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
531-70, 535-95, 541-70
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 - 9813/9050 - ISSUE 1 - 01/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
Copyright 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:
9813/9050-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
531-70, 535-95, 541-70 531-70, 535-95, 541-70
EN 9813/9050 EN 9813/9050
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
531-70, 535-95, 541-70 531-70, 535-95, 541-70
EN 9813/9050 EN 9813/9050
9813/9050-1
Notes:
9813/9050-1
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-15
01-06-06 Using the Manual ........................................................................................................... 01-16
01-09 Description
01-09-00 General ........................................................................................................................... 01-19
01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-31
9813/9050-1
2017-11-16
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9813/9050-1
2017-11-16
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01 - 1 9813/9050-1 01 - 1
Notes:
01 - 2 9813/9050-1 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

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

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

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

the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9813/9050-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual there are safety notices. Each notice

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

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

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

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

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

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.
Figure 1. The safety alert system symbol
01 - 4 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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, mirrors and cameras clean (when machine.
fitted).
If the machine is struck by lightning do not use the
Do not operate the machine if you cannot see clearly. machine until it has been checked for damage and
Modification of the machine's configuration by the malfunction by trained personnel.
user (e.g. the fitting of large and non-approved
attachments) may result in a restriction of the
machine visibility.
01 - 9 9813/9050-1 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 9813/9050-1 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 9813/9050-1 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12
Health and Safety .......................................... 01-13
(For: 531-70 [5AA], 535-95 [5AB])
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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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:
531-70 2902000
535-95 2902000
541-70 2902000
01 - 15 9813/9050-1 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 9813/9050-1 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 9813/9050-1 01 - 17
Notes:
01 - 18 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 01 - 23
01 - Machine
09 - Description
15 - Service Point Locations
Engine Compartment
Figure 4.
A B
H
C
G D
E
F
A Air filter B Transmission oil dipstick

C Water separator D Radiator
E Engine oil filter F Drive belt guard
G Engine oil dipstick H Engine oil filler cap
J Coolant expansion tank
01 - 24 9813/9050-1 01 - 24
01 - Machine
09 - Description
Battery Isolator
Figure 5.
A
A
A Battery isolator
01 - 25 9813/9050-1 01 - 25
01 - Machine
09 - Description
Hydraulic Oil Level Indicator and Filler
Figure 6.
C
A
A Hydraulic oil level indicator B Label - hydraulic oil filling point

C Hydraulic tank filler cap
Figure 7. Machines with External Sight Gauge

On some machines the sight gauge is mounted
externally.
A
Figure 8.
A
A Hydraulic oil level indicator
A Secondary hydraulic tank filler cap - If applicable
01 - 26 9813/9050-1 01 - 26
01 - Machine
09 - Description
Axles
Arrangement
Figure 9. Machines with Powered Track Rods
A A
A Axle fill/level plug
01 - 27 9813/9050-1 01 - 27
01 - Machine
09 - Description
Alternate arrangement
Figure 10. Machines with Powered Track Rods
A A
Figure 11. Machines with Double Acting Cylinders
A
A
01 - 28 9813/9050-1 01 - 28
01 - Machine
09 - Description
Filling the Tank

Figure 12.
A Fuel cap
01 - 29 9813/9050-1 01 - 29
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-31
01 - 30 9813/9050-1 01 - 30
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-31 or other chemicals, you must adhere to
Preparation .................................................... 01-32 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
the machine inoperable. Remove dirt using a
brush or damp cloth.
Clean the product with water and/or steam. Do not

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

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

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

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

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

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.
01 - 31 9813/9050-1 01 - 31
01 - Machine
33 - Cleaning
00 - General
Notice: The engine and other components could Preparation

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

after pressure washing or steam cleaning.
01 - 32 9813/9050-1 01 - 32
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-33 Fork
03-33-00 General ............................................................................................................................. 03-7
03-33-03 Carriage .......................................................................................................................... 03-10
03-82 Jib
03-82-00 General ........................................................................................................................... 03-13
03-82-06 Shackle ........................................................................................................................... 03-15
03-84 Hook
03-84-06 Snatch Block .................................................................................................................. 03-19
9813/9050-1
2017-08-14
Notes:
9813/9050-1
2017-08-14
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/9050-1 03 - 1
Notes:
03 - 2 9813/9050-1 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 9813/9050-1 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 9813/9050-1 03 - 4
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-7

03-33-03 Carriage .......................................................................................................................... 03-10
03 - 5 9813/9050-1 03 - 5
Notes:
03 - 6 9813/9050-1 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 9813/9050-1 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 9813/9050-1 03 - 8
33 - Fork
00 - General
Figure 13.
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 9813/9050-1 03 - 9
33 - Fork
03 - Carriage
03 - Carriage Install
1. The installation procedure is the opposite of the
Remove and Install removal procedure.
(For: 531-70 [5AA], 541-70 [5AD])
Two stage booms (P1)

Remove
2. Position the lift arm so that the fork carriage can
be safely supported when it is disconnected from
the lift arm assembly.
3. Discharge the hydraulic pressure.
4. Support the fork carriage.
5. Remove the bolt and tipping lever pivot pin.
6. Remove the lock nut and bolt from the pivot pin
trunnion.
7. Remove the pivot pin from its location.
8. Remove the fork carriage.
Figure 14.
B C
D A
A Fork carriage
B Bolt
C Tipping lever pivot
D Pivot pin
03 - 10 9813/9050-1 03 - 10
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-13

03-82-06 Shackle ........................................................................................................................... 03-15
03 - 11 9813/9050-1 03 - 11
Notes:
03 - 12 9813/9050-1 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 9813/9050-1 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 9813/9050-1 03 - 14
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 16.

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 15.
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 9813/9050-1 03 - 15
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 17.
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 9813/9050-1 03 - 16
84 - Hook
84 - Hook
Contents Page No.
03-84-06 Snatch Block .................................................................................................................. 03-19
03 - 17 9813/9050-1 03 - 17
Notes:
03 - 18 9813/9050-1 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 9813/9050-1 03 - 19
84 - Hook
06 - Snatch Block
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 18.
C A
A Mounting sockets
B Lynch pin
C Locking bar
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Lower the attachment so that it just clears the
ground.
3. Apply the park brake and stop the engine.
4. Remove the attachment.
4.1. Remove the lynch pin and locking bar.
4.2. Carefully slide the attachment off the forks.
4.3. Install the locking bar and secure with lynch
pin.
4.4. Store the attachment carefully to prevent
damage and corrosion.
Install
1. Space the forks, equally on either side of the
machine centreline, so that the mounting sockets
can be slid onto them.
2. Tighten the fork clamping screws to prevent
movement.
3. Install the attachment.
3.1. Remove the lynch pin and locking bar.
3.2. Slide attachment over the forks so that the
rear of the attachment butts against the
heels of the forks.
3.3. Install the locking bar and secure with lynch
pin.
03 - 20 9813/9050-1 03 - 20
Contents Page No.
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-7
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-11
06-06-06 Engine Compartment ..................................................................................................... 06-12
06-06-12 Front Cover .................................................................................................................... 06-15
06-06-14 Rear Cover ..................................................................................................................... 06-17
06-06-30 Undershield .................................................................................................................... 06-18
06-06-33 Lift Arm ........................................................................................................................... 06-19
06-06-39 Cab/Canopy ................................................................................................................... 06-20
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-25
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-45
06-12-24 Shim ............................................................................................................................... 06-46
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-55
06-42 Stabiliser
06-42-00 General ........................................................................................................................... 06-59
06-49 Step
06-49-00 General ........................................................................................................................... 06-63
06-54 Fender
06-54-00 General ........................................................................................................................... 06-65
06-57 Counterweight
06-57-00 General ........................................................................................................................... 06-69
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-71
06-63-06 Engine ............................................................................................................................ 06-72
06-63-09 Axle ................................................................................................................................ 06-74
06-63-12 Gearbox .......................................................................................................................... 06-75
06-63-15 Operator Protective Structure ........................................................................................ 06-76
06-66 Tools
06-66-00 General ........................................................................................................................... 06-79
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-81
06-69-03 Lift Arm ........................................................................................................................... 06-82
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-85
06-89 Window Guard
06-89-00 General ........................................................................................................................... 06-87
9813/9050-1
2017-12-01
Acronyms Glossary
FOPS Falling Object Protective Structure

OECD Organization for Economic
Cooperation and Development
9813/9050-1
2017-12-01
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9813/9050-1 06 - 1
Notes:
06 - 2 9813/9050-1 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 9813/9050-1 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 9813/9050-1 06 - 4
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 5 9813/9050-1 06 - 5
Notes:
06 - 6 9813/9050-1 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 9813/9050-1 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 9813/9050-1 06 - 8
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-11

06-06-06 Engine Compartment ..................................................................................................... 06-12
06-06-12 Front Cover .................................................................................................................... 06-15
06-06-14 Rear Cover ..................................................................................................................... 06-17
06-06-30 Undershield .................................................................................................................... 06-18
06-06-33 Lift Arm ........................................................................................................................... 06-19
06-06-39 Cab/Canopy ................................................................................................................... 06-20
06 - 9 9813/9050-1 06 - 9
Notes:
06 - 10 9813/9050-1 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 9813/9050-1 06 - 11
06 - Engine Compartment
Remove and Install
CAUTION The exhaust pipe becomes extremely 4. Support the cover using suitable overhead lifting
hot when the engine is running and will remain so equipment.
for some time after the engine is stopped. If you
touch the hot pipe you could be severely burned. 5. Remove the gas strut mount securing nut and
remove the strut from the support bracket.
A typical engine cover removal and installation 6. Remove the hinge bolts.
procedure is given below. Your machine may differ
from that shown. 7. Take the top engine cover away from the
machine with the lifting equipment.
Remove 8. Remove the exhaust outlet pipe. Refer to fuel
1. Make the machine safe. Refer to (PIL 01-03). system- Exhaust. Refer to (PIL 18-24).
2. Follow the general safety precautions. Refer to 9. Support the engine pod base.
(PIL 01-03). 10. Remove the bolts and washers and lower the
3. Open the engine compartment cover. Refer to engine pod complete along with the guards to the
(PIL 06-06) ground.
06 - 12 9813/9050-1 06 - 12
Figure 19.
A
D
C
G
F
A Engine pod cover B Hinge bolts

C Support bracket D Strut mount securing nut
E Engine pod base F Bolts
G Washers
06 - 13 9813/9050-1 06 - 13
Install
removal procedure. Additionally do the following
steps.
1.1. Tighten the bolts to the specified torque
value.
1.2. Tighten the strut mount securing nut to the
specified torque value.
Table 3. Torque Values

Item Description Nm
B Hinge bolts 18
D Strut mount securing nut 18
06 - 14 9813/9050-1 06 - 14
12 - Front Cover
12 - Front Cover Figure 20.
Remove and Install
Remove
2. Isolate the battery and remove the isolator key.
Refer to (PIL 33-03-03).
3. Open the top cover to gain access to the cover
securing bolts.
4. Remove the bolts (x3) located outside the cab
beneath the front window.
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 - 15 9813/9050-1 06 - 15
12 - Front Cover
Figure 21.
C C
C
B
D D
B Front cover assembly
C Bolt locations- from outside cab
D Bolt locations- from inside cab (floor pan not
shown)
Install
steps.
2. Tighten the fasteners to the correct torque value.
3. Make sure the washer fluid level is correct and
that the window wash/wipe system operates
correctly.
06 - 16 9813/9050-1 06 - 16
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 22.
B
A Key
B Rear cover
Close
1. Position the rear cover.
2. Use the key to lock the rear cover.
06 - 17 9813/9050-1 06 - 17
30 - Undershield
30 - Undershield
Figure 23. 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 - 18 9813/9050-1 06 - 18
33 - Lift Arm
33 - Lift Arm
Remove and Install
Remove- Lift Arm Nose Cover

2. Fully lower the lift arm.
3. Remove the securing bolts.
4. Remove the cover from the inner lift arm nose.
Figure 24.
1 Securing bolts
2 Cover
Install
removal procedure.
06 - 19 9813/9050-1 06 - 19
39 - Cab/Canopy
39 - Cab/Canopy
Remove and Install
Install
Remove
1. Make the machine safe. Refer to (PIL 01-03). removal procedure. Additionally do the following
step.
Refer to (PIL 33-03-03). 1.1. Tighten the floor cover bolts to the correct
torque value.
3. Lift and remove the floor mat.
4. Remove the floor cover bolts (X6). Cab Rear Cover
5. Remove the cover. Remove
Figure 25. Access Plate- Cab Floor 1. Make the machine safe. Refer to (PIL 01-03).
3. Remove the rear cover bolts (X5).
A
4. Remove the cover.
B
A Cab
B Access plate- cab floor
06 - 20 9813/9050-1 06 - 20
39 - Cab/Canopy
Figure 26. Cab Rear Cover

A
C
A Cab B Rear cover

C Bolts (X5) D Rubber flap
06 - 21 9813/9050-1 06 - 21
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 26.
1.2. Tighten the bolts to the correct toque value.
06 - 22 9813/9050-1 06 - 22
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-25

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-45
06-12-24 Shim ............................................................................................................................... 06-46
06 - 23 9813/9050-1 06 - 23
Notes:
06 - 24 9813/9050-1 06 - 24
12 - Lift Arm
00 - General
Introduction .................................................... 06-25
Hydraulic Ram Operated Lift Arms
Technical Data ............................................... 06-28 The lift arms on these machines are extended and
Operation ....................................................... 06-30 retracted by hydraulic rams. No chain system is
Calibrate ........................................................ 06-31 used. There are differences in the configuration
and location of components depending on machine
Lubricate ........................................................ 06-32
model. Refer to Table 4.
Remove and Install ....................................... 06-34
Disassemble and Assemble .......................... 06-37 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
531-70 2 Section, 2 stage
06 - 25 9813/9050-1 06 - 25
12 - Lift Arm
00 - General
Figure 27.
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 - 26 9813/9050-1 06 - 26
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 - 27 9813/9050-1 06 - 27
12 - Lift Arm
00 - General
Technical Data
For: 531-70 [5AA], 541-70 [5AD] Figure 28. 2 Stage (2 section) Lift Arm
................................................... Page 06-28
For: 535-95 [5AB] ...................... Page 06-28
(For: 531-70 [5AA], 541-70 [5AD])

A
Wear pad Clearance- 2 Stage (2 section)
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).
B
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
(For: 535-95 [5AB])
Wear Pad Clearance- 3 Stage (3 section)

Lift Arm
Make sure that the wear pads are installed in the
correct way round to prevent fouling. Refer to body
and framework- wear pads, refer to (PIL 06-30).
Use the dome headed Tuf-Lok bolts at position B and

position 3-C.
The intermediate to outer lift arm, bottom right hand

wear pad (shown at position A) may vary. Refer to
parts catalogue.
06 - 28 9813/9050-1 06 - 28
12 - Lift Arm
00 - General
Figure 29. 3 Stage Lift Arm
2
2
Table 6. Maximum Gap

Dimension Maximum Gap
1 3mm
2 1.5mm
3 21–25mm
4 37–41mm
06 - 29 9813/9050-1 06 - 29
12 - Lift Arm
00 - General
Operation
(For: 535-95 [5AB])
Figure 30. Telescopic Operation- 3 Stage (3 Section) Lift Arm

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

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

phase the telescopic service hoses will be damaged.
06 - 30 9813/9050-1 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 33.
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 31.
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 32. 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 9813/9050-1 06 - 31
12 - Lift Arm
00 - General
Lubricate
For: 531-70 [5AA], 541-70 [5AD]

................................................... Page 06-32
For: 535-95 [5AB] ...................... Page 06-33
(For: 531-70 [5AA], 541-70 [5AD])
Figure 34.
B F
A
C
E
G H
J K
M N
P Q
1. Make the machine safe. Refer to (PIL 01-03). 2. Apply grease to all the points and linkages.
06 - 32 9813/9050-1 06 - 32
12 - Lift Arm
00 - General
(For: 535-95 [5AB])
Figure 35.
A
H

2. Apply the correct grease to all the points and
linkages.
06 - 33 9813/9050-1 06 - 33
12 - Lift Arm
00 - General
Remove and Install
2. Fully lower the lift arm. Open the rear access

(For: 531-70 [5AA], 541-70 [5AD]) cover and disconnect the displacement ram
(if installed) by removing bolts 1, nuts 1 and
Special Tools washers 1.
Description Part No. Qty.
Slide Hammer Kit 993/68100 1 3. Use the slide hammer kit to remove the pivot pin.
Refer to (PIL 06-30). Operate the carriage crowd
The complete lift arm assembly has a mass of control to retract the displacement ram.
approximately the specified value. 3,000kg Special Tool: Slide Hammer Kit (Qty.: 1)
The lift ram has a mass of approximately the 4. Lower the lift arm onto a suitable support in the
specified value. 250kg semi-raised position to gain access to the lift ram
rod end and the displacement rams head end.
Support the ram with a suitable lifting equipment.
5. Support the lift arm ready for removal with
suitable lifting equipment. Use lifting shackles of
Remove suitable capacity fitted to the forward and rear
1. Make the machine safe. Refer to PIL (01-03). lifting points.
06 - 34 9813/9050-1 06 - 34
12 - Lift Arm
00 - General
Figure 36.
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 - 35 9813/9050-1 06 - 35
12 - Lift Arm
00 - General
6. 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
7. Use the slide hammer kit to remove the pivot pin. steps.
Refer to (PIL 06-30).
1.1. Check the hydraulic oil level and refill if
8. Lower the ram onto suitable packing material to necessary. Refer to (PIL 30-00).
protect the piston rod.
1.2. Grease all pivot pins. Refer to (PIL 75-06).
9. Discharge the hydraulic pressure. Refer to (PIL
1.3. For the main pivot pins types 2 and 3,
30-00).
identify the position and quantity of all
10. Put a label on the extension ram hoses to help washers and spacers for the machine
installation. model. Align the locking plate and install
spacer and large washer 1, washers 2 and
11. Make sure the lift arm is fully supported. Note bolt 1.
there will be one of three types of main pivot pin 1.4. For main pivot pins types 2 and 3, tighten
for the lift arm. the bolt to the specified torque value.
11.1. Type 1- Remove the bolt 3 and withdraw Torque: 476N·m
the pivot pin 3. Refer to Figure 36.
11.2. Types 2 and 3- Remove the items 1 to 6,
noting the quantity and arrangement of the
spacers. Refer to Figure 37.
Figure 37. Types 2 and 3
(531-70 and 541-70 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
12. Carefully lift the lift arm clear of the machine,
checking for any remaining connections. Lower
the lift arm onto suitable packing material.
06 - 36 9813/9050-1 06 - 36
12 - Lift Arm
00 - General
Disassemble and Assemble
For: 531-70 [5AA], 541-70 [5AD] 7.2. Put label on the hoses at the steel pipes
................................................... Page 06-37 on the underside of the lift arm to help
For: 535-95 [5AB] ...................... Page 06-40 installation.
7.3. Disconnect and remove the hoses.
(For: 531-70 [5AA], 541-70 [5AD]) 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
sections. The lift arm sections can be separated with 7.5. Then pull out the hoses through the
the lift arm assembly removed or installed to the apertures under the lift arm in the direction
machine as required. of the arrow Y.
CAUTION! You can be injured if you use incorrect or 7.6. Plug all the open ports and hoses to prevent
faulty lifting equipment. You must identify the weight contamination.
of the item to be lifted then choose lifting equipment 7.7. Put label on the auxiliary service hoses at
that is strong enough and suitable for the job. Make the steel pipes on the underside of the lift
sure that lifting equipment is in good condition and arm and at the front of the lift arm to help
complies with all local regulations. installation.
WARNING! Hydraulic fluid at system pressure can 7.8. Disconnect and remove the hoses.
injure you. Before connecting or removing any
hydraulic hose, residual hydraulic pressure trapped 7.9. Pull out the hoses in the same way as the
in the service hose line must be vented. Make tilt ram hoses. Refer to 7.4 and 7.5.
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
serious injury or be killed. 8.2. Make sure that the lift arm assembly is fully
supported by the outer lift arm and then
Disassemble remove the upper and side wear pads.
8.3. Lift the front of the inner lift arm clear of
The following procedures can be carried out without the lower wear pads and then remove them.
the need to separate the lift arm sections or remove Label all the wear pads and keep them
the lift arm from the machine. together with their shims.
1. Make the machine safe. Refer to (PIL 01-03). 8.4. Support the front end of the inner lift arm
and draw it out from the outer section.
8.5. Before the inner section is all the way out
30-00).
attach suitable lifting equipment. Make sure
3. Remove the fork carriage. Refer to (PIL 03-33). the section is fully supported by the lifting
equipment and then draw it free from the
4. Remove the tilt ram. Refer to (PIL 30-15). outer section.
5. Remove the lift arm nose cover (if installed). If the lift arm assembly has been removed from the
Refer to (PIL 06-06). machine, make sure that it is securely supported.
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.
To ensure that the hoses do not become Assemble
damaged or tangled, they must be removed
before attempting to separate the lift arm 1. The assembly procedure is the opposite of
sections. Remove the hoses as follows: the disassembly procedure. Additionally do the
following steps.
7.1. Remove the hose clamps.
06 - 37 9813/9050-1 06 - 37
12 - Lift Arm
00 - General
1.1. Check the length of the hose pairs. The 1.3. Assemble the lift arm sections so that the lift
hose lengths must be equal to within +/- arm is fully retracted.
1mm for each service pair (tilt ram pair, and
1.4. To enable alignment of the rod end pivot
auxiliary service pair).
of the extension ram, install the hydraulic
1.2. Do not renew individual hoses. The hoses hoses so that the lift arm can be extended.
can stretch over time. New hoses may
1.5. Make sure that the hose routing is correct.
not be the same length. Renew all four
Do not cover any hoses.
telescopic service hoses if any of the hoses
are damaged. 2. Do the following steps for 526-56 machines only:
Figure 38.
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 38. 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 38.
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 - 38 9813/9050-1 06 - 38
12 - Lift Arm
00 - General
Figure 39.
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 - 39 9813/9050-1 06 - 39
12 - Lift Arm
00 - General
X Arrow X Y Arrow Y
3.1. The tilt ram and auxiliary service hoses 7.7. Then pull out the hoses through the
pass through the guide channels in the top apertures under the lift arm in the direction
of the inner lift arm. When all the hoses are of arrow Y.
correctly connected, install the clamps at
7.8. Plug all the open ports and hoses to prevent
the inside of the inner lift arm.
contamination.
3.2. Check that the lift arm wear pad shimming
7.9. Put a label on the auxiliary service hoses on
is correct. Refer to Body and Framework-
the underside of the lift arm and at the front
Lift Arm. Refer to (PIL 06-12).
of the lift arm to help installation.
Table 7. Torque Values 7.10. Disconnect the auxiliary hoses connected
Item Description Nm at the steel pipes.
1 45º Coupling 50 7.11. Remove the auxiliary service hoses.
7.12. Pull out the hoses in the same way as the
tilt ram hoses. Refer to 7.6 and 7.7.
(For: 535-95 [5AB])
7.13. Plug all the open ports and hoses to
Unless the lift arm fabrications are damaged there prevent contamination.
is normally no requirement to separate the lift arm 7.14. Put a label on the inner extension ram
sections. The lift arm sections can be separated with hoses on the underside of the lift arm to
the lift arm assembly removed or installed to the help installation.
machine as required.
7.15. Remove the inner extension ram hoses
connected at the steel pipes.
Disassemble
7.16. Pull out the hoses through the apertures
1. Make the machine safe. Refer to (PIL 01-03). under the lift arm in the direction of the
arrow Y.
30-00). 7.17. Plug all the open ports and hoses to
prevent contamination.
3. Remove the fork carriage. Refer to (PIL 03-33).
8. Remove the inner lift arm.
4. Remove the tilt ram. Refer to (PIL 30-15).
8.1. Remove the front wear pads from the
5. Remove the inner extension ram. Refer to (PIL intermediate lift arm.
30-15).
8.2. Make sure that the lift arm assembly is fully
6. Remove the outer extension ram. Refer to (PIL supported by the outer lift arm and then
30-15). remove the upper and side wear pads.
7. Remove the telescopic hydraulic service hoses. 8.3. Lift the front of the inner lift arm clear of the
To ensure that the hoses do not become lower wear pads and then remove them.
damaged or tangled they must be removed 8.4. Put a label on the wear pads and keep them
before attempting to separate the lift arm together with the shims.
sections. Remove the hoses as follows:
8.5. Support the front end of the inner lift arm
7.1. Remove the bolts 2 and remove the lift arm and pull it out from the intermediate section.
hose guide roller assembly. 8.6. Make sure that the intermediate section
7.2. Remove the bolts 1 and remove the hose does not move.
guide. 8.7. Before you pull out the inner lift
7.3. Put a label on the hoses at the steel pipes arm completely, attach suitable lifting
on the underside of the lift arm to help equipment.
installation. 8.8. Make sure that the section is fully supported
7.4. Disconnect the hoses at the steel pipes. by the lifting equipment and then pull it out
from the intermediate section.
7.5. Remove the tilt ram hoses.
7.6. Pull out the hoses from the rear in the 9. If the lift arm assembly has been removed
direction of the arrow X. from the machine, make sure that it is securely
supported. When the inner lift arm sections is
06 - 40 9813/9050-1 06 - 40
12 - Lift Arm
00 - General
removed, forces may cause the whole assembly 10.5. Support the front end of the intermediate
to move. lift arm and pull it out from the outer
section.
10. Remove the intermediate lift arm.
10.6. Before you pull out the intermediate lift
10.1. Remove the front wear pads from the outer arm completely, attach suitable lifting
lift arm. equipment.
10.2. Make sure that the lift arm assembly is fully 10.7. Make sure that the section is fully
supported by the outer lift arm and then supported by the lifting equipment and
remove the upper and side wear pads. then pull it out from the outer section.
10.3. Lift the front of the intermediate lift clear 11. If the lift arm assembly has been removed
of the lower wear pads and then remove from the machine, make sure that it is securely
them. supported. When the intermediate lift arm section
10.4. Put label on the wear pads and keep them is removed, forces may cause the whole
together with the shims. assembly to move.
06 - 41 9813/9050-1 06 - 41
12 - Lift Arm
00 - General
Figure 40. 3 Stage Lift Arm
H
H
B
N X
F G
E
L
H
D
G J
K J
H
C
U
T
G
A
H
H
J
Y G C
J
A Outer lift arm B Inner lift arm

C Intermediate lift arm D Inner extension ram
E Outer extension ram F Tilt ram
G Extension ram hoses H Auxiliary service hoses
J Tilt ram hoses K Hose guide
L Bolts 1 M Bolts 2
06 - 42 9813/9050-1 06 - 42
12 - Lift Arm
00 - General
N Guide roller assembly T Intermediate lift arm front wear pads

U Outer lift arm front wear pads X Arrow X
Y Arrow Y
06 - 43 9813/9050-1 06 - 43
12 - Lift Arm
00 - General
Assembly
1. The assembly procedure is the opposite of
the disassembly procedure. Additionally do the
following steps.
1.1. Check the length of the hose pairs. The
hose lengths must be equal to within +/-
1mm for each service pair (tilt ram pair,
inner extension ram pair and auxiliary
service pair).
1.2. Do not renew individual hoses. The hoses
can stretch over time. New hoses may
not be the same length. Renew all six
telescopic service hoses if any of the hoses
are damaged.
1.3. Assemble the lift arm sections so that the lift
arm is fully retracted. Install the extension
ram followed by the inner ram. Refer to (PIL
30-00).
1.4. To enable alignment of the rod end pivot
of the inner ram, the hydraulic hoses must
be installed so that the lift arm can be
extended. The length of the inner and
intermediate lift arm sections protruding
from the outer section must be kept equal
to avoid damage to the telescopic service
hoses.
1.5. Make sure that the hose routing is correct.
Do not cross over any hose. The tilt ram and
auxiliary service hoses are routed through
the hose guide and along the tray fitted to
the top of the inner extension ram.
1.6. Lubricate the lift arm hose runs. Refer to
(PIL 06-00).
1.7. Make sure that the lift arm wear pad
shimming is correct. Refer to Technical
Data (PIL 06-12).
1.8. Pivot the hose guide roller assembly so
as to take up the hose slack. Do not
use excessive force when setting the roller
assembly.
06 - 44 9813/9050-1 06 - 44
12 - Lift Arm
12 - Pivot Link Lever (Upper)
12 - Pivot Link Lever (Upper)
Adjust
4. If the gap is more than the specified value, add

(For: 531-70 [5AA], 541-70 [5AD]) the correct quantity of shims to get the correct
measurement. Add the shims equally at the two
The figure (Refer to Figure 41. ) shows the lift arm sides to make sure that the lift arm is at the centre
viewed from the rear of the machine. of the pivot.
1. Measure the gap 1 and the gap 2 as shown in the
figure. Refer to Figure 41. 4.1. Later shims do not have handles.
2. Add the values of gap 1 and the gap 2. Total gap 5. When the total gap is of the correct value, if the
= gap 1 + gap 2. shim has handles, snap the handle from the shim
at the crease.
3. Make sure that the total gap is not more than the
specified value.
Figure 41.
X Y
X Gap 1 Y Gap 2
Figure 42.
B
A Handled shim (earlier type)

B Crease
C Handle
06 - 45 9813/9050-1 06 - 45
12 - Lift Arm
24 - Shim
24 - Shim Technical Data

Technical Data ............................................... 06-46 For: 531-70 [5AA], 541-70 [5AD]
................................................... Page 06-46
Adjust ............................................................ 06-50
For: 535-95 [5AB] ...................... Page 06-48
(For: 531-70 [5AA], 541-70 [5AD])
Number of plain washers to be installed under bolts
Table 8. Machines
Machine Table
536-60 Refer to Table 9.
536-70 and 531-70 Refer to Table 10.
Table 9. 536-60 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 3 2
1.6–3mm 1 2
3.2–6mm 0 1
6.2–8mm 0 0
Lower 0mm 3 N/A
1.6–3mm 2 N/A
3.2–8mm 1 N/A
Table 10. 536-70 and 531-70 Machines

(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
06 - 46 9813/9050-1 06 - 46
12 - Lift Arm
24 - Shim

(Front) (Rear)
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

Wear Pad Shim Thickness Number of washers Number of Washers
(Front) (Rear)
Top 2.1–4.2mm 3
4.7–6.4mm 2
6.9–8mm 1
Side 0.5–2.5mm 2
3–4.5mm 1
5–6.5mm 0
7–8mm 0
1.6–4.2mm 2
4.7–6.4mm 1
Lower 1.6–4.2mm 3 2
4.7–6.4mm 2 1
6.9–8mm 1

(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
0.7–3mm 2 N/A
3.2–6mm 1 N/A
06 - 47 9813/9050-1 06 - 47
12 - Lift Arm
24 - Shim
(For: 535-95 [5AB])
Figure 43. 3 Stage (3 section) Lift Arm
F
B
D
H J
K E
C
K
J
06 - 48 9813/9050-1 06 - 48
12 - Lift Arm
24 - Shim
Table 14. Number of Plain Washers to be installed under Bolt

Detail Shim Thickness Number of Washers
A
(1)
0mm 3
1.6–4.6mm 1
over 4.6mm 0
B
(1)
0mm 4
2–3mm 3
4–6mm 2
7–8mm 1
C
(1)
0–1.6mm 6
3–5mm 5
6mm 4
D
(1)
0mm 4
1.6–3.6mm 3
6mm 2
E
(1)
0mm 4
1.6–3.2mm 3
3.6–6mm 2
F
(2)
0mm 4
2–3mm 3
4–6mm 2
7–8mm 1
G
(2)
0–8mm 0
H
(2)
0–1.6mm 6
3–5mm 5
6mm 4
J
(2)
0mm 4
1.6–3.2mm 3
6mm 2
K
(2)
0mm 4
1.6–3.2mm 3
3.6–6mm 2
(1) Intermediate to the outer lift arm.
(2) Inner to the intermediate lift arm.
06 - 49 9813/9050-1 06 - 49
12 - Lift Arm
24 - Shim
Adjust Figure 45. 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 44. A Inner boom
B Outer boom
Make sure that the threaded insert remains a tight fit Figure 46. 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 44.
D
D Chamfer depth
06 - 50 9813/9050-1 06 - 50
12 - Lift Arm
24 - Shim
Figure 47. Figure 48.

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 - 51 9813/9050-1 06 - 51
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 - 52 9813/9050-1 06 - 52
12 - Lift Arm
24 - Shim
Figure 51.
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert
Table 15. 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 - 53 9813/9050-1 06 - 53
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-55
06 - 54 9813/9050-1 06 - 54
30 - Pivot Pins
00 - General
Introduction .................................................... 06-55 Pivot pins are a short shaft or pin that supports
Lubricate ........................................................ 06-56 something that turns. Pivot pins are installed in
Remove and Install ....................................... 06-56 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 - 55 9813/9050-1 06 - 55
30 - Pivot Pins
00 - General
Lubricate Remove and Install

Special Tools
Extension Ram Pivot Pin Description Part No. Qty.
Slide Hammer Kit 993/68100 1
Use another pivot pin to support the ram while
greasing the other pivot pin. Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
1. Make the machine safe. Refer to (PIL 01-03). look different.
2. Follow the general health and safety procedures. 1. Prepare the pivot pin for removal, remove the
Refer to (PIL 01-03). locking device e.g. pivot pin retaining bolt.
3. Remove the inner extension ram pivot pin and 2. Prepare the slide hammer kit.
apply waxoyl. Refer to (PIL 06-30).
Special Tool: Slide Hammer Kit (Qty.: 1)
4. Install the inner extension ram pivot pin.
2.1. Install the slide hammer onto the slide bar.
5. Remove the tilt ram pivot pin and coat with
waxoyl. Refer to (PIL 06-30). 2.2. Determine the thread size of the pivot pin
and then install the appropriate adaptor.
6. Install the tilt ram pivot pin. Use the spanner flats to securely install the
adaptor.
Figure 52.
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 - 56 9813/9050-1 06 - 56
30 - Pivot Pins
00 - General
Figure 53. Typical Machine
A Adaptor
B End stop
C End stop
D Spanner flats
E Slide bar
F Slide hammer
06 - 57 9813/9050-1 06 - 57
42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ........................................................................................................................... 06-59
06 - 58 9813/9050-1 06 - 58
42 - Stabiliser
00 - General
Introduction .................................................... 06-59 The stabilisers are a safety device to stop the
Health and Safety .......................................... 06-60 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 - 59 9813/9050-1 06 - 59
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 - 60 9813/9050-1 06 - 60
49 - Step
49 - Step
Contents Page No.
06-49-00 General ........................................................................................................................... 06-63
06 - 61 9813/9050-1 06 - 61
Notes:
06 - 62 9813/9050-1 06 - 62
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 54. 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 - 63 9813/9050-1 06 - 63
54 - Fender
54 - Fender
Contents Page No.
06-54-00 General ........................................................................................................................... 06-65
06 - 64 9813/9050-1 06 - 64
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 55.
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 56.
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 - 65 9813/9050-1 06 - 65
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 57.
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 16. 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 - 66 9813/9050-1 06 - 66
57 - Counterweight
57 - Counterweight
Contents Page No.
06-57-00 General ........................................................................................................................... 06-69
06 - 67 9813/9050-1 06 - 67
Notes:
06 - 68 9813/9050-1 06 - 68
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 - 69 9813/9050-1 06 - 69
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-71

06-63-06 Engine ............................................................................................................................ 06-72
06-63-09 Axle ................................................................................................................................ 06-74
06-63-12 Gearbox .......................................................................................................................... 06-75
06-63-15 Operator Protective Structure ........................................................................................ 06-76
06 - 70 9813/9050-1 06 - 70
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 - 71 9813/9050-1 06 - 71
06 - Engine
06 - Engine
The engine data labels are attached to the cylinder

block as shown.
Figure 58.
B
A C
A Engine data label - rocker cover B Engine identification number

C Stamp
The data label includes the engine identification

number.
Table 17. Example of the engine identification number
SH 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 18.
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 - 72 9813/9050-1 06 - 72
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 19. 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 58.
06 - 73 9813/9050-1 06 - 73
09 - Axle
09 - Axle
The axles have a serial number stamped on a data

plate as shown.
Figure 59. Front axle
A Data plate - front axle

Figure 60. Rear axle
B Data plate - rear axle
06 - 74 9813/9050-1 06 - 74
12 - Gearbox
12 - Gearbox
The gearbox has a serial number stamped on a data

plate as shown.
Figure 61. Power-shift Transmission
A
A Data plate
06 - 75 9813/9050-1 06 - 75
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 62.
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 63.
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 - 76 9813/9050-1 06 - 76
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 - 77 9813/9050-1 06 - 77
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-79
06 - 78 9813/9050-1 06 - 78
66 - Tools
00 - General
00 - General
Introduction
All tools must be kept in the toolbox (if installed) when

not in use.
06 - 79 9813/9050-1 06 - 79
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-81

06-69-03 Lift Arm ........................................................................................................................... 06-82
06 - 80 9813/9050-1 06 - 80
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 - 81 9813/9050-1 06 - 81
03 - Lift Arm
03 - Lift Arm Lift Arm Raised

If you raise the lift arm to get access for maintenance,
Remove and Install you must install the maintenance strut on the lift arm.
Before you install the maintenance strut remove any
WARNING You could be killed or injured if the lift
load on the forks and empty shovels or attachments.
arm drops while you are working under it. Install
the lift arm maintenance strut as instructed before Figure 65.
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
sure that the safety strut is only used with the
correct JCB retaining bolt or securing device.
Never substitute this bolt or securing device,
always use the correct JCB part.
Make sure that the strut and bolt/securing device Lift arm raised
is installed correctly. Never use a strut intended
for another machine. If in doubt, consult your JCB Installing the Maintenance Strut
dealer.
WARNING Do not drive the machine with the
maintenance strut fitted. 2. Retract the lift arm.
CAUTION You will have to climb onto the
machine to install or remove the strut. Take care, 3. Raise the lift arm.
especially if the machine is wet. Remove mud and 4. Stop the engine and remove the ignition key.
oil before climbing onto the machine. Do not use
the exhaust as a handhold. It can burn you. 5. Remove the maintenance strut from its stowage
position.
Lift Arm Lowered Figure 66.
Figure 64.
A
A
A Boom lowered
1. Park the machine on level, solid ground. A Maintenance strut
2. Lower the boom. 6. Install the maintenance strut.
3. Put the attachment flat on the ground. 7. Place the strut around the lift ram piston rod.
Secure it in position with the strap.
4. Stop the engine and remove the starter key.
6. Make sure there are no loose articles in the
enclosure.
7. If necessary, put chocks against the two sides of
06 - 82 9813/9050-1 06 - 82
03 - Lift Arm
Figure 67.
A Maintenance strut
B Lift arm
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.
10. If necessary, put blocks against the two sides of
Removing the Maintenance Strut

1. Raise the lift arm to take the weight off of the strut.
2. Stop the engine and remove the ignition key.
3. Remove the maintenance strut.
4. Secure the strut in its stowage position.
5. Lower the lift arm to the ground.
06 - 83 9813/9050-1 06 - 83
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-85
06 - 84 9813/9050-1 06 - 84
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 68.
A Gauge
B Safety Pin
06 - 85 9813/9050-1 06 - 85
89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ........................................................................................................................... 06-87
06 - 86 9813/9050-1 06 - 86
89 - Window Guard
00 - General
00 - General Figure 69. 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 - 87 9813/9050-1 06 - 87
Notes:
06 - 88 9813/9050-1 06 - 88
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
9813/9050-1
2017-12-21
Acronyms Glossary
ECU Electronic Control Unit

HVAC Heating Ventilation Air Conditioning
LLMI Longitudinal Load Moment Indicator
TXV Thermal Expansion Valve
9813/9050-1
2017-12-21
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-6
09 - 1 9813/9050-1 09 - 1
Notes:
09 - 2 9813/9050-1 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 9813/9050-1 09 - 3
00 - General
There are different variants of hydraulic control

This cab is certified to category 1 according to levers. The cab layout is the same except the control
EN15695-1-2009. levers.
Cab Layout
The layout shown below is for a typical machine.
Figure 70. 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
09 - 4 9813/9050-1 09 - 4
00 - General
N Ignition switch P Instrument panel

R Inclinometer S LLMI (Longitudinal Load Moment Indicator)
T Load control system
Single lever control variant

The single lever control can be mounted on the right
side console, in the arm rest or in an adjustable
control pod.
Figure 71.
1
2
3
1 Hydraulic control lever

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

available on all models)
Figure 72.
3
1
3
1 Transmission dump switch

2 Stabiliser control levers
3 Hydraulic control levers
09 - 5 9813/9050-1 09 - 5
03 - Cab Frame
03 - Cab Frame
Remove and Install
9. Disconnect the engine accelerator cable (if

installed).
Make sure that any attachments on the machine are 10. Disconnect the accelerator pedal electrical
correctly attached. Engage the park brake, remove connectors (if installed).
has wheels use blocks to prevent unintentional 11. Make sure that all wheels are blocked to prevent
movement. movement of the machine. Release the park
brake and disconnect the park brake cable.
Air Conditioning Maintenance
12. On machines with dual lever controls, disconnect
The air conditioning system is a closed loop system
the control levers from the control valve
and contains pressurised refrigerant. No part of the
connection rods.
system should be disconnected until the system
has been discharged by a refrigeration engineer 13. On machines with parallel servo control levers,
or a suitably trained person. You can be severely label and disconnect the hoses at the servo
frostbitten or injured by escaping refrigerant. control valves. Disconnect the control levers from
Notice: Make sure you label all hoses / pipes and the control valve connection rods.
electrical connectors (if installed) before removal to
aid identification during subsequent installation. 14. Disconnect the manual steer mode valve cable
(if installed) from the lever.
Cab 15. Disconnect the chassis electrical harness and
cab earth strap.
Remove
16. Undo the fuel filler hose clip. Loosen the fuel tank
1. Make the machine safe. filler hose on fuel tank filler neck so that the two
separate later.
17. Disconnect the braking system components.
2. Install the safety strut.
Refer to: PIL 01-03-27. 17.1. 550-80 and 560-80 Machines- For details
of disconnecting the brake valve.
17.2. On machines with cab mounted brake
Refer to: PIL 30-00-00. servo, disconnect the brake pipe and
servo hose. Cap all open hoses and pipes
4. Remove the battery cover and disconnect the to prevent fluid loss and ingress of dirt.
battery.
17.3. Disconnect brake pipe at the master
Refer to: PIL 33-03-00. cylinder. Cap all open hoses and pipes to
5. Remove the bolts and remove the cab front prevent fluid loss and ingress of dirt.
cover. 18. Disconnect hitch cable (if installed).
19. For machines with manual transmission
6. Disconnect all hydraulic hoses from the steering disconnect the cables to the gear lever.
unit. Cap all open hoses and ports to prevent fluid
loss and ingress of dirt. 20. Unscrew and remove the cab mounting bolts.
7. Remove the heater cover (if installed). Undo the 21. Attach appropriate lifting equipment to the ROPS
hose clips and disconnect the heater hoses. (Roll-Over Protective Structure).
8. If applicable, once the system has been 22. Carefully lift the cab from the machine, make sure
discharged, disconnect the air conditioning that all connections have been released and are
hoses at the TXV (Thermal Expansion Valve). clear of any obstruction. Cap off fuel tank filler
Some machines are installed with a cab roof neck to prevent contamination.
mounted air conditioning condenser. Disconnect
the condenser hoses at the rear of the cab.
09 - 6 9813/9050-1 09 - 6
03 - Cab Frame
Install 1.4. Correctly connect and adjust the cables to

the gear lever (if installed).
removal procedure. Additionally do the following 1.5. If applicable, recharge the air conditioning
steps. system.
1.1. Tighten the cab mounting bolts to the
correct torque value. 1.6. Check the hydraulic fluid level.
1.2. Bleed the brakes. Refer to: PIL 30-00-00.
Refer to: PIL 24-00-00. 1.7. Make sure that all cables are connected and
correctly adjusted. Make sure that they are
1.3. Adjust the accelerator cable and pedal (if routed and secured correctly.
installed).
1.8. Make sure that all electrical and hydraulic
services operate correctly.
Figure 73.
B
J B
G
B
C
D
E
F
B
09 - 7 9813/9050-1 09 - 7
03 - Cab Frame
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 9813/9050-1 09 - 8
03 - Cab Frame
Figure 74.
K
K
R
Z
W
X
K Dual lever controls M Transmission gear lever
09 - 9 9813/9050-1 09 - 9
03 - Cab Frame
O Manual steer mode lever P Clip

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 9813/9050-1 09 - 10
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-13
09 - 11 9813/9050-1 09 - 11
Notes:
09 - 12 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 78.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 76.
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 9813/9050-1 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 79.
Consumables
Description Part No. Size
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
Surface Cleaning Fluid 4103/1204 1L
A 12.5mm
B 9mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10min
2.1. Laminated glass - leave installed until the
Figure 80. 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 9813/9050-1 09 - 16
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 82.

the sealant will melt.
Figure 81.
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 83.
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 9813/9050-1 09 - 17
09 - Window
00 - General
Figure 84. 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 86. 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 87.
face of the cab frame aperture.
Figure 85.
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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 88.
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 9813/9050-1 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 9813/9050-1 09 - 23
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-25
09 - 24 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 09 - 27
Notes:
09 - 28 9813/9050-1 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 9813/9050-1 09 - 29
18 - Door
00 - General
Figure 89. 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 9813/9050-1 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 9813/9050-1 09 - 31
18 - Door
03 - Lock
03 - Lock
Remove and Install
09 - 32 9813/9050-1 09 - 32
18 - Door
12 - Handle
12 - Handle Figure 90.
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 9813/9050-1 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 9813/9050-1 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 91.
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 9813/9050-1 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 9813/9050-1 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 92.
A Rubber gaiter
B Switch
C Electrical connector
D Switch connector
E Screw
F Switch location dowel
G Hole in mounting bracket
09 - 37 9813/9050-1 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 9813/9050-1 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 93.
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 9813/9050-1 09 - 39
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
Figure 94.
Remove
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
8.2. Disconnect all connections and remove the C Screw 1
panel. D Screw 2
8.3. Remove the steer mode control knob. Figure 95.
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
6 and then remove the upper right hand panel. F
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 9813/9050-1 09 - 40
30 - Trim Panel
09 - Dashboard
Figure 96.
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 9813/9050-1 09 - 41
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 42 9813/9050-1 09 - 42
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-45
09 - 43 9813/9050-1 09 - 43
Notes:
09 - 44 9813/9050-1 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 9813/9050-1 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 9813/9050-1 09 - 46
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-49
09 - 47 9813/9050-1 09 - 47
Notes:
09 - 48 9813/9050-1 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 98.
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 97.
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 9813/9050-1 09 - 49
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-51
09 - 50 9813/9050-1 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 99.
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 9813/9050-1 09 - 51
Notes:
09 - 52 9813/9050-1 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
9813/9050-1
2017-12-21
Acronyms Glossary
FEAD Front End Accessory Drive

PAG Polyalkyline Glycol
RPM Revolutions Per Minute
TXV Thermal Expansion Valve
9813/9050-1
2017-12-21
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9813/9050-1 12 - 1
Notes:
12 - 2 9813/9050-1 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 9813/9050-1 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 9813/9050-1 12 - 4
00 - General
Technical Data
Table 20. Binary pressure switch settings

Item Specification
Low pressure 2bar (29.0psi)
High pressure 26bar (376.8psi)
Table 21. 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 22. 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 23. 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 9813/9050-1 12 - 5
00 - General
Heater Only
Figure 100.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 24.
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 9813/9050-1 12 - 6
00 - General
Machines with Air Conditioning
Figure 101.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 25.
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 26. 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 9813/9050-1 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 9813/9050-1 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 102.
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 9813/9050-1 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 103.
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 9813/9050-1 12 - 10
00 - General
thermostat switch contacts close. The compressor

clutch engages and refrigeration re-starts.
Figure 104.
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 9813/9050-1 12 - 11
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 27. Page 12-12
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 28. Page 12-12
Compressor clutch continually cuts out Table 29. Page 12-12
Poor performance- Compressor function tests Table 30. Page 12-13
Compressor not achieving 24 bar pressure Table 31. Page 12-13
No air conditioning Table 32. Page 12-13
Table 27. 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 28. 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 29. 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 9813/9050-1 12 - 12
00 - General
Table 30. 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 31. 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 32. 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 9813/9050-1 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 9813/9050-1 12 - 14
00 - General
Discharge and Pressurise 10. Close the valves and remove all equipment.
Figure 105.
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 9813/9050-1 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 106. Use only PAG oil in R-134a systems.
Figure 107.

