and install the lift arm
maintenance strut. Refer to body and framework-
Remove maintenance strut, refer to (PIL 06-69).
1. Follow the general safety precautions. Refer to 3. Remove the screws and washers.
(PIL 01-03).
4. Remove the chaff guard from the machine.
Figure 1774.
A Chaff guard B Screws

C Washers
33 - 911 9813/9400-1 33 - 911

84 - Sensor
72 - Chassis
Install
1. The installation is the opposite of the removal
procedure.
2. Tighten all fasteners to the correct torque. Refer
to (PIL 72).
33 - 912 9813/9400-1 33 - 912

86 - Solenoid
86 - Solenoid
Contents Page No.
33-86-00 General ......................................................................................................................... 33-915
33 - 913 9813/9400-1 33 - 913

Notes:
33 - 914 9813/9400-1 33 - 914

86 - Solenoid
00 - General
00 - General
Remove and Install
(For: 506-23 [T4F], 509-23 [T4F], Agri-

Xtra)
The solenoid valves are not serviceable parts.
Replace the solenoid valve assembly if it is defective.
Remove
This procedure is the same for all of the solenoid
valves.
1. Disconnect the solenoid valve electrical

connections.
2. Remove the screws and remove the end casing.
3. Support the clamping plate and remove the
screw.
4. Pull the solenoid valve out from the housing.
Figure 1775.
C
D
A
B
E
A Screw 1
B Clamping plate
C Screw 2
D End casing
E Solenoid valve
Install
removal procedure.

Item Nm
A 4.5
C 1
33 - 915 9813/9400-1 33 - 915

Notes:
33 - 916 9813/9400-1 33 - 916

Contents Page No.
72-00 Fasteners and Fixings

72-00-00 General ............................................................................................................................. 72-3
72-03 Screws
72-03-00 General ............................................................................................................................. 72-7
72-06 Bolts
72-06-00 General ........................................................................................................................... 72-11
72-18 Bearings
72-18-00 General ........................................................................................................................... 72-15
72-21 Clips
72-21-03 Worm Drive .................................................................................................................... 72-17
72-36 Threaded Insert
72-36-00 General ........................................................................................................................... 72-23
9813/9400-1
2017-09-25
Notes:
9813/9400-1
2017-09-25
Contents Page No.
72-00-00 General ............................................................................................................................. 72-3
72 - 1 9813/9400-1 72 - 1
Notes:
72 - 2 9813/9400-1 72 - 2
00 - General
00 - General Fastener Type Colour Part Number

Suffix
Zinc Nickel - Black, chalky N (e.g.
Introduction black texture 1315/3712N)
Zinc flake - Black, slight B (e.g.
JCB Fasteners (Before September 2017) black gloss 1315/3712B)
Some external fasteners on JCB machines are Torque and Angle Tightening
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet Insufficient pre-load of a bolted joint can cause
and replaces the original Zinc and Yellow Plating major problems, such as cylinder head warp, leaking
used on earlier machines. The two types of fasteners gasket joints etc. There are several methods of
can be readily identified by colour and part number achieving an accurate pre-load of a bolted joint, the
suffix. Refer to Table 1. Fastener Types. two main methods used on the JCB engine are:
Table 694. • Torque Control Tightening - Using a torque
Fastener Type Colour Part Number meter to control the torque is the most
Suffix popular means of controlling pre-load, and
in the majority of instances this method is
Zinc and Yellow Golden Finish Z (e.g. adequate. It should be noted that with this
1315/3712Z) process, the majority of the torque is used
Dacromet Mottled Silver D (e.g. to overcome friction, therefore slight variations
Finish 1315/3712D) in the frictional conditions can lead to large
changes in the bolt pre-load.
Note: As the Dacromet fasteners have a lower torque • Angle Control Tightening - Where a more
setting than the Zinc and Yellow fasteners, the torque precise pre-load is required, the torque and
figures used must be relevant to the type of fastener. angle tightening method is used. The bolt
is tightened to a predetermined torque (this
A Dacromet bolt should not be used in conjunction may be done in stages), and then as a
with a Zinc or Yellow plated nut, as this could final sequence, the bolt is tightened to a
change the torque characteristics of the torque predetermined angle - this method of tightening
setting further. For the same reason, a Dacromet nut the bolts results in a smaller variation in the
should not be used with a Zinc or Yellow plated bolt. final pre-load. It is critical that the predetermined
tightening angle is accurately achieved, failure
All bolts used on JCB machines are high tensile and to tighten accurately to the specified angle could
must not be replaced by bolts of a lesser tensile result in the bolt pre-load being incorrect - this
specification. will lead to eventual failures. It is good practice
to replace all bolts that have been tightened
Dacromet bolts, due to their high corrosion using the torque + angle procedure.
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
Tightening Method
applications. They are not used in applications
such as gearbox or engine joint seams or internal The following example explains the recommended
applications. torque and angle procedure. A torque angle gauge
should be used for accuracy, but as a visual check,
JCB Fasteners (After September 2017) the bolts can be match marked as described below.
1. Tighten the bolt to the specified torque (specified