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 9813/9050-1 12 - 16
00 - General
Be sure to connect to the liquid port when Figure 109.

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 108.
A396790
Table 33.
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 9813/9050-1 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 9813/9050-1 12 - 18
00 - General
Adjust
For compressor drive belt adjustment, please see

(PIL 15-18).
12 - 19 9813/9050-1 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 9813/9050-1 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.
11. Carefully remove the unit sufficiently to access
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 110.

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 9813/9050-1 12 - 21
03 - HVAC Unit
00 - General
Figure 111.
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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 12 - 24
03 - HVAC Unit
Check (Operation) Figure 112.
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 9813/9050-1 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 113.
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 9813/9050-1 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 9813/9050-1 12 - 27
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 34. Page 12-28
Blower does not operate Table 35. Page 12-28
Table 34. 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 35. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 28 9813/9050-1 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 114.
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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 12 - 31
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-33
12 - 32 9813/9050-1 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 9813/9050-1 12 - 33
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 36. Page 12-34
Blower does not operate Table 37. Page 12-34
Table 36. 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 37. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 34 9813/9050-1 12 - 34
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-37
12 - 35 9813/9050-1 12 - 35
Notes:
12 - 36 9813/9050-1 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.
12 - 37 9813/9050-1 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 115.
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 9813/9050-1 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 9813/9050-1 12 - 39
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-41
12 - 40 9813/9050-1 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 9813/9050-1 12 - 41
12 - Receiver Drier
00 - General
Check (Condition) Figure 117.
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 118.
5. Make sure that the pipes are correctly clamped.
Figure 118.
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 116.
Figure 116.
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 117.
12 - 42 9813/9050-1 12 - 42
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-45
12 - 43 9813/9050-1 12 - 43
Notes:
12 - 44 9813/9050-1 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 12 - 47
15 - Condenser
00 - General
Figure 119.
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 9813/9050-1 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 9813/9050-1 12 - 49
15 - Condenser
00 - General
Figure 120.
A C
B
C
A Condenser matrix B Pipe stub

C Nuts
12 - 50 9813/9050-1 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 9813/9050-1 12 - 51
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-53

12-18-06 Fresh Air ........................................................................................................................ 12-54
12 - 52 9813/9050-1 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 9813/9050-1 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 121.
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 9813/9050-1 12 - 54
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-57
12 - 55 9813/9050-1 12 - 55
Notes:
12 - 56 9813/9050-1 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 122.
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 9813/9050-1 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 9813/9050-1 12 - 58
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-61
12 - 59 9813/9050-1 12 - 59
Notes:
12 - 60 9813/9050-1 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 9813/9050-1 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 9813/9050-1 12 - 62
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-41
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-45
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-53
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-57
15-12-03 Main Bearing .................................................................................................................. 15-69
15-12-06 Front Oil Seal ................................................................................................................. 15-71
15-12-09 Rear Oil Seal ................................................................................................................. 15-74
15-12-12 Pulley .............................................................................................................................. 15-76
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-79
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-87
15-18-03 Drive Belt ....................................................................................................................... 15-89
15-18-21 Tensioner ........................................................................................................................ 15-94
15-18-24 Idler Pulley ..................................................................................................................... 15-95
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-97
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-105
15-24-09 Dust Valve .................................................................................................................... 15-108
15-28 Crankcase Breather
15-28-00 General ......................................................................................................................... 15-111
15-30 Valve
15-30-00 General ......................................................................................................................... 15-115
15-30-12 Valve Spring ................................................................................................................. 15-120
15-30-24 Stem Seal .................................................................................................................... 15-121
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-123
15-33-06 Big-End Bearing ........................................................................................................... 15-127
15-36 Piston
15-36-00 General ......................................................................................................................... 15-133
15-36-03 Piston Ring ................................................................................................................... 15-144
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-147
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-149
9813/9050-1
2017-12-15
15-42-06 Rocker Cover ............................................................................................................... 15-155
15-42-09 Push Rod ..................................................................................................................... 15-157
15-42-21 Tappet ........................................................................................................................... 15-159
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-165
15-45-09 Dipstick ......................................................................................................................... 15-168
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-171
15-51-03 Crankshaft Gear ........................................................................................................... 15-175
15-51-06 Camshaft Gear ............................................................................................................. 15-176
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-177
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-178
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-181
15-54-03 Housing ........................................................................................................................ 15-184
15-54-09 Gear Ring ..................................................................................................................... 15-186
15-54-12 Drive Plate .................................................................................................................... 15-187
15-57 Oil Filler
15-57-00 General ......................................................................................................................... 15-191
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-193
15-60-06 Pressure Relief Valve ................................................................................................... 15-197
15-63 Mount
15-63-00 General ......................................................................................................................... 15-201
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-205
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-209
15-72-03 Pulley ............................................................................................................................ 15-215
15-72-06 Voltage Regulator ......................................................................................................... 15-216
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-219
15-75-03 Solenoid ....................................................................................................................... 15-227
15-75-06 Brush Gear ................................................................................................................... 15-228
15-80 Glow Plug
15-80-00 General ......................................................................................................................... 15-231
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-235
15-84-03 Crankshaft Position ...................................................................................................... 15-245
15-84-06 Camshaft Position ........................................................................................................ 15-249
15-84-13 Mass Air Flow (MAF) ................................................................................................... 15-254
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-256
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-259
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-262
15-84-24 Fuel Temperature ......................................................................................................... 15-265
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-268
15-84-33 Coolant Temperature .................................................................................................... 15-271
15-84-43 Engine Oil Level ........................................................................................................... 15-274
15-87 Switch
15-87-03 Engine Oil Pressure ..................................................................................................... 15-279
15-90 Air Intake
9813/9050-1
2017-12-15
15-90-00 General ......................................................................................................................... 15-283
9813/9050-1
2017-12-15
Acronyms Glossary
ABDC After Bottom Dead Centre

ATDC After Top Dead Centre
BBDC Before Bottom Dead Centre
BTDC Before Top Dead Centre
CAN Controller Area Network
CCV Crankcase Ventilation
DC Direct Current
DTI Dial Test Indicator
ECM Engine Control Module
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
HLA Hydraulic Lash Adjuster
IMV Inlet Metering Valve
LMS Loadall Monitoring System
MAF Mass Air Flow
PRV Pressure Relief Valve
PTO Power Take-Off
TCV Turbocharger Control Valve
TDC Top Dead Centre
TMAP Temperature Manifold Air Pressure
9813/9050-1
2017-12-15
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/9050-1 15 - 1
Notes:
15 - 2 9813/9050-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-4 engine assembly. For specific engine technical
Technical Data ................................................. 15-6 information refer to the technical data section.
Component Identification ................................. 15-7
Make sure that the correct engine service tools,
Operation ....................................................... 15-12 consumables and torque figures are used when you
Diagram ......................................................... 15-16 perform service procedures.
Fault-Finding .................................................. 15-17
Drain and Fill ................................................. 15-27 Renewal of oil seals, gaskets, and any component
showing obvious signs of wear or damage is
Clean ............................................................. 15-27 expected as a matter of course.
Check (Condition) .......................................... 15-28
Check (Leaks) ............................................... 15-29 It is expected that components will be cleaned and
Check (Pressure) .......................................... 15-29 lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
Remove and Install ....................................... 15-31 excessive loss of hydraulic fluid, engine oil, coolant
Store and Recommission .............................. 15-35 and ingress of dirt.
Basic Description
The JCB engine is a 4 cylinder diesel engine in
which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle. Cylinder
number one is at the front or crankshaft pulley end
of the engine.
Figure 123.
B
C
A
1 2 3 4
D
A Front of engine (viewed from crankshaft pulley
end)
B Exhaust manifold side of engine
C Rear of engine (Flywheel end of engine)
D Inlet manifold side of engine
The engine is started by an electric starter motor. The

starter motor turns the engine via a pinion and teeth
on the engine flywheel. Refer to: PIL 15-75-00.
When the engine runs the crankshaft drives the

camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. The engine has 16 valves,
2 inlet and 2 exhaust valves for each cylinder.
15 - 3 9813/9050-1 15 - 3
15 - Engine
00 - Engine
00 - General
The camshaft drives a high pressure fuel pump Health and Safety
via gears. The pump is part of the electronically
controlled common rail fuel injection system. Refer
Hot Components
to: PIL 18-18-15.
Touching hot surfaces can burn skin. The engine and
Air is drawn into the engine, via the inlet manifold machine components will be hot after the unit has
and exhaust gases exit via the exhaust manifold. The been running. Allow the engine and components to
engine uses a turbocharger which pressurises the air cool before servicing the unit.
at the inlet manifold. Refer to: PIL 18-35-00.
Turning the Engine
A mechanical lubrication oil pump is driven by the Do not try to turn the engine by pulling the fan or fan
camshaft via gears. The pump pressurises and belt. This could cause injury or premature component
circulates oil for engine lubrication and cooling failure.
purposes. Refer to: PIL 15-60-00.
Notice: The engine and other components could
A drive belt driven by the crankshaft, drives a be damaged by high pressure washing systems.
coolant circulation pump, alternator, radiator cooling Special precautions must be taken if the machine is
fan and other ancillaries such as an air conditioning to be washed using a high pressure system.Make
compressor.Refer to: PIL 15-18-00. sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 4 9813/9050-1 15 - 4
15 - Engine
00 - Engine
00 - General
accordance with local regulations. Use authorised

waste disposal sites.
15 - 5 9813/9050-1 15 - 5
15 - Engine
00 - Engine
00 - General
Technical Data
Table 38.
Description FL Engine
Engine Variants Turbocharged with Intercooler
Emission compliance US-EPA Tier 4, EU Stage IV
Rated speed 2200 RPM (Revolutions Per Minute)
Weight (Dry) (Dry weight-No cooling fan drive) 345kg
Number of cylinders 4
Nominal bore size 92mm
Stroke 112mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.98L
Compression ratio 16.5: 1
Engine Compression Compression variance between each cylinder should
be no greater than 3.5bar (50.7psi)
Direction of rotation (viewed from front {crankshaft Clockwise
pulley} end)
Valves 4 per cylinder
Lubricating oil pressure (Dependent on engine tem- 1.6–4.5bar (23.2–65.2psi)
perature and speed)
Filter type Screw-on canister (with drain facility)
Pressure to open filter by-pass valve 1.6bar (23.2psi)
Oil pressure relief valve
(1)
Remote recirculation valve with gallery sensing
Oil pressure relief valve setting
(1)
3.5bar (50.7psi)
Oil pressure switch setting
(1)
0.6bar (8.7psi) falling
Oil pump
(1)
6/7 gerotor pump with safety valve
Combustion system Common rail direct Injection
High pressure fuel pump High pressure with electronically controlled fuel me-
tering
(1) The oil pump and PRV (Pressure Relief Valve) are non-serviceable parts
15 - 6 9813/9050-1 15 - 6
15 - Engine
00 - Engine
00 - General
The following identifies the main components of a

typical engine assembly. Some variants may differ in
detail.
Figure 124.
U
A
T
A
S A
R
B
P
C
M
E
L
K
F
J G
H
A EGR (Exhaust Gas Recirculation) valve B EGR cooler

C High pressure fuel pump D Engine oil filler cap (side)
E Engine oil dipstick F Oil cooler
G Fuel filter H Oil drain plug (sump)
J Lubrication oil sump K Crankshaft pulley
L Oil filter housing drain plug M FEAD (Front End Accessory Drive) belt auto
tensioner
N Coolant pump P Alternator
Q Engine oil filter R Thermostat housing
S Rocker cover T Engine oil filler cap (top)
U ECM (Engine Control Module)
15 - 7 9813/9050-1 15 - 7
15 - Engine
00 - Engine
00 - General
Figure 125.
V
U
AD
X
Y
AC
P
AB
Z
AA
U ECM V CCV (Crankcase Ventilation) System

W Turbocharger X Turbocharger oil feed pipe
Y Turbocharger oil drain pipe P Alternator
Z Coolant inlet connector AA Starter motor
H Oil drain plug (sump) AB Flywheel
AC Exhaust Manifold AD Injector cover
15 - 8 9813/9050-1 15 - 8
15 - Engine
00 - Engine
00 - General
Figure 126.
AE
AB
AK
AJ
AH
AF
AG
AB Flywheel AE PTO (Power Take-Off) idler gear (optional)

AF Crankshaft drive gear AG Oil pump
AH Camshaft drive gear AJ High pressure fuel pump drive gear
AK Camshaft
15 - 9 9813/9050-1 15 - 9
15 - Engine
00 - Engine
00 - General
Figure 127.
AQ
AP
AN
AM
AL
K Crankshaft pulley AL Connecting rod

AM Crankshaft AN Main bearing
AP Glow plug AQ Fuel injector
15 - 10 9813/9050-1 15 - 10
15 - Engine
00 - Engine
00 - General
Figure 128.
AR
AS
BD
AT
BC
AU
BB
AV
BA
AZ
AY
AX
AW
AR Rocker arm
AS Rocker shaft
AT Exhaust valve spring
AU Exhaust valve
AV Push rod
AW Hydraulic tappet
AX Piston
AY Piston ring - oil control
AZ Piston ring - compression No.2
BA Piston ring - compression No.1
BB Inlet valve
BC Inlet valve spring
BD Valve bridge piece
15 - 11 9813/9050-1 15 - 11
15 - Engine
00 - Engine
00 - General
Operation
It is important to note that number 1 cylinder is firing

The Four Stroke Cycle - 4 Cylinder and about to start its power stroke. Rotating the
Engine crankshaft a further full rotation would position the
pistons as described but the engine would be at a
This section describes the cycle sequence, for the 4 different stage in its four stroke cycle, with number 1
cylinder engine. cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons The stages in the four stroke cycle for each cylinder
in numbers 1 and 4 cylinders are at top dead centre are as follows:
and pistons in numbers 2 and 3 cylinders are at
bottom dead centre.
Table 39. The Four Stroke Cycle

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

number 1 cylinder will be next to fire. Number 3
A cylinder is said to be firing, when the fuel / air cylinder is starting its compression stroke and is next
mixture ignites and the piston is about to start its in the cycle, followed by cylinders 4 and 2.
power stroke.
The firing order is therefore; 1, 3, 4, 2.
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Figure 129.
CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

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

four stroke engine, the crankshaft revolves twice.
Induction
Figure 130.
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the 3

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

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

both temperature and pressure. The high pressure 746030
generated propels the piston downward turning the 1 Induction stroke
crankshaft and producing energy. 2 Compression stroke
3 Power stroke
Exhaust 4 Exhaust stroke
A Camshaft
Once the piston has reached the bottom of its travel, B Camshaft lobe - Inlet valve operation
the exhaust valves open and momentum stored C Camshaft lobe - Exhaust valve operation
in the flywheel forces the piston up the cylinder BDC Bottom dead centre
expelling the exhaust gases. TDC TDC (Top Dead Centre)
In a running engine these four phases are
continuously repeated. Each stroke is half a
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Figure 131.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
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Diagram
Electrical Operation and Schematics signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
The schematic diagram shows a typical system. CAN (Controller Area Network)bus to tell the Engine
For machine specific schematics, refer to electrical ECU that the transmission is in Neutral.
system- general, refer to (PIL 33-00).
The engine ECU provides power to the engine
The schematic is shown with the ignition switch compartment fusebox to energise the start relay, the
set to position III and the transmission set to N. A fuel pump relay, the starter motor and the fuel pump.
Figure 132.
Charge
D+
W
A
ECU
F
M
D
+VE -VE
3
4
5 H
1 6
2 7 M
E 8
9 K
10
J
C ECU
+VE G -VE
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU
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Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 40. Page 15-17
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 41. Page 15-18
Engine - Will Not Crank or Cranks Slowly Table 42. Page 15-18
Engine - Starts Then Stops Table 43. Page 15-19
Engine- Poor Running Table 44. Page 15-19
Engine - Poor Running at Idle Table 45. Page 15-20
Engine - Noise Excessive Table 46. Page 15-21
Engine - Compression Knocks Table 47. Page 15-21
Engine - Reduced Power Output Table 48. Page 15-22
Engine - Will Not Reach Maximum RPM Table 49. Page 15-22
Engine - RPM Surges Table 50. Page 15-23
Engine - Vibration Excessive Table 51. Page 15-23
Engine - Exhaust Smoke Excessive (Black Smoke) Table 52. Page 15-24
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 53. Page 15-24
Engine - Will Not Shut Off Table 54. Page 15-25
Lubricating Oil - Consumption Excessive Table 55. Page 15-25
Lubricating Oil - Contaminated Table 56. Page 15-25
Lubricating Oil - Pressure Low Table 57. Page 15-26
Lubricating Oil - Pressure High Table 58. Page 15-26
Table 40. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)
Cause Remedy
No fuel in supply tank. Check the level in the fuel tank, use sight gauge or
dipstick. Replenish as required.
Ignition switch or starter electrical system failure. Check the operation of the ignition switch. Check the
correct electrical wires for open or short circuits.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Defective fuel lift pump (fuel supply inadequate). Check that the lift pump operates and delivers fuel
to the high pressure fuel pump. Check the correct
electrical wires for open or short circuits. Check
fuses.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel inlet restriction. Maximum inlet restriction to fuel lift pump must not
exceed the specified amount:
Pressure: 0.133bar (1.9psi)
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction. Remove as required. Check
the air filter elements for signs of blocking. Replace
as required.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
properly. connected to the top of the fuel tank.
One or more fuel injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
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Cause Remedy
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Do all the
necessary fault finding checks before removal of the
high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
Table 41. Engine - Will Not Start or Difficult to Start (Exhaust Smoke)
Cause Remedy
Starting procedure incorrect. Verify proper starting procedure.
Air intake system blocked or restricted. Visually check the air intake for blockage or
obstruction, remove as required. Check the air filter
elements for signs of blocking, replace as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
Fuel is contaminated or incorrect grade diesel fuel Stop the engine. Replace the fuel filters. Operate
used. the engine with a temporary supply of the correct
grade of clean fuel. Monitor the engine performance.
Dirty fuel will cause damage to the high pressure fuel
pump and injectors.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
Check fuel inlet restriction. Maximum inlet restriction to fuel transfer pump must
not exceed 100 mm Hg
Engine compression low in one or more cylinders. Check the engine compression.
Cranking speed too slow. See Also: Table 42. 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 42. Engine - Will Not Crank or Cranks Slowly

Cause Remedy
Starting electrical circuit connections loose or Clean and tighten connections.
corroded.
Battery charge low. Check battery voltage, charge the battery or
replace as required. Make sure that the alternator is
functioning correctly and charging the battery.
No electrical connection to starter solenoid. Check voltage to solenoid.
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Cause Remedy
Crankshaft rotation restricted. Manually turn the engine and check for any severe
rotational resistance.
Solenoid or starter motor fault. Replace starter motor.
Starter motor operating but not cranking. Remove the starter motor and check for broken teeth
on the ring gear or broken starter motor spring.
Table 43. 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 44. Engine- Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 45. Engine - Poor Running at Idle
Engine is cold, coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
Check the correct electrical wires for open or short
circuits.
Fuel injection lines leaking. Replace defective high pressure fuel lines. Do not
repair defective fuel lines. If there is a fuel leak
remove and discard the necessary components and
install new ones.
system
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
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Cause Remedy
restriction.
pump and injectors.
Engine is cold - Thermostat fault. Drain Coolant, Remove and replace Thermostat.
Low Power (particularly at high speed) Exhaust back pressure high, Catalyst problem,
Check Servicemaster Diagnostics.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 45. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
install new ones.
system.
inadequate). fuel to the injection pump.
restriction.
pump and injectors.
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Table 46. 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 52. Engine - Exhaust Smoke
Excessive (Black Smoke)
pump and injectors.
Turbocharger noise. Check turbocharger impeller and turbine wheel for
housing contact.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Worn crank/connecting rod bearings (knocking under Check/replace rod and main bearings.
load).
Excessive camshaft bearing wear. Check bearings (engine overhaul required).
Worn or damaged pistons and/or piston rings. Check piston assemblies (engine overhaul required).
Gear train noise. Visually inspect and measure gear backlash.
Replace gears as required.
Loss of Pilot injection on one or more cylinders. Use service master to disable pilot injections to
identify audibly if they are still present.
Table 47. Engine - Compression Knocks

Cause Remedy
system.
pump and injectors.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Coolant operating temperature incorrect. Check and if necessary replace engine thermostat.
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Table 48. Engine - Reduced Power Output

Cause Remedy
Oil level incorrect. Check oil level.
Engine overload. Check for added loading from malfunctioning
hydraulic controls.
Throttle position sensor (TPS) system defective. Check the throttle assembly. Check the electronic
fault codes.
pump and injectors.
Turbocharger boost control pipe leaking or damaged, Check boost control pressure. Inspect and tighten
or wastegate diaphragm ruptured. fittings, repair pipes, replace wastegate assembly.
install new ones.
restriction.
system.
inadequate). fuel to the injection pump. Check fuses.
as required.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
high pressure fuel pump
Engine in reduced torque or limp home mode. Check the electronic fault codes.
Table 49. Engine - Will Not Reach Maximum RPM

Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
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Cause Remedy
system.
inadequate). fuel to the injection pump. Check fuses.
pump and injectors.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 50. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
system.
Table 51. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 45. Engine - Poor Running at Idle
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and
torque figures.
Fan hub faulty. Inspect/replace the fan hub. Refer to the machine's
service manual for correct installation and torque
figures.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
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Cause Remedy
Alternator bearing worn or damaged. Check/replace the alternator.
Transmission misaligned. Check/repair Transmission alignment.
Drive line components worn or unbalanced. Check and inspect drive line components such as
propshafts. Refer to the machine's service manual for
correct installation and torque figures.
Table 52. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check for added loading from malfunctioning
hydraulic controls.
as required.
Air leak between the turbocharger and the intake Check/repair leaks in the air crossover tube, hoses,
manifold. or manifold cover.
Intercooler faulty. Check for blocked cooler matrix.
Exhaust leak at the manifold or turbocharger Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Turbocharger wastegate faulty. Repair or replace turbocharger.
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
Table 53. Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Cause Remedy
Improper starting procedure. Verify proper starting procedure.
pump and injectors.
Diesel or hydraulic oil in sump. Check oil consistency. If oil contamination is
suspected check equipment such as PTO (Power
Take-Off) pump for hydraulic oil leaks past the seal
into the engine. Drain, flush and fill with clean oil.
Coolant temperature too low (over-cooling) - light Check the thermostat and replace if necessary.
blue or white high speed/light load.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
- white/ blue smoke at operating temperature. connections at the injectors.
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Cause Remedy
Coolant leaking into combustion chamber. Check the EGR (Exhaust Gas Recirculation) Cooler
for leaks. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 54. Engine - Will Not Shut Off

Cause Remedy
Stop switch or stop switch electrical system failure. Check the operation of the stop switch. Check the
correct electrical wires for open or short circuits.
Lubrication oil is being burned in the cylinders See Also: Table 55. Lubricating Oil - Consumption
Excessive
Table 55. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level over-full. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Tier 4 Final Engines require a special oil grade. Refer Check for reduced viscosity from dilution with fuel.
to (PIL 75-03). Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Crankcase ventilation (CCV) system blocked. Check the breather tube area for signs of lubricating
oil loss.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
Valve guide seals are leaking. Replace valve guide stem seals as required.
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
Table 56. Lubricating Oil - Contaminated

Cause Remedy
Coolant in the lubricating oil, internal engine Check oil cooler O-rings. If necessary change the oil
component leaks. cooler.
Lubricating oil sludge excessive. Change oil and filter. Review oil and filter change
period. If operating in arduous applications, change
more frequently. Make sure the correct lubricating oil
is being used.
Fuel in the lubricating oil, engine operating too cold. Review the operation for excessive idling resulting in
the engine running below normal temperature.
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Table 57. 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 58. Lubricating Oil - Pressure High

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

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

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

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

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

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

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

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

working on the high pressure fuel system. Refer to:
PIL 18-00-00.
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Check (Leaks) Check (Pressure)

Special Tools
Before you start the machine, do a check for oil leaks: Description Part No. Qty.
Pressure Gauge (0-70 892/00346 1
Bar)
2. Get access to the engine compartment (if
applicable) This test is used to diagnose suspected poor
compression in one or more of the engine cylinders.
3. Check the engine and the area below for oil Use ServiceMaster to control the test.
leaks.
4. Close the engine cover (if applicable).
Engine Oil Pressure
5. If necessary, contact your JCB dealer. Use the following procedures to measure the engine
oil pressure. Several factors can influence the engine
oil pressure, the following conditions are assumed:
• The correct engine oil has been used. Refer to:

PIL 15-21-00.
• The engine oil level is correct. Refer to: PIL
75-03-03.
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Get access to the engine.
3. Disconnect the electrical connector to the oil
pressure switch, remove the switch from the oil
cooler housing.
4. Install a suitable adaptor into the vacant pressure
switch port (M10 x 1.5mm thread) and a pressure
test gauge. Make sure that the gauge has a
sealing washer as shown.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
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Figure 133. • Low oil level - typically evident as a loss of

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

B Sealing washer
5. Start the engine and allow a few seconds to
gain oil pressure, increase the engine revs to
the rated speed. Record the pressure gauge
reading. Check that the pressure is within the
specified tolerance.
6. Remove the pressure gauge and install the
pressure switch.
High Lubrication Oil Pressure

High oil pressure will be evident when starting in cold
conditions. Typically the pressure will be 1 to 2 bar
and higher in cold operation, the pressure should
drop when the engine reaches normal operating
temperature.
If the pressure remains high when operating

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

Several factors can be the cause of low lubricating
oil pressure:
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Remove and Install Figure 134.
Special Tools
Description Part No. Qty. Q P
Fuel Injector equipment 320/B9321 1 B
Cap Kit (430 Engine)
Lifting Brackets (430 320/B9421 1 M
Engine)
Engine Lifting Spreader 892/01382 1
Bar
J G
Lifting Equipment
equipment is in good condition and complies with all H
local regulations.
N
The lifting equipment used must be an approved
type and capable of lifting the engine safely. The
recommended lifting equipment is shown. Use a A
A
spreader bar when lifting the engine. Never attempt
to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
an assistant. Inspect the lifting brackets for signs Figure 135.
of damage. The brackets must be correctly torqued
to the crankcase. Make sure the lifting equipment F F
does not damage any of the engine dressing and the R
rocker cover.
The following component identification is for a typical
engine installation. There will be some component
differences depending on the machine variant.
Before attempting to remove the engine ensure that
all the necessary components have either been
removed, or safely disconnected from the engine. D
E
A
A
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15 - Engine
00 - Engine
00 - General
Figure 136. 4. Get access to the engine.
Remove
S 1. Disconnect and remove the battery.
2. Drain the engine oil.
K
3. Drain the engine coolant.
C
4. Remove the cooling pack.
5. Disconnect the air inlet hose.
L 6. Disconnect the turbocharger outlet hose.
7. Disconnect the charge air hose.
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine
block connectors. Release the hose clips and
disconnect the hoses.
10. Disconnect the top coolant hose.
11. Disconnect the bottom coolant hose.
12. Disconnect the wiring connections from the
A Engine mounting bolts starter motor.
B Front lifting bracket - front Refer to: PIL 15-75-00.
C Lifting bracket fixing bolts
D Fuel pipe - return to tank 13. Disconnect the wiring connections from the
E Fuel pipe - feed from lift pump alternator.
F Electrical connector - ECM (Engine Control
Module)
G Electrical connections - alternator 14. Disconnect the fuel supply and return pipes.
H Hose connection - cab heater Plug all the open ports and hoses to prevent
J Electrical connections - starter motor contamination.
K Rear lifting bracket
L Gearbox/hydraulic pump to engine mounting Special Tool: Fuel Injector equipment Cap Kit
bolts (430 Engine) (Qty.: 1)
M Top coolant hose
15. Disconnect the electrical harness at the ECM
N Bottom coolant hose
machine side connector. Important: Do not touch
P Air inlet hose
the connector pins on the ECM or harness
Q Turbocharger outlet hose
connectors. Cover the connectors to prevent
R Charge air inlet hose
contamination.
S Exhaust pipe
16. Make sure that all relevant harnesses and hoses
Before Removal are unclipped from the engine and tied out of the
way.
the engine has been running, let it cool before 17. If necessary, drain the hydraulic tank. Disconnect
you start the service work. and plug the hydraulic suction and delivery lines
at the transmission pump and gear pump. Label
2. Position the machine on firm level ground. Make the hoses to aid installation.
the machine safe.
18. Remove the gearbox/hydraulic pump to engine
retaining bolts and pull the gearbox/hydraulic
3. Discharge the hydraulic pressure. pump clear of the engine.
15 - 32 9813/9050-1 15 - 32
15 - Engine
00 - Engine
00 - General
18.1. Make sure that the torque converter stays Figure 137.
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Special Tool: Lifting Brackets (430 Engine) (Qty.: T
1)
Special Tool: Engine Lifting Spreader Bar (Qty.:
1)
20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
21. Raise the engine and lift it clear of the machine.
22. Lower the engine into a suitable stand that is
capable of supporting the weight of the engine.
U
A
A
A Lifting brackets
T Lifting equipment
U Spreader bar
Install
step.
2. It is vitally important that the torque converter
is installed at the gearbox and engine flywheel
correctly. Failure to locate the torque converter
correctly will result in damage to the gearbox oil
pump on engine start up.
15 - 33 9813/9050-1 15 - 33
15 - Engine
00 - Engine
00 - General
3. Fill the cooling system.

3.1. When you fill the cooling system make
sure you use the correct water/antifreeze
mixture. A 50% mixture should be
maintained even if frost protection is not
required.
4. Fill and check the hydraulic fluid level.
5. Fill and check the engine oil level. Make sure the
correct oil is used.
6. Check the hydraulic, fuel and cooling systems for
leaks.
7. Check the operation of all drive and hydraulic
services.
15 - 34 9813/9050-1 15 - 34
15 - Engine
00 - Engine
00 - General
Store and Recommission
If an engine is to be placed into storage, all external

Engines should be stored in the original shipping signs of surface coating damage or corrosion should
packaging. Damaged or disturbed packaging should be cleaned and re-coated. Electrical connectors and
be made weatherproof immediately. components should be coated with a protective
spray.
If an engine is shipped with oil, it should be stored in
the correct (upright) position. Capping Engine Openings
If an engine is shipped dry of oil, after 6 months it
All openings on the engine must be suitably capped
should be filled with oil to the correct level and re-
to prevent ingress of water and contamination by
inhibited, refer to hot test description.
foreign particles.
All floor stock engines should be stored under cover
in dry conditions and not subjected to extreme
variations in temperature or humidity.
15 - 35 9813/9050-1 15 - 35
15 - Engine
00 - Engine
00 - General
Figure 138.
A ECM (Engine Control Module) machine harness B Machine harness interconnect connector cap
connector cap
C Fuel pipe – return to tank cap D Fuel pipe – feed from lift pump cap
E Coolant circuit bleed pipe cap F Air intake cap
15 - 36 9813/9050-1 15 - 36
15 - Engine
00 - Engine
00 - General
Figure 139.
G Turbocharger intake cap H Coolant top hose cap

J Turbocharger compressor outlet cap K Coolant bottom hose cap
L Cab heater feed and return spigots M Heavy duty PTO (Power Take-Off)
15 - 37 9813/9050-1 15 - 37
15 - Engine
00 - Engine
00 - General
Figure 140. 2.9. Place in storage, under cover on level

ground or shelving.
2.10. Record details of work as required.
2.11. Do not expose to extremes of temperature
or humidity.
Notice: Do not operate the starter motor for more
than 20s at one time. Let the starter motor cool for
at least 2min.
Table 59. Oil Pressure Switch Set Points

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

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

life antifreeze mixture.
1.1. Inspect packaging for signs of damage.
3. Hot test engine according to the hot test profile.
1.2. Inspect the caps for signs of damage. Refer to Table 60.
1.3. Inspect openings for signs of water or dirt 4. Drain engine oil and replace engine oil filter.
ingress.
1.4. Inspect the engine for signs of external 5. Refill with the correct oil and inhibit the cooling
corrosion. system using the correct product.
1.5. Inspect the engine for signs of fluid leaks. 6. Record details of work as required.
2. From storage: Hot Test Description

2.1. Remove the air intake caps. WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
2.2. Make sure the engine oil level is correct. the manufacturer's instructions and safety
2.3. Using a suitable power supply at the correct precautions.
voltage, crank the engine over for the
specified time period. All engines despatched from JCB will have been
Duration: 20s subjected to a hot test (checking items such as oil
pressure, engines speeds, torque values etc.) and
2.4. During cranking, check that the oil pressure therefore the interior surfaces will have been coated
switch opens using a multimeter. The switch with engine oil.
is closed when there is no or low oil
pressure and opens when oil pressure All coolant galleries are coated with CRODAFLUID
reaches a set point. After three separate PA75 corrosion inhibitor.
cranking periods, If the oil pressure switch
does not open (indicating no, or low oil Stored engines will require re-inhibiting every 12
pressure), contact your JCB engine dealer. months, this will include hot testing the engine using
2.5. Recap all engine openings. a dynamometer. The hot test profile is:
2.6. Coat any exposed bare metal with a Table 60. Hot Test Profile
suitable product.
Stage Mode Speed Torque Time
2.7. Electrical connectors and components (rpm) (Nm) (secs)
should be coated with a protective spray if 1 Speed/ 830 0 50
exposed. Torque
2.8. Cover in weatherproof packaging. 2 Speed/ 1300 50 60
Torque
15 - 38 9813/9050-1 15 - 38
15 - Engine
00 - Engine
00 - General
Stage Mode Speed Torque Time

(rpm) (Nm) (secs)
3 Speed/ 2500 0 60
Torque
4 Speed/ 1300 0 25
Torque
5 Speed/ 800 0 35
Torque
15 - 39 9813/9050-1 15 - 39
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-41
15 - 40 9813/9050-1 15 - 40
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-41 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-42 The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and

connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 141.
A
A Crankcase
B Crankshaft
15 - 41 9813/9050-1 15 - 41
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 61. Crankcase and Bedplate Data

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

Second stage 50N·m
Third stage Slacken and tighten to 50N·m
Final stage Turn a further 180°
Surface finish for cylinder head joint
(3)
Rz < 15m, Rmax < 20
Diameter of first oversize bore 92.5–92.52mm
Diameter of second oversize bore 93–93.02mm
Main bearing bore (without bearings)
Numbers 1 to 4 76.02–76.039mm
Number 5 84.02–84.039mm
Camshaft bore
Numbers 1 to 4 50.04–50.07mm
Number 5 (bush) 60.04–60.07mm
Permissible wave profile wt < 10m (2.5mm distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
15 - 42 9813/9050-1 15 - 42
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-45
15 - 43 9813/9050-1 15 - 43
Notes:
15 - 44 9813/9050-1 15 - 44
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-45 The cylinder head is located above the cylinders
Technical Data ............................................... 15-46 on top of the crankcase. It closes in the top of the
Component Identification ............................... 15-47 cylinder, forming the combustion chamber. This joint
Remove and Install ....................................... 15-48 is sealed by a cylinder head gasket.
The cylinder head also provides the space for the

passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves and fuel injectors.
15 - 45 9813/9050-1 15 - 45
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 62. Cylinder Head Data

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

- Side to side 0.03mm
Valve recess depth
- Inlet 0.95mm
- Exhaust 0.95mm
Valve seat angle
- Inlet 120° (inclusive)
- Exhaust 90° (inclusive)
Cylinder head bolts torque
(2)
- First stage 50
- Second stage 115
- Final stage Torque angle + 90°
Surface finish for cylinder head joint Rz < 15 Rmax < 20m
Permissible wave profile wt < 10m (2.5mm distance)
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
15 - 46 9813/9050-1 15 - 46
15 - Engine
06 - Cylinder Head
00 - General
Figure 142.
A Cylinder head bolts

B Cylinder head
C Cylinder head gasket
15 - 47 9813/9050-1 15 - 47
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 9. Remove the fuel injector cover.