Table 695. torque values will be detailed in the relevant PIL
Fastener Type Colour Part Number sections).
Suffix
2. Mark a line across the centre of the bolt, and a
Zinc flake-silver White alu- D (e.g. second line on the part to be clamped - the two
minium (sil- 1315/3712D) lines should be aligned. Refer to Figure 1776.
ver-grey), Dull
Zinc and heavy Silver (Bright iri- V (e.g.
trivalent passi- descent) 1315/3712V)
vated with seal
Zinc Nickel - sil- Dark, dull silver Not assigned
ver/grey grey
72 - 3 9813/9400-1 72 - 3
00 - General
Figure 1776.
0°
3. Mark a third line at the specified torque angle - in

this instance the additional torque angle is 90°.
This line must be marked the specified angle in
a clockwise direction (to further tighten the bolt).
Figure 1777.
+90°
4. In some instances, angle torque tightening can

be specified in two stages, for instance in this
example, the first angle quoted is 90° and then a
second angle of 180°. The additional 180° angle
is from the LAST tightened position. Refer to
Figure 1778.
Figure 1778.
+180°
+90°
5. Tighten the bolt so that the line on the bolt

aligns with the angle(s) marked on the item to
be clamped - remember, to ensure complete
accuracy an angle gauge should be used.
72 - 4 9813/9400-1 72 - 4
03 - Screws
03 - Screws
Contents Page No.
72-03-00 General ............................................................................................................................. 72-7
72 - 5 9813/9400-1 72 - 5
Notes:
72 - 6 9813/9400-1 72 - 6
03 - Screws
00 - General
Introduction ...................................................... 72-7 Use the torque setting tables (Technical Data) only
Technical Data ................................................. 72-8 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 696. Up to September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 697. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
72 - 7 9813/9400-1 72 - 7
03 - Screws
00 - General
Technical Data
Table 698. Torque Settings - Internal

Hexagon Headed Capscrews (Zinc)
Bolt Size
mm N·m
3 2
4 6
5 11
6 19
8 46
10 91
12 159
16 395
18 550
20 770
24 1,332
72 - 8 9813/9400-1 72 - 8
06 - Bolts
06 - Bolts
Contents Page No.
72-06-00 General ........................................................................................................................... 72-11
72 - 9 9813/9400-1 72 - 9
Notes:
72 - 10 9813/9400-1 72 - 10
06 - Bolts
00 - General
Introduction .................................................... 72-11 Use the torque setting tables (Technical Data) only
Technical Data ............................................... 72-12 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 699. Up to September 2017

no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 700. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
Verbus-Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Figure 1779.
72 - 11 9813/9400-1 72 - 11
06 - Bolts
00 - General
Technical Data Table 703. Torque Settings -

Coarse Metric Grade 8.8 Fasteners
Bolt Tread Hexa- Condi- Condi-
From JCB standard STD00019 issue 15.
Size Pitch gon (A/ tion 1 tion 2
1. This information does not apply to:- F)
mm mm mm N·m N·m
1.1. Hydraulic fittings (i.e. BSP, SAE O-ring 4 0.7 7 2.9 2.6
boss, UNF, four bolt split flange and JIC).
5 0.8 8 5.8 5.2
1.2. Locking type fasteners (those with a nylon 6 1 10 9.9 9
insert, or with distorted thread nuts such as
8 1.25 13 24 22
Cleveloc).
10 1.5 17 47 43
2. For information on fastener conditions, refer to 12 1.75 19 83 74
fasteners and fixings, bolts, general, introduction. 14 2 22 132 119
16 2 24 205 184
Table 701. Torque Settings - UNF S Fasteners 20 2.5 30 400 360
Bolt Treads Hexa- Condi- Condi- 24 3 36 690 621
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,372 1,235
F) 36 4 55 2,399 2,159
in in in N·m N·m
(1/4 in) 28 7/16 11.2 10 Table 704. Torque Settings - Coarse
(5/16 in) 24 1/2 22.3 20 Metric Grade 10.9 Fasteners
(3/8 in) 24 9/16 40 36 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 64 57 Size Pitch gon (A/ tion 1 tion 2
F)
(1/2 in) 20 3/4 98 88
mm mm mm N·m N·m
(9/16 in) 18 13/16 140 126
4 0.7 7 4 3.6
(5/8 in) 18 15/16 196 177
5 0.8 8 8.1 7.3
(3/4 in) 16 1 1/8 343 309
6 1 10 13.9 12.5
(7/8 in) 14 1 15/16 547 492
8 1.25 13 34 30
(1 in) 12 1 1/2 814 732
10 1.5 17 67 60
(1 1/8 in) 12 1 7/8 1,181 1,063
12 1.75 19 116 104
(1 1/4 in) 12 2 1/4 1,646 1,481
14 2 22 185 167
16 2 24 288 259
Table 702. Torque Settings - UNF X Fasteners 20 2.5 30 562 506
Bolt Treads Hexa- Condi- Condi- 24 3 36 971 874
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,930 1,737
F)
36 4 55 3,374 3,036
in in in N·m N·m
(1/4 in) 28 7/16 17.6 15.9 Table 705. Torque Settings - Coarse
(5/16 in) 24 1/2 35.2 31.6 Metric Grade 12.9 Fasteners
(3/8 in) 24 9/16 64 57 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 101 91 Size Pitch gon (A/ tion 1 tion 2
(1/2 in) 20 3/4 155 139 F)
(9/16 in) 18 13/16 221 199 mm mm mm N·m N·m
(5/8 in) 18 15/16 310 279 4 0.7 7 4.8 4.4
(3/4 in) 16 1 1/8 542 488 5 0.8 8 9.8 8.8
(7/8 in) 14 1 15/16 864 777 6 1 10 16.6 15
(1 in) 12 1 1/2 1,285 1,156 8 1.25 13 40 36
(1 1/8 in) 12 1 7/8 1,865 1,679 10 1.5 17 80 72
(1 1/4 in) 12 2 1/4 2,598 2,339 12 1.75 19 139 125
14 2 22 223 200
16 2 24 345 311
72 - 12 9813/9400-1 72 - 12
06 - Bolts
00 - General
Bolt Thread Hexa- Condi- Condi-

Size Pitch gon (A/ tion 1 tion 2
F)
mm mm mm N·m N·m
20 2.5 30 674 607
24 3 36 1,165 1,048
30 3.5 46 2,316 2,084
36 4 55 4,049 3,644
Table 706. Torque Settings - Rivet Nuts / Bolts

Bolt Size
mm N·m
3 1.2
4 3
5 6
6 10
8 24
10 48
12 82
72 - 13 9813/9400-1 72 - 13
18 - Bearings
18 - Bearings
Contents Page No.
72-18-00 General ........................................................................................................................... 72-15
72 - 14 9813/9400-1 72 - 14
18 - Bearings
00 - General
00 - General
Check (Condition)
1. Carefully inspect all rollers, cages and cups
for wear, chipping, or nicks to determine the
condition of the bearings for further use.
2. Do not replace a bearing cone or cup individually.
Replace the mating cup and the cone at the same
time.
3. After inspection, lubricate the bearings with a
suitable clean oil.
4. Wrap the bearings in clean lint free cloth or paper
to protect them until you install the bearings
again.
72 - 15 9813/9400-1 72 - 15
21 - Clips
21 - Clips
Contents Page No.
72-21-03 Worm Drive .................................................................................................................... 72-17
72 - 16 9813/9400-1 72 - 16
21 - Clips
03 - Worm Drive
03 - Worm Drive Introduction

Introduction .................................................... 72-17 There are three types of the plain worm drive clips.
Technical Data ............................................... 72-18
Component Identification ............................... 72-20 • Standard worm drive clip
• Heavy duty worm drive clip
• Spring assisted worm drive clip
Spring assisted worm drive clip contains a spring

insert on the inside of the band to provide
compensation against hose compression set.
Use the torque setting tables (Technical Data) only

where no torque setting is specified in the text.
72 - 17 9813/9400-1 72 - 17
21 - Clips
03 - Worm Drive
Technical Data
Dimensions
Figure 1780.
C
J
H
Table 707.
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Standard worm drive clips and spring assisted worm drive clips
8–16mm 0.7mm 13mm 9mm 7mm 21mm 11mm
12–22mm 21mm
16–27mm up 0.8mm 14.6mm 12mm 30mm 12.5mm
to 60–80mm
70–90mm 36mm
up to 160–
180mm
72 - 18 9813/9400-1 72 - 18
21 - Clips
03 - Worm Drive
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Heavy duty worm drive clips
172–206mm 0.7mm 23.1mm 16mm 7mm 37mm 13mm
Torque Values
Table 708. Standard Worm Drive Clip
Clamping Part number Torque values
range
8–16mm 2201/0001 2 -0/+0.5N·m
12–22mm 2201/0003 3 -0/+0.5N·m
16–27mm 2201/0005 5 -0/+0.5N·m
20–32mm 2201/0006 5 -0/+0.5N·m
25–40mm 2201/0007 5 -0/+0.5N·m
35–50mm 2201/0008 5 -0/+0.5N·m
40–60mm 2201/0010 5 -0/+0.5N·m
50–70mm 2201/0012 5 -0/+0.5N·m
60–80mm 2201/0013 5 -0/+0.5N·m
70–90mm 2201/0014 5 -0/+0.5N·m
80–100mm 2201/0015 5 -0/+0.5N·m
90–110mm 2201/0016 5 -0/+0.5N·m
100–120mm 2201/0021 5 -0/+0.5N·m
120–140mm 2201/0017 5 -0/+0.5N·m
130–150mm 2201/0018 5 -0/+0.5N·m
150–170mm 2201/0019 5 -0/+0.5N·m
160–180mm 2201/0020 5 -0/+0.5N·m
Table 709. Heavy Duty Worm Drive Clip