Description Part No. Qty. Refer to: PIL 18-18-04.
Torque Wrench 993/70111 1
(10-100Nm) 10. Remove the high pressure fuel pipes.
Consumables
Description Part No. Size 11. Remove the injector leak-off, leak-off pipe to fuel
Cleaner/Degreaser 4104/1557 0.4L filter, and return to tank low pressure fuel pipes.
- General purpose Refer to: PIL 18-96-06.
solvent based parts
cleaner 12. Remove the fuel injectors.
Before Removal
13. Remove the fuel rail.
This procedure requires service parts. Make sure Refer to: PIL 18-18-12.
you have obtained the correct parts before you start.
Refer to the Parts Catalogue. 14. Remove the EGR (Exhaust Gas Recirculation)
system.
15. Remove the exhaust manifold pressure sensor
2. Make sure that the engine is safe to work on. If assembly.
you start the service work. Refer to: PIL 15-84-16.
3. Get access to the engine. 16. Remove the exhaust manifold and turbocharger
assembly.
4. Drain the coolant. Refer to: PIL 18-24-04.
17. Remove the glow plugs.
5. Remove the engine wiring harness. Refer to: PIL 15-80-00.
6. Remove the ECM (Engine Control Module). 18. Disconnect the charge air inlet hose.
19. Remove the rocker cover.
7. Remove the thermostat. Refer to: PIL 15-42-06.
20. Remove the rocker assembly.
8. Disconnect the CCV (Crankcase Ventilation) Refer to: PIL 15-42-00.
pipes.
15 - 48 9813/9050-1 15 - 48
15 - Engine
06 - Cylinder Head
00 - General
Figure 143.
12
12
13 X
11
10 6 2 3 7
9 5 1 4 8
0° +90 °
1-10 Cylinder head fixing bolts (x10) 11 Cylinder head

12 Location dowels (x2) 13 Cylinder head gasket
X Cylinder head gasket identification holes Y Matchmarks
21. Remove the push rods. Make a note of the 3. Using a suitable cleaning agent, carefully remove
order to make sure that they are installed in their all traces of the head gasket material from the
original positions. cylinder head and crankcase mating faces.
Consumable: Cleaner/Degreaser - General
Remove purpose solvent based parts cleaner
1. Progressively remove the cylinder head bolts in 4. Check the cylinder head and crankcase mating
reverse order, starting at bolt 10. The bolts MUST faces for signs of damage and distortion.
NOT be re-used. Discard the bolts.
2. Carefully lift the cylinder head from the
crankcase. If necessary use a soft face hammer. Before Install
DO NOT use a lever to separate the cylinder
head from the crankcase. Discard the head 1. Obtain the correct new cylinder head bolts. The
gasket. original bolts MUST NOT be re-used.
15 - 49 9813/9050-1 15 - 49
15 - Engine
06 - Cylinder Head
00 - General
2. Obtain the correct replacement head gasket.

Note the number of cylinder head gasket
identification holes.
3. Make sure that all items are clean and free from
Install
steps.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in three stages, use the
torque and angle method.
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-10) to the 1st stage pre-torque.
Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
4.2. Tighten the bolts, starting with the middle
pair and working outwards (in sequence 1-
10) to the 2nd stage pre-torque.
4.3. Repeat the 2nd stage pre-torque. Refer to
step 4.2.
4.4. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-10) to
the final stage torque. As a visual check,
matchmark the bolts to the cylinder head
before you start. When the bolts have
been angle tightened, the matchmarks will
appear as shown at Y. Refer to Figure 143.
Table 63. Torque Table

Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
1-10 (Final Stage) 90°
15 - 50 9813/9050-1 15 - 50
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-53
15 - 51 9813/9050-1 15 - 51
Notes:
15 - 52 9813/9050-1 15 - 52
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-53 The bedplate acts as the main strength component
Remove and Install ....................................... 15-54 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 144.
1
1 Bedplate
2 Crankcase
15 - 53 9813/9050-1 15 - 53
15 - Engine
09 - Bedplate
00 - General
Remove and Install

15 - 54 9813/9050-1 15 - 54
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-57

15-12-03 Main Bearing .................................................................................................................. 15-69
15-12-06 Front Oil Seal ................................................................................................................. 15-71
15-12-09 Rear Oil Seal ................................................................................................................. 15-74
15-12-12 Pulley .............................................................................................................................. 15-76
15 - 55 9813/9050-1 15 - 55
Notes:
15 - 56 9813/9050-1 15 - 56
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-57 The crankshaft is housed inside the crankcase. It is
Technical Data ............................................... 15-58 connected to the piston via a connecting rod, they
Component Identification ............................... 15-59 form a simple mechanism that converts reciprocating
Operation ....................................................... 15-60 motion into rotating motion. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-61
15 - 57 9813/9050-1 15 - 57
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 64.
Main bearing journal diameter (x4)
- min 71.98mm
- max 72mm
Main rear bearing journal diameter (x1)
- min 79.98mm
- max 80mm
Connecting rod bearing journal diameter
- min 64.98mm
- max 65mm
Maximum wear and ovality on journals No visible damage/wear or marks
Crankshaft induction hardness 55 HRc min on surface
Thrust washer width
- min 2.44mm
- max 3.04mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
Crankshaft gear
(1)
49 teeth
(1) The crankshaft gear is not available as a separate item. The gear must be heated on to the crankshaft in the
correct timed position. Specialist fixtures are used during the production process to achieve the correct timing.
15 - 58 9813/9050-1 15 - 58
15 - Engine
12 - Crankshaft
00 - General
Figure 145.
B
A Crankcase
B Crankshaft
C Crankshaft position sensor target wheel
15 - 59 9813/9050-1 15 - 59
15 - Engine
12 - Crankshaft
00 - General
Operation
diameter of the upper main bearing shell allows oil

Lubrication transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
engine.
Figure 146.
1 Main gallery 2 Drillings (x5)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
15 - 60 9813/9050-1 15 - 60
15 - Engine
12 - Crankshaft
00 - General
Check (Condition) Blocked or restricted oilways will cause oil

starvation at the big end bearings.
1. Measure the crankshaft journal diameters to 4. Check that the piston cooling saddle jets are
confirm they are within service limits. clear. If the saddle jets cannot be cleared, replace
the saddle jets.
Figure 149.
Figure 147.
B
A Crankcase
B Crankshaft
C Crankshaft position sensor target wheel
2. Check the main bearing surfaces for damage and
excessive wear.
Figure 148.
E Saddle jets
D Main bearing shells

3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
15 - 61 9813/9050-1 15 - 61
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Special Tools Refer to: PIL 15-45-09.

12. Remove the bolts (x2) and disconnect the
Template for Sealant 320/02333 1 turbocharger oil drain pipe.
Bedplate to Crankcase
(430 Engine) 13. Remove the oil sump.
Crankshaft Turning Tool 320/A3170 1 Refer to: PIL 15-45-00.
(Major Repair) (430
Engine) 14. It is not necessary to remove the cylinder head
Torque Wrench 993/70111 1 assembly to remove the crankshaft. If however
(10-100Nm) the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
Consumables for example) remove it now.
Description Part No. Size Refer to: PIL 15-06-00.
Cleaner/Degreaser 4104/1557 0.4L
- General purpose 15. Remove the starter motor.
solvent based parts Refer to: PIL 15-75-00.
cleaner
16. Remove the flywheel.
method and device. 17. Remove the rear crankshaft oil seal.
Before Removal
18. Remove the flywheel housing.
1. This procedure requires service parts. Make Refer to: PIL 15-54-03.
sure you have obtained the correct service parts
before you start, refer to the Parts Catalogue. 19. Remove the oil pump.
2. Make sure that the engine is safe to work on. If Refer to: PIL 15-60-00.
you start the service work. 20. Remove the bolt securing the fuel hose to the
bedplate.
Figure 150.
4. Remove the engine.
5. Remove the fuel filter.
6. Remove the drive belt.
Refer to: PIL 15-18-03. E
7. Remove the crankshaft pulley.

8. Remove the front crankshaft oil seal.
E Fuel pipe retaining bolt
21. Remove the main bearing caps.
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase. Refer to: PIL 15-12-03.
10. Remove the dipstick. 22. Set the engine to TDC (Top Dead Centre).
11. Remove the dipstick tube.
15 - 62 9813/9050-1 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Special Tool: Crankshaft Turning Tool (Major Remove

Repair) (430 Engine) (Qty.: 1)
1. Remove the bedplate peripheral bolts.
Figure 151.
O
O
O
9 5 1 4 8
10 6 2 3 7
O
O O
O
P
N
O
1-10 Main bearing bolts (x10) N Bedplate

O Bedplate peripheral bolts (x12) P O-ring
2. Progressively remove the main bearing bolts in Figure 152.

reverse order starting at bolt 10. The bolts MUST R
NOT be re-used. Discard the bolts. N
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
suitable lifting equipment (if the bedplate is lifted
manually, two people will be required). DO NOT
use a lever to separate the bedplate. R
N Bedplate
R Lifting bolts (obtain locally)
4. Remove the bedplate.
15 - 63 9813/9050-1 15 - 63
15 - Engine
12 - Crankshaft
00 - General
5. Use suitable lifting equipment to carefully lift the Figure 154.

crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
6. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
Figure 153.
A
B
A Thrust washers
B Crankshaft D Main bearing shells
C Rear main bearing
9. It is recommended that the bearing shells are
7. Put labels on the thrust washers to make sure replaced. If however they are to be used again,
that they are installed in the correct positions put labels on the shells to make sure that they
during assembly. are installed in their original positions during
assembly.
8. Carefully lift out the bearing shells.
10. Inspect the crankshaft and main bearings for
damage and excessive wear.
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.

Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
steps.
15 - 64 9813/9050-1 15 - 64
15 - Engine
12 - Crankshaft
00 - General
2. Make sure that all items are clean and free from 4. Use suitable lifting equipment (if the crankshaft
damage and corrosion. is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
3. Install the upper bearing shells as follows: DO NOT rotate the crankshaft, the bearing shells
can become dislodged. Make sure that the
Figure 155. connecting rods are located onto the crankshaft
journals.
G
4.1. Make sure that the connecting rods are
located onto the crankshaft journals.
4.2. Make sure that the crankshaft is installed
so that the engine timing is correct. The
single mark on the crankshaft drive gear
must locate between the two marks on the
camshaft drive gear.
Figure 156.
J
L
K
D M
Y J Camshaft drive gear timing marks

K Crankshaft drive gear timing mark
L Camshaft drive gear
M Crankshaft drive gear
D Main bearing shells
G Bearing location tab 5. Install the thrust washers as follows:
Y Oil-way holes
3.1. Use a suitable degreasing agent to make
sure that the surfaces of the upper bearing
shells are clean.
3.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
3.3. Make sure that the oil-way holes in the
bearing saddles align with the holes in the
bearing shell. If the holes are even partially
misaligned the piston cooling oil jet will be
restricted, causing the engine to fail.
3.4. Lubricate the upper bearing shells with
clean engine oil.
15 - 65 9813/9050-1 15 - 65
15 - Engine
12 - Crankshaft
00 - General
Figure 157. 5.2. Make sure that they are installed in the
correct positions, with the two oil slots
A facing outwards from the bearing saddle.
5.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
5.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged.
H 6. Check that the crankshaft end float is within
service limits.
7. Install the four lifting bolts to the bedplate as
shown.
A 8. Lubricate the lower bearing shells with clean

engine oil. If the bearings have been removed,
make sure that the location tab engages in the
slot as shown.
9. The sealant template is used on the crankcase,
NOT the bedplate.
Special Tool: Template for Sealant Bedplate to
Crankcase (430 Engine) (Qty.: 1)
B
C 10. Locate the location tabs on the template using
a location dowel and a fixing bolt. Use the
A Thrust washer templates as a guide apply a bead of sealant
B Crankshaft around the crankcase/bedplate mating face as
C Rear main bearing shown to the dimension specified.
H Oil slot - thrust washers Length/Dimension/Distance: 1.5mm
5.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
15 - 66 9813/9050-1 15 - 66
15 - Engine
12 - Crankshaft
00 - General
Figure 158.
V S
S
T
X
S Location dowels T Template location tab

U Sealant template V Sealant bead
W Crankcase X Sealant join
11. Remove the fixing bolt. Remove the sealant 13. The bedplate is heavy. Two people will be
template, make sure you do not smudge the required to lift and rotate the bedplate safely
sealant. Discard the templates. on to the crankcase. Install new main bearing
bolts 1-10. Tighten the bolts to the correct
12. Add a bead of sealant around the location dowel torque value, starting in the centre and working
and the bolt holes so as to join the sealant beads. outwards (in sequence 1-10) to the 1st stage pre-
torque.
15 - 67 9813/9050-1 15 - 67
15 - Engine
12 - Crankshaft
00 - General
Special Tool: Torque Wrench (10-100Nm) (Qty.:

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

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

Item Torque Value
1-10 (2nd Stage) 50N·m
1-10 (3rd Stage) Loosen then tighten to
50N·m
1-10 (Final Stage) 180
E 10 ± 1N·m
O 47 ± 2N·m
15 - 68 9813/9050-1 15 - 68
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-69 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-70 bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 159.
A Main bearing
B Crankshaft
15 - 69 9813/9050-1 15 - 69
15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition) Remove and Install

1. Check the bearing shell surfaces for signs of
2. Measure the crank pin diameters to confirm they
are within service limits.
3. Renew any parts that are worn or not within the
specified tolerances.
15 - 70 9813/9050-1 15 - 70
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 160.

Crankshaft Front Oil 320/A3126 1
Seal Installation Tool
(430 Engine)
A
This procedure requires service parts. Make sure
you have obtained the correct service parts before B
you start. Refer to Parts Catalogue.
Remove C
D
2. Make sure that the engine is safe to work on. If A Crankshaft oil seal
the engine has been running, let it cool before B Crankcase
you start the service work. C Bedplate
D Crankshaft
4. Remove the drive belt. Install
Refer to: PIL 15-18-03. 1. Make sure that the counterbore and the
crankshaft hub are clean and free from damage
5. Remove the crankshaft pulley. and corrosion. Use a suitable degreasing agent
Refer to: PIL 15-12-12. to clean all traces of oil and grease from the
counterbore. The oil seal has a special coating
6. Use a suitable lever behind the lip of the and MUST be installed dry without lubricant.
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not 2. Install the crankshaft oil seal guide to the
to scratch or damage the counterbore or the crankshaft hub, using the bolts 1 (x3).
crankshaft hub. Damaged or dirty sealing faces Special Tool: Crankshaft Front Oil Seal
will cause the oil seal to fail. The crankshaft oil Installation Tool (430 Engine) (Qty.: 1)
seal must not be reused. Discard the crankshaft
oil seal.
15 - 71 9813/9050-1 15 - 71
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 161.
D Crankshaft E Crankshaft oil seal guide

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

guide. Make sure that the seal is installed the
correct way around. Install the crankshaft oil seal
cup on to the oil seal guide and install the spacer
and the bolt 2.
4. Tighten the bolt 2 to push the seal squarely
into the counterbore until the oil seal cup comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore.
15 - 72 9813/9050-1 15 - 72
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 162.
B
F E D
G
A C
A Crankshaft oil seal
B Crankcase
C Bedplate
D Crankshaft
E Crankshaft oil seal guide
F Bolts 1 (x3)
G Crankshaft oil seal cup
H Spacer
J Bolt 2
5. Remove the crankshaft seal installation tool.
6. Install the crankshaft pulley.
7. Install the drive belt.
15 - 73 9813/9050-1 15 - 73
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install

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

you have obtained the correct service parts before
B C
Remove
the engine has been running, let it cool before A Crankshaft oil seal
you start the service work. B Crankshaft
C Flywheel housing
3. Get access to the engine. If necessary, remove
the engine. Install
1. Make sure that the counterbore and the
4. Remove the flywheel. crankshaft hub are clean and free from damage
and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
5. Use a suitable lever behind the lip of the counterbore. The oil seal has a special coating
seal, carefully prise out the oil seal from the and MUST be installed dry without lubricant.
counterbore in the flywheel housing. Take care
2. Install the crankshaft oil seal guide to the
not to scratch or damage the counterbore or the
crankshaft hub, using the bolts 1 (x2).
crankshaft hub. Damaged or dirty sealing faces
will cause the oil seal to fail. The crankshaft oil Special Tool: Crankshaft Rear Oil Seal
seal must not be reused. Discard the crankshaft Installation Tool (430 Engine) (Qty.: 1)
oil seal.
Figure 164.
F
E D
G
H
15 - 74 9813/9050-1 15 - 74
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
D Crankshaft oil seal guide E Bolts 1 (x2)

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

guide. Make sure that the seal is installed the
correct way around. Install the crankshaft oil seal
cup on to the oil seal guide and install the spacer
and the bolt 2.
4. Tighten the bolt 2 to push the seal squarely
into the counterbore until the oil seal cup comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore.
Figure 165.
F E D B
H G
A
E C
A Crankshaft oil seal
B Crankshaft
C Flywheel housing
D Crankshaft oil seal guide
E Bolts 1 (x3)
F Crankshaft oil seal cup
G Spacer
H Bolt 2
5. Remove the crankshaft seal installation tool.
6. Install the flywheel.
7. If necessary, install the engine.
15 - 75 9813/9050-1 15 - 75
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Special Tool: Torque Wrench (10-100Nm) (Qty.:

1)
Remove and Install 4. The bolts are tightened using a torque and angle
method.
Special Tools
Torque Wrench 993/70111 1 Figure 167.
(10-100Nm)
Before Removal
you start, refer to the Parts Catalogue.
C
3. Get access to the engine. C Angle gauge (obtain locally)
4. Remove the drive belt. After Replacement
1. Install the drive belt.
Remove Refer to: PIL 15-18-03.
1. Remove the fixing bolts and withdraw the pulley Table 66.
from the crankshaft.
Item Torque Value Torque Angle
Figure 166. (Nm) (Degrees)
B (1st stage) 75N·m
B (Final stage) 90°
A
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
Install
steps.
3. Replace the fixing bolts. Tighten the bolts in two
stages to the correct torque value.
15 - 76 9813/9050-1 15 - 76
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-79
15 - 77 9813/9050-1 15 - 77
Notes:
15 - 78 9813/9050-1 15 - 78
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-79 The camshaft is an important component in an
Technical Data ............................................... 15-80 internal combustion engine.
Component Identification ............................... 15-80
Operation ....................................................... 15-81 The relationship between the rotation of the camshaft
and the rotation of the crankshaft is of critical
Check (Condition) .......................................... 15-83 importance. Since the valves control the flow of the
Remove and Install ....................................... 15-83 air/fuel mixture intake and exhaust gases, they must
be opened and closed at the appropriate time during
the stroke of the piston. For this reason, the camshaft
is connected to the crankshaft directly, via a gear
mechanism.
When the engine runs the crankshaft drives the

camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle. Refer to: PIL 15-00-00.
15 - 79 9813/9050-1 15 - 79
15 - Engine
15 - Camshaft
00 - General
Technical Data Component Identification
Table 67. Camshaft Data Figure 168.

Camshaft journal diame-
ter
- 4 off 49.99–49.97mm
- 1 off 59.99–59.97mm
Camshaft lobe wear lim-
its A
Inlet lift 7.161–7.271mm E C D
Exhaust lift 7.2–7.31mm B
Camshaft bore diameter
- 4 off 50.07–50.04mm A Camshaft
B Camshaft drive gear
- 1 off 60.07–60.04mm C Exhaust lobe
Camshaft gear
(1)
98 teeth D Inlet lobe
(1) The camshaft gear is not available as a separate E Camshaft position sensor target wheel
item. The gear must be heated on to the camshaft
in the correct timed position. Specialist fixtures are
used during the production process to achieve the
correct timing.
15 - 80 9813/9050-1 15 - 80
15 - Engine
15 - Camshaft
00 - General
Operation
during the cycle it follows that the camshaft is driven

As the crankshaft rotates the camshaft also rotates, at half crankshaft (engine) speed.
driven by a gear on the crankshaft. The inlet and
exhaust valves are opened by lobes on the camshaft Lubrication
in time with the cycle.
Oil is fed from the main gallery via a drilling to the
The diagrams show the position of the camshaft camshaft bearing. A groove around the diameter of
at each part of the four stroke cycle. Refer to: PIL the bearing and connecting the cross drilling ensures
15-00-00. that oil is always fed to the centre drilling. Oil is then
transferred to the remaining camshaft bearings by
It can be seen that for a complete cycle the camshaft
further cross drillings in the shaft. The cam lobes and
revolves once. Since the crankshaft revolves twice
tappets are 'splash' lubricated.
Figure 169.
A
B D
A
D B
A Main gallery B Camshaft bearing
15 - 81 9813/9050-1 15 - 81
15 - Engine
15 - Camshaft
00 - General
C Groove D Centre drilling
15 - 82 9813/9050-1 15 - 82
15 - Engine
15 - Camshaft
00 - General

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

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure you
fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
15 - 83 9813/9050-1 15 - 83
15 - Engine
15 - Camshaft
00 - General
Figure 170. After Installation

1. The after installation procedure is the opposite
of the before removal procedure. Additionally do
the following step.
2. Replace the rear crankshaft oil seal.
A Camshaft and drive gear assembly
Install
1. Lubricate the camshaft with clean engine oil.
2. Insert the camshaft into the crankcase. Make
sure you fully support the camshaft to prevent
the lobes contacting the bearing surfaces in the
crankcase. The bearing surfaces can easily be
damaged by the sharp hard edges on the cam
lobes.
2.1. Make sure that the camshaft is installed
so that the engine timing is correct. The
single mark on the crankshaft drive gear
must locate between the two marks on the
camshaft drive gear.
Figure 171.
J
L
K
J Camshaft drive gear timing marks

K Crankshaft drive gear timing mark
L Camshaft drive gear
M Crankshaft drive gear
15 - 84 9813/9050-1 15 - 84
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-87

15-18-03 Drive Belt ....................................................................................................................... 15-89
15-18-21 Tensioner ........................................................................................................................ 15-94
15-18-24 Idler Pulley ..................................................................................................................... 15-95
15 - 85 9813/9050-1 15 - 85
Notes:
15 - 86 9813/9050-1 15 - 86
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-87 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-88 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-88 the coolant pump. Depending on the machine
application, the belt is configured to drive engine
mounted accessories, such as the alternator, cooling
fan and air conditioning compressor.
Some applications have a second pulley on the

crankshaft which drives a dedicated fan belt. The belt
drives an engine mounted cooling fan.
15 - 87 9813/9050-1 15 - 87
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 172.
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
WARNING! The engine has exposed rotating parts. F
engine cover open.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
C
G
B
E
D
A H
A Crankshaft drive pulley
B Coolant pump drive pulley
C Alternator drive pulley
D Idler pulley
E Tensioner
F Idler pulley/ cooling fan drive pulley
G Idler pulley/ air conditioning compressor drive
pulley
H Drive belt
15 - 88 9813/9050-1 15 - 88
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-89 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-90 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-90 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-91 also be configured to drive the engine mounted
accessories.
The belt is maintained at a constant tension by a
spring loaded tensioner. To achieve the necessary
belt/pulley contact area the belt is routed around
idler wheels as required. The configuration varies
depending on the accessories installed.
15 - 89 9813/9050-1 15 - 89
15 - Engine
18 - Engine Belt
03 - Drive Belt
Health and Safety Check (Condition)

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

2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 173.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 90 9813/9050-1 15 - 90
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust
Adjustment is not possible with this drive belt. A

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct
tension.
15 - 91 9813/9050-1 15 - 91
15 - Engine
18 - Engine Belt
03 - Drive Belt
Remove and Install
2. Using a 1/2 inch square drive inserted into the

Remove tensioner square drive socket, carefully rotate
the tensioner fully anticlockwise.
Figure 174.
A
D
C
A Drive belt B Example of frayed drive belt (refer to Check

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

4. Slowly release the spring force by rotating the 1. The installation procedure is the opposite of the
tensioner unit in the opposite direction. removal procedure. Additionally do the following
step.
15 - 92 9813/9050-1 15 - 92
15 - Engine
18 - Engine Belt
03 - Drive Belt
2. Before you install the new belt, check that the

tensioner roller and the pulleys rotate smoothly
and that there is no play in the bearings.
15 - 93 9813/9050-1 15 - 93
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner
Remove and Install
Remove
2. Using a 1/2 inch square drive inserted into the
tensioner square drive socket, carefully rotate
the tensioner fully anticlockwise.
3. Remove the belt from the tensioner pulley.
Figure 175.
D
C E
A
B
A Tensioner
B Bolt 1
C Bolt 2
D Drive belt
E Tensioner square drive socket
4. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
5. Remove the bolts (x2) and remove the tensioner.
Install
step.
2. Tighten the bolts to the correct torque value.

Item Description Nm
B M8 bolt 22–24
C M10 bolt 55 ± 5
15 - 94 9813/9050-1 15 - 94
15 - Engine
18 - Engine Belt
24 - Idler Pulley
24 - Idler Pulley Install

step.
Remove 2. Tighten the bolt to the correct torque value.
1. Make the machine safe. Table 69. Torque Values

Refer to: PIL 01-03. Item Nm
C 55 ± 5
3. Remove the dust cover.
Figure 176.
A Idler pulley
B Dust cover
4. Remove the bolt.
Figure 177.
A Idler pulley
C Bolt
5. Remove the idler pulley.
15 - 95 9813/9050-1 15 - 95
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-97
15 - 96 9813/9050-1 15 - 96
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-97 The oil filter is a spin on type which screws on and
Health and Safety .......................................... 15-98 off the oil filter head.
Operation ..................................................... 15-100
Check (Level) .............................................. 15-100
Remove and Install ..................................... 15-102
15 - 97 9813/9050-1 15 - 97
15 - Engine
21 - Oil Filter
00 - General
Health and Safety

Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 98 9813/9050-1 15 - 98
15 - Engine
21 - Oil Filter
00 - General
Figure 178.
C
1
C
G
F
J
A K
C
2
H A
D B
F
A
1 Oil filter state - engine running 2 Oil filter state - engine stopped
A Oil filter housing B Oil filter drain down plug
C Oil filter D Filter element
E Anti-drain seal F O-ring
G Anti-drain pipe H Spring
J Oil gallery - from cooler to filter head K Oil gallery - from filter head to main oil gallery
15 - 99 9813/9050-1 15 - 99
15 - Engine
21 - Oil Filter
00 - General
Operation Check (Level)
At Engine Running Engine oil and oil filter replacement must be

completed in accordance with the service schedules.
The oil pump delivers oil at pressure to the oil filter Failure to replace the oil and filter at the
via a port. The anti-drain seal is forced off its seat and recommended interval could cause serious engine
oil flows through a large area paper element. Filtered failure. Refer to: PIL 78-24.
oil enters the inner part filter before leaving the filter
head via a port. 1. Make the machine safe.
At Engine Stopped
With the engine stopped oil pressure in the galleries 3. Check that the oil level is between the two marks
and filter decays. The anti-drain seal falls on on the dipstick.
its seat and oil is prevented from draining from
the filter assembly. The anti-drain pipe prevents Figure 179.
approximately half the filters oil capacity from A
draining. These features help protect the engine from
oil starvation on start up.
A Dipstick
C Marks
4. If necessary, add recommended oil through one
of the filler points.
15 - 100 9813/9050-1 15 - 100

15 - Engine
21 - Oil Filter
00 - General
Figure 180.
B
B
A Dipstick
B Oil filler point
15 - 101 9813/9050-1 15 - 101

15 - Engine
21 - Oil Filter
00 - General
Remove and Install
CAUTION Oil will gush from the hole when the accordance with local regulations. Use authorised
drain plug is removed. Keep to one side when you waste disposal sites.
remove the plug.
CAUTION It is illegal to pollute drains, sewers Drain the oil when the engine is warm as
or the ground. Clean up all spilt fluids and/or contaminants held in suspension will then be drained
lubricants. with the oil.
Used fluids and/or lubricants, filters and
Figure 181.
1 2 3
H
D
A
F
C G E
A Dipstick B Filler point

C Drain plug D O-ring
E Drain plug F Filter canister
G Filter head H Seal
1. Make the machine safe. 6. Loosen and remove the filter housing drain plug.
Drain the oil.
2. Get access to the engine compartment.
7. Install the filter housing drain plug. Tighten the
3. Place a suitable container below the sump drain filter housing drain plug to the correct torque
plug. value.
4. Remove the sump drain plug and O-ring. Drain Torque: 24–28N·m
the oil in to a suitable container.
8. Remove the filter canister.
5. Clean the sump drain plug. Install the sump drain
plug with a new O-ring. Tighten the sump drain 8.1. Use a chain wrench if necessary.
plug to the correct torque value. 9. Clean the seal face of the filter head.
Torque: 45–55N·m
15 - 102 9813/9050-1 15 - 102

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

engine oil.
11. Install and tighten the new filter canister with your
hand.
12. Tighten the new filter canister to the correct
torque value.
Torque: 17–21N·m
13. Add the correct specification and quantity of oil
through one of the filler points to the maximum
mark on the dipstick.
13.1. Clean the spilt oil.
14. Fit the filler cap and make sure to secure the filler
cap.
15. Operate the engine at idle speed until the oil
pressure low warning light has extinguished and
the new filter primed before the engine speed is
increased above idle speed.
16. Check for leaks.
17. Check the oil level when the oil has cooled.
17.1. Fill with clean engine oil, if necessary.
15 - 103 9813/9050-1 15 - 103

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

15-24-09 Dust Valve .................................................................................................................... 15-108
15 - 104 9813/9050-1 15 - 104

15 - Engine
24 - Air Filter
00 - General
Introduction .................................................. 15-105 Engine performance and durability will be severely
Health and Safety ........................................ 15-106 affected if the quality of the air intake is poor.
Check (Condition) ........................................ 15-106
Remove and Install ..................................... 15-107 A dirty and blocked air cleaner element will reduce
the amount of air entering the combustion chamber
which can cause engine mis-firing, black smoke and
low output power.
A dirty and blocked air filter can also lead to abrasion

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

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

installed.
15 - 105 9813/9050-1 15 - 105

15 - Engine
24 - Air Filter
00 - General

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

with a vacuum switch. The switch will detect if there
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual
indicator.
15 - 106 9813/9050-1 15 - 106

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

every other time the outer element is changed. As
a reminder, mark the inner element with marker pen
each time the outer element is changed.
F
Remove E
D
3. Depress the clips and lift off the cover.
4. Remove the outer element. Take care not to tap
or knock the element.
5. If the inner element is to be changed, lift up pulls
and remove the inner element.
G
C
B Clips
C Cover
D Outer element
E Inner element
F Housing
G Air holes
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that dust valve is at the bottom.
15 - 107 9813/9050-1 15 - 107

15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve
Check (Condition)
• Check the dust valve for rips/tears.
• Check there are no obstructions.
• Check that the dust valve is free of dirt and dust.
• Check that the dust valve securely attached to
the air filter housing.
15 - 108 9813/9050-1 15 - 108

15 - Engine
28 - Crankcase Breather
Contents Page No.
15-28-00 General ......................................................................................................................... 15-111
15 - 109 9813/9050-1 15 - 109

Notes:
15 - 110 9813/9050-1 15 - 110

15 - Engine
00 - General
Introduction .................................................. 15-111 The crankcase breather allows excess combustion
Remove and Install ..................................... 15-112 gasses and vapours to leave the engine preventing
excessive pressure build up inside the crankcase.
The gasses and vapours leave the engine through
the rocker cover before passing through an oil
separator. A small amount of charge air pressure
is used to extract the clean gasses once they have
been through the oil separator.
Figure 183.
A
D B
C
A Crankcase breather
B Air inlet
C Rocker cover
D Crankcase breather vent pipe
15 - 111 9813/9050-1 15 - 111

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

G
G Bolts 2 (x10)
2. Make sure that the engine is safe to work on. If H Crankcase breather oil separator
the engine has been running, let it cool before J Turbo control valve
10. If installed remove the clamping plates (x2).
3. Disconnect and remove the crankcase breather
to air intake pipe. Figure 186.
Figure 184.
K
C
B
A K
E K Clamping plates x2
11. Remove the crankcase breather oil separator.
D Remove and discard the gasket. Do not reuse
the gasket.
A Crankcase breather to air intake pipe
B Crankcase breather vent pipe Install
C Electrical connectors
D Turbo control valve hoses 1. The installation procedure is the opposite of the
E Bolts 1 (x2) removal procedure. Additionally do the following
F Harness support bracket steps.
4. Disconnect the crankcase breather vent pipe. 2. Replace the gasket.
5. Disconnect the electrical connectors from the 3. Tighten the bolts to the correct torque value.
turbo control valve and the exhaust manifold
temperature sensor. 4. Make sure that the rubber grommet is correctly
seated on the spigot when the crankcase
6. Remove the cable ties securing the wiring breather vent pipe is installed.
harness to the crankcase breather oil separator.
5. Replace the cable ties.
7. Disconnect the hoses from the turbo control
valve. Table 70. Torque Values
Item Nm
8. Remove the bolts 1 (x2) and remove the harness
support bracket. F 10 ± 1
G 10 ± 1
9. Remove the bolts 2 (x10) and remove the turbo
control valve and bracket.
15 - 112 9813/9050-1 15 - 112

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

15-30-12 Valve Spring ................................................................................................................. 15-120
15-30-24 Stem Seal .................................................................................................................... 15-121
15 - 113 9813/9050-1 15 - 113

Notes:
15 - 114 9813/9050-1 15 - 114

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

clearance between the rocker and push rods.
The valves extend through the cylinder head. There

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

head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.
15 - 115 9813/9050-1 15 - 115

15 - Engine
30 - Valve
00 - General
Technical Data
Table 71. Inlet and Exhaust Valve Data

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

ter
- min 5.992mm
- max 6.008mm
Valve face angle
- Inlet 60.5°
- Exhaust 45.1°
Valve length 111.05–111.55mm
Valve sealing Stem seal with garter
spring
Valve head depth (below
cylinder head surface)
- Inlet 0.624–1.024mm
- Exhaust 0.6–1mm
Valve timing -0.1mm lash (compen-
sated)
(1) The valve spring is an asymmetric coil pitch
spring. The spring is assembled with a particular
orientation.
15 - 116 9813/9050-1 15 - 116

15 - Engine
30 - Valve
00 - General
Figure 187.
F
G
E
K J
D
C
B
A Camshaft gear B Crankshaft gear

C Camshaft D HLA (Hydraulic Lash Adjuster) (x8)
E Push rods (x8) F Rocker - exhaust (x4)
G Rocker - inlet (x4) H Rocker shaft
J Valve - inlet (x8) K Valve - exhaust (x8)
L Bridge piece (x8) M Valve spring (x16)
N HLA Guide (x4)
15 - 117 9813/9050-1 15 - 117

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

Description Part No. Qty. Refer to: PIL 15-06-00.
Valve Stem Seal 320/03890 1
Installation Tool (430 5. Measure the valve recession with a suitable DTI
Engine) (Dial Test Indicator). Clean the carbon deposits
from a small area of the valve heads for location
of the DTI probe. If the valve recession is outside
Before Removal the serviceable limits, it is advisable to obtain a
1. This procedure requires service parts. Make new or reconditioned cylinder head assembly.
sure you have obtained the correct service parts Refer to: PIL 15-06-00.
before you start. Refer to Parts Catalogue.
6. To aid removal and Installation, use a wooden
2. Make sure that the engine is safe to work on. If valve stand to retain the valves after removal.
the engine has been running, let it cool before Add labels to make sure that the valves are
you start the service work. correctly replaced.
Figure 188. Valve Stand

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

the retainer and valve spring.
1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure Figure 190.
that the springs are compressed squarely. C
Figure 189.
D
B
A
C Retainer
D Valve spring
3. Turn the cylinder head on its side and withdraw
the inlet valves and exhaust valves as shown.
A Spring compressor tool
B Collets
15 - 118 9813/9050-1 15 - 118

15 - Engine
30 - Valve
00 - General
Figure 191. If there is evidence of wear or damage to the valves,

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

F Inlet valves
G Exhaust valves 1. The installation procedure is the opposite of the
4. When removing, note the respective position of steps.
each valve. Use a suitable valve stand to keep
the valves together and identify them with their 2. Install the new valve stem seals as shown. Use
respective cylinder. The exhaust valves have the installation tool to avoid damaging the seals.
smaller diameter heads. Pre-assemble the seal into the tool. Locate the
tool over the valve guide and gently press the
5. Remove the valve stem seals. Discard the seals. seal into place. Lubricate the seal with P80 fluid.
Figure 192. Special Tool: Valve Stem Seal Installation Tool
(430 Engine) (Qty.: 1)
3. With the cylinder head on its side, insert the
J H inlet valves and exhaust valves as shown. Make
sure that the valves are installed in the correct
positions. Lubricate the valve stems with clean
engine oil before assembly. Carefully push the
end of the valve stem through the stem seals.
4. Install the valve springs on to the valve stems,
together with a retainer.
4.1. Make sure that the valve springs are
orientated correctly, the white painted end
of the valve spring must go at the top.
5. Use the spring compressor tool to compress
H Valve stem seals each valve spring and insert the collets. Make
J Punch tool sure that the collets are correctly seated in the
valve stem grooves before you remove the spring
Inspection compressor tool.
1. Carefully clean the carbon deposits from the After Installation

valves, take care not to damage the valve seats.
1. Pop the valves by tapping the valve stems in turn
2. Check that the valves and valve seats are not using a rubber mallet.
cracked, burnt or damaged.
3. Check the valve stems and valve guides for wear.
15 - 119 9813/9050-1 15 - 119

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

15 - 120 9813/9050-1 15 - 120

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

15 - 121 9813/9050-1 15 - 121

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

15-33-06 Big-End Bearing ........................................................................................................... 15-127
15 - 122 9813/9050-1 15 - 122

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-123 The connecting rod connects the piston to the
Technical Data ............................................. 15-124 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-124 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-125
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-125 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-126 the angle between the connecting rod and the piston
can change as the rod moves up and down and
rotates around the crankshaft.
The small end of the connecting rod attaches to the

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

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

the big end of the connecting rod so that pressurised
lubricating engine oil squirts out on to the thrust
side of the cylinder wall to lubricate the travel of the
pistons and piston rings.
15 - 123 9813/9050-1 15 - 123

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 72. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 69.02–69.039mm
ameter
Connecting rod side
clearance
min 0.07mm
max 0.42mm
Big end bearings
Width 25–25.25mm
Thickness (at centre) 1.991–1.997mm
Small end bearings
Inside diameter 36.02–36.034mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 124 9813/9050-1 15 - 124

15 - Engine
33 - Connecting Rod
00 - General

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

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 125 9813/9050-1 15 - 125

15 - Engine
33 - Connecting Rod
00 - General

15 - 126 9813/9050-1 15 - 126

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

Introduction .................................................. 15-127 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-128 bearings at the big-end of the connecting rod.
15 - 127 9813/9050-1 15 - 127

15 - Engine
33 - Connecting Rod

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

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 128 9813/9050-1 15 - 128

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

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

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear.
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
4. Install the lower bearing shell to the big-end
bearing cap. Lubricate the bearing shell with
15 - 129 9813/9050-1 15 - 129

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

to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new big end bearing cap bolts. Tighten the
new bolts in three stages to the correct torque
value.
1)
5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
5.2. The bolts are tightened using a torque and
angle method.
Figure 195.
0° +90°
Figure 196.
T3
T3 Angle gauge (obtain locally)
After Installation

Item Torque Value Angle (de-
(Nm) grees)
2 (1st Stage) 35
2 (2nd Stage) 65
2 (Final Stage) 90
15 - 130 9813/9050-1 15 - 130

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

15-36-03 Piston Ring ................................................................................................................... 15-144
15 - 131 9813/9050-1 15 - 131

Notes:
15 - 132 9813/9050-1 15 - 132

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-133 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-134 expanding combustion gases in the combustion
Component Identification ............................. 15-135 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-136 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-137
Calibrate ...................................................... 15-137 The pistons are cast from aluminium alloys for
Remove and Install ..................................... 15-139 increased strength and improved fatigue life.
Disassemble and Assemble ........................ 15-142
The connecting rod is attached to the piston by a
swivelling piston pin. This pin is mounted within the
piston, The pin itself is of hardened steel and is fixed
in the piston, but free to move in the connecting rod.
The pins are prevented from moving sideways and
the ends of the pin digging into the cylinder wall by
circlips.
15 - 133 9813/9050-1 15 - 133

15 - Engine
36 - Piston
00 - General
Technical Data
Table 74. Piston Data

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

Piston skirt 91.861–91.879mm
Piston pin 35.994–36mm
(1) Nominal measurement is 0.426mm
(2) Measure at gauge diameter 88.01 ± 0.38mm
15 - 134 9813/9050-1 15 - 134

15 - Engine
36 - Piston
00 - General
Figure 197.
TOP
B
C B
TOP
C
D
F
Da G
TOP
H
E
D
A Piston B Piston ring - compression No.1

C Piston ring - compression No.2 D Piston ring - oil control ring
Da Spiral wire - oil control ring E Connecting rod
F Piston pin G Retaining circlip (x2)
H Piston orientation cut out J Main bearing cap orientation mark
15 - 135 9813/9050-1 15 - 135

15 - Engine
36 - Piston
00 - General
Operation
The jets spray oil directly to the under side of the

The groove around the diameter of the upper main pistons effectively transferring heat away from the
bearing shells allows oil transfer to an oil jet located top of the pistons. Oil spray also enters the small end
in the crankcase bearing saddle. Jets are installed at bearing bushes via a feed hole on the top of each
the main bearing positions. connecting rod.
Figure 198.
2
3
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft
15 - 136 9813/9050-1 15 - 136

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

1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
Piston Height Measurement Above
diameter, piston pin bore and the clearance in Cylinder Block- DTI Method
the piston ring grooves to confirm they are within
service limits. In the event of sufficient liquid entering the engine, a
hydraulic lock can occur. This may result in bending
Refer to: PIL 15-36-00. of one or more of the connecting rods. Bending of the
connecting rod(s) can occur even when the engine is
2. Check the piston pin for signs of damage and cranked by the starter motor.
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston. Bending of the connecting rod may be very slight and
Refer to: PIL 15-36-00. can be checked by carrying out this procedure prior
to a full strip down:
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged 1. With the cylinder head removed, make sure the
or worn the connecting rod must be renewed as a surface of the engine block and piston are clean.
complete assembly.
2. Zero a DTI (Dial Test Indicator) on the top face
of the cylinder block adjacent to the area on the
piston to be measured. The aim of the procedure
is to use the DTI to take a measurement across 2
locations on the piston that are on the axis of the
gudgeon pin. This will be towards the front and
rear of the engine.
3. Rotate the engine and bring the piston up until
it is 3mm below the engine block face. Carefully
reposition the zeroed DTI above the area of the
piston to be measured.
4. Rotate the engine to bring the piston up to
exactly TDC (Top Dead Centre) and record the
measurement at position 1.
5. Repeat steps 2 to 4 for position 2.
6. Calculate the average of the 2 readings to give
a figure of the piston height above the cylinder
block.
7. Compare the reading obtained to the technical
data.
7.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
7.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
8. Repeat steps 2 to 7 to check all connecting rods/
pistons.
9. If any connecting rods are bent, strip the engine
and check for further damage.
10. If the engine is serviceable, any connecting rod
that is bent must be replaced.
15 - 137 9813/9050-1 15 - 137