range
172–194mm 2201/0022 10 -0/+0.5N·m
184–206mm 2201/0023 10 -0/+0.5N·m
Table 710. Spring Assisted Worm Drive Clip

range
16–27mm 2206/1627 5 -0/+0.5N·m
20–32mm 2206/2032 5 -0/+0.5N·m
25–40mm 2206/2540 5 -0/+0.5N·m
30–45mm 2206/3045 5 -0/+0.5N·m
35–50mm 2206/3550 5 -0/+0.5N·m
40–60mm 2206/4060 5 -0/+0.5N·m
50–70mm 2206/5070 5 -0/+0.5N·m
60–80mm 2206/6080 5 -0/+0.5N·m
70–90mm 2206/7090 5 -0/+0.5N·m
72 - 19 9813/9400-1 72 - 19
21 - Clips
03 - Worm Drive
Component Identification Figure 1783. Spring Assisted Worm Drive Clip

A B
Figure 1781. Standard Worm Drive Clip
C
A B
C
D
F
E
A Screw support flange

B Asymmetric housing
C Asymmetric extension
A Screw support flange D Short housing saddle
B Asymmetric housing E Stamped inside
C Asymmetric extension F Spring insert
D Short housing saddle G Identification of material/clamping range
E Stamped inside
F Identification of material/clamping range
Figure 1782. Heavy Duty Worm Drive Clip
A Extended bridge
B Band width (16mm)
C Identification of clamping range
72 - 20 9813/9400-1 72 - 20
36 - Threaded Insert
Contents Page No.
72-36-00 General ........................................................................................................................... 72-23
72 - 21 9813/9400-1 72 - 21
Notes:
72 - 22 9813/9400-1 72 - 22
00 - General
Introduction .................................................... 72-23 A threaded insert also known as a rivet nut is a
Technical Data ............................................... 72-24 one piece fastener installed blind from one side of
Remove and Install ....................................... 72-24 the machine body/framework. The threaded insert is
compressed so that a section of its shank forms an
upset against the machine body/framework, leaving
a durable thread.
Figure 1784.
A Threaded insert
B Durable thread
Threaded inserts are installed to various parts of

the machine body and framework. They are used in
a number of applications, for instance, hose clamp
and hydraulic valve retention etc. Various sized
threaded inserts are available, refer to technical data
to determine the correct size of threaded insert to be
used for particular applications.
If for any reason a new threaded insert is required,

the correct installation procedure must be followed.
Refer to Remove and Install.
72 - 23 9813/9400-1 72 - 23
00 - General
Technical Data Remove and Install

Consumables
Table 711. Specifications Description Part No. Size
Thread Outside Materi- Total Drill Threaded Insert (M10 x 826/01104 -
Diame- Diame- al Thick- Rivet Hole Di- 23mm)
ter ter ness Length ameter Threaded Insert (M10 x 826/01105A -
mm mm mm mm mm 26mm)
(inch) (inch) (inch) (inch) Threaded Insert (M6 x 826/01099 -
M5 7 0.25–3 14 7.1 16mm)
M5 7 3–5.5 17 7.1 Threaded Insert (M6 x 826/01101 -
M6 9 0.5–3 16 9.1 19mm)
M6 9 3–5.5 19 9.1 Threaded Insert (M8 x 826/01102 -
18mm)
M8 11 0.5–3 18 11.1
Threaded Insert (M8 x 826/01103 -
M8 11 3–5.5 21 11.1
21mm)
M10 13 1–3.5 23 13.1
M10 13 3.5–6 26 13.1 The threaded insert installation tool is available from
Bolhoff Fastenings Ltd. www.bolhoff.com.
Install
1. Drill a hole in the machine body/framework where
the threaded insert is to be installed, refer to
technical data for the correct size.
2. De-burr the hole edges.
3. Screw the threaded insert on to the mandrel of
the installation tool. The bottom of the mandrel
should be in line with the bottom of the threaded
insert.
Consumable: Threaded Insert (M6 x 16mm)
Figure 1785.
A Threaded insert
4. Wind the body of the installation tool down the
threaded mandrel until it touches the head of the
threaded insert.
72 - 24 9813/9400-1 72 - 24
00 - General
Figure 1786.
B Head of threaded insert