15 - Engine
36 - Piston
00 - General
Figure 199. 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 200. Straight Edge Measurement
G
F
E
A Gudgeon pin axis

B Line of measurement above gudgeon pin axis K
C Piston measurement point 1
D Piston measurement point 2
L
Piston Height Measurement Above
Cylinder Block- Straight Edge Method
If a DTI is not available, a calibrated straight E Straight edge
edge may be used to take a measurement. The F Measurement position 1
measurement will be less accurate. G Measurement position 2
H Cylinder block- top face
1. With the cylinder head removed, make sure the J Gudgeon pin axis
surface of the engine block and piston are clean. K Piston
L Connecting rod
2. Rotate the engine until the piston to be measured
is at TDC.
3. Position the straight edge on top of the piston
along the axis of the gudgeon pin.
4. Use feeler gauges to measure the gap between
the cylinder block face and underside of the
straight edge on both sides, position 1 and
position 2.
15 - 138 9813/9050-1 15 - 138

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

Before Removal Refer to: PIL 33-45-06.
This procedure requires service parts. Make sure 4. Remove the fuel injector cover.
The following procedure is for one piston and
connecting rod assembly. Each assembly must be Refer to: PIL 18-18-03.
replaced in the same cylinder bore. Label each piston
and connecting rod assembly to make sure it is 6. Remove the rocker cover.
installed in the correct position on assembly. Refer to: PIL 15-42-06.
1. Make sure that the engine is safe to work on. If 7. Remove the cylinder head assembly.
the engine has been running, let it cool before Refer to: PIL 15-06-00.
15 - 139 9813/9050-1 15 - 139

15 - Engine
36 - Piston
00 - General
Figure 201.
H G
E
C
D
F
F
J
A Piston B Piston rings

C Connecting rod D Big end bearing cap
E Piston cut out - intake side of crankcase F Big end bearing cap orientation marks
G Shortest side of connecting rod - intake side of H Longest side of connecting rod - exhaust side of
crankcase crankcase
J Big end bearing cap bolts
15 - 140 9813/9050-1 15 - 140

15 - Engine
36 - Piston
00 - General
Remove Table 75. Torque Table

The piston and connecting rod assemblies are (Nm) grees)
removed through the top of the crankcase.
J (1st Stage) 35
1. Remove the big end bearing caps. J (2nd Stage) 65
J (Final Stage) 90
2. Use a suitable scraper and wire wool to clean off
the carbon deposits from around the top of the
cylinder bore. Take care not to scratch or damage
the cylinder bore.
3. Use a hammer and a short length of wood to
tap the piston from the connecting rod side. Take
care not to scratch or damage the cylinder bore
or the connecting rod bearing surface.
Before Installation
1. Check the big end bearings and the crank shaft
for signs of wear.
Install
2. Make sure that the big end bearing shells are
installed correctly.
3. Lubricate the cylinder bore with clean engine oil.
4. Lubricate the big end bearings with clean engine
oil.
5. Use a suitable compressor tool to compress the
piston rings.
6. Insert the piston and connecting rod assembly
into the cylinder bore. Make sure that the longest
side of the connecting rod is on the exhaust
side of the crankcase and the piston cut-out is
on the intake side of the engine. Take care not
to damage the cooling jets when you guide the
connecting rod down the cylinder bore and over
the crank pin diameter.
7. Install the big end bearing cap. Make sure that
it is orientated correctly, the orientation mark
should be on the same side as the orientation
mark on the connecting rod.
8. Install new big end bearing cap bolts. Tighten the
bolts in three stages to the correct torque value.
After Installation
15 - 141 9813/9050-1 15 - 141

15 - Engine
36 - Piston
00 - General
Disassemble and Assemble side of the connecting rod is on the same side as
the cut out in the piston.
4. Install new circlips. Make sure that they are
Dismantle installed correctly in the groove in the piston.
1. Clamp the connecting rod in a vice. Take care not 5. Lubricate the piston with clean engine oil. Install
to damage the connecting rod. the piston rings to the piston in sequence as
2. It is recommended that the piston rings are follows:
renewed. If they are to be reused, label the 5.1. Install the spiral wire for the oil control ring
rings to ensure they are installed in the correct in the bottom groove and locate the locking
positions and the correct way up on assembly. wire inside both ends of the spiral as shown.
Carefully remove the piston rings from the piston. Using a piston ring expander tool to install
To avoid damage or distortion to the rings, use a the oil control ring in the bottom groove and
suitable piston ring expander tool. Note that the locate the locking wire inside both ends of
oil control ring is installed with a spiral wire. Pull the spiral as shown. Make sure that the
the wire apart and remove it. ring gap is positioned 180° to the locking
3. Remove the circlips and push out the piston pin. wire. The correct ring orientation can also
be determined from the profile shape of the
Figure 202. ring.
5.2. Install the No.2 compression ring into the
middle groove. New rings have a reference
number etched on one face. Make sure
that this face is installed uppermost in the
piston groove. The correct ring orientation
can also be determined from the profile
shape of the ring.
A 5.3. Install the No.1 compression ring into the
B top groove. New rings have a reference
number etched on one face. Make sure
that this face is installed uppermost in the
C piston groove. The correct ring orientation
can also be determined from the profile
B shape of the ring.
A Piston Refer to: PIL 15-36-00.
B Circlip (x2)
C Piston pin 6. Rotate the piston rings so that the ring gaps are
120° apart as shown.
4. Use a suitable cleaning agent, clean the carbon
deposits from the piston.
Inspect
1. Inspect the pistons for signs of wear or damage.
Assemble
following steps.
3. Lubricate the piston pin with clean engine oil.
Assemble the connecting rod to the piston and
insert the piston pin. Make sure that the short
15 - 142 9813/9050-1 15 - 142

15 - Engine
36 - Piston
00 - General
Figure 203.
0°
12
12
0°
120°
15 - 143 9813/9050-1 15 - 143

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

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

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

shaped profile, to act as oil scrapers.
15 - 144 9813/9050-1 15 - 144

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-147
15 - 145 9813/9050-1 15 - 145

Notes:
15 - 146 9813/9050-1 15 - 146

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 147 9813/9050-1 15 - 147

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

15-42-06 Rocker Cover ............................................................................................................... 15-155
15-42-09 Push Rod ..................................................................................................................... 15-157
15-42-21 Tappet ........................................................................................................................... 15-159
15 - 148 9813/9050-1 15 - 148

15 - Engine
00 - General
Introduction .................................................. 15-149 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-150 system consisting of rocker arms and a shaft.
Component Identification ............................. 15-151
Operation ..................................................... 15-152 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-152 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-153 raised and lowered by a rotating lobe of the camshaft
via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 149 9813/9050-1 15 - 149

15 - Engine
00 - General
Technical Data
Table 76. Rocker Levers, Rocker Shafts and Hydraulic Lash Adjuster Data
Rocker lever bore diameter
- min 21mm
- max 21.021mm
Rocker shaft diameter
- min 20.959mm
- max 20.98mm
HLA (Hydraulic Lash Adjuster) stem diameter
- min 21.387mm
- max 21.405mm
HLA bore diameter
- min 21.444mm
- max 21.473mm
Tappet height (maximum) 55.25mm
15 - 150 9813/9050-1 15 - 150

15 - Engine
00 - General
Figure 204.
B
A
D B
E
D B
E
D
E
D
A Rocker shaft assembly B Rocker shaft fixing bolts (x4)

C Rocker shaft oil feed Pedestal D Pedestal clamps (x4)
E Bridge pieces (x8)
15 - 151 9813/9050-1 15 - 151

15 - Engine
00 - General
Operation Check (Condition)
When the camshaft lobe raises the outside of the 1. Check the rocker shaft and rocker bushings for
rocker arm, the inside presses down on the valve signs of damage and excessive wear. Measure
stem to open the valve. When the outside of the the rocker shaft diameter and rocker bearing
rocker arm is permitted to return due to the camshafts bushes to confirm they are within service limits.
rotation, the inside rises to allow the valve spring to Refer to Technical Data. Note: The rocker
close the valve. bearing bushes are not renewable. If a rocker
bearing bush is damaged or worn the rocker
Lubrication must be renewed as a complete assembly.
Oil is fed from the main gallery via a drilling which
passes up through the crankcase and the cylinder 2. Make sure that all oil-ways and cross drillings in
head to a small transfer gallery under the rocker shaft the rocker shaft, rocker arms and pedestals are
pedestal. The oversize rocker shaft fixing bolt hole clear and free from debris. Use an air line to blow
allows oil to pass into a drilling in the centre of the through cross drillings.
rocker shaft. Further cross drilling’s transfer oil to
each of the rocker pivot bushes. Two cross drillings
in each rocker transfer oil to the end insert providing
an oil pressure feed to the valve bridge and push rod
end.
15 - 152 9813/9050-1 15 - 152

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

B Bridge pieces
4. Loosen the bolts (x4) and remove the rocker C Push rods
shaft assembly. Do not remove the bolts from the
6. Remove the push rods from the crankcase, keep
rocker assembly.
the push rods in order so that they can be
Figure 205. installed in their original positions.
Before Installation
damage and corrosion. If components within the
rocker assembly are damaged or worn, they
must be replaced.
A
2. Make sure that all oilways and cross drillings in
the cylinder head, rocker shaft, rocker arms and
pedestals are clear and free from debris. Use an
3 1 2 4 air line to blow through the cross drillings.
Install
1-4 Bolts (x4) removal procedure. Additionally do the following
A Rocker shaft assembly steps.
5. Remove the bridge pieces from the valves, keep 2. Use a suitable degreasing agent to clean the top
the bridge pieces in order so that they can be of the cylinder head.
installed in their original positions.
3. Make sure that the push rods engage correctly
with the camshaft tappets.
4. Make sure that the valve bridges engage
correctly with the valve tips.
5. Tighten the bolts (x4) (in sequence 1-4) to the first
stage torque. Refer to Figure 205.
6. Tighten the bolts (x4) (in sequence 1-4) to the
second stage torque. Refer to Figure 205.
7. The hydraulic tappets take time to leak down and
settle in to their working positions. Make sure that
the engine is not started for the specified time
15 - 153 9813/9050-1 15 - 153

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

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

Item Description Nm
1-4 Stage 1 12
1-4 Stage 2 24 ± 2
15 - 154 9813/9050-1 15 - 154

15 - Engine
06 - Rocker Cover
06 - Rocker Cover 11.1. Plug all the open ports and hoses to
Remove and Install Special Tool: Fuel Injector equipment Cap

Kit (430 Engine) (Qty.: 1)
Special Tools
Fuel Injector equipment 320/B9321 1 Refer to: PIL 18-18-03.
13. Remove the EGR (Exhaust Gas Recirculation)
assembly.
Remove
This procedure requires service parts. Make sure 14. Remove the EGR diffuser.
you start, refer to the Parts Catalogue. Refer to: PIL 18-27-15.
1. Make the machine safe. 15. Remove the cable ties (x5) securing the wiring
harness to the rocker cover.
Figure 207.
you start the service work. A A A
A
3. Disconnect the charge air hose.
4. Remove the air intake adaptor.
TMAP (Temperature Manifold Air Pressure) A Cable ties (x5)
sensor.
16. Remove the bolts 1 (x2) that secure the wiring
5.1. If necessary remove the TMAP sensor. harness to the rocker cover.
Refer to: PIL 15-84-17. Figure 208.
6. Remove the TCV (Turbocharger Control Valve)
assembly.
7. Remove the crankcase breather system.
B
8. Remove the ECM (Engine Control Module) and B
the ECM mounting bracket.
B Bolts 1 (x2)
9. Remove the injector cover.
17. Loosen the bolts 2 (x18). The bolts are captive
Refer to: PIL 18-18-04. and will remain in the rocker cover.
10. Remove the injector leak-off pipes.
10.1. Plug all the open ports and hoses to
Special Tool: Fuel Injector equipment Cap
11. Remove the injector high pressure fuel pipes.
15 - 155 9813/9050-1 15 - 155

15 - Engine
06 - Rocker Cover

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

Item Nm
C 9±1
15 - 156 9813/9050-1 15 - 156

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

Introduction .................................................. 15-157 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-158 and close the valves. They are moved by the cams
on the camshaft. One end is pushed up by the cam
and the other end makes contact with the rocker
arms which rotates and pushes the valve open.
15 - 157 9813/9050-1 15 - 157

15 - Engine
09 - Push Rod
Remove and Install

15 - 158 9813/9050-1 15 - 158

15 - Engine
21 - Tappet
21 - Tappet Introduction
Introduction .................................................. 15-159
Hydraulic Tappet
Operation ..................................................... 15-160 A hydraulic tappet is a device for maintaining zero
Remove and Install ..................................... 15-161 valve clearance in an internal combustion engine.
The zero tolerance allows the valve train to operate
with zero clearance leading to quieter operation,
longer engine life, and eliminating the need for
periodic adjustment of valve clearance.
15 - 159 9813/9050-1 15 - 159

15 - Engine
21 - Tappet
Component Identification Operation

Figure 211. The operating principle of the hydraulic tappet is
J based on the incompressibility of the liquids and on
controlled leakage.
The pressurised oil flows from an opening in the

main gallery into a feed hole in the tappet body
which is connected to the low pressure chamber.
This maintains a constant flow of oil in the low
and high pressure chambers. The oil can enter the
high pressure chamber only through the non return
valve and leaves through the clearance between the
plunger and the tappet body (controlled leakage).
Figure 212.
A
B
K F
E
C
D
C
D
B E
A
A Roller assembly
B Roller axle
C Axle retaining clip
D Tappet body
E Spring
F High pressure chamber
G Piston A Rocker shaft
H Low pressure chamber B Rocker arm
J Piston retainer clip C Push rod
K Non-return valve D Tappet
E Tappet oil feed hole
The high pressure chamber is refilled when the

tappet is on the bottom of the cam base and the
spring keeps the plunger pressed. This eliminates
the clearance in the entire valve-rocker arm-push
rod-tappet-cam system.
15 - 160 9813/9050-1 15 - 160

15 - Engine
21 - Tappet
The tappet body moves away from the plunger Remove and Install
creating a slight vacuum in the high pressure
chamber and causes the valve to open, thus allowing
the oil in the low pressure chamber to flow into Before Removal
the high pressure chamber. This re-establishes the
quantity of oil required for optimal running conditions. 1. This procedure requires service parts. Make sure
you have obtained the correct parts before you
Difficult operating conditions start, refer to the Parts Catalogue.
For correct functioning of the hydraulic tappets, the 2. Make the machine safe.
pressure chamber of the plunger must always be Refer to: PIL 01-03.
filled with oil. But, this is not possible when the engine
is not running and oil leakages may cause partial 3. Make sure that the engine is safe to work on. If
emptying of the tappets. This situation will cause the engine has been running, let it cool before
too much clearance which will make itself apparent you start the service work.
through an unusual ticking sound that is not to be
confused with the normal ticking of the injectors. 4. Drain the engine coolant.
1. Starting from cold: The engine has not been
used for some time and the oil may have leaked 5. Remove the rocker cover.
out of the pressure chamber of the tappets. Refer to: PIL 15-42-06.
Moreover, lubricant flows with greater difficulty
at low temperatures, and hence several seconds 6. Remove the rocker assembly and push rods.
may go by before the tappets are once again
supplied with oil. Refer to: PIL 15-42-00.
2. Engine very hot: At minimum speed, the oil 7. Remove the cylinder head.
pressure is low and tiny air bubbles may form Refer to: PIL 15-06-00.
inside it (more than 5% of its volume). This
causes the lubricant to become compressible Remove
and the tappet is squeezed slightly creating
clearance and, thus making a noise. 1. Remove the tappet guides (x4).
3. Starting and stopping the engine repeatedly Figure 213.
(very rare): In this situation, the tappets may
empty temporarily. A
4. An oil with a viscosity not adequate to the B

environmental conditions of the engine, may
affect the proper functioning of the hydraulic
tappets.
In all four cases the ticking must not last too long.
If this is not the case, the problem is definitely due
to a manufacturing fault, wear and tear or dirt, which
can be drawn in by the oil and get between the non-
return valve and its seat inside the plunger, thus
compromising the functioning of the tappets. In this
case, replace the hydraulic tappets.
A Crankcase
B Tappet guide
2. Use a magnetic probe to remove the tappets (x8).
Make a note of the tappet order so that they are
installed in their original positions.
15 - 161 9813/9050-1 15 - 161

15 - Engine
21 - Tappet
Figure 214. After Installation

2. The tappets will be pushed down and out of the
tappet guide and onto the camshaft lobes when
C the rocker assembly and push rods are installed.
C Tappet
D Magnetic probe
Install
1. Lubricate the tappets with clean engine oil.
2. Install the tappets into the bottom of the tappet
guide. the tappets should be a snug fit in the
tappet guide. Make sure that they are orientated
correctly with the rollers facing down
Figure 215.
C
C
E E
B Tappet guide
C Tappet
E Roller assembly
3. Install the tappet guide and tappets assembly.
15 - 162 9813/9050-1 15 - 162

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

15-45-09 Dipstick ......................................................................................................................... 15-168
15 - 163 9813/9050-1 15 - 163

Notes:
15 - 164 9813/9050-1 15 - 164

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-165 The lubrication system distributes oil around the
Remove and Install ..................................... 15-166 engine by a system of galleries and drillings in the
crankcase and cylinder head. The oil lubricates and
seals the moving parts of the engine, reducing friction
and wear. In addition the oil plays an important role in
cooling the engine by carrying heat from the engine
to the cooler. A piston cooling jet sprays oil onto the
underside of the pistons to keep them cool. Refer to
(PIL 15-36).
Oil is drawn from the oil sump by the integral oil pump
via the suction strainer. The strainer prevents any
large particles of debris passing through, which may
damage the pump.
The oil passes from the outlet side of the pump in to

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

through the oil cooler and filter. Refer to (PIL 15-69
and PIL 15-21).
After cooling and filtering, the oil passes into the

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

bearings it reverts to sump pressure and splash
lubricates the internal components such as rocker
tips, cam lobes and timing gear teeth. Gravity
drains the oil via drains into the cylinder head and
crankcase, back into the oil sump.
15 - 165 9813/9050-1 15 - 165

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

Figure 216. 1. Lightly smear the inside of the new oil pick up
seal with clean engine oil and install into the
bedplate. DO NOT install the seal on to the
oil sump as this may damage the oil pick up
seal. Damage to the seal could cause a drop
B in oil pressure and subsequently damage to the
C engine.
A 2. Install the oil sump location dowel into the

position shown.
Special Tool: Oil Sump Location Dowel (Qty.: 1)
Figure 218.
A Oil sump
B Bolts (x19)
C Oil level sensor
5. Remove the bolts (x19) and remove the oil sump
from the engine. The oil sump may be difficult to
remove due to adhesion of sealing compound.
If necessary, carefully lever the mating flanges
apart. Do not use excessive force, the oil sump F
could be damaged. Make sure that you do not
damage the sealing face on the bedplate or the
oil sump.
F Oil sump location dowel position
6. Remove the oil pick up seal. The oil pick up seal
MUST NOT be re-used. Discard the oil pickup 3. Use the fixing bolts to locate the template to
seal. the oil sump mating face. Make sure that the
15 - 166 9813/9050-1 15 - 166

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

are on different centres).
Special Tool: Template for Sealant Oil Sump -
Pressed (430 Engine) (Qty.: 1)
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the
template as a guide as shown. Note the beads
around holes.
Consumable: Clear Silicone Sealant
5. Carefully remove the template without smudging
the sealant beads.
6. Apply a bead of sealant so as to join the sealant
beads around holes with the bead around the oil
sump flange.
7. After applying the sealing compound, the oil
sump must be installed and the bolts torque
tightened within the specified time period.
Duration: 5min
8. Carefully insert the oil suction tube outlet into
the oil pick up seal on the engine. Once the
oil suction tube has located in to the seal, slide
the oil sump on to the engine. Make sure that
the oil sump locates correctly with the location
dowel through the bolt hole on the oil sump. Avoid
smudging the sealant beads. Take care not to
damage the oil pick up seal when you install the
oil sump. Damage to the seal could cause a drop
in oil pressure and subsequent damage to the
engine.
9. Loosely install the oil sump bolts by hand.
Remove the location dowel to install the last bolt.
After Installation.
1. Allow the sealant to cure for the specified time
period.
Duration: 20min
2. Fill the engine with the recommended engine oil.
3. Start the engine and check for oil leaks.

Item Nm
B 24 ± 2
15 - 167 9813/9050-1 15 - 167

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

3. Remove the bolt 1 and bolt 2.
4. Remove the dipstick assembly through the EGR
(Exhaust Gas Recirculation) coolant hoses.
Figure 219.
A Bolt 1
B Bolt 2
Install
steps.
2. Make sure that all sealing faces are clean and
the sealing hole in the bedplate (for the dipstick
tube) is free from debris.

Item Nm
A 24 ± 2
B 24 ± 2
15 - 168 9813/9050-1 15 - 168

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

15-51-03 Crankshaft Gear ........................................................................................................... 15-175
15-51-06 Camshaft Gear ............................................................................................................. 15-176
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-177
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-178
15 - 169 9813/9050-1 15 - 169

Notes:
15 - 170 9813/9050-1 15 - 170

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-171 The timing gears are located inside a case at the
Component Identification ............................. 15-172 flywheel end of the engine.
Operation ..................................................... 15-173
Check (Condition) ........................................ 15-174 The engine must be timed so that the camshaft
operates the valves at the correct times relative to
the crankshaft position.
Valve timing is achieved by ensuring that the

camshaft drive gear is meshed to the crankshaft gear
at their correct angular positions, refer to Engine-
General, Operation, The Four Stroke Cycle (PIL
15-00) for more information about valve timing.
15 - 171 9813/9050-1 15 - 171

15 - Engine
51 - Timing Gear
00 - General
Figure 220.
C E
D A
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO (Power Take-Off) idler gear
15 - 172 9813/9050-1 15 - 172

15 - Engine
51 - Timing Gear
00 - General
Operation
• High pressure fuel pump gear - The high

All the gears are driven via the crankshaft gear as pressure fuel pump is driven via the camshaft
follows: gear.
• Oil pump gear - The oil pump is driven via the
• Camshaft gear - The camshaft is driven at half camshaft gear.
crankshaft speed. • Heavy duty PTO (Power Take-Off) idler gear -
The heavy duty PTO idler gear is driven via the
camshaft gear.
Figure 221.
E
B
D
A
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO idler gear
15 - 173 9813/9050-1 15 - 173

15 - Engine
51 - Timing Gear
00 - General
Check (Condition)
1. Inspect the gears for wear or damage. If one or
more of the gears are worn or damaged, replace
them.
15 - 174 9813/9050-1 15 - 174

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

the end of the crankshaft and cannot be removed
individually. If the gear is damaged or worn the
complete crankshaft and gear assembly must be
replaced. Refer to Crankshaft- Remove and Install
(PIL 15-12).
15 - 175 9813/9050-1 15 - 175

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

the end of the camshaft and cannot be removed
individually. If the gear is damaged or worn the
complete camshaft and gear assembly must be
replaced. Refer to Camshaft- Remove and Install
(PIL 15-15).
15 - 176 9813/9050-1 15 - 176

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

to crankshaft or camshaft removal the engine must
be inverted. If the gear components only are being
removed (for inspection/renewal) then the engine
need not be inverted.
Remove
2. Remove the high pressure fuel injection pump.
3. Loosely install the high pressure fuel pump and
fixing nut to retain the gear.
4. Remove the flywheel. Refer to (PIL 15-54-00).
5. Remove the flywheel housing. Refer to (PIL
15-54-03).
6. Remove the fixing nut and remove the high
pressure fuel pump drive gear.
Figure 222.
A Fixing nut
B High pressure fuel pump drive gear
Install
1. Use the fixing nut to loosely install the high
pressure fuel pump and the drive gear. DO NOT
lock the gear to the taper on the fuel pump drive
shaft.
2. Install the flywheel housing. Refer to (PIL
15-54-03).
15 - 177 9813/9050-1 15 - 177

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
15 - Heavy Duty PTO Gear
Remove and Install
Remove
2. Remove the starter motor. Refer to (PIL 15-75).
3. Remove the flywheel. Refer to (PIL 15-54).
4. Remove the flywheel housing. Refer to (PIL
15-54).
5. Remove the bolts (x3).
Figure 223.
B
A
A Bolts (x3)
B Heavy duty PTO (Power Take-Off) idler gear
6. Remove the heavy duty PTO idler gear.
Install
steps.
2. Make sure that the idler gear is orientated so that
the part number is visible.

Item Nm
A 65 ± 5
15 - 178 9813/9050-1 15 - 178

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

15-54-03 Housing ........................................................................................................................ 15-184
15-54-09 Gear Ring ..................................................................................................................... 15-186
15-54-12 Drive Plate .................................................................................................................... 15-187
15 - 179 9813/9050-1 15 - 179

Notes:
15 - 180 9813/9050-1 15 - 180

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-181 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-182 systems, where the energy source is not continuous.
Remove and Install ..................................... 15-182 In such cases, the flywheel stores energy when
torque is applied by the energy source, and it
releases stored energy when the energy source is
not applying torque to it.
In a reciprocating engine, a flywheel is used to

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

stores energy when torque is exerted on it by a firing
piston, and it releases energy to its mechanical loads
when no piston is exerting torque on it.
15 - 181 9813/9050-1 15 - 181

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

Figure 224.
Remove
2 This procedure requires service parts. Make sure

1
3. Remove the engine fro the machine.
5. Remove the bolts (x10) and withdraw the
flywheel from the crankshaft hub. The bolts
MUST NOT be reused. Discard the bolts.
1 Flywheel
2 Flywheel gear ring Figure 225.
A Bolts (x10)
B Flywheel
Install
step.
2. Replace the bolts (x10).
The bolts are tightened using a torque and angle
method.
15 - 182 9813/9050-1 15 - 182

15 - Engine
54 - Flywheel
00 - General

Figure 226.
C Angle gauge (obtain locally)

(Nm) grees)
A (1st Stage) 40
A (2nd Stage) 120
15 - 183 9813/9050-1 15 - 183

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

cover.

Special Tools
Template for Sealant 320/05400 1
Flywheel Housing G
to Gear Case (430
Engine)
Removal
H
G Access cover
Refer to: PIL 01-03. H Bolts (x2)
2. Make sure that the engine is safe to work on. If 7. Remove and discard the crankshaft rear oil seal.
the engine has been running, let it cool before Take care not to damage the seal bore in the
you start the service work. housing.
Before Installation
1. Carefully remove all traces of the old sealant
4. Remove the flywheel. compound from the flywheel housing mating
Refer to: PIL 15-54-00. faces.
5. Remove the flywheel housing fixing bolts 1 (x13) 2. Use a suitable degreasing agent to clean the
and the flywheel housing fixing bolts 2 (x7) and inside of the flywheel housing.
then separate the flywheel housing from the
crankcase. 3. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
Figure 227. or damage is evident, the components must be
E renewed.
B Installation
C Anaerobic sealant will not start to cure whilst it
is open to the atmosphere, however when air is
excluded (for instance when the two parts are put
B together) it will immediately start to harden. Make
B sure that all the necessary tools, bolts etc. are readily
F available prior to assembling the components. The
parts must be installed and torque tightened within
B
5min with a maximum permissible time of 15min
B
C removal procedure. Additionally do the following
D steps.
B
A
3. Make sure that the dowels (x2) are installed to
the mating face of the flywheel housing.
A Flywheel housing
B Flywheel housing fixing bolts 1 (x13) 4. Install the sealant template on the housing.
C Flywheel housing fixing bolts 2 (x7)
D CCV (Crankcase Ventilation) hose Special Tool: Template for Sealant Flywheel
E CCV hose fixing bolt Housing to Gear Case (430 Engine) (Qty.: 1)
F Crankshaft rear oil seal 5. Locate the holes in the template onto the two
dowels in the flywheel housing.
15 - 184 9813/9050-1 15 - 184

15 - Engine
54 - Flywheel
03 - Housing
Figure 229. 10. Install the flywheel housing on to the crankcase

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

K Fixing points Refer to: PIL 15-54-00.
6. Use the template as a guide, apply a continuous 3. Install the starter motor.
bead of sealant around the flywheel housing
mating face Refer to: PIL 15-75-00.
Length/Dimension/Distance: 1.5mm Table 83. Torque Values

7. Remove the fixing bolts and remove the Item Nm
template. Make sure that you do not smudge the B 47
sealant. Discard the template. C 47
8. Apply a continuous bead of sealant around H 24 ± 2
location A on the flywheel housing.
Figure 230.
M
L Location A
M Location B
9. Spread the sealant at locations A and B on the
flywheel housing to the specified length. Do not
add or remove any sealant.
15 - 185 9813/9050-1 15 - 185

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an oven
Before Removal to make sure that the heat is applied evenly
around the circumference. Do not heat the gear
1. This procedure requires service parts. Make ring above
sure you have obtained the correct service parts Temperature: 200°C (391.7°F)
before you start.
3. When sufficiently heated, install the gear ring into
2. Remove the flywheel from the crankshaft hub. position over the flywheel. Make sure that the
gear ring is installed the correct way around.
Figure 231.
X After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 186 9813/9050-1 15 - 186

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

Introduction .................................................. 15-187 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-188 bolted to the engine flywheel and a coupling clamped
to the input shaft of the wheel drive pump. Both are
contained within the engine bell housing and rear
support frame to which the wheel drive pump is fixed.
Figure 232.
B
A Drive plate
B Coupling (PIL 2731)
15 - 187 9813/9050-1 15 - 187

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 84. Torque Values

Item Nm
Consumables
Description Part No. Size C 23
Strength)
Remove
1. Make the machine safe with the lift arm and cab
raised. Refer to (PIL 01-03).
2. Remove the Wheel drive pump and coupling,
refer to (PIL 27-31).
3. Remove the bolts, remove the drive plate from
the flywheel.
Install
removal procedure. additionally do the following
steps.
2. Make sure that the drive plate is installed with
the flat face against the flywheel and the boss is
facing outwards.
3. Coat the threads of the bolts with JCB
Threadlocker and Sealer and tighten to the
correct torque value.
(Medium Strength)
Figure 233.
A Drive plate
C Bolts
E Boss
15 - 188 9813/9050-1 15 - 188

15 - Engine
57 - Oil Filler
57 - Oil Filler
Contents Page No.
15-57-00 General ......................................................................................................................... 15-191
15 - 189 9813/9050-1 15 - 189

Notes:
15 - 190 9813/9050-1 15 - 190

15 - Engine
57 - Oil Filler
00 - General
00 - General
Remove and Install

Depending on the engine variant, an oil filler neck or the engine has been running, let it cool before
an oil filler blanking plate may be installed. you start the service work.
Remove 3. Get access to the engine.
1. Make the machine safe. 4. Remove the bolts (x3).
Refer to: PIL 01-03. 5. Remove the oil filler neck or blanking plate and
the track seal.
Figure 234.
A
B
C
D
C
E
B
D
E
A
A Oil filter neck/blanking plate B Bolts (x3)

C Track seal D Location tab
E Cut out
Install Table 85. Torque Values

Item Nm
removal procedure. Additionally do the following B 24 ± 2
steps.
2. Make sure that the track seal is not damaged. If
necessary install a new seal.
2.1. Make sure that the seal is correctly installed
in its groove on the oil filler neck or blanking
plate. The location tab must locate correctly
in the cut out.
4. Start the engine and check for leaks.
15 - 191 9813/9050-1 15 - 191

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

15 - 192 9813/9050-1 15 - 192

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-193 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-194 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-195 the crankshaft.
The pump consists of two rotors, one running inside
the other. The outer rotor has one more lobe than the
inner rotor and turns on a different axis.
When rotated the gap between the inner and outer

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

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

pump body. As oil pressure increases it acts on a
spool to overcome the pressure of the spring. As the
spool moves it uncovers a port allowing pressurised
oil directly back to the oil sump. The spool is set to
activate at 9.5–11.5bar (137.7–166.7psi).
15 - 193 9813/9050-1 15 - 193

15 - Engine
60 - Oil Pump
00 - General
Figure 235.
C B
K E
G H
D
A Oil pump B Inner rotor
C Outer rotor D Inlet port
E Outlet port F Engine oil pressure relief valve port - return to
inlet port
G Safety valve assembly H Oil pump pressure safety valve port - return to
oil sump
J Safety valve spring K Oil pump pressure safety valve pressure port
15 - 194 9813/9050-1 15 - 194

15 - Engine
60 - Oil Pump
00 - General

1. Check the oil pump internal parts for signs of
Remove
2. Use feeler gauges to measure the inner and
outer rotor clearance, and the rotor end float to Refer to: PIL 01-03.
confirm they are within service limits.
Refer to: PIL 15-12-00. the engine has been running, let it cool before
Figure 236.
A
B
A Oil pump
B Bolts (x4)
8. Remove the oil pump.
Install
steps.
2. Lubricate the pump rotor with clean engine oil.
15 - 195 9813/9050-1 15 - 195

15 - Engine
60 - Oil Pump
00 - General

Item Nm
B 24 ± 2
15 - 196 9813/9050-1 15 - 196

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

Introduction .................................................. 15-197 The oil PRV (Pressure Relief Valve) is located in the
Remove and Install ..................................... 15-198 crankcase next to the oil pump.
As the oil pressure rises in the main gallery, the PRV

sensing channel at the gallery end pressurises and
moves the plunger against spring pressure. As the
plunger moves, it uncovers ports in the PRV body
allowing recirculation of oil flow from outlet of the
oil pump directly into the inlet port. With low engine
speeds, when the achieved gallery pressure is less
than PRV spring pressure, the plunger sits back on
its seat closing the recirculation channel and allowing
entire oil flow into block galleries.
15 - 197 9813/9050-1 15 - 197

15 - Engine
60 - Oil Pump
Remove and Install
Remove
1. Make the machine safe
3. Clean the area around the oil pressure relief
valve assembly.
4. Remove the oil pressure relief valve assembly.
Make sure that no dirt or debris is allowed to enter
the engine.
Figure 237.
A
A Oil pressure relief valve
Install
steps.
2. Make sure that there is no debris or
contamination in the pressure relief valve port.
3. Tighten the oil pressure relief valve to the correct
torque value.

Item Nm
A 24 ± 4
15 - 198 9813/9050-1 15 - 198

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-201
15 - 199 9813/9050-1 15 - 199

Notes:
15 - 200 9813/9050-1 15 - 200

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-201 Engine mounts support the engine and in some
Remove and Install ..................................... 15-202 cases the transmission, they dampen noise and
vibration. The mounts isolate the engine and
transmission from the chassis so that vibrations and
noise are not transmitted to the rest of the machine.
Most engine mounts consist of metal attachment

plates and large rubber insulator blocks. The rubber
portions of the mount are flexible and provide the
cushioning that dampens the engine vibrations.
The metal bracket part of the mount provides the
mechanical support and attachment points for the
engine mounts.
15 - 201 9813/9050-1 15 - 201

15 - Engine
63 - Mount
00 - General
Remove and Install
Remove
3. Remove the engine compartment cover.
4. Remove the engine.
5. Remove the engine mounts.
Install
removal procedure.
15 - 202 9813/9050-1 15 - 202

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-205
15 - 203 9813/9050-1 15 - 203

Notes:
15 - 204 9813/9050-1 15 - 204

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-205 The oil cooler allows the transfer of heat from the
Component Identification ............................. 15-206 engine oil to the engine coolant. It is located on the
Check (Condition) ........................................ 15-206 side of the crankcase. It is a non-serviceable part
Remove and Install ..................................... 15-207 and must be replaced if it is faulty. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 205 9813/9050-1 15 - 205

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

Figure 238. 1. Inspect the sealing faces on the oil cooler matrix,
oil cooler housing and the crankcase. Make sure
that the faces are clean and free from scale or
C2 damage.
2. Inspect the sealing gasket and o-rings for signs
C1 of damage. If in doubt, renew the gasket or O-
rings.
O2
O1
C1 Coolant inlet
C2 Coolant outlet
O1 Oil inlet
O2 Oil outlet
15 - 206 9813/9050-1 15 - 206

15 - Engine
69 - Oil Cooler
00 - General
Remove
C
2. Make sure that the engine is safe to work on. If E
the engine has been running, let it cool before D
3. Drain the coolant.
C
C Bolts 2 (x6)
4. Clean the area around the oil cooler. D Oil cooler
E Fuel pipe
8. Remove the bolts 2 (x6).
5. Remove the bolts 1 (x2) that secure the harness
bracket to the engine. 9. Remove the oil cooler and gasket from the
engine. Make sure any residual oil or coolant
Figure 239. is cleaned up. The gasket must not be reused,
discard the gasket.
Install
steps.
A 2. Clean the mating faces of the engine and the oil

cooler.
3. Replace the gasket.
4. Install the oil cooler.
B
5. Install the bolts 2 (x6) and loosely tighten to
locate the oil cooler and gasket on to the engine.
A Bolts 1 (x2)
B Harness bracket Table 88. Torque Values
6. Move the harness to gain access to the oil cooler. Item Nm
A 10 ± 1
7. Remove the fuel pipe from the mounting clip. C 24 ± 2
15 - 207 9813/9050-1 15 - 207

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

15-72-03 Pulley ............................................................................................................................ 15-215
15-72-06 Voltage Regulator ......................................................................................................... 15-216
15 - 208 9813/9050-1 15 - 208

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-209 The alternator is a three phase generator having a
Health and Safety ........................................ 15-210 rotating field winding and static power windings.
Technical Data ............................................. 15-210
Component Identification ............................. 15-211 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) ........................................ 15-211 warning light to the field winding. This creates
Remove and Install ..................................... 15-213 a magnetic field which supplements the residual
Disassemble and Assemble ........................ 15-214 magnetism in the rotor poles. As the engine is
started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 209 9813/9050-1 15 - 209

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 - 210 9813/9050-1 15 - 210

15 - Engine
72 - Alternator
00 - General

Figure 241.
Charging Circuit Test
1. Make sure that all the battery and alternator
D connections are in place, secure and making
good metal - to - metal contact, especially the
earth connections to chassis and engine.
2. Make sure that the battery is fully charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If
the oil pressure warning remains on stop the
engine immediately and investigate the engine
lubrication system.
A Alternator Check 1
B Regulator and brush assembly
C Drive pulley With the ignition switch ON, check that the heater
D Tie bolts motor and screen wiper will operate.
If they operate normally, check the warning light bulb

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

the ignition switch. Check for cable disconnection
before condemning the switch itself.
Check 2
1. Stop the engine and turn the ignition switch to
OFF.
2. Check the battery voltage at the battery.
2.1. If the battery voltage is not within the
specified amount, charge or replace the
battery.
Voltage: 12.5–12.7V
3. Check the condition of the battery terminals.
Clean off any dirt or corrosion.
4. If applicable, check the battery specific gravity.
Do not attempt to check the specific gravity of a
sealed maintenance free battery. If the specific
gravity is not within the specified tolerance,
charge or replace the battery. 1.23 - 1.26
5. Check the voltage between terminal B+ on the
alternator and earth.
5.1. The multimeter should show battery
voltage.
15 - 211 9813/9050-1 15 - 211

15 - Engine
72 - Alternator
00 - General
5.2. If the reading is zero, check the cables 8.1. Red lead to amps socket (A) on the
for continuity, particularly at the starter multimeter.
terminals.
8.2. Black lead to negative on multimeter.
6. If the voltage is correct, check the alternator. 8.3. Right side slider to DC voltage
Alternator Charging Test 8.4. Left side slider to 200 Shunt
Figure 242. 9. FLUKE 85

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

commencing the test switch on the working lights 11.5. Open or short circuited field (rotor)
for windings.
Duration: 3min 11.6. Open or short circuited power (stator)
windings.
3. Alternatively, operate the starter for a few
moments with the ESOS (Engine Shut-Off 12. If any fault is found, replace the complete
Solenoid) fuse removed. alternator.
4. Install an open type shunt between the battery
positive lead and the battery positive terminal.
Current: 100A
5. Connect a Multimeter positive lead to machine
side of the shunt and negative lead to battery side
of the shunt.
6. Connect the leads to the multimeter and set the
multimeter to the relevant range as follows.
7. AVO 2002
7.1. Red lead to volts (middle) socket on
multimeter.
7.2. Black lead to negative on multimeter.
7.3. Right side slider to DC (Direct Current)
voltage.
7.4. Left side slider,Refer to Figure 242.
8. AVO 2003
15 - 212 9813/9050-1 15 - 212

15 - Engine
72 - Alternator
00 - General
Remove
B
2. Disconnect the battery.
A
3. Remove the FEAD (Front End Accessory Drive)
belt.
4. Disconnect the electrical leads from the
alternator terminals. Label the leads to assist with
installation. B
Figure 243. A Alternator

B Bolts (x2)
D+
Install
steps.
2. Make sure that you connect the electrical leads
to the alternator in the correct positions.
3. Tighten the electrical connections to the correct
torque value.
B+
Item Nm
B 47 ± 4
W D+ 3.8
B+ 16
W 3.8
D+ Terminal D+
B+ Terminal B+
W Terminal W
5. Remove the bolts (x2) and remove the alternator
from the engine.
15 - 213 9813/9050-1 15 - 213

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

1. The voltage regulator and brush set is a
combined assembly. Refer to (PIL 15-72-06).
Drive Pulley
1. Refer to (PIL 15-72-03).
15 - 214 9813/9050-1 15 - 214

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

complete alternator. Refer to: PIL 15-72-00.
15 - 215 9813/9050-1 15 - 215

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

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

complete alternator. Refer to: PIL 15-72-00.
15 - 216 9813/9050-1 15 - 216

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

15-75-03 Solenoid ....................................................................................................................... 15-227
15-75-06 Brush Gear ................................................................................................................... 15-228
15 - 217 9813/9050-1 15 - 217

Notes:
15 - 218 9813/9050-1 15 - 218

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-219 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-220 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-220 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-221 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-221 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-223 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-225 pinion with the starter ring gear on the flywheel of the
engine.
The solenoid also closes high current contacts for the

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

use, the electrical components are designed only
to operate for a time period of 30 seconds before
overheating.
15 - 219 9813/9050-1 15 - 219

15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Refer to Electrical System- General, Technical Data
and lower the loader arm. Stop the engine and (PIL 33-00).
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
15 - 220 9813/9050-1 15 - 220

15 - Engine
75 - Starter Motor
00 - General

Figure 245. 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 246.
1.1. Reading in start position approximately

Voltage: 10V
Voltage: 20V
1.2. Minimum permissible reading in start
position
Voltage: 9.5V
Voltage: 18V
1.3. A low reading probably indicates a fault in
the starter motor.
2. Connect the multimeter between the starter main
terminal and the commutator end bracket. In the
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5V
Voltage: 1V
15 - 221 9813/9050-1 15 - 221

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

B Commutator end bracket (Starter earth B Starter earth connection
connection) C Solenoid terminal
2.1. Minimum permissible reading in start D Start relay feed
position E Start relay switched output
H Battery positive and solenoid connection
Voltage: 9V
Voltage: 17V 4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
2.2. If the reading is within this limit, continue to
and earth.
3. If the reading is outside the limit, proceed
to 4. 4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage
3. Connect the multimeter between the solenoid increases to
terminal and a good earth. Minimum permissible
reading in start position Voltage: 8V
Voltage: 16V
Voltage: 8V
Voltage: 16V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 248. 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 250.
C Solenoid terminal
4. If the reading is less than specified, connect
the multimeter between the start relay switched
output and earth. A fault is indicated with the
wiring from the start relay to the solenoid if the
reading increases to
Voltage: 8V
Voltage: 16V
B Starter earth connection
15 - 222 9813/9050-1 15 - 222

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

permissible voltage, a high resistance in the
earth lead or connections is indicated.
Figure 253.
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 251.
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 252. 3. Disconnect the battery negative lead followed by
the positive lead from the battery terminals.
4. Remove the security nut and bolt, remove the
security cover (if installed).
5. Disconnect the electrical leads from the starter
motor terminals. Label the leads to make sure
they are installed in the correct positions on
assembly.
6. Undo the bolts (x3) and withdraw the starter
motor from the flywheel housing.
H Battery positive and solenoid connection Inspection

8. Finally install the engine stop fuse. 1. Check the drive pinion splines for damage and
excessive wear.
2. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 223 9813/9050-1 15 - 223

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

Item Nm
A 15 ± 3
D 47 ± 4
E 3.6 ± .6
15 - 224 9813/9050-1 15 - 224

15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor. For cleaning cover.
and checking purposes only, dismantle the motor as
1.6. Carefully install the commutator end cover,
follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 225 9813/9050-1 15 - 225

15 - Engine
75 - Starter Motor
00 - General
Figure 254.
A
F C A
B
D P
E N
P G
H
K
M
743740-C1 J
L
A Starter solenoid B Screws - starter solenoid (3 off)

C Sealing ring - solenoid D Solenoid actuator rod
E Pinion lever arm F Tie bolts (2 off)
G Commutator end cover H Screws - commutator end cover (2 off)
J Brush set K Commutator
L Sealing ring - commutator end cover M Wave washer
N Cable connector post P Pinion gear
15 - 226 9813/9050-1 15 - 226

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

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

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

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

the complete starter motor.
15 - 228 9813/9050-1 15 - 228

15 - Engine
80 - Glow Plug
80 - Glow Plug
Contents Page No.
15-80-00 General ......................................................................................................................... 15-231
15 - 229 9813/9050-1 15 - 229

Notes:
15 - 230 9813/9050-1 15 - 230

15 - Engine
80 - Glow Plug
00 - General
Introduction .................................................. 15-231 A glow plug is a heating device used to help
Operation ..................................................... 15-232 start diesel engines. In cold weather, diesel engines
Remove and Install ..................................... 15-232 can be difficult to start because the mass of the
crankcase and cylinder head absorb the heat of
compression, preventing ignition due to the higher
surface to volume ratio.
The glow plug is a pencil shaped piece of metal with

a heating element at the tip. The heating element,
when electrified, heats due to its electrical resistance.
15 - 231 9813/9050-1 15 - 231

15 - Engine
80 - Glow Plug
00 - General
Operation Remove and Install
The glow plugs are controlled by the ECM (Engine The glow plugs for cylinders 1, 3 and 4 can be
Control Module). The ECM takes signals from engine removed without the need to remove any other
sensors such as the engine coolant temperature components. The glow plug for cylinder 2 requires
sensor to determine whether the glow plugs are the removal of the turbocharger to gain access. Refer
required and for how long. The glow plugs will be to: PIL 18-35-00.
activated when the ambient temperature is below
0°C (32.0°F). The glow plugs will be deactivated by Remove
the ECM after a predetermined time period.
3. Disconnect the electrical connector.
Figure 255.
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
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15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-235

15-84-03 Crankshaft Position ...................................................................................................... 15-245
15-84-06 Camshaft Position ........................................................................................................ 15-249
15-84-13 Mass Air Flow (MAF) ................................................................................................... 15-254
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-256
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-259
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-262
15-84-24 Fuel Temperature ......................................................................................................... 15-265
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-268
15-84-33 Coolant Temperature .................................................................................................... 15-271
15-84-43 Engine Oil Level ........................................................................................................... 15-274
15 - 233 9813/9050-1 15 - 233

Notes:
15 - 234 9813/9050-1 15 - 234

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-235 The engine sensors continually send signals to the
Technical Data ............................................. 15-236 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-238 control the smooth running of the engine and related
Fault-Finding ................................................ 15-240 components.
Check (Operation) ....................................... 15-244 The ECM processes signals from the sensors
continually and its response will be based on an
evaluation of the combination of sensor signals.
After removal from the engine, protect the sensors

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

be replaced in the event of damage.
15 - 235 9813/9050-1 15 - 235

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

Sensor (TMAP)
Atmospheric Output voltage +/- V
Table 92. pressure bar V
Crankshaft Position Sensor (psi)
Type Hall effect 0.98 -0.025/ 1.84 0.05
Tightening torque 7.5 ± 0.75N·m +0.025
(14.2 -0.4/+0.4)
Table 93.
Table 96.
Camshaft Position Sensor
Rail Pressure Sensor
Type Hall effect
Type The rail pressure sensor
Tightening torque 8 ± 2N·m
is integral with the com-
mon rail.
Table 94.
Coolant Temperature Sensor Table 97.
Type Temperature dependent resis- MAF (Mass Air Flow) Sensor
tance
Type Air flow sensor
Tightening 22 ± 4N·m
torque Tightening torque 10 ± 1N·m
Thread diame- M12 x 1.5.
ter Table 98.
Temperature v Resistance Table Fuel Temperature Sensor
Temperature °C Resistance Ω +/- % Type Temperature dependent resis-
(°F) tance. Integral with the low pres-
25 (77.0) 2,062 5.7 sure fuel circuit.
50 (121.9) 833 4.3 Tightening 10 ± 1N·m
torque
100 (211.9) 187 2
Temperature v Resistance Table
110 (229.8) 144 2.4
Temperature °C Resistance Ω +/- %
Table 95. (°F)
-40 (-39.9) 47,000 15
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) 0 (32.0) 5,700 10
Fixing screw 7 ± 1.4N·m 25 (77.0) 2,000 5
tightening 40 (103.9) 1,150 6
torque 60 (139.9) 581 7
Fixing screw M6 80 (175.9) 316 8
thread diameter 100 (211.9) 182 10
Supply voltage 5V 120 (247.8) 110 15
Temperature Sensor
Type Temperature dependent resis- Table 99.
tance Intercooler Outlet Temperature Sensor
Temperature v Resistance Table Type Temperature dependent resis-
Temperature °C Resistance Ω +/- % tance.
(°F) Tightening 10 ± 1N·m
5 (41.0) 4,707 4.66 torque
10 (50.0) 3,791 4.55 Temperature v Resistance Table
15 (59.0) 3,075 4.44 Temperature °C Resistance Ω +/- %
20 (68.0) 2,510 4.33 (°F)
25 (77.0) 2,062 4.22 -40 (-39.9) 47,000 15
30 (86.0) 1,715 4.12 0 (32.0) 5,700 10
Pressure Sensor 25 (77.0) 2,000 5
Type Piezo-resistive 40 (103.9) 1,150 6
Atmospheric Pressure v Voltage 60 (139.9) 581 7
15 - 236 9813/9050-1 15 - 236

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

80 (175.9) 316 8
100 (211.9) 182 10
120 (247.8) 110 15
Table 100.
Exhaust Manifold Pressure Sensor
Type Pressure transducer
Tightening torque 15–18N·m
Table 101.
Exhaust Manifold Temperature Sensor
Type Temperature dependent resis-
tance.
Tightening 45 ± 5N·m
torque
Temperature v Resistance Table
Temperature °C Resistance Ω +/- %
(°F)
25 (77.0) 4,000,000 5
Table 102.
Oil Pressure Switch
Set pressure 0.6bar (8.7psi) falling.
Switch mode Normally open.
Maximum pressure 27.5bar (398.5psi)
Maximum working pres- 13.8bar (200.0psi)
sure
Tightening torque 14 ± 2N·m
Thread diameter M10 x 1.5.
15 - 237 9813/9050-1 15 - 237

15 - Engine
84 - Sensor
00 - General
Figure 256.
G
H
F
D E
A High pressure rail fuel pressure sensor B Crankshaft position sensor

C Camshaft position sensor D Oil level sensor
E Oil pressure switch F Fuel temperature sensor
15 - 238 9813/9050-1 15 - 238

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

sensor
Figure 257.
J Exhaust manifold pressure sensor K Coolant temperature sensor

L Exhaust temperature sensor M MAF (Mass Air Flow) sensor
15 - 239 9813/9050-1 15 - 239

15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 103. Page 15-240
Water in Fuel Sensor Fault Table 104. Page 15-240
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 105. Page 15-241
Crankshaft Position Sensor Table 106. Page 15-242
Camshaft Position Sensor Table 107. Page 15-242
MAF (Mass Air Flow) Sensor Table 108. Page 15-243
Table 103. 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 104. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
If no faults is found, proceed to ECM connection
fault'.
15 - 240 9813/9050-1 15 - 240

15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
Wiring fault Check the harness continuity and machine and
engine earth contacts. Repair/ replace as necessary.
Table 105. TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure)
Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM.
If sensor supply voltage is OK, proceed to 'Air inlet
circuit fault'.
Air inlet circuit fault Check the consistency of barometric pressure
reading. Verify the integrity of the air inlet circuit:–
Before turbo, air filter, turbo to charge air cooler,
charge air cooler to intake.
Check all the hose connections for air leaks, repair
as necessary.
necessary.
fault'.
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM
necessary.
If no fault found, raise Techweb Helpdesk call.
15 - 241 9813/9050-1 15 - 241

15 - Engine
84 - Sensor
00 - General
Table 106. Crankshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to ECM connection fault'.
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the crankshaft position sensor target wheel if
damaged, replace with a new crankshaft.
If no fault is found raise Techweb Helpdesk call.
Table 107. Camshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to Step 4.
15 - 242 9813/9050-1 15 - 242

15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the Cam target wheel if damaged, replace
with new camshaft.
Table 108. MAF (Mass Air Flow) Sensor

Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM
If sensor supply voltage is OK, proceed to 'Air inlet
fault'.
Air inlet fault Check all the hose connections for air leaks, repair
as necessary.
If no fault is found proceed to 'Sensor connection
faulty'.
necessary.
Sensor failure If sensor is out of specification replace.
If no faults is found, proceed to Step 5.
necessary.
If no fault is found proceed to Step 6.
If no fault found, raise Techweb Helpdesk call.
15 - 243 9813/9050-1 15 - 243

15 - Engine
84 - Sensor
00 - General
Check (Operation)
1. Check the applicable fuse. Refer to (PIL 33-09).
2. Check the display for related fault codes. Refer
to (PIL 33-57).
3. Using Servicemaster perform the required
diagnostic tests. Refer to (PIL 33-57).
4. Check the sensor condition, make sure the
sensor or housing is not damaged, broken,
contaminated or subjected to excess heat. If
necessary replace sensor and make sure the
damage can not reoccur.
5. Check the condition of sensor to harness
connection, make sure the seals are in place,
check for signs of corrosion or contamination.
Repair/replace as necessary
6. Check the sensor location and make sure it is
mounted correctly. Where applicable check the
sensor is tightened to the correct torque. Refer to
the applicable sensor procedure for details.
7. Check the sensor is of the correct type and
specification. If incorrect replace with correct
sensor. Refer to the applicable sensor procedure
for details.
8. Disconnect the sensor, check sensor voltage
supply at the harness connector (Refer
to the applicable sensor Technical Data
and Component Identification procedures.
Alternatively refer to engine electrical
schematic). If the voltage supply is faulty,
disconnect all other sensors in turn until voltage
supply returns. Trace the supply fault and rectify.
9. Check the sensor resistance. Refer to the
applicable sensor Technical Data. If sensor is out
of specification replace.
10. Disconnect the harness from the engine ECM
(Engine Control Module) and inspect. Check
seals are in place, check for signs of corrosion or
contamination.
11. Check the harness continuity. Check the
machine and engine earth contacts. Repair /
replace as necessary
15 - 244 9813/9050-1 15 - 244

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

Introduction .................................................. 15-245 The crankshaft position sensor is a device used
Operation ..................................................... 15-246 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-247 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-247 (Engine Control Module) to control the ignition
system timing and other engine parameters.
15 - 245 9813/9050-1 15 - 245

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

A signal is generated by the crankshaft mounted determine the timing of fuel injection.
target wheel and crankshaft position sensor. It is
Figure 258.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

3 Camshaft target wheel 4 Crankshaft position sensor
5 Crankshaft mounted target wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse-injector solenoid coil D1-D2 Fuel Injection
TDC TDC (Top Dead Centre)
15 - 246 9813/9050-1 15 - 246

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

1. Carefully inspect the sensor. If it is found to be The crankshaft position sensor is a non-serviceable
defective, replace the sensor. item. If the sensor is defective it must be replaced.
2. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the Before Removal
sensor and cannot be replaced. 1. Make sure that the engine is safe to work on. If
3. Remove the HVAC (Heating Ventilation Air
Conditioning) compressor (if installed) or the idler
pulley bracket.
4. Clean the sensor and the adjacent area of the
crankcase.
Figure 259.
A
A
B B
CC
A Crankshaft position sensor

B Electrical connector
C Bolt
D O-ring
Remove
1. Remove the cable ties that secure the electrical
wires to the crankcase.
2. Remove the electrical connector from the
mounting clip on the crankcase.
4. Remove the bolt.
15 - 247 9813/9050-1 15 - 247

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

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

Item Nm
C 7.5 ± .75
15 - 248 9813/9050-1 15 - 248

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

Introduction .................................................. 15-249 The camshaft position sensor is a device that detects
Operation ..................................................... 15-250 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-251 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-252 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
15 - 249 9813/9050-1 15 - 249

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

A signal is generated by the camshaft mounted target (which cylinder is firing).
wheel and camshaft position sensor. This information
is used by the ECM (Engine Control Module) to The ECM will select the correct cylinder for fuel
injection.
Figure 260.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

3 Camshaft target wheel 4 Crankshaft position sensor
5 Crankshaft mounted target wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse - injector solenoid coil D1-D2 Fuel Injection
TDC TDC (Top Dead Centre)
15 - 250 9813/9050-1 15 - 250

15 - Engine
84 - Sensor
Check (Operation)
1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
15 - 251 9813/9050-1 15 - 251

15 - Engine
84 - Sensor
Remove and Install

Before Removal crankcase.

Figure 261.
B
A
A Camshaft position sensor B Bolt

C Electrical connector D O-ring seal
15 - 252 9813/9050-1 15 - 252

15 - Engine
84 - Sensor
Remove
2. Disconnect the electrical connector at the sensor.
3. Remove the bolt.
4. Remove the sensor from the crankcase together
with the O-ring.
The camshaft position sensor is a non-serviceable

item. If the sensor is defective it must be replaced.
Install
steps.
installed.
3. Apply a small amount of grease to the O-ring.
4. Carefully push the sensor into the location bore
in the crankcase. Do not use excessive force.
5. Tighten the bolt to the correct torque value.

Item Nm
B 8±2
15 - 253 9813/9050-1 15 - 253

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

Introduction .................................................. 15-254 The MAF (Mass Air Flow) sensor measures the
Operation ..................................................... 15-255 amount of air coming into the engine. It is integrated
Remove and Install ..................................... 15-255 into the turbocharger compressor housing.
Figure 262.
A MAF sensor
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15 - Engine
84 - Sensor
13 - Mass Air Flow (MAF)
The MAF (Mass Air Flow) sensor produces a digital Remove

signal measuring air flow.
Figure 263.
C
B
A MAF (Mass Air Flow) sensor

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

Item Nm
C 10 ± 1
15 - 255 9813/9050-1 15 - 255

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

Introduction .................................................. 15-256 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-257 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-257 cylinders 1 and 2 exhaust outlet ports.
Figure 264.
A Exhaust manifold temperature sensor
15 - 256 9813/9050-1 15 - 256

15 - Engine
84 - Sensor
Operation Check (Operation)
The exhaust manifold temperature sensor measures For the full inspection and testing procedure, refer to
the exhaust gas temperature from the engine, before the help files in ServiceMaster.
it reaches the turbocharger. The analogue voltage
signal is 1–4.5V.
15 - 257 9813/9050-1 15 - 257

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

serviceable item. If the sensor is faulty or damaged
it must be replaced.
Before Removal
2. Get access to the exhaust manifold temperature
sensor.
Remove
Figure 265.
A Exhaust manifold temperature sensor

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

Item Nm
B 45 ± 5
15 - 258 9813/9050-1 15 - 258

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

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

cylinder head.
Figure 266.
A Exhaust manifold pressure sensor
15 - 259 9813/9050-1 15 - 259

15 - Engine
84 - Sensor
The exhaust manifold pressure sensor measures For the full inspection and testing procedure, refer to
the exhaust pressure from the engine. To attain an the help files in ServiceMaster.
accurate and stable reading, the take-off point is
piped from the exhaust manifold between cylinders
3 and 4. This is fed to a sample chamber where the
sensor is screwed directly into the pressure path. The
analogue voltage signal is 0.5–4.5V.
15 - 260 9813/9050-1 15 - 260

15 - Engine
84 - Sensor
Before Removal
Remove
C
Figure 267.
G F C
C Banjo bolt
F Exhaust pressure pipe
B
G Harness support clip
D
A 3. Remove the exhaust pressure pipe.
4. Remove the bolt and remove the exhaust
C manifold pressure sensor manifold.
E
Install
A Exhaust manifold pressure sensor
steps.
C Banjo bolt 2. Replace the sealing washers.
D Bolt
E Exhaust manifold pressure sensor manifold 3. Tighten the exhaust manifold pressure sensor
and the bolts to the correct torque value.
Sensor
Item Nm
2. Disconnect the electrical connector at the A 15–18
exhaust manifold pressure sensor. C 7–9
3. Remove the sensor from the exhaust pressure D 22–26
sensor manifold. The exhaust manifold pressure
sensor is a non-serviceable item. If the sensor is
faulty or damaged it must be replaced.
Manifold pressure take off pipe

1. Remove the glow plug wiring harness support
clip from the exhaust pressure pipe.
2. Remove the banjo bolts securing the exhaust
pressure pipe to the exhaust manifold and the
sensor manifold. Discard the sealing washers.
15 - 261 9813/9050-1 15 - 261

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

Pressure (TMAP)
The TMAP (Temperature Manifold Air Pressure)
Introduction .................................................. 15-262 sensor is located in a port on top of the air inlet part
Operation ..................................................... 15-263 of the rocker cover. It measures the inlet manifold
Check (Operation) ....................................... 15-263 boost air pressure and temperature. The sensor
incorporates a piezo-resistive element and resistor.
Figure 269.
A
A TMAP Sensor
15 - 262 9813/9050-1 15 - 262

15 - Engine
84 - Sensor
The TMAP (Temperature Manifold Air Pressure) 1. Remove oil and sludge contamination from the
sensor measures the inlet manifold boost air sensor.
pressure and temperature. The sensor produces an
analogue signal voltage proportional to air pressure. 2. Carefully inspect the sensor. If it is defective,
replace it.
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
15 - 263 9813/9050-1 15 - 263

15 - Engine
84 - Sensor
Remove and Install 3. Carefully push the sensor into its location bore in
the rocker cover. Do not use excessive force.
The TMAP (Temperature Manifold Air Pressure) 4. Tighten the bolt to the correct torque value.
sensor is a non-serviceable item. If the sensor is
defective, it must be replaced. Table 114. Torque Values
Item Nm
Before Removal C 7 ± 1.4
engine.
Figure 270.
B
C
A TMAP
C Bolt
D O-ring seal
Remove
2. Remove the bolt.
3. Remove the sensor from the inlet manifold. Make
sure that you recover the O-ring.
Install
steps.
installed.
15 - 264 9813/9050-1 15 - 264

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

Introduction .................................................. 15-265 The fuel temperature sensor is located on the
Operation ..................................................... 15-266 crankcase above the oil cooler.
Check (Operation) ....................................... 15-266
Remove and Install ..................................... 15-267 Figure 271.
A Fuel temperature sensor
15 - 265 9813/9050-1 15 - 265

15 - Engine
84 - Sensor
The fuel temperature sensor detects the fuel For the full inspection and testing procedure, refer to
temperature as it enters the high pressure fuel the help files in ServiceMaster.
injection pump.
15 - 266 9813/9050-1 15 - 266

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

fuel filter to fuel injection pump low pressure fuel
pipe. If it is defective, the complete assembly must
be replaced. Refer to: PIL 18-96-06.
15 - 267 9813/9050-1 15 - 267

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

Introduction .................................................. 15-268 The fuel rail pressure sensor measures the fuel
Operation ..................................................... 15-269 pressure in the common rail.
Check (Operation) ....................................... 15-269
A Fuel rail pressure sensor
15 - 268 9813/9050-1 15 - 268

15 - Engine
84 - Sensor
The fuel rail pressure sensor measures the fuel For the full inspection and testing procedure, refer to
pressure in the fuel rail. This allows the ECM (Engine the help files in ServiceMaster.
Control Module) to control the IMV (Inlet Metering
Valve) to deliver the correct amount of fuel to the high
pressure fuel pump. This keeps the fuel pressure in
the fuel rail constant at all engine RPM (Revolutions
Per Minute).
15 - 269 9813/9050-1 15 - 269

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

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
15 - 270 9813/9050-1 15 - 270

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

Introduction .................................................. 15-271 The coolant temperature sensor is located on the
Operation ..................................................... 15-272 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-272
A Coolant temperature sensor
15 - 271 9813/9050-1 15 - 271

15 - Engine
84 - Sensor
The coolant temperature sensor detects the 1. For the full inspection and testing procedure,
temperature of the coolant in the cylinder head. refer to the help files in ServiceMaster.
The signal from the sensor is used to drive the

coolant temperature status display in the cab.
On engines with electronically controlled fuel

injection the ECM (Engine Control Module)
processes the signal to determine the engine
operating temperature. The ECM adjusts the
injection timing and the amount of fuel injected, this
can facilitate cold starting.
15 - 272 9813/9050-1 15 - 272

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

serviceable item. If the sensor is faulty or damaged
it must be replaced.
Before Removal
Install
2. Make sure that the engine is safe to work on. If steps.
2. Tighten the coolant temperature sensor to the
3. Fill the cooling system with the recommended
Refer to: PIL 21-00-00. coolant mixture.
Figure 274. Refer to: PIL 21-00-00.
4. Start the engine and check for coolant leaks.

Item Nm
A 22 ± 4
B
A Coolant temperature sensor

C Encapsulated washer
Remove
3. Remove the sensor from the cylinder head.
4. Plug all the open ports to prevent contamination.
15 - 273 9813/9050-1 15 - 273

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

Introduction .................................................. 15-274 The engine oil level sensor is used to warn the
Operation ..................................................... 15-275 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-275 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-276 mounted on the engine oil sump.
15 - 274 9813/9050-1 15 - 274

15 - Engine
84 - Sensor
The engine oil level sensor is a normally closed 1. For the full inspection and testing procedure refer
switch. When the oil level drops below a certain point to the help files in ServiceMaster.
the switch will open and the low oil warning light will
be illuminated.
15 - 275 9813/9050-1 15 - 275

15 - Engine
84 - Sensor
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
1. Make the machine safe. engine has cooled sufficiently before you start.
Figure 275.
A
C
B
D
E
A Engine oil level sensor B Oil level sensor float

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

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

Item Nm
C 10 ± 1
15 - 276 9813/9050-1 15 - 276

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-03 Engine Oil Pressure ..................................................................................................... 15-279
15 - 277 9813/9050-1 15 - 277

Notes:
15 - 278 9813/9050-1 15 - 278

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

Introduction .................................................. 15-279 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-280 crankcase.
Check (Operation) ....................................... 15-280
A Engine oil pressure switch
15 - 279 9813/9050-1 15 - 279

15 - Engine
87 - Switch
The oil pressure switch contacts open when the 1. For the full inspection and testing procedure,
engine oil pressure is below 0.6bar. refer to the help files in ServiceMaster.
15 - 280 9813/9050-1 15 - 280

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

item. If the switch is faulty or damaged it must be
replaced.
Remove
3. Clean the area around the oil pressure sensor.
4. Disconnect the electrical connector at the engine
oil pressure switch.
5. Remove the switch from the crankcase.
6. Discard the sealing washer. Plug all the open
ports and hoses to prevent contamination.
Figure 277.
A Engine oil pressure switch
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the

Item Nm
A 14 ± 2
15 - 281 9813/9050-1 15 - 281

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-283
15 - 282 9813/9050-1 15 - 282

15 - Engine
90 - Air Intake
00 - General

Check (Condition) ........................................ 15-283 Refer to: PIL 15-24-00.
15 - 283 9813/9050-1 15 - 283

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

adaptor or a throttle valve may be installed.
Remove
H
J
4. Disconnect the air intake pipe.
5. Disconnect the quick connectors (x2) from the H Track seal ring
sides of the adaptor housing. J Track seal location tab
Figure 278.
Install
E F G 1. The installation procedure is the opposite of the
B steps.
C 2. Make sure that the track seal ring is not
damaged. If necessary install a new seal.
A in its groove on the housing. The location
tab must locate correctly in the cut out.
D Figure 280.
B
A Air intake adapter

B Bolt 2 (x4)
C Quick connectors - CCV (Crankcase Ventilation)
to air intake adapter
D Quick connectors - TCV (Turbocharger Control
Valve) to air intake adapter
E Bolt 1 (x1)
F Inlet air temperature sensor J
G Electrical connector
7. Remove the bolt 1 (x1).
8. Remove the sensor from the top of the adaptor J Track seal location tab
housing.
9. Remove the bolt 2 (x4).
4. Start the engine and make sure that there are no
10. Remove the track seal and the adaptor housing. air leaks.
15 - 284 9813/9050-1 15 - 284

15 - Engine
90 - Air Intake
00 - General

Item Nm
B 10 ± 1
E 10 ± 1
15 - 285 9813/9050-1 15 - 285

Notes:
15 - 286 9813/9050-1 15 - 286

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-13
18-06 Level Sender
18-06-00 General ........................................................................................................................... 18-19
18-09 Filter
18-09-00 General ........................................................................................................................... 18-23
18-09-03 Filter Element ................................................................................................................. 18-26
18-09-09 Pre-Filter Element .......................................................................................................... 18-27
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-31
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-35
18-18 Injection
18-18-00 General ........................................................................................................................... 18-39
18-18-03 Injector ............................................................................................................................ 18-50
18-18-04 Injector Cover ................................................................................................................. 18-55
18-18-07 Injector Seal ................................................................................................................... 18-57
18-18-12 Rail ................................................................................................................................. 18-58
18-18-15 Pump .............................................................................................................................. 18-60
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-67
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-75
18-24-04 Outlet Manifold ............................................................................................................... 18-77
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-83
18-27-03 Actuator .......................................................................................................................... 18-89
18-27-15 Diffuser ........................................................................................................................... 18-91
18-35 Turbocharger
18-35-00 General ........................................................................................................................... 18-93
18-35-06 Wastegate Valve ............................................................................................................ 18-96
18-39 Fuel Cooler
18-39-00 General ........................................................................................................................... 18-99
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-103
18-96-03 High Pressure Pipe ...................................................................................................... 18-104
18-96-06 Low Pressure Pipe ....................................................................................................... 18-107
9813/9050-1
2017-12-14
Acronyms Glossary

DLA Data Link Adaptor
IMV Inlet Metering Valve
MAF Mass Air Flow
NOx Nitrogen Oxide
TCV Turbocharger Control Valve
WIF Water in Fuel
9813/9050-1
2017-12-14
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/9050-1 18 - 1
Notes:
18 - 2 9813/9050-1 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for
Health and Safety ........................................... 18-4 engine damage due to the use of incorrect or
Technical Data ................................................. 18-4 contaminated fuel is much greater with common
Fault-Finding .................................................... 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Discharge and Pressurise ............................... 18-7 and cleanliness requirements, refer to Consumable
Clean ............................................................... 18-7 Products Refer to: PIL 75-00-00. Technical Data,
Check (Pressure) ............................................ 18-9 Fuel, Acceptable and Unacceptable Fuels and
Bleed ............................................................. 18-11 Cleanliness Requirements.
For information about the fuel injection system. Refer

to: PIL 18-18.
Common Rail Fuel Injection

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

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

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

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

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

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9813/9050-1 18 - 3
00 - General

Fuel Table 119. Fuel System Data
Fuel is flammable, keep naked flames away from the
High pressure pump Delphi DFP 6.2.0
fuel system. Stop the engine immediately if a fuel
type
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Direction of rotation from Anticlockwise
engine running. Completely wipe off any spilt fuel drive end
which could cause a fire. There could be a fire and Fuel lift pump type Electrically operated
injury if you do not follow these precautions. Fuel filter micron rating
Fluid Under Pressure Pre-filter 9 micron
Fine jets of fluid at high pressure can penetrate the Main filter 2 micron
skin. Keep face and hands well clear of fluid under Fuel filter restriction -
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Pre-filter 0.2bar (2.9psi)
leaks and then examine the cardboard for signs of Main filter 0.7bar (10.1psi)
fluid. If fluid penetrates your skin, get medical help
immediately. Fuel return restriction - 0.3bar (4.3psi)
maximum
WARNING! Do not open the high pressure fuel Injector information Electronically controlled
system with the engine running. Engine operation solenoid actuated in-
causes high fuel pressure. High pressure fuel spray jectors. Each injector is
can cause serious injury or death. marked with a unique
Notice: Do not allow dirt to enter the fuel system. calibration code.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the system
could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
18 - 4 9813/9050-1 18 - 4
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 120. Page 18-5
Fuel/Oil- Leaking from Exhaust Manifold Table 121. Page 18-5
General Fuel System Faults Table 122. Page 18-5
Exhaust Gas Recirculation Table 123. Page 18-6
Table 120. Fuel Consumption Excessive

Cause Remedy
Additional load on engine. Check/repair accessories and vehicle components.
Refer to the equipment manufacturer's procedures.
Operator technique. Review operation for correct gear shifts, deceleration
and idling.
Fuel leaks. Check for external leaks at the fuel tank, fuel lines,
filters and lift pump WARNING: Do not repair
defective fuel lines. If there is a fuel leak remove and
discard the necessary components and install new
ones.
Air intake or exhaust leaks.
ECM (Engine Control Module)or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
Table 121. Fuel/Oil- Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Review operation for correct gear shifts, deceleration
conditions. and idling.
Air intake or exhaust leaks.
Turbocharger lubricating oil drain line obstructed. Check/clean line.
Exhaust leak at the Manifold or Turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Check for a cracked manifold.
Valve guide seals are leaking. Replace valve guide stem seals as required.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
Table 122. General Fuel System Faults

Cause Remedy
Fuel supply fault Check the low pressure circuit connections are
secure.
Check the fuel pressure in low circuit/tank level.
Check the fuel type (EN590 Specification).
Check for the external diesel fuel leaks.
Check the filter is not blocked
Check the fuel lift pump operation (Refer to
ServiceMaster help files).
Replace/repair as necessary.
If no faults are found, proceed to "Engine does not
start," or "Engine starts," depending on symptoms
18 - 5 9813/9050-1 18 - 5
00 - General
Cause Remedy
Engine does not start Complete the ‘Static Injector Leak Test’.
If the injector back leak is above the limit, replace
injector(s) as necessary.
If the injector back leak is OK check the rail pressure
is above 300 bar, if not, replace the high pressure
pump.
If the rail pressure is OK and back leak is within
limits, raise Techweb Helpdesk Call.
Engine starts Complete the ‘Dynamic IMV (Inlet Metering Valve)
Test’.
If the IMV is faulty replace the high pressure pump.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
injector(s).
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 123. Exhaust Gas Recirculation

Cause Remedy
Air inlet circuit fault Check the air inlet circuit: – Valve position using
ServiceMaster – Check the EGR (Exhaust Gas
Recirculation) linkage – Vane state
If no fault is found proceed to 'EGR valve connection
fault'.
EGR valve connection fault Check the EGR valve connection. Check that the
supply voltage is correct. Repair as necessary.
Check that the EGR valve position can reach MIN
(0%) to MAX position (100%). Use ServiceMaster to
launch the learning procedure of the EGR position.
18 - 6 9813/9050-1 18 - 6
00 - General
Discharge and Pressurise Clean

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

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 7 9813/9050-1 18 - 7
00 - General
• Gases - Air, sulphur dioxide etc. which can Maintenance Environment, Common
create corrosive compounds if dissolved in the Rail Fuel Injection
fluid.
Depending on circumstances engine maintenance
These contaminants can appear during may be required in various working environments.
manufacture, assembly, operation and maintenance. Obviously procedures are best carried out in a
dedicated workshop equipped with a suitable clean
The main filter is rated at 2 micron = 0.002 mm
room, but in practice this is not always possible.
(0.0007874 in). The pre-filter is rated at 5 micron.
Listed are a few typical comparisons of micron size: Maintenance procedures requiring removal or
replacement of fuel system components, particularly
Figure 281.
high pressure components, require special
precautions to make the working environment
suitable, reducing the risk of contamination to an
absolute minimum.
Use the following guidelines to make sure you reduce

the chances of fuel system contamination when
C working in different environments:
B
Worksite - Open to weather
This repair site is not an acceptable location. Only
A
in extreme circumstances should a machine be
repaired on an open site. Use the guidelines below:
A 8 Microns • Clean the engine, Refer to: PIL 15-00-00. If
B 70 Microns the machine is on hard standing, clean away the
C 100 Microns material washed from the engine.
• Red Blood Cell = 8 microns (0.008 mm, • Place suitable clean boards on the ground
0.000315 in). around the machine.
• Human Hair = 70 microns (0.07 mm, 0.00275 • Erect clean plastic sheeting to shelter the
in). engine from wind and rain.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 • Wear a new disposable environmental type suit
in). when working on the fuel system. If the suit
• The smallest particle visible to the naked eye is becomes contaminated with mud, move away
40 microns (0.00157in) approximately. from the engine and change into a new suit.
• Use clean latex gloves (non-powdered).
The main filter and pre-filter must be changed in • Before you start work make sure that all the
accordance with the applicable service schedule required replacement parts and tools are on
and procedures. The water in fuel sensor must be site. Make sure that the replacement parts are
maintained to ensure correct operation at all times. still sealed inside their packaging.
• Cap all exposed ports and orifices immediately.
The potential for engine damage due to fuel Do not leave them open.
contamination is much greater when using common • High pressure fuel pipes MUST BE REPLACED
rail injection technology than with mechanical if any pipe joint is loosened or disconnected. DO
injection systems. This is because common rail NOT re-use the original pipe.
requires components with smaller manufacturing
tolerances, especially the fuel injectors. In addition, Worksite - Closed to weather from above
common rail operates at much higher fuel pressures,
over five times that of mechanical systems. This repair site is the least acceptable condition,
if possible move the machine to a more suitable
Similar pressures are used by commercial water environment. Use the guidelines below:
jet cutting machines to cut metal. Fortunately clean
diesel fuel has lubricating qualities that prevents • Clean the engine, Refer to: PIL 15-00-00.
erosion of components but it is obvious that Clean the floor of all material washed from the
contaminated fuel will cause serious damage at such engine.
high pressures. • Place suitable clean boards on the ground
around the machine.
18 - 8 9813/9050-1 18 - 8
00 - General
• Erect clean plastic sheeting to shelter the Check (Pressure)

engine from the wind and the possibility of
debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit When it is necessary to check the fuel rail pressure
when working on the fuel system. If it becomes function on a faulty machine, it is often difficult to
contaminated with mud, move away from the decide which component of the system has failed.
engine and change into a new suit. It is essential to keep in mind the principles of the
• Use clean latex gloves (non-powdered). function of the common rail fuel system:
• Before you start work make sure that all the
required replacement parts and tools are on Table 124.
site. Make sure that the replacement parts are Principle Function
still sealed inside their packaging.
• Cap all exposed ports and orifices immediately. Pressure production The pump compresses
Do not leave them open. the fuel at high pressure
• High pressure fuel pipes MUST BE REPLACED Pressure regulation The pressure thus pro-
if any pipe joint is loosened or disconnected. DO duced is accumulated in
NOT re-use the original pipe. a rail and measured and
regulated (the rail pres-
Vehicle Maintenance Workshop sure sensor, the ECU
(Electronic Control Unit)
Unless the workshop has a dedicated `sealable and the IMV (Inlet Me-
clean room' work bay, precautions must still be taken. tering Valve) function in
a closed loop, excess
• Clean the engine, Refer to: PIL 15-00-00. pressure is drained to
Clean the engine in the dedicated area and tank by the pressure lim-
then move it to the workshop. iting valve
• Clean the floor area around the machine. Pressure consumption This pressure is finally
• Erect clean plastic sheeting to shelter the consumed by the injec-
engine from any wind and the possibility of tors (injection into the
debris such as dirt and dust falling from above. engine cylinders and in-
• Ensure that workshop doors to the outside are jector management)
kept closed. A gust of wind through an open
door will easily blow sand particles into the air. This means that a pressure fault may come from
• Make sure your work wear is clean, non-flocking the producer, the regulator or the consumers. Simply
and lint free. If in doubt wear a new disposable studying the physical parameters of the rail pressure
environmental type suit. does not allow the disassociation of the producer and
the consumer.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the Symptoms
required replacement parts and tools are on • The engine won’t start or is difficult to start.
site. Make sure that the replacement parts are • The engine stalls while running.
still sealed inside their packaging • Lack of power and dashboard warning lamps
• Cap all exposed ports and orifices immediately. light: the recovery mode may lead to engine
Do not leave them open. stop.
• High pressure fuel pipes MUST BE REPLACED
if any pipe joint is loosened or disconnected. DO Hydraulic System Status Analysis
NOT re-use the original pipe.
Hydraulic flow balance is established as follows:
Injected flow + Back leaks flow (Flow consumed) =

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

• The Injector back leak flow increases sharply,
exceeding the pump capacity.
• This can happen when particles disturb the
internal injector sealing, increasing the back
leak flow from one/several injectors or the
pressure limiting valve.
18 - 9 9813/9050-1 18 - 9
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 283. Reduction in HP Pump Capacity
• Mechanical wear in the injector.
• Pressure limiting valve stuck open.
100 100
The capacity of the pump to supply the required
pressure is reduced due to internal pump wear,
pressure is reduced due to internal pump wear or a
fuel feed problem.
Figure 282. Increased Back Leak Flow
C
F
C
100 100
E D
0 0
B A
A Production
B Consumption
C Reduction in HP pump capacity
D Pressure deficit
E Pump capacity
E F Injected flow
G Back Leak flow
0 0
B A
A Production
B Consumption
C Increased back leak flow
D Pressure deficit
E Pump capacity
F Injected flow
Example
• Presence of air in the low pressure circuit.
18 - 10 9813/9050-1 18 - 10
00 - General
Bleed
WARNING Do not open the high pressure fuel bleed automatically when the lift pump is operated.
system with the engine running. Engine operation Make sure that as much air is removed from the fuel
causes high fuel pressure. High pressure fuel as possible before the engine is started.
spray can cause serious injury or death.
Do not try to bleed the high pressure fuel system by
WARNING Bleeding of the high pressure fuel loosening high pressure pipe connections even when
system by opening the high pressure lines is not the engine is stopped. To bleed the fuel system follow
required. High fuel pressure can persist for a the steps below.
period of time when the engine has stopped. High
pressure fuel spray can cause serious injury or 1. Turn on the ignition key to start the fuel lift pump.
death.
2. Do not start the engine. Allow the pump to run for
The engine installation contains an electrically the specified time.
operated fuel lift pump. The system is designed to Duration: 30s
Figure 284.
A Fuel lift pump (The installation position and pump

may differ on your machine)
3. Turn off the ignition key to stop the fuel lift pump. 5. Start the engine and make sure it runs smoothly.
3.1. Wait for the specified time and turn the
ignition key to start the pump.
3.2. Do not start the engine. Allow the pump to
run for the specified time.
Duration: 30s
4. Do the step 3 for two more times before you start
the engine.
18 - 11 9813/9050-1 18 - 11
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-13
18 - 12 9813/9050-1 18 - 12
03 - Tank
00 - General
Introduction .................................................... 18-13 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-14 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel
tank. Therefore, you must fill the fuel tank after you
operate the engine.
Drain the water and sediment from any fuel storage

tank at the recommended service intervals.
18 - 13 9813/9050-1 18 - 13
03 - Tank
00 - General
Clean
The diesel tank must be drained if there is a chance

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

2. Drain the diesel tank.
3. Drain the fuel from the low pressure fuel pipes.
4. Replace the fuel filters.
5. Refill the tank to the specified level with clean
diesel.
Percentage: 25%
6. Start the engine and leave it to run for the
specified time period.
Duration: 10min
7. Stop the engine.
8. Drain the water separator and the main fuel filter.
9. If there was any water or other liquid in the water
separator, repeat 6 to 8.
18 - 14 9813/9050-1 18 - 14
03 - Tank
00 - General
Remove and Install
8. Disconnect the fuel filler neck and breather pipe

Remove from the fuel tank. Take precautions to prevent
the ingress of debris.
9. Support the fuel tank and remove the holding
2. Make sure there is sufficient clearance under the strap fastenings.
machine to remove the fuel tank before you begin
work. 10. Carefully lower the fuel tank from the machine
making sure not to put strain on the fuel hoses.
3. Remove the battery or batteries. Refer to (PIL
33-03-00). 11. Put a label on the fuel feed and return hoses
before disconnecting to aid identification when
4. Remove the fuel tank drain plug and drain the replacing.
fuel tank.
12. Disconnect the fuel feed and return hoses.
5. Install a new seal and install the drain plug and
tighten to the correct torque value. 13. Put a label on the hoses to the fuel sender to help
installation.
6. Remove the access panel in the cab floor (if
installed). Refer to (PIL 06-06-39). 14. Plug all the open ports and hoses to prevent
contamination.
7. Remove the side step. Refer to (PIL 06-49).
15. Disconnect the fuel sender electrical connector.
16. Remove the fuel tank from machine.
18 - 15 9813/9050-1 18 - 15
03 - Tank
00 - General
Figure 285. Fuel Tank
C D
G
B A
F
C H
J
C098100-C1.eps
A Steps B Battery cover