5. Insert the threaded insert (assembled to the tool)
into the hole drilled in step 1.
6. Hold handle and at the same time draw the
mandrel into the installation tool by turning nut.
The threaded insert will contract in length and
form an upset (smooth bulge) seating itself
against the body/ framework. Note: The thread
of the threaded insert must not be stripped, take
care when upsetting the threaded insert.
Figure 1787.
C Handle
D Nut
E Body/Framework
7. Remove the installation tool.
72 - 25 9813/9400-1 72 - 25
Notes:
72 - 26 9813/9400-1 72 - 26
Contents Page No.
75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-03 Oil
75-03-00 General ............................................................................................................................. 75-9
75-03-03 Engine ............................................................................................................................ 75-10
75-06 Grease
75-06-00 General ........................................................................................................................... 75-13
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-17
75-09-03 Antifreeze ....................................................................................................................... 75-18
75-09-12 Diesel Exhaust Fluid (DEF) ........................................................................................... 75-20
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-23
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-27
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-31
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-37
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-43
9813/9400-1
2017-09-25
Acronyms Glossary

ISO International Organization for
Standardization
PTFE Polytetrafluoroethylene
9813/9400-1
2017-09-25
Contents Page No.
75-00-00 General ............................................................................................................................. 75-3
75 - 1 9813/9400-1 75 - 1
Notes:
75 - 2 9813/9400-1 75 - 2
00 - General
Introduction ...................................................... 75-3 JCB recommend that you use the JCB lubricants
Health and Safety ........................................... 75-4 shown as they have been verified by JCB for use
Technical Data ................................................. 75-6 on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.
Before you start work, make sure that:
• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.
Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.
75 - 3 9813/9400-1 75 - 3
00 - General
Health and Safety
Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
Fine jets of fluid at high pressure can penetrate the suitable closed receptacle and must be disposed
skin. Keep face and hands well clear of fluid under of in accordance with local environmental waste
pressure and wear personal protective equipment. regulations.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Handling
engine running. Completely wipe off any spilt fuel
CAUTION The temperature of the hydraulic oil
which could cause a fire. There could be a fire and
will be high soon after stopping the machine. Wait
injury if you do not follow these precautions.
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
75 - 4 9813/9400-1 75 - 4
00 - General
• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.
Figure 1788.
A B C D E F
A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions
First Aid - Oil Swallowing
Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15min. egg or vegetable oil. Get medical help.
If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
Skin
In the case of excessive skin contact, wash with soap
and water.
Spillage
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
Fires
WARNING Do not use water to put out an oil fire.
This will only spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon
dioxide, dry chemical or foam.
First Aid - Electrolyte

Eyes
In the case of eye contact, flush with water for 15min.
always get medical attention.
75 - 5 9813/9400-1 75 - 5
00 - General
Technical Data
JCB recommend that you use the JCB lubricants No warranty liability will be accepted for engine
shown as they have been verified by JCB for use failures where unacceptable fuel grades (or their
on JCB machines. However, you could use other equivalent) have been used at any stage.
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.
Table 712.
Item Capacity Fluid/Lubricant JCB Part Container
Number Size
(1)
Fuel Tank 146L Diesel Oil - See Tech-

nical Da-
ta, Fluids,
Lubricants
and Capac-
ities, Fuel.
DEF (Diesel Exhaust Flu- 13.5L DEF 4007/1019L 2.5 US Gal
id) Tank (minimum to maxi- 4007/1013L 2.5 US Gal
mum)
Engine (Oil)
(2)
Min12.5L - Max15L JCB Engine Oil UP 5W40 4001/3405U 5 US Gal
(API CJ-4) -30–46°C (-22.0–
114.7°F)
Engine (Coolant)
(3)
28L JCB Antifreeze HP/Coolant + 4000/1110U 1 US Gal
Water
Transmission (SS750 in- • Wet fill 11.5L JCB Transmission Fluid EP 4000/2505U 5 US Gal
stalled with 81kW engines) • Dry fill 13.5L 10W
Transmission (PS750 in- • Wet fill 17L JCB Transmission Fluid 4000/2505U 5 US Gal
stalled with 55kW and • Dry fill 19L EP 10, -32–40°C (-25.6–
55kW engines) 103.9°F)
(4)
JCB Transmission Fluid EP 4000/2506U 5 US Gal

SAE 30, -5–46°C (23.0–
114.7°F)
Transmission (PS760 in- • Wet fill 21L JCB Transmission Fluid 4000/2505U 5 US Gal
stalled with 93kW and • Dry fill 23L EP 10W, -32–40°C (-25.6–
108kW engines) 103.9°F)
JCB Transmission Fluid EP 4000/2506U 5 US Gal
SAE 30, -5–46°C (23.0–
114.7°F)
(4)
Dual Tech Variable Trans- • Wet fill 10.5L JCB Transmission Fluid 4000/2505U 5 US Gal
mission (HM560) • Dry fill 12.5L EP 10W, -32–40°C (-25.6–
103.9°F)
Gearbox JCB Transmission Fluid EP 4000/2505U 5 US Gal
10W
Front axle housing (512-26) 14.5L JCB Gear oil LS plus 4000/3905U 5 US Gal
Front axle housing (506-23 17.7L JCB Gear oil HP plus 4000/2205U 5 US Gal
(5)
and 509-23)
Hubs (512-26) 1.9L JCB Gear oil LS plus 4000/3905U 5 US Gal
Hubs (other machines) 1.9L JCB Gear oil HP plus 4000/2205U 5 US Gal
(5)
Rear axle housing (506-23, 10L JCB Gear oil HP plus 4000/2205U 5 US Gal
(5)
509-23)
Rear axle housing (512-26) 13.5L JCB Gear oil LS plus 4000/3905U 5 US Gal
Hubs (512-26) 1.9L JCB Gear oil LS plus 4000/3905U 5 US Gal
Hubs (506-23 and 509-23) 2L JCB Gear oil HP plus 4000/2205U 5 US Gal
(5)
75 - 6 9813/9400-1 75 - 6
00 - General
Item Capacity Fluid/Lubricant JCB Part Container

Number Size
(1)
Brake system
(6)
JCB Hydraulic fluid HP 15
(7)
4002/0503U 1 US Ga
Hydraulic tank (506-23, 115L JCB Optimum Performance 4002/2005U 5 US Gal
509-23)
(8)
Hydraulic Fluid 46 or JCB Op- or
112L timum Performance Hydraulic 4002/2705U
Hydraulic tank (512-26)
(8)
Fluid 68
Grease Points JCB Special HP Grease 4003/2017 0.4kg
(Blue)
(9)
Wear pad runways JCB Waxoyl 4004/0502 5L

Boom hoses JCB Special HP Grease (Blue) 4003/2017 0.4kg
Boom chain JCB Chain Lubricant 4004/0237A 0.3L
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB Dealer.
(2) Do not use ordinary engine oil.
(3) It is recommended that the cooling system be filled at a maximum rate of 6L per minute. If the fill rate is any
higher than this then there is a possibility of air becoming trapped in the system.
(4) Friction modified oils must not be used (eg Dexron ATF type).
(5) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
(6) Excluding 512-26 machines.
(7) Do not use ordinary brake fluid.
(8) This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used.
Fill with all cylinders closed. Watch level sight glass when filling.
(9) JCB Special HP Grease is the recommended specification grease. If JCB Special MPL-EP Grease is used,
all 50h greasing operations must be carried out at 10h intervals; all 500h greasing operations must be carried
out at 50h intervals.
75 - 7 9813/9400-1 75 - 7
03 - Oil
03 - Oil
Contents Page No.
75-03-00 General ............................................................................................................................. 75-9

75-03-03 Engine ............................................................................................................................ 75-10
75 - 8 9813/9400-1 75 - 8
03 - Oil
00 - General
00 - General
Introduction
New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:
1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.
First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.
SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.
SKIN - In the case of excessive skin contact, wash

with soap and water.
SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.
FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.
75 - 9 9813/9400-1 75 - 9
03 - Oil
03 - Engine
03 - Engine
Introduction
New engines DO NOT require a running-in period.

The engine/machine should be used in a normal
work cycle immediately. Glazing of the piston cylinder
bores, resulting in excessive oil consumption, could
occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle
for extended periods; (e.g. warming up without load).
A minimum API CJ4 grade oil must be used. Superior

grade oils may be more appropriate for heavy duty
applications (such as sustained high loads and
operation at elevated temperatures).
The choice of lubricant viscosity should be made

based on the lowest ambient temperature at which
the machine will be started and the maximum
ambient temperature at which it will operate.
The technical data section provides guidance as to

the temperature range that can be accommodated
by standard oil viscosities and can be used to select
an appropriate grade.
Important: When selecting the oil viscosity grade

make sure the oil conforms with or exceeds the
recommended specification.
75 - 10 9813/9400-1 75 - 10
06 - Grease
06 - Grease
Contents Page No.
75-06-00 General ........................................................................................................................... 75-13
75 - 11 9813/9400-1 75 - 11
Notes:
75 - 12 9813/9400-1 75 - 12
06 - Grease
00 - General
00 - General Consumable: JCB Autogrease