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

the correct torque value. Refer to (PIL 72).
1.3. Reinstall all pipework, electrical connectors,
brackets, cable ties and the filler neck.
steps.
Make sure that no hoses are twisted or
1.1. Make sure that all foam and rubber mats trapped.
and seals on the tank are in good condition 1.4. Make sure that all connections are tight and
(if installed). Install new parts if they are correctly connected and secured.
defective.
18 - 16 9813/9050-1 18 - 16
03 - Tank
00 - General
1.5. Fill the fuel tank with clean fuel. Refer to (PIL
75-00-00).
1.6. Bleed the fuel system. Refer to (PIL 18-00).
1.7. Check for leaks. Refer to (PIL 18-00).
18 - 17 9813/9050-1 18 - 17
06 - Level Sender
06 - Level Sender
Contents Page No.
18-06-00 General ........................................................................................................................... 18-19
18 - 18 9813/9050-1 18 - 18
06 - Level Sender
00 - General
00 - General
Remove and Install
Notice: Do not allow dirt to enter the fuel system. 2. Isolate the battery. Refer to (PIL 33-03-03).
thoroughly clean around the connection. When a 3. Carefully lower the fuel tank from the machine
component has been disconnected, for example making sure not to put strain on the fuel hoses.
a fuel pipe, always install protective caps and Refer to (PIL 18-03).
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the 4. Make sure that the area around the sender unit
fuel system. Dirt in the fuel system will seriously is clean. Make sure that no debris can enter the
damage the fuel injection equipment and could be fuel tank.
expensive to repair. 5. Disconnect the fuel sender electrical connector.
6. Disconnect the fuel feed and return hoses and
Remove plug the ends. Mark each hose before you
1. Make the machine safe. Refer to (PIL 01-03). disconnect them to make sure they are correctly
replaced.
Figure 286. Diesel Fuel Tank

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

C Fuel connection D Sender unit
E Bolts F O-ring
G Float X Installation orientation (pipe connections to point
towards the front of the machine)
18 - 19 9813/9050-1 18 - 19
06 - Level Sender
00 - General
7. Remove the bolts from the annular ring that

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

Item Nm
E 5
18 - 20 9813/9050-1 18 - 20
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-23

18-09-03 Filter Element ................................................................................................................. 18-26
18-09-09 Pre-Filter Element .......................................................................................................... 18-27
18 - 21 9813/9050-1 18 - 21
Notes:
18 - 22 9813/9050-1 18 - 22
09 - Filter
00 - General
Introduction .................................................... 18-23 The fuel filter consists of a paper element folded in
Component Identification ............................... 18-24 such a way as to give a very large surface area. It is
Operation ....................................................... 18-25 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-25 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 23 9813/9050-1 18 - 23
09 - Filter
00 - General
Figure 287.
1F
1E
A B
1D
2A
2B
2C
1A
1C
1B
A From tank B To fuel injection pump

1 Fuel pre-filter/water separator 1A Water bowl
1B Fuel pre-filter drain screw 1C Water level probe
1D Fuel pre-filter element 1E Electric lift pump
1F Lift pump controller 2 Main fuel filter
2A Main fuel filter element 2B Sediment bowl
2C Main fuel filter drain screw
18 - 24 9813/9050-1 18 - 24
09 - Filter
00 - General
Operation Drain and Fill
Fuel is pumped into the filter and passes through 1. Make the machine safe. Refer to (PIL 01-03).
the paper element where any dirt particles or water
droplets are retained. An integral sediment bowl at 2. Drain off any water in the filter element by turning
the bottom of the filter enables water to be drained the drain tap. Any fuel and water mix drained
off by means of a drain screw. must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
Refer to fuel and exhaust system, filter, component
3. Drain off any water in the water separator bowl.
identification, (PIL 18-09).
Any fuel and water mix drained must be disposed
of in accordance with local regulations. Do not
reuse the drained fuel.
18 - 25 9813/9050-1 18 - 25
09 - Filter
03 - Filter Element
03 - Filter Element 2. Tighten the filter element to the correct torque

value.
Remove and Install Special Tool: Final fuel filter removal tool - engine
mounted (430 Engine) (Qty.: 1)
Special Tools
3. Make sure that the drain valve is closed.
Final fuel filter removal 320/A7126 1 4. Bleed the fuel system.
tool - engine mounted
(430 Engine) Table 126. Torque Values
Item Nm
Remove B 35 ± 5
3. Get access to the filter.
4. Thoroughly clean the outside of the filter housing
and around the filter head.
5. Loosen the drain tap and allow the fuel to drain
into a suitable container.
5.1. Drained fuel must be disposed of in
accordance with local regulations. Do not
reuse the drained fuel.
Figure 288.
A Filter head
B Filter element
C Drain valve
6. Remove the filter element.
Special Tool: Final fuel filter removal tool - engine
mounted (430 Engine) (Qty.: 1)
Install
1. Install the filter element.
18 - 26 9813/9050-1 18 - 26
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-27 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-28 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 27 9813/9050-1 18 - 27
09 - Filter
09 - Pre-Filter Element
Remove and Install 5.1. Any fuel and water mix drained must
be disposed of in accordance with local
Special Tools regulations. Do not reuse the drained fuel.
6. Disconnect the water in fuel sensor electrical
Fuel pre-filter removal 320/A7127 1 connector.
tool - machine mounted
(430 Engine) 7. Unscrew the locking ring and remove the water
separator bowl.
Remove
8. If there is sediment in the water separator bowl,
1. Make the machine safe. Remove the water separator drain valve and
clean the bowl in clean fuel.
2. Get access to the filter assembly.
9. Unscrew the locking ring and remove the filter
3. Thoroughly clean the outside of the filter housing element. Discard the element. Do not reuse a
and around the filter head. filter element once it has been removed.
4. On machines with a fuel shut-off valve, set the Special Tool: Fuel pre-filter removal tool -
valve to isolate the fuel supply. machine mounted (430 Engine) (Qty.: 1)
5. Drain the water separator bowl into a suitable Install

container.
1. Install a new filter element and secure in position
Figure 289. with the locking ring.
2. Tighten the filter element locking ring to the
3. Install the water separator bowl and secure in
position with the locking ring.
4. Tighten the water separator bowl locking ring to
the correct torque value.
5. Make sure that the water separator drain valve
B is closed.
6. Connect the water in fuel sensor electrical
connector.
A
Item Nm
B 35 ± 5
C 27 ± 5
F
A Filter Element
B Filter Element locking ring
C Water separator bowl locking ring
D Water separator bowl
E Water separator drain valve
F Water in fuel sensor electrical connector
18 - 28 9813/9050-1 18 - 28
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-31

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-35
18 - 29 9813/9050-1 18 - 29
Notes:
18 - 30 9813/9050-1 18 - 30
00 - General
Introduction .................................................... 18-31 The water separator is integral with the fuel pre-filter
Drain and Fill ................................................. 18-32 and water separator.
Clean ............................................................. 18-33
Remove and Install ....................................... 18-34 Figure 290.
A Fuel lift pump

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

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

senses when the water is above a preset level.
The probe enables a suitable alarm/indicator device.
Water can be drained off by means of the drain
18 - 31 9813/9050-1 18 - 31
00 - General
screw installed in the base of the bowl. It is essential Drain and Fill
that the water trap is drained regularly. Water must
be drained and disposed of in accordance with
local regulations immediately if the probe signals an 1. Obey all fuel system health and safety
alarm. information. Refer to (PIL 18-00).
3. Position a suitable container under the drain tap.
4. Drain off any water in the water separator bowl
by turning the tap. Do not disconnect the water
in fuel electrical connector (if installed).
4.1. If there is sediment in the bowl after
draining, Remove the bowl and wash in
clean fuel. Refer to PIL 18-12-00).
4.2. Any fuel and water mix drained must
5. Tighten the drain tap to the correct torque value.
6. Make sure that the water in fuel electrical
connector is correctly installed.
Figure 291. Typical Engine
A Water separator
B Drain tap
18 - 32 9813/9050-1 18 - 32
00 - General
Table 128. Torque Values Clean

Item Nm
A 7 ± .7
Draining the Water Separator
2. Get access to the filter.
3. If there is water but no sediment, open the tap
to drain the water. If there is any sediment in
the bowl replace the fuel filter element. Do not
disconnect the electrical connector (if installed).
4. Tighten the drain tap when all the water is
drained.
Figure 292.
A Tap
B Bowl
18 - 33 9813/9050-1 18 - 33
00 - General
Remove and Install
Refer to Fuel and Exhaust system - Filter - Pre-Filter

Element. Refer to: PIL 18-09.
18 - 34 9813/9050-1 18 - 34
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-35 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-36 filter water bowl. A warning light will illuminate in
the instrument panel to indicate that water has
accumulated in the fuel filter water bowl and must be
drained.
18 - 35 9813/9050-1 18 - 35
04 - Water in Fuel Sensor
Remove and Install
Remove
3. Get access to the fuel pre-filter.
Figure 293.
B
A WIF (Water in Fuel) sensor/water separator
drain tap
5. Position a suitable container under the WIF
sensor/water separator drain tap.
5.1. Any fuel and water mix drained must
6. Remove the WIF sensor/water separator drain
tap.
Install
removal procedure.
18 - 36 9813/9050-1 18 - 36
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-39

18-18-03 Injector ............................................................................................................................ 18-50
18-18-04 Injector Cover ................................................................................................................. 18-55
18-18-07 Injector Seal ................................................................................................................... 18-57
18-18-12 Rail ................................................................................................................................. 18-58
18-18-15 Pump .............................................................................................................................. 18-60
18 - 37 9813/9050-1 18 - 37
Notes:
18 - 38 9813/9050-1 18 - 38
18 - Injection
00 - General
Introduction .................................................... 18-39 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-40 injectors via high pressure fuel pipes.
Operation ....................................................... 18-41
Fault-Finding .................................................. 18-44 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
the tubes are formed with conical nipples for sealing
in the sealing cones on the common rail and on
the injector at port. It is essential that the tubes
are maintained and installed correctly for safe and
effective engine operation.
Important: If the high pressure fuel pipes are

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
Fuel injection takes place when the solenoid coil is

energised by the ECM (Engine Control Module).
Combustion
The engine employs a direct injection system. Fuel
is injected directly into the cylinder, the mixing taking
place in the combustion chamber which is recessed
into the crown of the piston.
The process of mixing starts during the induction

stroke and continues throughout the compression
stroke. The inlet porting and combustion chamber
are carefully designed to ensure that when the fuel
is injected it is mixed thoroughly with the air.
The multi-point injector and high injection pressure

ensure a good distribution of fuel throughout the air
which aids mixing. The mixing process continues
until combustion is complete.
To further enhance efficient combustion, the ECM

initiates several separate injections of fuel during the
compression stroke. The timing of the fuel injections
is also varied by the ECM depending on engine
operating parameters.
18 - 39 9813/9050-1 18 - 39
18 - Injection
00 - General
Figure 294.
J C H
D D D D
B
N
T
P
Q
E
F G
S
A ECM (Engine Control Module) B Fuel injection pump

C Fuel rail D Fuel injectors
E Fuel filter (2 micron) F Fuel lift pump with pre-filter and water separator
(5 micron)
G Fuel tank H IMV (Inlet Metering Valve)
J Fuel rail pressure sensor K TMAP (Temperature Manifold Air Pressure)
sensor
L Camshaft position sensor M Crankshaft position sensor
N Coolant temperature sensor P Exhaust manifold temperature sensor
Q Exhaust manifold pressure sensor R MAF (Mass Air Flow) sensor
S Throttle position sensor T Fuel temperature sensor
18 - 40 9813/9050-1 18 - 40
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 295.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM (Engine Control Module) 2 Camshaft position sensor

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
A Camshaft sensor signal - Signal is B Crank position sensor signal - Signal is
generated by camshaft target disc 3 and generated by crankshaft mounted target
sensor 2. Processed by the ECM 1 to disc 5 and sensor 4. Processed by the
determine which cylinder to inject. ECM 1 to determine timing of injection.
C1-C2 Current pulse - injector solenoid coil - D1-D2 Fuel Injection - Start and duration of
Sent to the injector (6) solenoid coil by actual injection. It can be seen that
the ECM 1 to initiate injection. Time of there is a time shift between the current
pulse calculated by the ECM to control pulse and actual injection. This is
the amount of fuel injected. Pulse C1 due to electrical resistance and the
controls pilot injection. Pulse C2 controls individual characteristics on the fuel
the main injection. injector assembly 6. D1 indicates the
pilot injection and D2 the main injection.
Total fuel injected for one cycle = D1 +
D2.
TDC Top dead centre - Shows when piston
is at top dead centre in relation to the
injection sequence.
18 - 41 9813/9050-1 18 - 41
18 - Injection
00 - General
Injection Cycle to bleed from the control chamber and ultimately

back to the fuel tank via the bleed off lines.
It is important to remember that the injector solenoid
coil does not directly lift the injector needle. Instead Although the control chamber is still connected to the
it operates a tiny valve which causes a fuel pressure rail pressure different sized metering orifices K and
imbalance inside the injector. In this way the needle L cause the pressure in the chamber to fall below
is lifted hydraulically. The method of operation is as the rail pressure. The metering orifice ensures full rail
follows: pressure is maintained in the chamber around the
needle.
State 1 - No fuel injection
When the pressure imbalance in the chambers is
The solenoid coil is not energised. Fuel at rail sufficient to overcome spring the needle lifts and
pressure fills the small chamber around the needle. injection begins.
Fuel at rail pressure also fills the control chamber.
Since the surface area of the needle inside the Figure 297.
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 296. F
E
L R
K
F
J
M
J
Q
B
B Needle
E Spool valve
Q F Solenoid coil
J Spring
B K Metering orifice
L Metering orifice
M Metering orifice
B Needle Q Small chamber
F Solenoid coil R Control chamber
J Spring
Q Small chamber State 3 - Fuel injection
R Control chamber
When the flow of fuel to the injection nozzle is
State 2 - Fuel injection start established the metering orifice causes a pressure
drop in the small chamber. Since the needle is now
At the commencement of fuel injection the solenoid lifted its surface area subjected to the pressure in the
coil is energised by the ECM.The solenoid coil lifts small chamber is increased. The force is sufficient to
spool valve off its seat. Fuel at rail pressure is allowed keep the needle lifted.
18 - 42 9813/9050-1 18 - 42
18 - Injection
00 - General
H
G
M M
Q Q
B B
B Needle B Needle
M Metering orifice E Spool valve
Q Small chamber F Solenoid coil
G Spring
State 4 - Fuel injection stop H Calibration dowel
J Spring
To stop fuel injection the ECM de-energises the M Metering orifice
solenoid coil. The spool valve is pushed on to its seat Q Small chamber
by the force of the spring. Fuel no longer bleeds from R Control chamber
the control chamber.
A calibration dowel, selected during manufacture, is

used to finely set the force from the spring.
Fuel pressure inside the control chamber reaches

the rail pressure. Since the needle is lifted its
surface area under pressure from the fuel in the
small chamber is increased. Force from the fuel in
the control chamber is now insufficient to push the
needle on to its seat.
The only way to push the needle on to its seat is

to reduce the fuel pressure in the small chamber.
This is achieved by the metering orifice. As fuel flows
through the metering orifice a pressure drop in the
small chamber is produced. The needle is forced on
to its seat by pressure in the control chamber. Fuel
injection stops.
18 - 43 9813/9050-1 18 - 43
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 129. Page 18-44
Injector Trim Codes Table 130. Page 18-44
Open Circuit Injector Table 131. Page 18-45
Injection Bank Table 132. Page 18-45
Short Circuit Injector Table 133. Page 18-46
Engine Low on Power Table 134. Page 18-46
Injector Calibration Table 135. Page 18-47
Open Circuit Injector Table 136. Page 18-47
High Pressure Injection Diagnostics Table 137. Page 18-48
Fuel Rail Pressure Calibration Table 138. Page 18-48
IMV Table 139. Page 18-49
Table 129. Injector Calibration

Cause Remedy
Old/incorrect software version Check if the software is up to date or new software
that will solve this problem is available. Upgrade as
necessary. Re-flash the injector calibration codes,
respecting power down and up delay and taking care
of injector position; erase all the faults.
If no fault is found proceed to 'Injector cylinder
position and value fault'
Injector cylinder position and value fault Check that ‘individual injector corrections’ are
correctly entered in ECM (Engine Control Module).
Check the cylinder position and value.
If no faults is found, proceed to 'Injector program
fault'.
Injector program fault Re-flash the injector calibration codes, respecting
power down and up delay and taking care of injector
position; erase all the faults.
Electrical connection faulty Check the fuel injector connection and repair as
necessary.
If fault is found, raise a Techweb Helpdesk call.
Table 130. Injector Trim Codes

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Coolant temperature sensor – Air
temperature sensor – Fuel temperature sensor –
Barometric pressure sensor (built inside the ECM.
Check the knock sensors connection and screwing
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
18 - 44 9813/9050-1 18 - 44
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECMpins are damaged, replace ECM and re-flash
necessary.
Wiring fault Check the harness continuity and electrical
insulation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes faulty'.
Injector calibration codes faulty Check the injector calibration codes recorded inECM,
if found fault re-enter all injector calibration codes
(read then write) in correct position to reset learned
parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the Defect Trouble Code
(DTC) again with the diagnostic tool. If the problem is
still present change the knock sensor.
If no fault is found raise a Techweb Helpdesk call.
Table 131. Open Circuit Injector

Cause Remedy
Fuel injector fault Perform the injector buzz test, if the injector is faulty
it will not produce a buzzing sound. In such instances
raise Techweb Helpdesk call.
If no fault is found proceed to 'Injector connection
fault'.
Injector connection fault Check the resistance of injector – For solenoid, it
should be less than 1 ohm.
If the resistance is incorrect, change the injector and
calibrate it.
If no fault is found proceed to 'Electrical/ECM
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
necessary.
installation, repair/replace as necessary.
Table 132. Injection Bank

Cause Remedy
Injector connection fault Check the injector connections corresponding to
faulty bank, repair as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Check all the injectors individually. Replace the
injector and re-calibrate the ECM with the trim file of
the new injector.
If no fault is found proceed to
'Electrical/ECMconnection fault'.
18 - 45 9813/9050-1 18 - 45
18 - Injection
00 - General
Cause Remedy
Electrical/ECM connection fault Disconnect the harness from engineECM and
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
Table 133. 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 134. Engine Low on Power

Cause Remedy
Injector fault - electrical If an electrical injector fault is present raise Techweb
Helpdesk call.
fault'.
Injector connection fault Check the Individual Injector Corrections and injector
connections. If the problem with C3I or injector
connection is evident,replace/repair as necessary.
If no fault is found proceed to 'Fuel rail pressure'.
Fuel rail pressure Check the fuel rail pressure.
If no fault is found proceed to 'Engine Cylinder
compression fault'.
Engine Cylinder compression fault Run the compression test (automatic or manual),
if any of the engine cylinder pressure is not in the
limits, repair/replace as necessary.
If no fault is found proceed to 'Blocked inlet tubes'.
18 - 46 9813/9050-1 18 - 46
18 - Injection
00 - General
Cause Remedy
Blocked inlet tubes Check the fuel lines for any blockage and
contamination. Clean the fuel lines as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Swap the injectors with another. Re-write the trim
codes. Replace/repair as necessary and re-flash the
injector calibration codes.
Table 135. 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 136. Open Circuit Injector

Cause Remedy
it will not produce a buzzing sound. In such instances
fault'.
Injector connection fault Check the resistance of injector. – For solenoid, it
should be less than 1 Ohm.
If the resistance is incorrect, change the injector and
calibrate it.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
18 - 47 9813/9050-1 18 - 47
18 - Injection
00 - General
Table 137. High Pressure Injection Diagnostics

Cause Remedy
Pressure diagnostics fault Check the fault of type IMV (Inlet Metering Valve) or
rail pressure sensor, repair the corresponding fault.
If no fault is found proceed to 'High pressure system
fault'.
High pressure system fault Read the Diagnostic Trouble Code (DTC).
Connect the battery booster.
If the DTC links to high pressure control: – Check
the fuel feed circuit is in good condition – Check the
diesel fuel is present in the system – Check there is
no air bubbles or emulsion in the pipes – Check there
is enough fuel pressure in the inlet pump – Check
there are no high pressure circuit leaks – Check the
quality and type of the diesel fuel.
If the low pressure circuit is faulty, repair the low
pressure circuit.
If no faults are found, proceed to 'Engine does not
start' or 'Engine starts' depending on symptoms,
replace the corresponding injectors.
Engine does not start Perform the ‘Dynamic IMV Test’.
If the IMV is faulty replace the IMV.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
corresponding injector(s).
If the back leak is OK complete the ‘Pump Pressure
Build Capacity Test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise a Techweb
Helpdesk Call.
Table 138. Fuel Rail Pressure Calibration

Cause Remedy
repair/replace as necessary.
If no fault is found, proceed to 'ECM connection fault'.
necessary.
If no fault is found proceed to 'Sensor failure'.
page). If sensor is out of specification replace, the
sensor.
fault'.
18 - 48 9813/9050-1 18 - 48
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from engine ECU (Electronic
Control Unit) and inspect. Check seals are in place,
check for signs of corrosion or contamination.
necessary.
If no fault is found proceed to 'Rail pressure sensor
and rail fault'.
Rail pressure sensor and rail fault Replace the rail pressure sensor and rail.
If the problem still not solved, raise a Techweb
Helpdesk call.
Table 139. IMV

Cause Remedy
IMV (Inlet Metering Valve) connection fault Check the connection to IMV
If the IMV connection is faulty, replace the high
Pressure fuel injection pump.
If no fault is found proceed to 'ECM connection fault'.
ECMconnection fault Disconnect the harness from engine ECM and
If ECM pins are damaged, replace ECMand re-flash
necessary.
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the IMV electrical resistance around 5.3
ohms at 20 degrees C.
replace the high Pressure fuel injection pump if the
resistance fault occurs.
If no fault is found proceed to IMV buzz fault'.
IMV buzz fault Perform the IMV buzz test. If the IMV is not buzzing
replace the high Pressure fuel injection pump.
If the IMV buzzes, raise a Techweb Helpdesk call.
18 - 49 9813/9050-1 18 - 49
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-50 The fuel Injectors are electronically controlled and
Component Identification ............................... 18-51 incorporate a small solenoid valve. The injectors are
Check (Operation) ......................................... 18-51 supplied with pressurised fuel by the high pressure
Remove and Install ....................................... 18-53 fuel injection pump and when energised, the injector
atomizes the fuel into a fine mist so that it can burn
easily by the vehicle’s engine.
The fuel injectors are mounted in the inlet manifold

so that fuel is sprayed directly at the inlet valves. A
fuel supply rail connects all of the fuel injectors to the
fuel supply.
The injector tips are located inside the combustion

chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by O-ring.
Figure 300.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 50 9813/9050-1 18 - 50
18 - Injection
03 - Injector
Component Identification Check (Operation)

Special Tools
Figure 301. Description Part No. Qty.
Injector Leak-off Test 320/A7166 1
N Kit (430 Engine)
H
Data Link Adaptor 892/01174 1
(DLA) Kit
G
Injector Leak-off Test 892/12350 1
D F Kit ((Electronic Engine))
M
The injectors can be tested using Servicemaster
E diagnostics and by means of a leak-off test. To test
for a defective injector first use Servicemaster to
C diagnose the problems with the high pressure fuel
injection equipment, specifically when the engine
J does not start.
Set-up
The leak off test kit must be installed on the engine
and ServiceMaster used to test the engine.

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

2.1. If possible, do not disconnect the ECM
(Engine Control Module).
2.2. Install the oil filler blanking cap from the
L injector leak-off test kit.
Special Tool: Injector Leak-off Test Kit (430
Engine) (Qty.: 1)
A Multi-point injector nozzle 3. Mount the ECM so that the engine can be run
B Needle safely without risk of damage. Make sure that
C Spacer the harness or connectors are not excessively
D Nut stressed.
E Valve
F Solenoid coil 4. Operate the engine until it is within the specified
G Valve spring temperature.
H Calibration dowel
J Injector spring Temperature: 25–95°C (77.0–202.9°F)
L Electrical connector 5. Stop the engine.
M Return port (bleed off)
N High pressure port and filter element 6. Disconnect the bleed off pipe at each injector.
Cap the open connectors on the pipes with the
caps in the injector leak-off test kit.
Special Tool: Injector Leak-off Test Kit
((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Leak-off Test Kit (430
Engine) (Qty.: 1)
18 - 51 9813/9050-1 18 - 51
18 - Injection
03 - Injector
Figure 302. specified amount of fuel, a fault with the injector

or fuel injection system is indicated.
Volume: 0.037L
Figure 304.
C
A
A Injector
B Leak of test kit pipe
C Leak of pipe connector Cranking Bottle Leak off Test
Figure 303. 1. Use the engine diagnostic tool in Servicemaster
to run the test. Follow the on screen instructions.
2. At the end of the test there should not be more
that the specified amount of fuel in the test pipes.
If any of the pipes has more that the specified
amount of fuel a fault with the injector or fuel
injection system is indicated.
D C Length/Dimension/Distance: 100mm
Figure 305.
C Leak of pipe connector

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

1. Use the engine diagnostic tool in Servicemaster
to run the test. Follow the on screen instructions.
2. At the end of the test there should not be more
that the specified amount of fuel in the test
bottles. If any of the bottles has more that the
18 - 52 9813/9050-1 18 - 52
18 - Injection
03 - Injector
Special Tools
Fuel Injector equipment 320/B9321 1
B
Remove
This procedure requires service parts. Make sure C A
you start. Refer to the Parts Catalogue. E
D
Refer to: PIL 01-03. F
2. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at for the specified time A Injector
period before you start work. B Fuel leak-off pipe
C High pressure fuel pipe
Duration: 1h D Electrical connector
3. Remove the injector cover. E Bolt
F Injector clamp
7. Disconnect the fuel leak-off pipes.
4. Remove the crankcase breather system.
9. Remove the bolt.
5. Record which injector is for which cylinder. The
injectors must be installed in the same positions. 10. Remove the injector clamp.
6. Remove the high pressure fuel pipes. The high 11. Carefully pull the injector up to remove it from the
pressure fuel pipes must not be reused, discard engine.
the high pressure fuel pipes.
Refer to: PIL 18-96-03. 12. Remove and discard the sealing washer. The
sealing washer must not be reused.
18 - 53 9813/9050-1 18 - 53
18 - Injection
03 - Injector
D
A
G
A Correction factor (20 characters)
B Injector serial number
C JCB part number
D Manufacturers reference
H steps.
2. Install a new copper sealing washer and O-ring.
A Injector
G O-ring 3. Make sure that the injector is installed in the
H Copper sealing washer correct orientation, with the leak-off port facing
the front (FEAD (Front End Accessory Drive)
13. Remove and discard the O-ring. The O-ring must belt) of the engine. Make sure the injector is
not be reused. pushed fully into the cylinder head.
14. Install a clean protective cap over the nozzle of 4. Tighten the bolt to the correct torque value.
the injector.
5. Replace the high pressure fuel pipes.
Special Tool: Fuel Injector equipment Cap Kit
(430 Engine) (Qty.: 1) Refer to: PIL 18-96-03.
6. If a new injector has been installed, program the
Install ECM with the new correction factor.
The fuel injectors are not interchangeable between Refer to: PIL 33-57-03.
cylinders or other engines. Make sure you install the
injectors in the same positions. If a new injector is Table 140. Torque Values
installed, the ECM (Engine Control Module) must be Item Nm
re-programmed.
E 33 ± 2
When new injectors are installed, record the
correction factor code and which cylinder the injector
is installed into.
18 - 54 9813/9050-1 18 - 54
18 - Injection
04 - Injector Cover
04 - Injector Cover Figure 310.
Remove and Install C

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

C
2. Make sure that the engine is safe to work on.
If the engine has been running, let it cool down B Injector cover
before you start service work. C Captive bolts (x11)
3. Remove the ECM (Engine Control Module) and 6. Remove and discard the track seal. Do not reuse
the ECM mounting bracket. the track seal.
Install
4. Remove the cable ties that secure the harness to
the injector cover. 1. The installation procedure is the opposite of the
Figure 309. steps.
2. Install a new track seal. Make sure that the seal
is correctly located in the groove on the housing
with the locating tab in the cut-out.
Figure 311.
A
A
D E
A Cable ties
5. Loosen the bolts (x11) and remove the injector
cover. The bolts are captive to the injector cover,
do not attempt to remove them.
D Track seal
E Location tab
5. Check the condition of the oil cap O-ring. Replace
the O-ring if necessary.
18 - 55 9813/9050-1 18 - 55
18 - Injection
04 - Injector Cover

Item Nm
C 9±1
18 - 56 9813/9050-1 18 - 56
18 - Injection
07 - Injector Seal
07 - Injector Seal 2. Place supports under the rocker cover and tap in
the new seals using the special tool.
Remove and Install Special Tool: Injector Seal Installation Tool

(Electronic Engine) (Qty.: 1)
Special Tools
Figure 313.
Injector Seal 892/12346 1
E
Installation Tool
(Electronic Engine)
F
Remove
you start. Refer to the Parts Catalogue.
1. Make the machine safe. G

E Injector seal installation tool
Refer to: PIL 01-03. F Injector seals
2. Make sure that the engine is safe to work on. If G Wooden supports
the engine has been running, let it cool before 3. Install the rocker cover.
4. Install the fuel injectors.
5. Install the injector cover.
Refer to: PIL 15-42-06. After Installation
6. Put wooden supports under the rocker cover and 1. Start the engine and check for oil and fuel leaks.
tap out the injector seals using the special tool.
Discard the seals.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
Figure 312.
F E
G
E Injector seal installation tool
F Injector seals
G Wooden supports
Install
1. Remove all oil and sludge contamination from
inside the rocker cover.
18 - 57 9813/9050-1 18 - 57
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-58 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-59 pipe resembling a rail that is used to deliver fuel
to individual fuel injectors on internal combustion
engines. It is designed to have an outlet for each
injector, an inlet for a fuel supply and an outlet for a
fuel bleed off.
The fuel rail also incorporates a fuel rail pressure

sensor and a fuel pressure limiting valve. DO NOT
remove the fuel pressure limiting valve or the fuel rail
pressure sensor from the rail. If these components
are defective, replace the complete common rail
assembly.
Figure 314.
A Fuel rail assembly
18 - 58 9813/9050-1 18 - 58
18 - Injection
12 - Rail
Remove and Install Special Tool: Fuel Injector equipment Cap Kit
Special Tools
Description Part No. Qty. 8. Remove the fuel return pipe adaptor. The copper
sealing washer must not be reused, discard the
Fuel Injector equipment 320/B9321 1 copper sealing washer.
Figure 316.
Remove
you have obtained the correct parts before you start.
Refer to the Parts Catalogue. E

F
2. Obey all fuel system health and safety
information.
3. Make sure that the engine is safe to work on. The E Fuel return pipe adaptor
engine must cool and pressure in the fuel system F Copper sealing washer
must decay before you start work. If the engine
has been running, wait at least for the specified 9. Remove the bolts (x2)
time period before you start work.
10. Remove the fuel rail.
Duration: 1h
4. Clean the engine. Install
Refer to: PIL 15-00-00. 1. The installation procedure is the opposite of the
5. Remove the high pressure fuel pipes. The high steps.
pressure fuel pipes MUST NOT be reused.
Discard the high pressure fuel pipes. 2. Tighten the bolts to the correct torque value.
Special Tool: Fuel Injector equipment Cap Kit 3. Replace the fuel return pipe adaptor copper
(430 Engine) (Qty.: 1) sealing washer.
4. Tighten the fuel return pipe adaptor to the correct
6. Disconnect the fuel rail pressure sensor. torque value.
Figure 315. 5. Replace the high pressure fuel pipes.

C
Item Nm
B D 17 ± 2
E 25
A
D D
A Fuel rail
B Fuel rail pressure sensor
C Fuel return pipe
D Bolts (x2)
7. Disconnect the fuel return pipe from the fuel
pressure limiting valve.
18 - 59 9813/9050-1 18 - 59
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-60 The high pressure fuel injection pump is a rotary
Remove and Install ....................................... 18-61 type device that pumps fuel into the cylinders of
the engine. The pump is driven indirectly from the
crankshaft by gears.
18 - 60 9813/9050-1 18 - 60
18 - Injection
15 - Pump
Special Tools
FIP Gear Nut Catcher 320/A6603 1
(430 Engine)
Pump Gear Removal 892/01155 1 A
Tool
C-Shaped Ring 892/01179 1
C
Spanner
B
Remove
The following procedures include removal and
installation of high pressure fuel system components.
Before starting the procedures the engine assembly
must be cleaned.Refer to: PIL 15-00-00.
A IMV electrical connector
Service procedures on the high pressure fuel pump B Fuel tank return pipe
can only be carried out by specialist personnel with C Fuel inlet pipe
the relevant training and equipment.
4. Disconnect the fuel tank return pipe. Plug all the
This procedure requires service parts. Make sure open ports and hoses to prevent contamination.
1. Make the machine safe. 4.1. When removing components dirt and debris
Refer to: PIL 01-03. may become exposed or dislodged. Stop
the removal procedures and clean away the
2. Make sure that the engine is safe to work on. If exposed deposits.
you start the service work. Refer to: PIL 15-00-00.
3. Disconnect the electrical connector from the IMV 5. Disconnect the fuel inlet pipe. Plug all the open
(Inlet Metering Valve). ports and hoses to prevent contamination.
6. Remove the high pressure fuel pipe between
the fuel injection pump and the fuel rail. The
high pressure fuel pipe MUST NOT be reused.
Discard the high pressure fuel pipe. Plug all the
open ports and hoses to prevent contamination.
18 - 61 9813/9050-1 18 - 61
18 - Injection
15 - Pump
E Fuel injection pump gear cover

F O-ring
9. Insert the fuel injection pump nut catcher special
D High pressure fuel pipe tool.
7. Remove the fuel injection pump gear cover. Special Tool: FIP Gear Nut Catcher (430 Engine)
(Qty.: 1)
Figure 319.
10. Remove the nut securing the fuel injection pump
gear to the drive shaft. Remove the fuel injection
pump nut catcher special tool.
Figure 321.
E Fuel injection pump gear cover

8. Remove the O-ring from the fuel injection pump
gear cover. The O-ring MUST NOT be reused. G Fuel injection pump drive gear retaining nut
Discard the O-ring.
11. Remove the bolts (x3) securing the fuel injection
pump to the engine. When the bolts are removed
the pump will be held in place only by the taper
between the drive gear and the drive shaft.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
18 - 62 9813/9050-1 18 - 62
18 - Injection
15 - Pump
Figure 322. P Gear removal tool body

Q Gear removal tool bolt
R Fuel injection pump drive shaft
13. The fuel injection pump drive gear is located on
a taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel injection pump. Tap the end of the gear
removal tool bolt with a soft faced hammer. When
the taper breaks there will be an audible sound.
The pump drive gear connects to the injection
pump drive shaft by means of taper lock alone,
there is no mechanical locking key.
J
14. Remove the service tools and remove the fuel
J injection pump.
Install
H
1. Make sure that the taper surfaces on the fuel
injection pump drive shaft and gear are clean and
H Fuel injection pump free from oil and damage.
J Bolts (x3)
2. Make sure that the O-ring is correctly located on
12. Install the reaction cap over the fuel injection the fuel injection pump mounting face.
pump drive shaft. Screw the body to the housing.
Use a suitable ratchet drive and socket to screw Figure 324.
the bolt in until you feel a slight resistance.
Special Tool: Pump Gear Removal Tool (Qty.: 1)
Figure 323.
H
K L
M
N
S
P
S O-ring
3. Locate the pump on to the engine. Make sure that
H Fuel injection pump you locate the fuel injection pump drive gear on
K Crankcase to the drive shaft.
L Flywheel housing
M Fuel injection pump drive gear 4. Install the bolts (x3).
N Reaction cap
18 - 63 9813/9050-1 18 - 63
18 - Injection
15 - Pump

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

Item Nm
D 27 ± 2.7
E 35–40
G 65
J 24
18 - 64 9813/9050-1 18 - 64
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-67
18 - 65 9813/9050-1 18 - 65
Notes:
18 - 66 9813/9050-1 18 - 66
21 - Fuel Pump
00 - General
00 - General Technical Data

Technical Data ............................................... 18-67
Operation ....................................................... 18-71
Check (Pressure) .......................................... 18-71
Table 144. Pressure

Operating pressure 5.75 ± 0.5bar (83.3 ± 7.2psi)
Free flow delivery 4.3L/min at 0bar (0.0psi)
Table 145. Pump Electrical

Machine Minimum Maximum Minimum Maximum Minimum Maximum
Voltage V Voltage Voltage Resistance Resistance Current Draw Current Draw
(ohms) (ohms) (A) (A)
12 8 16 0.8 1.5 4 8
Table 146. Sensor

Item Resistance
WIF (Water in Fuel) sensor 220,000Ω
Table 147. Torque Information

Pre-filter to pump body 35 ± 5N·m
Drain bowl to pre-filter body 27 ± 5N·m
WIF sensor 7 ± 0.7N·m
Filter assembly mounting flange bolts (8.8) (X2) 45 ± 3N·m
18 - 67 9813/9050-1 18 - 67
21 - Fuel Pump
00 - General
The fuel lift pump is a non-serviceable component.

The fuel lift pump is a sealed electrical unit integral If any part is defective, replace the complete pump,
with the fuel pre-filter and water separator. filter and separator assembly.
18 - 68 9813/9050-1 18 - 68
21 - Fuel Pump
00 - General
Figure 325.
K
K
D E
H
400/D7339-4
C
A Fuel lift pump B Fuel pre-filter

C Water separator D Bleed port (if installed)
E Electrical connector F Fuel outlet
G Fuel inlet H Water in fuel sensor
18 - 69 9813/9050-1 18 - 69
21 - Fuel Pump
00 - General
J Electrical connector K Pump and filter assembly securing bolt (X2)
18 - 70 9813/9050-1 18 - 70
21 - Fuel Pump
00 - General
Operation Check (Pressure)

Special Tools
The pump draws fuel from the tank, through the water Description Part No. Qty.
separator, pumping it through the fuel filter and into LP Fuel Pressure 320/A7138 1
the fuel injection pump. The pump has a built in Gauge Hose (430
protection against running dry and will shut down Engine)
after 2min if no fuel is present.
When the ignition is set to ON the ECM (Engine
Control Module) energises the fuel lift pump. If the
engine is not started the pump is de-energised after
a period of 24s.
Alternatively use the JCB engine diagnostic tool

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

2. Clean the fuel lift pump and the surrounding area
reduce the risk of contamination. Refer to (PIL
18-00-00).
3. Connect a pressure gauge between the fuel lift
pump and the outlet fuel pipe. Make sure it is
located securely away from hot or moving parts.
Special Tool: LP Fuel Pressure Gauge Hose (430
Engine) (Qty.: 1)
4. Switch the ignition on.
5. Record the pressure on the gauge. If the
pressure is not within the specified tolerance,
a fuel restriction or a faulty fuel lift pump is
indicated. Refer (PIL 18-21-00).
18 - 71 9813/9050-1 18 - 71
21 - Fuel Pump
00 - General
Remove and Install
Remove
2. See fuel and exhaust system, general,
component identification (PIL 18-00-00).
4. Disconnect the fuel lift pump electrical connector.
5. Disconnect the WIF (Water in Fuel) sensor
electrical connector.
6. Label the fuel pipes to aid installation.
7. Disconnect the fuel pipes at the fuel lift pump
using the quick release connectors on the pipes.
8. Support the fuel lift pump and remove the bolts
(x2).
9. Remove the fuel lift pump and pre-filter/separator
assembly from the machine.
Install
removal procedure.
Refer to: PIL 72.
3. Bleed the fuel system.
18 - 72 9813/9050-1 18 - 72
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-75

18-24-04 Outlet Manifold ............................................................................................................... 18-77
18 - 73 9813/9050-1 18 - 73
Notes:
18 - 74 9813/9050-1 18 - 74
24 - Exhaust
00 - General
Introduction .................................................... 18-75 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-76 away from the controlled combustion inside the
Check (Condition) .......................................... 18-76 engine by means of an exhaust pipe. Depending on
the machine design, the exhaust gas will flow through
the following components:
• Cylinder head and exhaust manifold.