6. JCB EP Hammer Grease
Introduction Consumable: EP Hammer Grease
Special Tools 7. JCB Special Hammer Grease
Consumable: Special Hammer Grease
Grease Gun 892/00913 1
Attachment 8. JCB Special Slew Pinion Grease
Grease Gun 992/11300 1
Consumable: Special Slew Pinion Grease
Consumables
Description Part No. Size Greasing Procedure
EP Hammer Grease 4003/2107 0.4kg 1. Make the machine safe.
4003/2106 12.5kg
Moly Grease 4003/1326 12.5kg 2. If necessary, install any maintenance or
JCB Autogrease 4003/2305 0.5kg articulation struts.
Special HP Grease 4003/2017 0.4kg 3. Make a note of the following:
4003/2006 12.5kg
3.1. The machine must always be greased after
4003/2005 50kg pressure washing or steam cleaning.
Special Hammer 4003/1119 0.4kg
Grease 3.2. Greasing must be done with a grease gun.
Normally, two strokes of the gun should be
Special MPL-EP 4003/1501 0.4kg
sufficient.
Grease 4003/1506 12.5kg
Special Tool: Grease Gun (Qty.: 1)
4003/1510 50kg
Special Tool: Grease Gun Attachment (Qty.:
Special Slew Pinion 4003/1619 0.4kg 1)
Grease
3.3. Stop greasing when fresh grease appears
Special Slide Grease 4003/1115 0.4kg
at the joint.
There are various greasing points on the machine. 3.4. Use only the recommended type of grease.
You must grease the machine regularly to keep
3.5. Do not mix different types of grease, keep
it working efficiently. Regular greasing will also
them separate.
lengthen the machine's working life. You must grease
the machine as stated in the maintenance schedule. 4. Count off the grease points as you grease each
Refer to: PIL 78-24. one.
JCB grease is manufactured to provide significant 5. Install the dust caps after greasing (if installed).
load protection for your machine. It is recommended
to use only JCB grease on your machine because JCB Special HP Grease
they are specifically designed for the particular
application. The list of JCB greases comprises: JCB Special HP grease is a premium quality,
extreme pressure grease. It is recommended
1. JCB Special HP Grease
for use in arduous operating conditions, such
Consumable: Special HP Grease as high temperatures, excessive loading and
extensive exposure to water. The sophisticated
2. JCB Special MPL-EP Grease additive package combines with excellent adhesive
Consumable: Special MPL-EP Grease properties to give high performance protection to
your machine.
3. JCB Extreme Performance Moly Grease
Table 713. JCB Special HP Grease Properties
Grease Description Data
Colour Blue
4. JCB Special Slide Grease
Soap type Lithium complex
Consumable: Special Slide Grease
5. JCB Autogrease
75 - 13 9813/9400-1 75 - 13
06 - Grease
00 - General
Description Data Table 716. JCB Special Slide Grease Properties

Drop point 245°C (472.7°F) Description Data
Working temperature -20–150°C (-4.0– Colour Dark grey
range 301.8°F) Soap type Lithium
Drop point 180°C (355.7°F)
JCB Special MPL-EP Grease Working temperature -20–120°C (-4.0–
range 247.8°F)
JCB Special MPL-EP grease is a true multipurpose
grease. It is recommended for a wide range of
lubricating applications, such as pivot pins and wheel JCB Autogrease
bearings, where excellent anti wear and anti rust
performance is required. Its EP additive makes it JCB Autogrease is for use with the automatic
particularly suitable for the shock load and vibrating greasing system. It is a mineral oil based paste.
conditions found on machines. It contains an aluminium complex soap and solid
lubricants. It is suitable for use under water or in
Table 714. JCB Special high ambient temperatures. The specially designed
MPL-EP Grease Properties cartridges screw into the automatic greasing system
installed on the machine.
Description Data
Colour Brown The clear cartridge allows the operator to easily
Soap type Lithium monitor the grease usage from inside of the operator
Drop point 180°C (355.7°F) station.
Working temperature -20–130°C (-4.0– Table 717. JCB Autogrease
range 265.8°F)
Description Data
JCB Extreme Performance Moly Grease Colour Black
Soap type Aluminium complex, sol-
JCB Extreme Performance Moly grease is an id lubricants
advanced performance, multipurpose grease. It is Drop point 260°C (499.6°F)
recommended for heavily loaded bearing surfaces Working temperature -20–110°C (-4.0–
and in particular where limited or oscillating range 229.8°F)
motion causes fretting. The addition of molybdenum
disulphide provides extra protection against scoring
and wear. This grease is ideal for automotive, JCB EP Hammer Grease
industrial, agricultural and earthmoving equipment.
JCB EP Hammer grease is a unique formulation
Table 715. JCB Extreme aluminium complex grease for use where extremes
Performance Moly Grease Properties of pressure and temperature are likely to be
encountered. It is suitable for the hammer
Description Data applications where resistance to water washing and
Colour Grey Black migration may be critical.
Soap type Lithium
Drop point 185°C (364.7°F) Table 718. JCB EP Hammer Grease
Working temperature -20–120°C (-4.0– Description Data
range 247.8°F) Colour Black
Soap type Aluminium complex
JCB Special Slide Grease Drop point 250°C (481.6°F)
Working temperature -20–160°C (-4.0–
JCB Special Slide grease is formulated to provide range 319.8°F)
excellent protection under heavy load and extreme
pressure, where water and dirt are prevalent. It
maintains a film of lubrication on slow moving slides. JCB Special Hammer Grease
It has an excellent resistance to squeeze out and
superb corrosion resistance. JCB Special Hammer grease provides a highly
effective lubricant on slow moving slides and an
excellent corrosion resistant property. It combines
the self healing action of oils and the resistance to
drip of viscous compounds.
75 - 14 9813/9400-1 75 - 14
06 - Grease
00 - General
Table 719. JCB Special Hammer Grease