• EGR (Exhaust Gas Recirculation) system to
reduce air pollution (nitrous oxides).
• Turbocharger to increase the engine power.
• A silencer or muffler to reduce noise (if
installed).
The exhaust pipe carries the toxic and noxious gases

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 75 9813/9050-1 18 - 75
24 - Exhaust
00 - General

Exhaust Gases Excessive smoke from the exhaust stack combined
Machine exhaust gases can harm and possibly kill with a complaint of low power could be as a result of:
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure • Dirt or dust (unfiltered air) ingested directly into
there is good ventilation. If possible, install an the engine, resulting in damage to the cylinder
exhaust extractor. If you begin to feel drowsy, stop bores, there will also be a possible increase in
the machine at once and get into fresh air. oil consumption.
• Air leaks from the air hose connections.
Sparks • Exhaust manifold leaks.
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
WARNING! The engine has exposed rotating parts.
engine cover open.
18 - 76 9813/9050-1 18 - 76
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-77 The exhaust outlet manifold collects the exhaust
Component Identification ............................... 18-78 gases from the multiple cylinders and delivers it to
Check (Condition) .......................................... 18-79 the turbocharger or the exhaust pipe.
18 - 77 9813/9050-1 18 - 77
24 - Exhaust
Figure 326.
E
A F
A Exhaust manifold B Bolts (x10)

C Exhaust manifold to cylinder head gasket D Exhaust manifold to turbocharger gasket
E Exhaust manifold temperature sensor boss F Exhaust manifold pressure sensor boss
18 - 78 9813/9050-1 18 - 78
24 - Exhaust

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

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

3. Disconnect the air inlet and outlet hoses from the
turbocharger.
4. Disconnect the exhaust from the turbocharger.
5. Remove the oil pipes support clip.
6. Remove the bolts (x2) and remove the
turbocharger oil pipes. Make sure you do not
bend or damage the pipe. Discard the gasket.
Figure 327.
E
G
D
C
F
B
A
A Turbocharger oil drain bolts (x2)
B Turbocharger oil drain
C Turbocharger oil pipes support clip
D Turbocharger oil feed pipe
E Turbocharger oil feed banjo bolt - turbocharger
F Turbocharger oil feed banjo bolt - crankcase
G Actuator hose
7. Remove the turbocharger oil feed banjo bolts
(x2) and remove the turbocharger oil feed pipe.
Discard the sealing washers.
18 - 79 9813/9050-1 18 - 79
24 - Exhaust
8. Disconnect the turbocharger actuator hose. 2. Tighten the nuts (x4) to the correct torque value.
9. Remove the MAF (Mass Air Flow) sensor. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
3. Install the exhaust manifold and turbocharger
Figure 328. assembly to the engine. Make sure that you
replace the gasket.
H
4. Tighten the bolts (x10) (in sequence 1-10) to the
first stage torque.
K Special Tool: Torque Wrench (10-100Nm) (Qty.:
J 1)
Figure 330.
9 5 1 2 6
10 8 4 3 7
H MAF sensor 1-10 Exhaust manifold bolts tightening sequence

J Exhaust manifold temperature sensor 5. Tighten the bolts (x10) (in sequence 1-10) to
K Banjo bolt the final stage torque. Use the torque and angle
10. Remove the exhaust manifold temperature method.
sensor. Special Tool: Torque Wrench (10-100Nm) (Qty.:
Refer to: PIL 15-84-14. 1)
11. Remove the banjo bolt securing the exhaust
manifold pressure pipe to the exhaust manifold. 6. Install the exhaust manifold temperature sensor.
Discard the sealing washers. Refer to: PIL 15-84-14.
Refer to: PIL 15-84-16. 7. Install the MAF sensor.
12. Remove the bolts (x10) and remove the exhaust Refer to: PIL 15-84-13.
manifold and turbocharger assembly. Discard the
gasket. 8. Install the banjo bolt that secures the exhaust
manifold pressure pipe to the exhaust manifold.
13. Remove the nuts (x4) and remove the Make sure that you replace the sealing washers.
turbocharger from the exhaust manifold. Discard
the gasket.
9. Connect the actuator hose to the turbocharger.
Figure 329.
L 10. Install the turbocharger oil drain pipe. Make sure
N that you replace the gasket. Tighten the bolts to
11. Prime the top of the turbocharger with the
specified amount of fresh, clean engine oil. It is
Important not to run the turbocharger dry.
Volume: 0.2L
M
N
12. Install the oil feed pipe. Make sure that you
L Turbocharger replace the sealing washers.
M Exhaust manifold
N Nuts (x4) 13. Tighten the banjo bolts to the correct torque
value.
Install
14. Install the oil pipes support clip.
1. Install the turbocharger to the exhaust manifold.
Make sure that you replace the gasket. 15. Connect the exhaust pipe to the turbocharger.
18 - 80 9813/9050-1 18 - 80
24 - Exhaust
16. Connect the air inlet and outlet hoses to the

turbocharger.

Item Torque Value
1-10 (Final stage) 90
A 24 ± 2N·m
E 21 ± 1N·m
F 34–37N·m
N 24 ± 2N·m
18 - 81 9813/9050-1 18 - 81
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-83

18-27-03 Actuator .......................................................................................................................... 18-89
18-27-15 Diffuser ........................................................................................................................... 18-91
18 - 82 9813/9050-1 18 - 82
00 - General
Introduction .................................................... 18-83 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................... 18-84 a technique that re-circulates a portion of the
Check (Condition) .......................................... 18-85 exhaust gases back into the combustion chamber.
Remove and Install ....................................... 18-85 The system cools and controls the quantity of re-
circulated exhaust gas.
Disassemble and Assemble .......................... 18-87
The EGR valve is controlled by the CAN (Controller
Area Network)bus system (PIL 33-45), the valve
opens and closes to allow the exhaust gases to
flow back into the intake system via the EGR cooler.
This has the effect of lowering the combustion
temperature and reducing the formation of NOx
(Nitrogen Oxide).
In order to ensure full power is always available when

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

a feedback position sensor, linkage and a valve
mechanism. The valve actuator, which is controlled
by the CANbus system, position sensor and linkage,
drives the valve to the demanded position.
18 - 83 9813/9050-1 18 - 83
00 - General
Figure 331.
A
E
B
A Exhaust gas intake pipe B EGR (Exhaust Gas Recirculation) valve

C EGR actuator D EGR cooler
E EGR cooler coolant hoses F EGR actuator coolant hoses
G Diffuser
18 - 84 9813/9050-1 18 - 84
00 - General

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

EGR (Exhaust Gas Recirculation) actuator.
Figure 332.
A Electrical connector
B Coolant hoses
5. Disconnect the coolant hoses.
6. Remove the bolts 1 (x2) that secure the exhaust
gas intake pipe to the cylinder head.
18 - 85 9813/9050-1 18 - 85
00 - General
Figure 333. Install

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

4. When you fill the cooling system, make sure that
you use the correct water/antifreeze mixture. A
D C 50% mixture should be maintained even if frost
C Bolts 1 (x2) protection is not required.
D Bolts 2 (x2) Refer to: PIL 75-09-03.
E Bolt 3 (x1)
7. Remove the bolts 2 and the bolt 3. Remove the
EGR system from the engine. Item Nm
C 24 ± 2
8. Discard the exhaust gas inlet pipe gasket and the D 24 ± 2
exhaust gas inlet lobe seal.
E 24 ± 2
Figure 334. H 24 ± 2
F
F Exhaust gas inlet pipe gasket
G Exhaust gas inlet lobe seal
9. Remove the bolts 4 (x6) and remove the EGR
system mounting brackets.
Figure 335.
J J
H H
H Bolts 4 (x6)
J EGR system mounting brackets
18 - 86 9813/9050-1 18 - 86
00 - General
Disassemble and Assemble Figure 338.
Disassemble

system assembly from the engine.
2. Remove the cable tie. F
Figure 336. E
A
E EGR valve
A B F EGR cooler
7. Remove the studs (x3).
Figure 339.
A EGR valve coolant hoses

B Cable tie
3. Remove the EGR valve coolant hoses.
4. Remove the nuts (x3).
Figure 337. G
C D
F EGR cooler
G Studs (x3)
C
Install
C Nuts (x3) removal procedure. Additionally do the following
D Exhaust gas intake pipe steps.
5. Remove the exhaust gas intake pipe. Discard the 2. Make sure that all sealing faces are clean and
gasket. free from corrosion.
6. Remove the EGR valve. Discard the gasket. 3. Replace the gaskets and seals.
4. Replace the cable tie.
5. Tighten the bolts, nuts and studs to the correct
torque value.
18 - 87 9813/9050-1 18 - 87
00 - General

Item Nm
C 23–27
G 6±2
18 - 88 9813/9050-1 18 - 88
03 - Actuator
03 - Actuator Introduction
Introduction .................................................... 18-89 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ....................................... 18-90 smart electronic CAN driven device and can only be
evaluated with the use of Servicemaster.
The device does a self check on the operating range

to check the adaption window every time the ignition
is switched off and on. The unit is extremely sensitive
and constantly monitors the conditions it is operating
under. If it detects over voltage, under voltage, high
or low current, movement, temperature etc, if it is
working outside of it's desired limits in any way at all,
it will shut down until the fault is rectified.
18 - 89 9813/9050-1 18 - 89
03 - Actuator
Remove and Install
The EGR (Exhaust Gas Recirculation) electronic

actuator is not a serviceable component, if it fails
replace the EGR valve assembly.
18 - 90 9813/9050-1 18 - 90
15 - Diffuser
15 - Diffuser Figure 341.
Remove and Install
Remove
you start, refer to the Parts Catalogue. A
2. Make sure that the engine is safe to work on. If C
cooler assembly. Refer to (PIL 18-27-00). A EGR diffuser
C O-ring
Figure 340. Install
steps.
B
2. Replace the O-ring.
A 3. Tighten the bolts to the correct torque value.

Item Nm
B 10
A EGR diffuser
B Bolts (x2)
5. Remove the EGR diffuser.
6. Remove and discard the O-ring. The O-ring must
not be reused.
18 - 91 9813/9050-1 18 - 91
35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ........................................................................................................................... 18-93

18-35-06 Wastegate Valve ............................................................................................................ 18-96
18 - 92 9813/9050-1 18 - 92
35 - Turbocharger
00 - General
Introduction .................................................... 18-93 The turbocharger (turbo) is a turbine driven forced
Check (Condition) .......................................... 18-94 induction device that makes an engine more efficient
Check (Operation) ......................................... 18-95 and helps to produce more power for its size.
Engine exhaust gasses drive a turbine, which in turn
drives a compressor via a common shaft. The shaft
bearings are lubricated by a feed from the engine
lubrication system.
A turbocharged engine is more powerful and efficient

than a naturally aspirated engine because the turbine
forces more air, and proportionately more fuel, into
the combustion chamber than atmospheric pressure
alone.
Boost pressure control is achieved using a

mechanical wastegate valve in the turbine housing
allowing exhaust gasses to bypass the turbine when
opened. The control of this valve is via an electronic
TCV (Turbocharger Control Valve).
18 - 93 9813/9050-1 18 - 93
35 - Turbocharger
00 - General
Check (Condition) Figure 343.
1. Visually inspect for leaks at the turbocharger.

Make sure that all gaskets are in good condition,
replace as required.
2. Check the turbine and compressor blades inside
the turbocharger rotate freely and smoothly by
hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced.
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
4.2. Move the shaft sideways. 5.2. Move the shaft axially.
Figure 342. 5.3. Make sure that the shaft end float is within
the specified limits.
4.3. Make sure that the turbine shaft running

clearance is within the specified limits.
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.
18 - 94 9813/9050-1 18 - 94
35 - Turbocharger
00 - General

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 95 9813/9050-1 18 - 95
35 - Turbocharger
06 - Wastegate Valve
06 - Wastegate Valve Introduction

Introduction .................................................... 18-96 The TCV (Turbocharger Control Valve) is a solenoid
Operation ....................................................... 18-97 valve that controls the opening and closing of the
Remove and Install ....................................... 18-97 turbocharger wastegate. It is controlled by the ECM
(Engine Control Module).
Figure 344.
A TCV
18 - 96 9813/9050-1 18 - 96
35 - Turbocharger
06 - Wastegate Valve
The TCV (Turbocharger Control Valve) is supplied Remove

with a small amount of charge air from the air
intake. When the valve is closed, charge air is 1. Make the machine safe.
prevented from entering the wastegate actuator and
opening the wastegate. When the valve is open Refer to: PIL 01-03.
the charge air pressure moves the turbocharger 2. Make sure that the engine is safe to work on. If
wastegate actuator to open the wastegate. When the the engine has been running, let it cool before
TCV moves from open to closed in order to close the you start the service work.
wastegate, the pressure in the wastegate actuator
and pipework is vented to atmosphere. 3. Disconnect the MAF (Mass Air Flow) sensor
The ECM (Engine Control Module) uses signals
from the MAF (Mass Air Flow) sensor, TMAP Figure 345.
(Temperature Manifold Air Pressure) sensor, exhaust
manifold temperature sensor and throttle to control
the opening and closing of the TCV. This maintains C
optimum boost pressure in the engine depending on
the engine load and operating conditions.
The TCV is configured to maintain a maximum

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

Item Nm
F 24 ± 2
18 - 97 9813/9050-1 18 - 97
39 - Fuel Cooler
39 - Fuel Cooler
Contents Page No.
18-39-00 General ........................................................................................................................... 18-99
18 - 98 9813/9050-1 18 - 98
39 - Fuel Cooler
00 - General
00 - General
Remove and Install
4. If the engine is hot let it cool for one hour.

Remove 5. Open the engine compartment cover. Refer to
1. Make the machine safe. Refer to (PIL 01-03). (PIL 06-06).
2. Follow the general health and safety procedures. 6. Disconnect the fuel hoses from the matrix at the
Refer to (PIL 01-03). quick release couplings.
3. Switch off the engine before working in the 7. Support the matrix.
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.
Figure 346.
A
C
B
A Quick release couplings B Nuts

C Matrix
18 - 99 9813/9050-1 18 - 99
39 - Fuel Cooler
00 - General
Install
steps also.
1.1. Bleed the fuel system. Refer to fuel system-
general, refer to (PIL 18-00).
1.2. After installation, start the engine and check
for fuel leaks.
18 - 100 9813/9050-1 18 - 100

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

18-96-03 High Pressure Pipe ...................................................................................................... 18-104
18-96-06 Low Pressure Pipe ....................................................................................................... 18-107
18 - 101 9813/9050-1 18 - 101

Notes:
18 - 102 9813/9050-1 18 - 102

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

WARNING Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel
spray can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously
damage the fuel injection equipment and could be
expensive to repair.
18 - 103 9813/9050-1 18 - 103

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe Figure 347.
Remove and Install

Special Tools
Socket 17MM Offset - 331/27987 1
(HP Fuel pipes)
(10-100Nm)
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts Injector Fuel Pipes
before you start. Refer to the Parts Catalogue.
Remove
1.1. The high pressure fuel pipes MUST BE
REPLACED with new ones. 1. Remove the EGR (Exhaust Gas Recirculation)
1.2. The new fuel pipes must remain sealed system.
inside their bags before use. If a bag is open Refer to: PIL 18-27-00.
DO NOT USE the fuel pipe.
2. Remove the fuel injector cover.
3. Remove the fuel pipes one at a time as follows:
3. Obey all fuel system health and safety
information. 3.1. Remove the retaining clips.
Refer to: PIL 18-00-00. 3.2. Loosen the nut 2 at the fuel rail. Do not
remove the nut at this step.
4. Clean the engine. Additional cleaning must be
carried out prior to working on the high pressure Special Tool: Socket 17MM Offset - (HP
fuel system. Fuel pipes) (Qty.: 1)
Refer to: PIL 18-00-00. (Qty.: 1)
5. Make sure that the engine is safe to work on. Figure 348.
The engine must cool and pressure in the fuel B
system must decay before you start work. If the
engine has been running, wait for the specified
time period before you start work.
Duration: 1h
C
6. Always use a spanner at the top of the fuel pipe
nut (this will prevent damage to the nut). A
E
A Fuel pipe
B Nut 1
C Fuel injector
D Fuel rail
E Nut 2
18 - 104 9813/9050-1 18 - 104

96 - Fuel Pipe
3.3. Push the fuel pipe against the injector cone Figure 349.
and at the same time remove the nut 1.
3.4. Push the fuel pipe against the fuel rail cone
3.5. Make sure that there is no dirt or debris on
the fuel pipe or the connectors. D
3.6. Remove the fuel pipe.
contamination.
Special Tool: Fuel Injector equipment Cap E
4. Discard the old fuel pipes. A
Install
1. Install the fuel pipes one at a time as follows: B
1.1. locate the injector end of the fuel pipe C
against the correct injector cone.
A Fuel pipe
1.2. Tighten the nut 1 by hand. B Nut 1
1.3. locate the fuel rail end of the fuel pipe C Fuel injection pump
against the correct fuel rail cone. D Fuel rail
E Nut 2
1.4. Tighten the nut 2 by hand.
1.2. Push the fuel pipe against the fuel injection
1.5. Tighten the nut 1 to the correct torque value.
pump cone and at the same time remove
Special Tool: Socket 17MM Offset - (HP the nut 1.
Fuel pipes) (Qty.: 1)
1.3. Push the fuel pipe against the fuel rail cone
(Qty.: 1)
1.4. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1) 1.5. Remove the fuel pipe.
Special Tool: Torque Wrench (10-100Nm) 1.6. Plug all the open ports and hoses to prevent
(Qty.: 1) contamination.
1.7. Install the retaining clips. Special Tool: Fuel Injector equipment Cap
2. Install the fuel injector cover.
Refer to: PIL 18-18-04. 2. Discard the old fuel pipe.
3. Install the EGR system. Install

Refer to: PIL 18-27-00. 1. Install the fuel pipe as follows:
Fuel Injection Pump to Fuel Rail Pipe 1.1. locate the injector end of the fuel pipe
against the correct injector cone.
Remove 1.2. Tighten the nut 1 by hand.
1. Remove the fuel pipe as follows: 1.3. locate the fuel rail end of the fuel pipe
against the correct fuel rail cone.
1.1. Loosen the nut 2 at the fuel rail. Do not
remove the nut at this step. 1.4. Tighten the nut 2 by hand.
Special Tool: Socket 17MM Offset - (HP 1.5. Tighten the nut 1 to the correct torque value.
Fuel pipes) (Qty.: 1) Special Tool: Socket 17MM Offset - (HP
18 - 105 9813/9050-1 18 - 105

96 - Fuel Pipe

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

Item Nm
B 27 ± 2.7
E 27 ± 2.7
18 - 106 9813/9050-1 18 - 106

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 350.
Remove and Install

Special Tools
Fuel Injector equipment 320/B9321 1 A
Cap Kit (430 Engine) B
Before Removal
2. Make sure that the engine is safe to work on.
The engine must cool and pressure in the fuel
system must decay before you start work. If the
engine has been running, wait for the specified A Injector leak-off pipe connector - injectors
time period before you start work. B Injector leak-off pipe connector outer sheath
Duration: 1h 3.2. Pull the connector to disconnect it from the
injector. Make sure you do not overstress
3. Clean the engine. the leak-off pipe.
4. Disconnect the leak-off pipes from the fuel filter
4. Plug all the open ports and hoses to prevent return pipe.
contamination whenever a fuel pipe is removed
or disconnected. Figure 351.

Injector leak-off Pipes

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

Pipe
Remove
1. Remove the EGR system.
18 - 107 9813/9050-1 18 - 107

96 - Fuel Pipe
2. Disconnect the fuel supply connector. Figure 353.

3. Remove the retaining clips securing the pipe to
the engine.
M
Figure 352.
C
A L
K J
D
A J Return to tank pipe machine connector
K Retaining clip
L Fuel injection pump connector
M Fuel rail connector
N Fuel pipe
H
A 2. Remove the retaining clip.
D
A 3. Disconnect the fuel injection pump connector.
4. Disconnect the fuel rail connector.
5. Remove the fuel pipe.
F Install
E 1. The installation procedure is the opposite of the
G removal procedure.
C Injector leak-off pipe connector Fuel Filter To Fuel Injection Pump Pipe
D Retaining clips (x2)
E 3 way connector Remove
F Bolt 1
G Fuel filter connector 1. Make sure that the engine is fully clean. The fuel
H Fuel pipe filter to fuel injection pump pipe is on the 'clean'
side of the fuel filter. Any contamination will go
4. Remove the bolt 1 securing the three way directly into the high pressure fuel system.
connector to the engine.
5. Disconnect injector leak off pipes.
2. Disconnect the electrical connector from the fuel
6. Disconnect the fuel pipe from the fuel filter. temperature sensor.
Install
step.
2. Tighten the bolt 1 to the correct torque value.
Return To Tank Fuel Pipe

Remove
1. Disconnect the return to tank pipe from the
machine.
18 - 108 9813/9050-1 18 - 108

96 - Fuel Pipe
Figure 354. Table 154. Torque Values

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

Q Electrical connector
R Fuel injection pump connector
S Fuel pipe
T Fuel temperature sensor
U Bolt 2
3. Remove the retaining clips securing the fuel pipe
to the engine.
4. Disconnect the fuel injection pump connector.
5. Disconnect the fuel filter connector
Install
step.
2. Tighten the bolt 2 to the correct torque value.
After Installation
1. Make sure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced.
18 - 109 9813/9050-1 18 - 109

Notes:
18 - 110 9813/9050-1 18 - 110

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

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ............................................................................................................................. 21-9
21-03-03 Radiator .......................................................................................................................... 21-15
21-03-09 Transmission Oil Cooler ................................................................................................. 21-16
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-21
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-29
21-09 Pump
21-09-00 General ........................................................................................................................... 21-35
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-39
21-15 Heater
21-15-00 General ........................................................................................................................... 21-45
21-21 Inlet
21-21-00 General ........................................................................................................................... 21-47
21-42 Manifold
21-42-00 General ........................................................................................................................... 21-49
21-93 Hose
21-93-00 General ........................................................................................................................... 21-51
9813/9050-1
2017-11-23
Acronyms Glossary
CAC Charge Air Cooler

9813/9050-1
2017-11-23
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/9050-1 21 - 1
Notes:
21 - 2 9813/9050-1 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Drain and Fill ................................................... 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Check (Condition) ............................................ 21-5 quickly and then maintain it.
Check (Leaks) ................................................. 21-6
Check (Level) .................................................. 21-6
21 - 3 9813/9050-1 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 155.
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 9813/9050-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Condition)

Consumables
Description Part No. Size 1. Visually inspect the engine and related cooling
components for:
Antifreeze HP/ 4006/1101 5L
Coolant ASTM D6210 4006/1120 20L 1.1. Leaks.
Concentrate 4006/1103 200L 1.2. Cracked, burnt or perished hoses.
The graphic shows a typical engine cooling system, 1.3. Hose clips are in good condition and
the system you are working on may look slightly torqued to the correct value.
different.

2. Stop the engine and let it cool down.
4. Carefully loosen the cap just enough to let any
pressure escape. Remove the cap when all
pressure is released.
5. Disconnect the bottom radiator hose and allow
the coolant to drain into a suitable container.
6. Flush the system by pouring clean water into the
filler port.
7. Connect the bottom radiator hose.
8. Fill the expansion tank, using the necessary anti-
freeze solution, to the level indicated.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
9. Run the engine for a while to raise the coolant
to working temperature and pressure. Stop the
engine and check for leaks. Check the level in
the expansion tank and top up if necessary.
Figure 355.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 5 9813/9050-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
Check (Leaks) Check (Level)
Before you start the machine, inspect the system for 1. Make the machine safe.
leaks. Refer to: PIL 01-03.
1. Make the machine safe. Refer to (PIL 01-03). 2. Get access to the coolant expansion tank.
2. Get access to the cooling pack. 3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
3. Check the cooling system for leaks. cap and top up to the level indicated.
4. If necessary, contact your JCB dealer. 4. Install the filler cap and make sure it is tight.
5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
21 - 6 9813/9050-1 21 - 6
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ............................................................................................................................. 21-9

21-03-03 Radiator .......................................................................................................................... 21-15
21-03-09 Transmission Oil Cooler ................................................................................................. 21-16
21 - 7 9813/9050-1 21 - 7
Notes:
21 - 8 9813/9050-1 21 - 8
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction ...................................................... 21-9 The cooling pack contains the following major
Component Identification ............................... 21-10 components:
Clean ............................................................. 21-12
Check (Condition) .......................................... 21-12 • Radiator.
• Cooling fan.
Remove and Install ....................................... 21-13 • CAC (Charge Air Cooler).
Disassemble and Assemble .......................... 21-14 • Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 9 9813/9050-1 21 - 9
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 356.
F
E
B G
A
E
H
21 - 10 9813/9050-1 21 - 10
21 - Cooling System
03 - Cooling Pack
00 - General
Table 156.
Item Description
A Air to air inter cooler ma-
trix
B Hydraulic oil cooler ma-
trix
C Fuel lift pump and pre-
filter and water trap
D Fuel cooler matrix
E Hose to top of hydraulic
oil cooler
F Hose to bottom of hy-
draulic oil cooler
G Hose to motor P port
H Check valve
J Hose from motor T port
K Hose from motor D port
L Fan speed sensor
M Variable Speed Cooling
fan and hydraulic motor
assembly
N Proportional pressure
relief cartridge
P Cooling pack assembly
21 - 11 9813/9050-1 21 - 11
21 - Cooling System
03 - Cooling Pack
00 - General
If the radiator tubes/fins get clogged the radiator will 1. Make the machine safe. Refer to (PIL 01-03).
be less efficient.
2. Let the engine cool.
3. Get access to the cooling pack. Refer to (PIL
2. Open the engine cover. Refer to (PIL 06-06-06). 21-03)
3. Remove the undershield. Refer to (PIL 4. Check the hoses, radiator and fan for:
06-06-30).
4.1. Condition.
4. Use a soft bristle brush to remove all unwanted 4.2. Damage.
material from the rear of the radiator.
4.3. Security.
5. Release the fastener and pull the condenser
away from the radiator. 5. If necessary, Replace the system hoses/radiator.
6. Use the soft bristle brush to remove all unwanted

material from both sides of condenser and
the front of the radiator. Then push back the
condenser and lock in position with the fastener.
7. Make sure that the loosened material is removed
out of the engine compartment.
21 - 12 9813/9050-1 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install 1.1. Tighten the pipe clamps to the correct
torque value.
Although it is possible to remove individual 1.2. Fill the engine cooling system with the
components it is quicker and easier to remove correct type of coolant. Refer to (PIL 21-00).
the complete sub assembly, particularly if access 1.3. Operate the engine and check the fan motor
is necessary for engine overhaul or removal speed.
and replacement for example. See component
identification, Refer to: PIL 21-00-00. 1.4. Check the hydraulic fluid level. Refer to (PIL
30-00-00).
Disassembly 1.5. Check the transmission oil level and top up
as necessary.
2. Make sure that the engine and hydraulic systems
are cool before you start the removal procedure.
3. Remove the engine cover and side console
assembly. Refer to (PIL 06-06).
4. Put a label on the fuel lines, hoses and electrical
connectors to help installation.
5. Disconnect the fuel lines and electrical connector
from the fuel separator or remove the fuel
separator bolts, the fuel line clips and tie the
assembly safely out of the way.
6. Disconnect the radiator bottom hose and drain
the coolant.
7. Disconnect the radiator top hose.
8. Disconnect the fan motor electrical connections
(if installed).
9. Disconnect the electrical connectors from the
control solenoid and the speed sensor
10. Disconnect the transmission cooler hoses from
the chassis.
11. Plug all the open ports and hoses to prevent
contamination.
12. Disconnect the hydraulic hoses from the chassis.
contamination.
14. Disconnect the intercooler inlet and outlet hoses.
15. Support the cooling pack assembly, remove the
fusebox bolts and the fixing bolts.
16. Carefully lift and move the assembly away from
the machine.
Install
steps.
21 - 13 9813/9050-1 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
With the cooling pack removed from the machine

disassemble the components as necessary.
• Remove the transmission oil cooler. Refer to

(PIL 21-03-09).
• Remove the cooling fan motor. Refer to (PIL
21-05).
• Remove the hydraulic oil cooler. Refer to (PIL
21-03-12).
• Remove the fuel cooler. Refer to (PIL 18-39-00).
• Remove the air conditioning condenser. Refer
to (PIL 12-15-00).
21 - 14 9813/9050-1 21 - 14
21 - Cooling System
03 - Cooling Pack
03 - Radiator
03 - Radiator
Introduction
The radiator is a device in the cooling system that

removes heat from the coolant passing through it,
allowing the coolant to remove heat from the engine.
21 - 15 9813/9050-1 21 - 15
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Check (Condition)

Check (Condition) .......................................... 21-16 The liquid to liquid cooler is a possible source of
Remove and Install ....................................... 21-17 water contamination. It should be tested for possible
failure as follows:
1. Drain any remaining oil/water from the cooler.

2. Fit a blanking plug to the outlet of the cooler.
3. Connect an air supply to the transmission oil inlet.
4. The air test pressure must not exceed the
specified value.
Pressure: 6bar (87.0psi)
5. Submerge the cooler in a tank of water and apply
air pressure to test for leakage. If bubbles are
visible there is a breakdown between the water
and hydraulic circuits.
6. Replace the cooler. Refer to cooling system-
cooling pack, refer to (PIL 21-03).
7. If the cooler is not damaged, clean and make it
dry before you assemble it to the machine. Refer
to (PIL 21-03).
21 - 16 9813/9050-1 21 - 16
21 - Cooling System
03 - Cooling Pack
Remove and Install
4. Drain the engine coolant. Refer to (PIL 21-00).

Remove 5. Disconnect the electrical oil temperature sensor.
6. Carefully disconnect the oil feed and return
2. Follow the general health and safety procedures. hoses. The oil may be hot.
7. Remove the water hose clips and the retaining
3. Remove the engine cover base for easy access clips. Take out the cooler.
to the transmission oil cooler. Refer to (PIL
06-06).
Figure 357.
A
C D C C C
A Electrical oil temperature sensor B Oil feed and return hoses

C Retaining clips D Cooler
21 - 17 9813/9050-1 21 - 17
21 - Cooling System
03 - Cooling Pack
Install
steps.
1.1. Check the transmission oil level. Refer to
(PIL 27-00).
1.2. Fill the cooling system. Refer to (PIL 21-00).
1.3. Operate the machine, stop the engine and
check for water/oil leaks at the cooler hose
connections.
1.4. Check the transmission oil level. Refer to
(PIL 27-00).
1.5. Check the coolant level.
If a faulty oil cooler has been replaced with a new

one, the transmission may be contaminated with
water. Carry out the flushing procedure. Refer to (PIL
27-06).
After 50- 100 operating hours, drain the transmission

oil and check for signs of water contamination. There
should be no contamination. Refill the transmission
with fresh oil.
21 - 18 9813/9050-1 21 - 18
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-21
21 - 19 9813/9050-1 21 - 19
Notes:
21 - 20 9813/9050-1 21 - 20
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-21 The product is equipped with a hydraulically driven
Technical Data ............................................... 21-22 fan motor to provide air flow though the cooling pack.
Remove and Install ....................................... 21-24 Some products may have either a fixed speed fan or
a variable speed hydraulic fan.
On some products, the fan may be reversible to
assist with the removal of debris from the cooling
pack.
21 - 21 9813/9050-1 21 - 21
21 - Cooling System
05 - Fan Motor
00 - General
Technical Data
Variable Speed Fan Motor (JCB 430 Engines)

Table 157.
Type: Uni- directional gear motor
Direction of rotation: Clockwise (viewed from motor shaft end)
Motor displacement: 11 cc/rev
Fan speed (at maximum RPM (Revolutions Per Variable
Minute)):
Maximum pressure setting: 230bar (3,333.3psi)
Colour code (see sticker): Green
Solenoid current draw 1.4A
Solenoid to motor body tightening torque 40N·m
Weight (bare unit, no fan) 5kg
21 - 22 9813/9050-1 21 - 22
21 - Cooling System
05 - Fan Motor
00 - General
Figure 358.
B
A Cooling pack B Fan supply hydraulic pump section (Variflow

pump shown for illustration purposes, the fan
system operation is identical for gearpump
machines).
C Right hand cluster ECU (Electronic Control Unit) D Fan speed sensor
E Hydraulic cooling fan motor F Fan speed proportional solenoid
21 - 23 9813/9050-1 21 - 23
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
If the performance is below that specified, the

Variable Speed Fan motor should be renewed. Renewal of individual
components such as gears, bearings and housings
Your machine is installed with a variable speed fan. will not result in a permanent cure. If the motor
performance is satisfactory, but there is external
Before you remove the fan motor, check its leakage, it should be dismantled for re-sealing
performance. purposes only.
Figure 359.
B C E
G
D
F
E
A Fan retaining nut B Lock washer

C Drive key D Cooling fan motor tapered shaft
E Cooling fan motor F Fan
G Cooling pack
Remove 5. Disconnect the harness form the solenoid

6. Disconnect the harness from the speed sensor
Refer to: PIL 01-03. electrical connector.
2. Install the safety strut. Refer to (PIL 06-69). 7. Disconnect the harness from the direction
Refer to: PIL 06-69. solenoid (if installed).
3. Discharge the hydraulic pressure. 8. Disconnect and plug the feed and return hoses.
Refer to: PIL 30-00. 9. Disconnect and plug the case drain hose.
4. Mark the hydraulic feed and return hoses to help 10. Support the motor and fan assembly.
identification when you install.
21 - 24 9813/9050-1 21 - 24
21 - Cooling System
05 - Fan Motor
00 - General
11. Undo the fan bracket securing bolts (x4) and lift
the fan and motor assembly from the machine.
12. Prevent the fan from turning, release the tab
washer and then undo the fan retaining nut.
13. Withdraw the fan from the motor shaft. Retain the
drive key.
14. Undo the motor retaining bolts and remove the
motor.
Install
steps.
1.1. Install a new lock washer.
1.2. Tighten all the fastening nuts and bolts to
Refer to: PIL 72.
1.3. Make sure all hoses are attached to the
correct ports. The case drain hose (if
installed) must be fed in to a tank line
otherwise damage to the motor will occur.
1.4. Check and adjust the hydraulic fluid level.
Table 158. Torque Settings

Item Value
A 36N·m
21 - 25 9813/9050-1 21 - 25
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 26 9813/9050-1 21 - 26
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-29
21 - 27 9813/9050-1 21 - 27
Notes:
21 - 28 9813/9050-1 21 - 28
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-29 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-30 forced out of the machines radiator under pressure.
As the machine runs, the temperature of the coolant

circulating around the system increases, this causes
an increase of pressure in the cooling system. When
the pressure builds to a high enough point, the
radiator cap allows that pressure to escape into the
coolant tank through a rubber overflow tube that
is connected from the neck of the radiator to the
expansion tank.
Most of the coolant that is forced into the expansion

tank returns to the radiator naturally when the engine
is cold.
21 - 29 9813/9050-1 21 - 29
21 - Cooling System
06 - Expansion Tank
00 - General
Remove and Install
Consumables 5. Open the engine compartment cover. Refer to

Description Part No. Size (PIL 06-06).
JCB Threadlocker 4101/0250 0.01L 6. Drain the engine coolant. Refer to (PIL 21-00).
Strength) 7. Remove the bolts.
Remove 8. Remove the expansion tank cover.
1. Make the machine safe. Refer to (PIL 01-03). 9. Disconnect the coolant level sensor electrical
connector (if installed).
2. Follow the general health and safety procedures.
Refer to (PIL 01-03). 10. Loosen the hose clips and disconnect the hoses
from the expansion tank.
3. Switch off the engine before working in the
engine compartment. Remove the ignition key or 11. Support the expansion tank.
isolate battery to prevent the engine from being 12. Remove the expansion tank from the bracket.
started. Refer to (PIL 33-03).
4. If the engine is hot, let it cool for one hour.
21 - 30 9813/9050-1 21 - 30
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 360.
D A
E F E E
A Hose clips B Hoses

C Tank cover D Expansion tank
E Bolts F Bracket
21 - 31 9813/9050-1 21 - 31
21 - Cooling System
06 - Expansion Tank
00 - General
Install
steps.
1.1. Apply sealant to the bolts.
(Medium Strength)
1.2. Tighten the bolts to the specified torque
value.
1.3. Fill the engine cooling system with the
correct type of coolant. Refer to (PIL 21-00).
1.4. When the installation procedure is
complete, start the engine and check for
coolant leaks.

Item Description Nm
E Bolts 5
21 - 32 9813/9050-1 21 - 32
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-35
21 - 33 9813/9050-1 21 - 33
Notes:
21 - 34 9813/9050-1 21 - 34
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-35 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-36 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-36
Remove and Install ....................................... 21-37 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 35 9813/9050-1 21 - 35
21 - Cooling System
09 - Pump
00 - General

Figure 361. The coolant pump is driven via a pulley and front end
A accessory drive belt, the pump draws coolant from
the pump cavity. The coolant is pumped through the
outlet gallery to the oil cooler cavity in the left side
of the crankcase. As the coolant flows past the oil
cooler matrix, heat is exchanged from the oil to the
coolant. This enables the oil to function as a coolant
as well as a lubricant.
For cooling system operation.
D
C
A Coolant pump
B Drive pulley
C Track seal
D Impeller
21 - 36 9813/9050-1 21 - 36
21 - Cooling System
09 - Pump
00 - General
Remove
A
2. If the engine has been running, let it cool before
D
5. Remove the FEAD (Front End Accessory Drive)
belt.
Refer to: PIL 15-18-03. C
6. Remove the fixing screws.
Figure 362.
A Coolant pump
C Track seal
D Track seal location tab
B
The pump is a non-serviceable item. If the pump is
faulty or damaged it must be replaced.
Install
A removal procedure. Additionally do the following
steps.
2. Make sure that the mating face on the crankcase
is clean and free from damage or corrosion.
3. Install a new track seal.
B
A Coolant pump in its groove on the housing. The location
B Fixing screws tab must locate correctly in the cut-out.
7. Remove the coolant pump. 4. Tighten the screws to the correct torque value.
8. Remove and discard the track seal. 5. When you fill the cooling system, make sure that
you use the correct water/antifreeze mixture. A
50% mixture should be maintained even if frost
protection is not required.

Item Nm
B 24 ± 2
21 - 37 9813/9050-1 21 - 37
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-39
21 - 38 9813/9050-1 21 - 38
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-39 The thermostat is located between the engine and
Operation ....................................................... 21-40 the radiator. The function of the thermostat is to block
Check (Condition) .......................................... 21-41 the flow of coolant to the radiator until the engine has
Check (Operation) ......................................... 21-41 warmed up to a sufficient temperature.
Remove and Install ....................................... 21-42 When the engine is cold, no coolant flows through
the engine. Once the engine reaches its operating
temperature, generally about 95°C (203°F), the
thermostat opens. By letting the engine warm up as
quickly as possible, the thermostat reduces engine
wear, deposits and emissions.
21 - 39 9813/9050-1 21 - 39
21 - Cooling System
12 - Thermostat
00 - General
Operation diameter orifice allows trapped air to be expelled

from the system.
The thermostat is a wax element type and is Figure 365.

configured for by-pass blanking. The thermostat 7 3
functions as follows:
8 11
State A - Closed (Engine Cold)
When the engine is cold the wax pellet has
contracted into its housing. This allows the spring to
act against the thermostat body and move the valve
plate up against its seat, closing the outlet port to the 9
radiator. Since the bottom valve plate is connected
to the top valve plate it also moves up, opening the
bypass port. The coolant flows from the thermostat 1
housing inlet port into the bypass gallery.
Figure 364. 2
7 3
6
8 10
11 5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
9 5 Wax pellet
1 6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
2 9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
6
10
5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1mm
21 - 40 9813/9050-1 21 - 40
21 - Cooling System
12 - Thermostat
00 - General
Check (Condition) Check (Operation)

1. If the thermostat is suspected of being faulty, A period of 3–5min before the thermostat valve starts
perform a thermostat test, refer to Thermostat to operate is normal because of the time required to
- Check Operation to confirm its serviceability. heat soak the thermostat.
Note that the thermostat is a non-serviceable
item. If the thermostat is faulty or damaged it 1. Make sure that the engine is safe to work on. If
must be renewed. the engine has been running, let it cool before
2. Inspect the seal for damage or splits. If necessary
renew the seal. Make sure that the seal is 2. Remove the thermostat housing and the
correctly located. thermostat. Refer to (PIL 21-12).
3. Suspend the thermostat in a suitable container
of coolant. Use an external heat source to
gradually increase the temperature of the
coolant. Note: When working with boiling water,
all the necessary safety precautions must be
taken. Refer to Figure 366.
Figure 366.
4. Use a thermometer to measure the temperature

of the coolant.
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the
movement of the valve plate should be evident.
6. Record the start to open temperature, the fully
open temperature and the amount of valve lift
travel when fully open. Compare this with the
data in Technical Data (PIL 21-00).
21 - 41 9813/9050-1 21 - 41
21 - Cooling System
12 - Thermostat
00 - General
Remove and Install Install

Remove removal procedure. Additionally do the following
step.
2. Replace the seal.
the engine has been running, let it cool before 4. When you fill the cooling system, make sure that
you start the service work. you use the correct water/antifreeze mixture. A
50% mixture should be maintained even if frost
3. Drain the coolant. protection is not required.
Refer to: PIL 21-00-00. Refer to: PIL 75-09-03.
4. Disconnect the hose from the thermostat Table 161. Torque Values
housing.
Item Nm
5. Remove the bolts (x3). A 24 ± 2
Figure 367.
B
A
A Bolts (x3)
B Thermostat housing
6. Remove the thermostat housing.
7. Remove the thermostat.
Figure 368.
C Thermostat
D Seal
8. Remove the seal. The seal must not be reused,
discard the seal.
21 - 42 9813/9050-1 21 - 42
21 - Cooling System
15 - Heater
15 - Heater
Contents Page No.
21-15-00 General ........................................................................................................................... 21-45
21 - 43 9813/9050-1 21 - 43
Notes:
21 - 44 9813/9050-1 21 - 44
21 - Cooling System
15 - Heater
00 - General
00 - General Install
steps.
Before Removal 2. Install new track seals. Make sure that the seals
are correctly located in the groove on the housing
This procedure requires service parts. Make sure with the locating tab in the cut out.
you start. Refer to the Parts Catalogue. Figure 370.

3. Get access to the engine. C
D
4. Drain the coolant. D
Refer to: PIL 21-00-00. C Track seals (x2)
D Locating tab
The housing may be orientated differently to that
shown in the illustration, depending on the engine 3. Tighten the bolts to the correct torque value.
installation.
4. Connect the cab heater hoses.
Remove
After Installation
1. Disconnect the hoses from the cab heater spigot.
1. Fill the engine with the recommended coolant
2. Remove the bolts (x3). mixture.
3. Remove the cab heater spigot and the track seals Refer to: PIL 21-00-00.
(x2). The track seals must not be reused. Discard 2. Start the engine and check for coolant leaks.
the track seals.
Item Nm
A 24 ± 2
A
B
A Bolts (x3)
B Cab heater spigot
21 - 45 9813/9050-1 21 - 45
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-47
21 - 46 9813/9050-1 21 - 46
21 - Cooling System
21 - Inlet
00 - General
steps.
Before Removal 2. Install a new track seal. Make sure that the seal
This procedure requires service parts. Make sure with the locating tab in the cut-out.
you start, refer to the Parts Catalogue. Figure 372.

D
The housing may be orientated differently to that

shown in the illustration, depending on the engine
installation. C
C Track seal
Remove D Locating tab
1. Disconnect the radiator hose from the inlet elbow. 3. Tighten the bolts to the correct torque value.
2. Remove the bolts (x4). 4. Connect the radiator hose to the housing.
3. Remove the inlet elbow and the track seal. The
track seal must not be reused. Discard the track After Installation
seal. 1. Fill the engine with the recommended coolant
Figure 371. mixture.
A Table 163. Torque Values

Item Nm
A 24 ± 2
A
A Bolts (x4)
B Inlet elbow
21 - 47 9813/9050-1 21 - 47
21 - Cooling System
42 - Manifold
42 - Manifold
Contents Page No.
21-42-00 General ........................................................................................................................... 21-49
21 - 48 9813/9050-1 21 - 48
21 - Cooling System
42 - Manifold
00 - General
steps.
Before Removal 2. Install a new track seal. Make sure that the seal
This procedure requires service parts. Make sure with the locating tab in the cut-out.
you start, refer to the Parts Catalogue. Figure 374.