Description Data
Colour Dark grey
Soap type Lithium
Drop point 185°C (364.7°F)
Working temperature -15–120°C (5.0–
range 247.8°F)
JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.
Table 720. JCB Special Slew Pinion Grease

Description Data
Colour Black
Soap type Organically modified
clay
Working temperature -40–100°C (-39.9–
range 211.9°F)
75 - 15 9813/9400-1 75 - 15
09 - Fluids
09 - Fluids
Contents Page No.
75-09-00 General ........................................................................................................................... 75-17

75-09-03 Antifreeze ....................................................................................................................... 75-18
75-09-12 Diesel Exhaust Fluid (DEF) ........................................................................................... 75-20
75 - 16 9813/9400-1 75 - 16
09 - Fluids
00 - General
00 - General
Introduction
It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.
However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.
Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.
Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.
The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.
75 - 17 9813/9400-1 75 - 17
09 - Fluids
03 - Antifreeze
03 - Antifreeze Introduction
Introduction .................................................... 75-18
Coolant Mixtures
Technical Data ............................................... 75-19 Check the strength of the coolant mixture at least
once a year, preferably at the start of the cold period.
Do not use solutions of more than 60% or damage to
the engine may occur. Replace the coolant mixture
according to the intervals shown in the machine's
maintenance schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion. Always
renew the antifreeze every two years.
The protection provided by High Performance

Antifreeze and Inhibitor is shown below. If any
other antifreeze is used, refer to the manufacturer's
instructions and make sure that a corrosion inhibitor
is included.
Table 721.
Solution Maintains cir- Protects
culation down against dam-
to: age down to:
50% Concen- -33°C (-27.4°F) -40°C (-39.9°F)
tration (Stan-
dard)
60% Concen- -42°C (-43.5°F) -56°C (-68.7°F)
tration (Stan-
dard)
Important: Do not exceed a 60% concentration, as

the freezing protection provided reduces beyond this
point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).
75 - 18 9813/9400-1 75 - 18
09 - Fluids
03 - Antifreeze

CAUTION The cooling system is pressurised CAUTION Antifreeze can be harmful. Obey the
when the coolant is hot. When you remove the manufacturer's instructions when handling full
cap, hot coolant can spray out and burn you. strength or diluted antifreeze.
Make sure that the engine is cool before you work
on the cooling system. Check the strength of the coolant mixture at least
CAUTION Antifreeze can be harmful. Obey the once a year, preferably at the start of the cold period.
manufacturer's instructions when handling full
strength or diluted antifreeze. Replace the coolant mixture according to the
intervals shown in the machine's Service Schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion.
The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
Table 722.
Concentration Level of protection
50% (Standard) Protects against dam-

Service Manual: Foreword

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: Foreword

Uploaded by

Copyright:

Available Formats

Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADALL (ROUGH TERRAIN

Copyright 2017 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

506-23, 509-23, 512-26 506-23, 509-23, 512-26

SERVICE MANUAL SERVICE MANUAL

506-23, 509-23, 512-26 506-23, 509-23, 512-26

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual and on the machine, there are safety

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system (shown) also helps to identify

Figure 1. The safety alert system

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

Lift Arm Lowered

A Lift arm lowered

Lift Arm Raised

Health and Safety

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-15

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-00 General ........................................................................................................................... 01-19

A main structural support is designed to carry an

When used normally the machine lifts and places

The machine is intended to be used in normal

03 - Log Moving/Object Handling

Do not use the machine to move or handle logs

06 - Optional Equipment and

A wide range of optional attachments are available

12 - Main Component Locations

A Lift arm B Carriage

15 - Service Point Locations

A Air filter B Transmission oil dipstick

Hydraulic Oil Level Indicator

A Hydraulic oil level indicator

A Label - hydraulic oil filling point B Hydraulic oil level indicator

Machines without External Sight Gauge

A Hydraulic oil level indicator