E
3. Get access to the engine. C
Refer to: PIL 21-00-00. D
Remove
1. Remove the oil filter.
2. Disconnect the coolant hoses (x2).
Figure 373.
B C Coolant manifold
D Track seal
E Locating tab
A
C 4. Fill the engine with the recommended coolant
mixture.
B
5. Start the engine and check for coolant leaks

Item Nm
B 24 ± 2
A Coolant hoses (x2)
B Bolts (x3)
C Coolant manifold
4. Remove the coolant manifold and the track seal.
The track seal must not be reused. Discard the
track seal.
21 - 49 9813/9050-1 21 - 49
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-51
21 - 50 9813/9050-1 21 - 50
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-51 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-52 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-52 between the engine and the radiator/cooling pack.
21 - 51 9813/9050-1 21 - 51
21 - Cooling System
93 - Hose
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the 1. Visually inspect the engine and related cooling
cap, hot coolant can spray out and burn you. components for:
Make sure that the engine is cool before you work
on the cooling system. 1.1. Leaks.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and
tightened to the correct torque value.
21 - 52 9813/9050-1 21 - 52
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ........................................................................................................................... 24-11
24-03-01 Master Cylinder .............................................................................................................. 24-17
24-03-39 Piston ............................................................................................................................. 24-20
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-24
24-03-46 Vacuum Pump ................................................................................................................ 24-27
24-03-50 Light Switch .................................................................................................................... 24-32
24-03-57 Pressure Sensor ............................................................................................................ 24-36
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-43
24-18-03 Switch ............................................................................................................................. 24-47
24-18-06 Cable .............................................................................................................................. 24-48
24-18-15 Pad ................................................................................................................................. 24-53
24-18-18 Caliper ............................................................................................................................ 24-54
24-18-21 Disc ................................................................................................................................ 24-61
9813/9050-1
2018-01-12
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
9813/9050-1
2018-01-12
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/9050-1 24 - 1
Notes:
24 - 2 9813/9050-1 24 - 2
24 - Brake System
00 - Brake System
00 - General

Health and Safety ........................................... 24-3 Brake Fluid
Technical Data ................................................. 24-5 Use of incorrect brake fluid will cause serious
Fault-Finding .................................................... 24-6 damage to the seals of the braking system. This will
Check (Level) .................................................. 24-9 result in brake failure.
Service Brake Bleeding
Before bleeding the service brake system, park on
level ground and set the park brake to on. Put blocks
on both sides of the wheels on one axle to prevent
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If
you do not take these precautions the machine could
run over you.
Park Brake Maintenance
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the
machine could run over you.
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 9813/9050-1 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 9813/9050-1 24 - 4
24 - Brake System
00 - Brake System
00 - General
Technical Data
Single axle service brakes system

Table 165. 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 166. 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 167. 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 168. 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
24 - 5 9813/9050-1 24 - 5
24 - Brake System
00 - Brake System
00 - General
Fault-Finding
Fault
One or more brakes do not apply. (Brake travel not excessive, brakes not Table 169. Page 24-6
pulling to one side)
Pedal travel excessive (but not touching floor) Table 170. Page 24-6
Pedal hard to operate Table 171. Page 24-6
Pedal touches floor under constant pressure- no fluid loss Table 172. Page 24-7
Pedal touches floor under constant pressure and fluid loss Table 173. Page 24-7
Poor braking (not pulling to one side) Table 174. Page 24-7
Brakes not releasing Table 175. Page 24-7
Poor braking when hot Table 176. Page 24-8
Excessive brake noise in operation (Due to the metal to metal contact of oil Table 177. Page 24-8
immersed brakes, limited noise can be heard which is consistent and normal
with this type of design).
Fluid loss when machine standing (for example- overnight). (Conform that Table 178. Page 24-8
the fault is as indicated by checking that the brake pedal does not touch the
floor when it is operated under constant pressure).
Table 169. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side)
Cause Remedy
Master cylinder fault. Check master cylinder to identify fault area, service
as necessary. Refer to (PIL 24-03-01).
Friction/counter plate distortion. Replace friction/counter plates- both sides of relevant
axle.
Table 170. Pedal travel excessive (but not touching floor)

Cause Remedy
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03).
Bleed the brake system. Refer to (PIL 24-00-00).
Leak in hydraulic system. Check for fluid loss at master cylinder and brake
piston, all pipes and fittings for loose connections.
correct as necessary. Refer to (PIL 24-03-39).
Check fluid reservoir level. Check for fluid/air leaks,
axle.
Table 171. Pedal hard to operate

Cause Remedy
Tightness at pedal pivot. Check the pedal pivot. Free-off/lubricate.
Fluid contamination/seal damage. Flush system and renew all hydraulic seals. Bleed
the brake system. Refer to (PIL 24-00-00).
Misaligned push rod/pedal. Check and correct as necessary.
Kinked or crushed brake pipes. Check/replace brake pipework.
Vacuum failure due to low vacuum at source. Check/service engine mounted exhauster unit as
(Machines fitted with servo assisted brakes only). necessary.
Blocked/leaking vacuum pipe. (Machines fitted with Check/renew vacuum pipe. Refer to (PIL 24-03-96).
servo assisted brakes only).
Servo defect. (Machines fitted with servo assisted Replace the servo unit.
brakes only).
24 - 6 9813/9050-1 24 - 6
24 - Brake System
00 - Brake System
00 - General
Table 172. Pedal touches floor under constant pressure- no fluid loss
Cause Remedy
axle.
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
Table 173. Pedal touches floor under constant pressure and fluid loss
Cause Remedy
External fluid leaks. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03)
Internal fluid leaks. Bleed the brake system. Refer to (PIL 24-00-00).
Table 174. Poor braking (not pulling to one side)

Cause Remedy
Friction plates worn beyond limits or distorted. Replace friction/counter plates- both sides of relevant
axle.
Annular piston fault. See table 'Brakes not releasing', item 'Annular brake
piston(s) binding in axle'.
Incorrect/low axle oil. Fill the axle with correct type of oil.
Vacuum failure Check vacuum source/pipes, service as necessary.
Table 175. Brakes not releasing

Cause Remedy
Brake pedal spring fault. Install a new spring.
Master cylinder fault (plunger stuck in bore). Check master cylinder to identify fault area, service
Blocked hole in master cylinder reservoir cap Install a new reservoir cap.
Brake pedal free travel incorrect. Adjust pedal free travel.
Fluid contamination/seal damage. Flush system and replace hydraulic seals. Refill with
clean fluid.
Annular brake piston(s) binding in axle. Check that correct brake fluid has been used
(incorrect fluid could swell the annular brake piston
seals).
Check if annular brake piston seals are in good
condition.
Check that annular brake piston rotates freely in its
housing with no seals installed.
Check that the annular brake piston seal retracts the
piston approximately to the specified value.
Length: 0.5mm
Kinked or crushed brake pipes. Check and replace pipes as necessary.
Friction/counter plates not free on splines and/or Check friction/counter plates for free movement,
dowels. replace if necessary- both sides of relevant axle.
24 - 7 9813/9050-1 24 - 7
24 - Brake System
00 - Brake System
00 - General
Table 176. Poor braking when hot

Cause Remedy
Moisture in system vaporising when axle is hot. Strip axle and clean annular piston to remove
moisture.
Remove master cylinder and check for corrosion,
service as necessary.
Flush system and replace hydraulic seals. Refill with
clean fluid.
Table 177. Excessive brake noise in operation (Due to the metal to metal contact of oil immersed brakes,
limited noise can be heard which is consistent and normal with this type of design).
Cause Remedy
Deterioration of axle oil or wrong type of axle oil Change axle oil. Refer to check level (PIL 20-00)
Axle oil loss. Refill axle with correct oil and check for leaks. Refer
to (PIL 20-00).
Friction plates worn beyond limits. Renew friction/counter plates on both sides of
relevant axle.
Friction/counter plates in poor condition. Check for distortion or surface pitting and/or
roughness of the plates. (Annular grooving of counter
plates is acceptable).
Table 178. Fluid loss when machine standing (for example- overnight). (Conform that the fault is as
indicated by checking that the brake pedal does not touch the floor when it is operated under constant
pressure).
Cause Remedy
Severe damage or slight cut/nick in the brake piston Test the brake piston seals for leakage. If necessary,
seal. strip axle and renew seal(s).
External leakage through brake pipe connections etc. Check for and repair leaking connections.
24 - 8 9813/9050-1 24 - 8
24 - Brake System
00 - Brake System
00 - General
Check (Level) 3.2. Add the recommended fluid slowly.

3.3. Replace the tank cap.
WARNING Faulty brakes can kill. If you have
to top up the brake reservoir frequently, get the 3.4. Clean any spilt fluid.
brake system checked by your JCB Dealer. Do
not use the machine until the fault has been put
right.
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.
The brake fluid tank is in the panel in front of the cab.

Pull the release knob to open the panel.
Figure 375.
A Knob
2. Check the brake fluid level. The correct fluid level
is marked on the tank.
3. If necessary, add more fluid:
Figure 376.
A
A Tank cap
B Tank
3.1. Remove the tank cap.
24 - 9 9813/9050-1 24 - 9
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ........................................................................................................................... 24-11

24-03-01 Master Cylinder .............................................................................................................. 24-17
24-03-39 Piston ............................................................................................................................. 24-20
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-24
24-03-46 Vacuum Pump ................................................................................................................ 24-27
24-03-50 Light Switch .................................................................................................................... 24-32
24-03-57 Pressure Sensor ............................................................................................................ 24-36
24 - 10 9813/9050-1 24 - 10
24 - Brake System
03 - Service Brake
00 - General
Introduction .................................................... 24-11 The service brake is used to stop the machine when
Component Identification ............................... 24-12 it is in motion.
Diagram ......................................................... 24-13
Bleed ............................................................. 24-15 The service brake is a hydraulic system. The
machine operator applies pressure to the brake
Disassemble and Assemble .......................... 24-16 pedal in the cab.
The pedal is connected to the master cylinder which

supplies hydraulic pressure to the applicable brake
units to apply the brakes.
The brake packs are located in the axle- some

machines have front and rear brakes whilst some
machines only have front axle brakes.
24 - 11 9813/9050-1 24 - 11
24 - Brake System
03 - Service Brake
00 - General
An electrical switch is fitted to the pedal assembly for

Single axle service brakes system operation of the rear facing brake lights.
The front axle integral brake packs are multi-disc Auto 4-wheel braking
plates that are immersed in oil. The brake packs
are actuated hydraulically by a single foot pedal and To achieve 4-wheel braking, engage the 4WD (Four
master cylinder. Wheel Drive). In this way all 4 wheels are effectively
braked via the machine transmission.
On machines with servo assisted brakes, the
assistance is provided by means of an engine driven When 2WD (Two Wheel Drive) is selected, operating
vacuum pump and remotely mounted servo unit the brake pedal will automatically select 4-wheel
which is located on the front of the cab. drive. This gives increased braking effect. The
transmission will switch back to 2- wheel drive when
The brake hydraulic fluid tank is situated outside the the brake pedal is released.
cab, below the front windscreen.
Figure 377.
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 - 12 9813/9050-1 24 - 12
24 - Brake System
03 - Service Brake
00 - General
Diagram
Single axle service brakes system

Hose and pipework- Machines with trailer brakes
Figure 378.
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 - 13 9813/9050-1 24 - 13
24 - Brake System
03 - Service Brake
00 - General
Hose and pipework- Machines without trailer brakes
Figure 379.
D
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
24 - 14 9813/9050-1 24 - 14
24 - Brake System
03 - Service Brake
00 - General
Bleed Figure 381. Servo unit
Single axle service brake system

WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn
cause brake failure.

2. Follow all the care and safety procedures. Refer
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 B
procedure.
5. Bleed the brake system in the applicable
sequence as follows:
5.1. Machines without servo brakes- Bleed at
the point on the front axle.
Figure 380. Front axle
B Bleed point on servo unit

6. Attach a tube to the applicable bleed screw.
A
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 Bleed point on front axle return quickly to its stop.
5.2. Machines with servo brakes- Bleed at the 9. Continue to bleed the air normally until all the air
point on the servo unit and the point on the is removed. Push the pedal fully and close the
front axle. bleed screw.
10. Top up the tank to the full mark.
24 - 15 9813/9050-1 24 - 15
24 - Brake System
03 - Service Brake
00 - General
Refer to driveline, axle, general, dissasemble and

assemble, (PIL 27-20-00).
24 - 16 9813/9050-1 24 - 16
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Remove and Install

Remove and Install ....................................... 24-17 The master cylinder is a non-serviceable part. If it is
Disassemble and Assemble .......................... 24-19 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 382. 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 - 17 9813/9050-1 24 - 17
24 - Brake System
03 - Service Brake
Figure 383. Twin axle brak- Figure 384.

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 - 18 9813/9050-1 24 - 18
24 - Brake System
03 - Service Brake
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 19 9813/9050-1 24 - 19
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-20
Technical Data ............................................... 24-21
Brake Piston Seal Leakage
Check (Leaks) ............................................... 24-21 The most common reason for internal piston seal
Disassemble and Assemble .......................... 24-23 leakage is a build-up of axle contamination. It is
caused as a result of excessive brake wear caused
by extended service periods.
Two types of internal leakage can occur within the

axle or hub:
• Low Pressure Leaks- Seal damage, or scoring

to seal component surfaces, caused by a build-
up of metal particles.
• High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
Do the low pressure leak test first. Low pressure

leaks are difficult to find using a high pressure test.
The seals and other components can distort and form
a seal under pressure.
Do the low pressure or high pressure leak test

without disassembling the axle. Refer to brakes-
service brake, refer to (PIL 24-03).
Make sure that you do the leak test only when the
axle is cold.
24 - 20 9813/9050-1 24 - 20
24 - Brake System
03 - Service Brake
39 - Piston
Technical Data Check (Leaks)

Special Tools
Refer to brakes- general, refer to (PIL 24-00). Description Part No. Qty.
Bar)
Consumables
JCB Hydraulic Fluid HP 4002/0501 1L
15 4002/0503 5L
WARNING Before working on the brake system,

make sure that the machine is on solid level
ground. Put blocks on all wheels to prevent the
machine rolling.
WARNING Do not use the machine with any part
of its brake system disconnected or inoperative.
When the test has been completed, make sure all
brake system components are installed and the
system is operating correctly.
The most common reason for internal piston seal

leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service
periods.
Two types of internal leakage can occur within the

axle or hub:
1. Low Pressure Leaks- Seal damage, or scoring to

seal component surfaces, caused by a build-up
of metal particles.
2. High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
The low pressure leak test should be performed

first. Low pressure leaks are difficult to find using a
high pressure test- seals and other components can
distort and form a seal under pressure.
The following procedures explain how to check for

low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.

2. Disconnect the brake piston feed pipe (or hose,
as applicable) at port 1.
contamination.
4. Completely remove the pipe and install a plug at
port 2.
5. Fill both brake piston housings with JCB Light
Hydraulic Fluid through the port 1 and port 3.
Consumable: JCB Hydraulic Fluid HP 15
24 - 21 9813/9050-1 24 - 21
24 - Brake System
03 - Service Brake
39 - Piston
Figure 385. 7. Test for a high pressure leak as follows:

7.1. Install a hand pump installed with a
pressure gauge of the specified value to the
D brake piston port.
A
Special Tool: Pressure Gauge (0-70 Bar)
(Qty.: 1)
B C
7.2. Fill the hand pump with the correct
Hydraulic Fluid.
7.3. Use the hand pump to generate a pressure
in the brake piston housing. Do not exceed
the specified value.
A Port 1 Pressure: 69bar (1,000.0psi)
B Pipe
C Port 2 7.4. If the pressure falls off rapidly, or if no
D Port 3 pressure reading can be obtained, the
piston seal is severely damaged. Install a
6. Test for a low pressure leak as follows: new seal.
6.1. Install an adaptor with a piece of clear tube 7.5. Repeat the 7.1 to step 7.4 at port 4.
to the brake piston port.
Figure 387.
6.2. Make sure you keep the tube vertical during
the test. Use tape to attach the tube to the
side of the machine.
6.3. Fill the tube until approximately three X
quarters full with the correct Hydraulic Fluid.
6.4. Use a suitable pen to mark the level line of
the brake fluid on the tube.
6.5. 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 E
wear.
6.6. Repeat the step 6.1 to step 6.5 at port 4. F
Figure 386.
E Port 4
F Brake piston port
X X Brake fluid level line
8. Put the brake system back to the original
condition as follows:
8.1. Connect all the brake pipes and bleed
the brake system. Refer to brakes- service
brake. Refer to (PIL 24-03).
E For twin axle brake systems, do this procedure on
the other axle, if applicable.
F
E Port 4
F Brake piston port
X Brake fluid level line
24 - 22 9813/9050-1 24 - 22
24 - Brake System
03 - Service Brake
39 - Piston
Refer to driveline- front axle, refer to (PIL 27-20).
24 - 23 9813/9050-1 24 - 23
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit Check (Leaks)

Check (Leaks) ............................................... 24-24 Refer to (PIL 24-03-46).
24 - 24 9813/9050-1 24 - 24
24 - Brake System
03 - Service Brake
Remove and Install
4. Disconnect and install a plug on the master

Servo unit- Single axle brakes cylinder output pipe. Install a plug on the cylinder
port.
Remove 5. Disconnect and install a plug on the cylinder
1. Make the machine safe. Refer to (PIL 01-03). output hose. Install a plug on the cylinder port.
2. Follow the general health and safety procedures. 6. Loosen the securing bolts (x3) and slide the
Refer to (PIL 01-03). servo unit out of its mounting bracket.
3. Disconnect the servo vacuum hose. 7. Make sure you carefully keep the washers (if
installed).
Figure 388.
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 - 25 9813/9050-1 24 - 25
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 - 26 9813/9050-1 24 - 26
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump Introduction

Introduction .................................................... 24-27 The service brake system requires vacuum
Component Identification ............................... 24-28 assistance to operate.
Check (Leaks) ............................................... 24-28
Remove and Install ....................................... 24-30 On machines with standard hydraulic service brakes
the vacuum assistance is provided by a vacuum
pump mounted on the engine.
24 - 27 9813/9050-1 24 - 27
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Component Identification Check (Leaks)

Figure 389. JCB 430 Engine The procedure explains how to determine if the brake
servo vacuum system is functioning correctly.
The following test equipment is used to carry out this

A test:
• Vacuum gauge (range up to 1 bar).

• T-adaptor.
• Vacuum hose- 2 lengths x 75 mm (3 inch) long.
• Clips- worm drive.
Brake Vacuum Test (if applicable)

2. Open the engine compartment cover. Refer to
(PIL 06-06).
A Brake Exhauster (Vacuum) 3. Disconnect the brake vacuum line at the brake
vacuum pump and connect a vacuum gauge
directly to the pump.
3.1. The location of the vacuum pump may
differ depending on the specification of your
machine.
4. Run the engine at 1500 RPM (Revolutions Per
Minute) and note the reading on the vacuum
gauge:
4.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
4.2. If there is little or no vacuum, renew the
vacuum pump.
5. Remove the vacuum gauge from the pump port
and connect it again into the brake vacuum line
using a T-adaptor.
6. Run the engine at 1500 RPM and note the
reading on the vacuum gauge:
6.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
6.2. If there is little or no vacuum, check the
vacuum hose connections for leaks.
6.3. Check the security of the clips and then do
step 7.
7. Switch OFF the engine and monitor the vacuum
gauge reading:
7.1. Make sure that the mercury (Hg) level stays
above the specified value after 60 seconds.
24 - 28 9813/9050-1 24 - 28
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
7.2. Check that the vacuum is sufficient for 3 or 4

pedal operations. The vacuum must decay
slowly with each pedal operation.
8. The brake vacuum pump and brake servo unit
are non-serviceable parts. If they are suspected
as being faulty, install new parts.
Figure 390. Typical Vacuum Pump Installation
A Brake vacuum line

B T-adaptor
24 - 29 9813/9050-1 24 - 29
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Remove and Install
7. Install a cap on the open ends of the hoses to

If the brake performance is poor and the brake servo prevent the ingress of dirt. Tie the hoses out of
vacuum is suspected, do the brake vacuum test the way.
before you install a new servo exhauster unit. Refer
to brakes- service brake. Refer to (PIL 24-03). 8. Remove the screws and carefully take out the
servo exhauster unit from the engine. Discard the
Remove gasket.
1. Make the machine safe. Refer to (PIL 01-03) Install

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).
4. Open the engine compartment cover. Refer to The special adaptor is installed with an oil feed
(PIL 06-06). restrictor orifice (3 mm diameter). Check to make
sure that the orifice is not blocked before installing
5. Remove the clip and release the brake vacuum the servo exhauster unit.
hose from the pipe stub.
6. Disconnect the oil feed hose. removal procedure. Additionally do the following
steps.
Figure 391. JCB 430 Engine

B C
D
24 - 30 9813/9050-1 24 - 30
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
A Gasket (not shown) B Screw (X2)

C Vacuum pipe stub D Lubrication pipe and restrictor
E Drive gear F O-ring seal
1.1. Make sure that the servo exhauster unit

flange and the engine mating face is clean.
Install a new seal.
1.2. Carefully align the gear so that the gear
teeth engages with the drive gear in the
engine.
1.3. Tighten the screws to the specified torque
value.
1.4. On completion, make sure the brakes work
correctly.

Item Nm
B 47
24 - 31 9813/9050-1 24 - 31
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-32 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-33 harness.
Figure 392.
3 2 1 3 2 1
24 - 32 9813/9050-1 24 - 32
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 394.
Brake Light Switch- Proximity Type
Figure 393.
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 - 33 9813/9050-1 24 - 33
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 395.
A Electrical connector B Bracket

C Screw D Switch
24 - 34 9813/9050-1 24 - 34
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 35 9813/9050-1 24 - 35
24 - Brake System
03 - Service Brake
57 - Pressure Sensor
57 - Pressure Sensor Component Identification

Component Identification ............................... 24-36 The Footbrake Pressure Transducer is located on
Diagram ......................................................... 24-37 the brake servo.
Check (Operation) ......................................... 24-40
Remove and Install ....................................... 24-40 Figure 396.
2
2 Footbrake Pressure Transducer
24 - 36 9813/9050-1 24 - 36
24 - Brake System
03 - Service Brake
Diagram
Figure 397.
Wires and Connectors
The Footbrake Pressure Transducer is connected to
the Chassis harness.
2 3
1 4
1 4
2 3
Machines with Gearpump Parallel Hydraulic System
Table 181. Harness Connector C027

Connectors Pins Pins Pins Pins Details
C027 1 2 3 4
C010 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
Machines with Electro Servo Hydraulic System (excluding 526-56)

C018 1 2 3 4
Point - Refer to
(PIL 33-00-90)
24 - 37 9813/9050-1 24 - 37
24 - Brake System
03 - Service Brake

33-00-50)
fer to (PIL 33-09)
P069 - 9 Transmission
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 - 38 9813/9050-1 24 - 38
24 - Brake System
03 - Service Brake
Schematic Diagram
Figure 398.
- 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 - 39 9813/9050-1 24 - 39
24 - Brake System
03 - Service Brake

Special Tools WARNING Before working on the brake system,
Description Part No. Qty. make sure that the machine is on solid level
Servicemaster 892/01033 1* ground. Put blocks on all wheels to prevent the
Electronic Test Kit 892/01174 machine rolling.
Data Link Adaptor
(DLA) Kit Figure 399.
*Unless otherwise stated, you can use any of the
tools shown.
Test Procedures
1. Use the applicable Servicemaster diagnostics
tool to identify faults. Ensure that the applicable
control interface operates correctly. Rectify as
required. Refer to (PIL 33-57).
Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
2. Test the applicable wires and connectors for 1
continuity, shorts to battery and shorts to earth.
Rectify as required.
2
1 Brake servo
2 Electrical connector
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 - 40 9813/9050-1 24 - 40
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-43

24-18-03 Switch ............................................................................................................................. 24-47
24-18-06 Cable .............................................................................................................................. 24-48
24-18-15 Pad ................................................................................................................................. 24-53
24-18-18 Caliper ............................................................................................................................ 24-54
24-18-21 Disc ................................................................................................................................ 24-61
24 - 41 9813/9050-1 24 - 41
Notes:
24 - 42 9813/9050-1 24 - 42
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-43 The park brake also called the hand brake is a
Technical Data ............................................... 24-44 latching brake usually used to keep the vehicle
Operation ....................................................... 24-44 stationary. It is also used to prevent a vehicle from
Check (Condition) .......................................... 24-45 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Adjust ............................................................ 24-45
The park brake usually consists of a cable directly
connected to the brake mechanism on one end, and
to a hand-operated lever, on the floor at the side of
the driver.
24 - 43 9813/9050-1 24 - 43
24 - Brake System
18 - Park Brake
00 - General
Technical Data Operation
Table 184. Park Brake The park brake is Independent of the service brakes.
It operates on the drive to the front axle by means of
Description Acceptable Tolerances
a disc mounted on the gearbox output shaft.
Disc minimum thickness 8.9mm
Pad minimum thickness 1mm 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.
Figure 400.
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.
24 - 44 9813/9050-1 24 - 44
24 - Brake System
18 - Park Brake
00 - General
Check (Condition) Adjust

WARNING Oil on the brake disc will reduce WARNING The park brake must not be used to
brake effectiveness. Keep oil away from the slow the machine from travelling speed, except
brake disc. Remove any oil from the disc with in an emergency, otherwise the efficiency of the
a suitable solvent. Read and understand the brake will be reduced. Whenever the park brake
solvent manufacturer's safety instructions. If the has been used in an emergency the brake pack
pads are oily, install with the new pads. must be renewed.
1. Follow the brake pad removal instructions. refer working on it. Park the machine on level ground
to (PIL 24-03). and lower the loader arm. Stop the engine and
2. Make sure that the minimum thickness of the is engaged. Disconnect the battery to prevent the
friction material on either pad is 1mm (0.04 in), engine being started. Block all four wheels.
but it is recommended to install new pads as it
may not be possible to adjust pads worn to this Notice: Over adjustment or failure to disengage
limit. the park brake properly will cause excessive wear
of the park brake mechanism.
3. Check the condition of the disc surface. Install a
new disc if the surface is badly warped, pitted or
Before you try to adjust the park brake after an
worn.
emergency stop, remove and install new brake
4. Make sure the actuator is adjusted correctly. friction components. Install other new components if
necessary.
The park brake must be engaged fully when the

lever is vertical. The park brake indicator light should
illuminate when the brake is engaged with the
forward and reverse lever away from neutral (starter
switch at IGN).
Do the park brake adjustment as follows:
1. Disengage the park brake (lever horizontal).

2. Pull and turn the handle grip clockwise, half a
turn.
3. Test the park brake. Refer to brakes- park brake,
4. If the brake fails the test, repeat steps 1, 2 and 3.
5. If no more adjustment is possible and the pin is
at the end of its travel, then adjust the cable at
the calliper. Refer to brakes- service brake, refer
to (PIL 24-18).
24 - 45 9813/9050-1 24 - 45
24 - Brake System
18 - Park Brake
00 - General
Figure 401.
A
A Handle grip
B Pin
24 - 46 9813/9050-1 24 - 46
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.
6. Remove the switch.
Figure 402.
B G D
F
C
A Rubber gaiter
B Switch
D Switch connector
E Screw
F Dowel
G Mounting bracket
24 - 47 9813/9050-1 24 - 47
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-48 If the adjustment of the park brake lever is not
Remove and Install ....................................... 24-50 sufficient, then adjust the cable at the calliper.
If it is not possible to adjust at the lever or at the

calliper, then change the brake pads.
Make sure that you install a new cable if the cable is

worn or damaged.
1. Park the machine and make it safe.

2. Follow the care and safety procedures. Refer to
(PIL 01-03).
3. Disengage the park brake (lever horizontal).
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 - 48 9813/9050-1 24 - 48
24 - Brake System
18 - Park Brake
06 - Cable
Figure 403.
C
A Hand grip
B Pin
C Locknuts
Figure 404.
D
D Operating lever
24 - 49 9813/9050-1 24 - 49
24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
Consumables Remove
JCB Threadlocker 4101/0250 0.01L 1. Make the machine safe. Obey all care and safety
and Sealer (Medium procedures Refer to (PIL 01-03).
4101/0251 0.05L
Strength) 2. Release the park brake lever (lever horizontal).
Figure 405.
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 - 50 9813/9050-1 24 - 50
24 - Brake System
18 - Park Brake
06 - Cable
Figure 406.
K
K
N L
M
P
Install
Table 185. 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 - 51 9813/9050-1 24 - 51
24 - Brake System
18 - Park Brake
06 - Cable
7. Adjust the sleeve and the locknut 2 until you get

the dimension measured between the sleeve and
the locknut at the time of removal.
8. If a new cable is installed make sure that the
dimension between the sleeve and the locknut
will be of the specified value.
Dimension: 15mm
9. Tighten the locknut 2.
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
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.
13. Adjust the cable. Refer to (PIL 24-18-06).

Item Description Nm
K Bracket fixing bolts 3
24 - 52 9813/9050-1 24 - 52
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 - 53 9813/9050-1 24 - 53
24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Component Identification

Check (Condition) .......................................... 24-55
Figure 407.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
Item Description
Table 187. R Housing
S Shaft seal
Item Description
A Carrier side pad
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
Q Bearing ring
24 - 54 9813/9050-1 24 - 54
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 - 55 9813/9050-1 24 - 55
24 - Brake System
18 - Park Brake
18 - Caliper
Remove and Install
2. Release the park brake lever (horizontal).

Safety Critical Installation
This is a safety critical installation. Do not attempt 3. Remove the pin and disconnect the clevis joint,
to do this procedure unless you are skilled and note which of the three holes on the lever is used.
competent to do so.
4. Remove the clip and disconnect the cable from
Installation and mounting of the park brake caliper the bracket.
requires tightening of the mounting bolts to a specific
torque figure. Do not attempt to do this job unless you 5. Support the caliper and remove the two mounting
have the correct tools available. bolts and hardened washers.
6. Lift the caliper clear of the brake disc.
Remove
7. Do not remove transmission mounting bracket,
1. Make the machine safe. Refer to (PIL 01-03). unless it is necessary to be replaced.
Figure 408.
A B C D
E
B
A Clip B Mounting bolts

C Clevis joint D Pin
E Operating lever F Transmission mounting bracket
24 - 56 9813/9050-1 24 - 56
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 - 57 9813/9050-1 24 - 57
24 - Brake System
18 - Park Brake
18 - Caliper
7. Push out the rotor the remove the ball spacer and
Safety Critical Installation
the ball bearings.
This is a safety critical installation. Do not attempt
to do this procedure unless you are skilled and 8. Make sure you keep the ball bearings properly in
competent to do so. a container.
Installation and mounting of the park brake caliper 9. Push out the mounting bushes and then remove
requires tightening of the mounting bolts to a specific the dust seals.
torque figure. Do not attempt to do this job unless you
have the correct tools available. 10. Remove the O-rings.
11. Remove the rotor seal and then the bearing ring.
Disassembly
12. Note that the rotor seal may be located on the
1. Remove the caliper and the brake pads. Refer to rotor shaft or may have been left in the calliper
remove and install (PIL 24-18-18). housing.
2. Hold the lever against the tension of the spring. 13. It is not necessary to replace the shaft seal
3. Remove the screw and both the washer 1, unless it is excessively worn or damaged.
washer 2. 13.1. If removal is necessary, use a suitable
4. Note the position of the lever with respect to the spacer block and a bench press to push
splines of the rotor shaft. the seal out from inside the housing.
13.2. Clean out any remains of the seal after
5. Mark the end of the shaft and lever to assist in removal.
assembly.
Before assembly make sure all parts are clean
6. Remove the lever and the spring.
and serviceable. Refer to park brake caliper-check
condition (PIL 24-18-18).
24 - 58 9813/9050-1 24 - 58
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 409.
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 189. 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 410.
Q Bearing ring
R Housing
S Shaft seal
Assembly
Before assembly make sure all parts are clean and
serviceable.
24 - 59 9813/9050-1 24 - 59
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 410.
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 410.
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 190. Torque table

Item Torque value
Screw 13–16N·m
24 - 60 9813/9050-1 24 - 60
24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................... 24-61 A disc brake is a wheel brake that slows the rotation
Check (Condition) .......................................... 24-62 of the wheel by the friction caused by pushing brake
Remove and Install ....................................... 24-63 pads against a brake disc with a set of calipers.
24 - 61 9813/9050-1 24 - 61
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 - 62 9813/9050-1 24 - 62
24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
Special Tools 8. If necessary remove the oil seal. Do not damage

Description Part No. Qty. the seal housing.
Flange Spanner 992/04800 1
Install
Remove 1. Make sure that the oil seal interface on the brake
1. If installed remove the park brake caliper. 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
lips of the seal.
3. Clean the brake disc and the gearbox around the
brake disc. Make sure no contamination enters 3. Install the brake disc onto the output shaft.
the gearbox when the brake disc is removed. 4. Install the washer.
4. Hold the brake disc with the service tool and 5. Hold the brake disc with the service tool.
remove the output shaft stake nut. Discard the
stake nut. 6. Install a new stake nut.
Special Tool: Flange Spanner (Qty.: 1) 7. Progressively tighten the nut to the correct torque
5. Remove the washer. value.
6. Lift off the brake disc. If necessary use a soft 8. Stake the nut to the shaft with a square ended
faced mallet to remove the brake disc. staking tool.
7. Do not use a steel hammer, damage can occur

to the output shaft bearing.
24 - 63 9813/9050-1 24 - 63
24 - Brake System
18 - Park Brake
21 - Disc
Figure 411.
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 - 64 9813/9050-1 24 - 64
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-00-03 Manual Steer Mode System .......................................................................................... 25-18
25-00-06 Auto Steer Mode System ............................................................................................... 25-24
25-01 Pump
25-01-00 General ........................................................................................................................... 25-37
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-39
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-45
25-09 Mode Valve
25-09-03 Manual Mode Valve ....................................................................................................... 25-51
25-09-06 Auto Mode Valve ............................................................................................................ 25-58
25-12 Column
25-12-00 General ........................................................................................................................... 25-61
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-65
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-71
25-33 Link Arm
25-33-00 General ........................................................................................................................... 25-81
9813/9050-1
2017-10-02
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
LS Load Sense
9813/9050-1
2017-10-02
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3

25-00-03 Manual Steer Mode System .......................................................................................... 25-18
25-00-06 Auto Steer Mode System ............................................................................................... 25-24
25 - 1 9813/9050-1 25 - 1
Notes:
25 - 2 9813/9050-1 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 ......................................................... 25-8 Manual Steer Mode System
Fault-Finding .................................................. 25-10 In a manual steer system, there are three steering
Check (Leaks) ............................................... 25-13 modes available:
Check (Pressure) .......................................... 25-14
Adjust ............................................................ 25-15 1. 2WS (Two Wheel Steer) (front axle only)- only
the front wheels are steered.
Bleed ............................................................. 25-16
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 9813/9050-1 25 - 3
00 - General

Engine/Steering Failure Table 192.
If the engine or steering fails, stop the machine as
Model Rexroth Bosch Eaton 160cc
quickly as possible. Do not operate the machine until
LAGC 160
the fault has been corrected.
Volumetric 160 cc/rev 160 cc/rev
Working Under the Machine displacement
Make the machine safe before getting beneath it. gerotor 1:
Make sure that any attachments on the machine are Volumetric - -
correctly attached. Engage the park brake, remove displacement
the ignition key, disconnect the battery. If the machine gerotor 2:
has wheels use blocks to prevent unintentional Relief Valve Op- 195–200bar 175bar
movement. erating Pres- (2,826.1– (2,536.2psi)
Fluid Under Pressure sure (at 1500 2,898.5psi)
RPM (Rev-
Fine jets of fluid at high pressure can penetrate the olutions Per
skin. Keep face and hands well clear of fluid under Minute))
pressure and wear personal protective equipment.
Hold a piece of cardboard close to suspected Shock valve op- 250bar 235bar
leaks and then examine the cardboard for signs of erating pres- (3,623.2psi) (3,405.8psi)
fluid. If fluid penetrates your skin, get medical help sure- if installed
immediately.
Hydraulic Pressure
Before connecting or removing any hydraulic hose,
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
WARNING! When getting access for maintenance
work, make sure no-one is in a position to be caught
and/or crushed by the wheels when the steering
wheel is turned.
25 - 4 9813/9050-1 25 - 4
00 - General
Manual Steer Mode System
Figure 412.
B
A
A Steer mode selection lever B Steer mode selection unit

C Steer mode unit cable D Steer mode valve
25 - 5 9813/9050-1 25 - 5
00 - General
Figure 413.
A Steer mode switch B Front steer proximity switch

C Rear steer proximity switch
Figure 414. Auto Steer Mode Valve
C B
D A
1
25 - 6 9813/9050-1 25 - 6
00 - General
1 Located under the LH centre of the chassis
25 - 7 9813/9050-1 25 - 7
00 - General
Operation
steer unit, which in turn directs the flow to the steer

The main components of the steering system are the rams on the axles.
priority valve (PIL 25-03) , the load sensing steer
unit (PIL 25-06), the steer mode control valve (PIL When the steering lock is achieved, the pressure
25-09) (if installed) and the double acting steer rams signal in the load sense line ceases. The priority
or power track rods as applicable (PIL 25-18 and or valve then directs the oil from the hydraulic pump
19). into the main hydraulic system for operation of the
hydraulic services.
When the you turn the steering wheel, a pressure
signal (demand) is generated in the load sense line The maximum steering system pressure is set by a
from the steer unit to the priority valve. The priority relief valve housed inside the steer unit.
valve then directs oil from the hydraulic pump to the
Figure 415. Machine with Power Track Rods
A,B
D
E
C
25 - 8 9813/9050-1 25 - 8
00 - General
Figure 416. Machine with Steer Rams
F
D
A, B
F
C
Table 193.
Item Description
A Hydraulic pump
B Priority valve
C Steer unit
D Control valve
E Power track rods
F Steer rams
25 - 9 9813/9050-1 25 - 9
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 194. Page 25-10
Steering wheel turns on its own. Table 195. Page 25-10
Machine will not turn when the steering wheel turned. Table 196. Page 25-10
Steering 'drifts' out of phase during operation. Table 197. Page 25-11
Steering fails to respond to selected mode (solenoid operated mode valve Table 198. Page 25-11
only).
Table 194. 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 195. 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 196. 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 - 10 9813/9050-1 25 - 10
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 197. 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 198. 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 - 11 9813/9050-1 25 - 11
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 - 12 9813/9050-1 25 - 12
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 417.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 13 9813/9050-1 25 - 13
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 418. 1)
G H Figure 419.
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 - 14 9813/9050-1 25 - 14
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 420.
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 421.
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 - 15 9813/9050-1 25 - 15
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 - 16 9813/9050-1 25 - 16
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 - 17 9813/9050-1 25 - 17
03 - Manual Steer Mode System
Operation
Figure 422. Right turn shown

Manual Steer Mode System
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 L R
between the steer unit and the front power track
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track
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 P

system only operates the front power track rod.
B
E
If the steering wheel is turned to the left, the oil flow T
is reversed and the machine will turn in the opposite
direction. D
V
Table 199.
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 - 18 9813/9050-1 25 - 18
4-wheel steer selected Figure 423. 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

direction. P
E
B
D T
Table 200.
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 - 19 9813/9050-1 25 - 19
track rod through the valve spool. The front power Figure 424. 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 201.
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 - 20 9813/9050-1 25 - 20
Machines with steer rams Figure 425.
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 202.
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 - 21 9813/9050-1 25 - 21
4-wheel steer selected Figure 426.
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 203.
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 - 22 9813/9050-1 25 - 22
Crab steer selected Figure 427.
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 204.
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 - 23 9813/9050-1 25 - 23
06 - Auto Steer Mode System
Operation
Figure 428.
There are 3 steering modes available:
F
• 2WS (Two Wheel Steer) (front axle only)
• 4WS (Four Wheel Steer)
• Crab steer
In the 2WS mode, only the front wheels are steered.

In 4WS mode, both the axles are steered, giving a
L R
smaller turning circle. The crab steer mode allows the
machine to be driven diagonally.
The system is prevented from changing mode until

all the wheels are in the straight ahead position. This E.C.U.
is detected by proximity sensors on the front and

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
S
straight ahead position.
V
The operation of the steer mode switch, solenoids
and proximity switches is controlled by the hydraulic
control ECU (Electronic Control Unit) and the
transmission control ECU. Refer to steering system- T
A
Hydraulic Operation and Schematics
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.
B
With the spools of steer mode control valve in
the 2WS position (solenoid energised), there is a
hydraulic connection between the steer unit and the A Solenoid Energised
front power track rod. The oil feed to the rear axle B Rear power track rod
power track rod is blocked by the spool assembly and F Front power track rod
the axle is held in the straight ahead position by the L Left
locked-up hydraulic oil in the track rod ram. R Right
S Steer unit
When the steering wheel is turned, the steering unit V Control valve
operates only the front power track rod.
is reversed and the machine will turn in the opposite The illustrations shown are for the purpose of circuit
direction. explanation only. Actual installations may not be as
shown.
25 - 24 9813/9050-1 25 - 24
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 429. 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 - 25 9813/9050-1 25 - 25
Figure 430. 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 - 26 9813/9050-1 25 - 26
2- wheel steer
Figure 431.
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 205. 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 - 27 9813/9050-1 25 - 27
4- wheel steer
Figure 432.
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 206. 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 - 28 9813/9050-1 25 - 28
Crab steer
Figure 433.
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 207. 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 - 29 9813/9050-1 25 - 29
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 434. 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 435.
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 - 30 9813/9050-1 25 - 30
S Steer unit Figure 436.

T Tank
V Steer mode valve
Operation- Crab 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 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 - 31 9813/9050-1 25 - 31
2- wheel steer
Figure 437.
F1 R1
A D
B C
F2 R2
C
F1 D
R1
A
FR B
S
F2 R2
R L
S Steer unit
Table 208.
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 - 32 9813/9050-1 25 - 32
4- wheel steer
Figure 438.
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 209.
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 - 33 9813/9050-1 25 - 33
Crab steer
Figure 439.
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 210. 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 - 34 9813/9050-1 25 - 34
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-37
25 - 35 9813/9050-1 25 - 35
Notes:
25 - 36 9813/9050-1 25 - 36
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 37 9813/9050-1 25 - 37
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-39
25 - 38 9813/9050-1 25 - 38
03 - Priority Valve
00 - General
00 - General Component Identification

Operation ....................................................... 25-41
Gear pump machines
Clean ............................................................. 25-43 The priority valve is mounted on the side of the gear
pump.
Figure 440.
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 441.
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 - 39 9813/9050-1 25 - 39
03 - Priority Valve
00 - General
Figure 442.
A Control valve block priority inlet section
25 - 40 9813/9050-1 25 - 40
03 - Priority Valve
00 - General
Operation
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 443. 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 211. 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 - 41 9813/9050-1 25 - 41
03 - Priority Valve
00 - General
Figure 444. Gear pump type valve shown
LS P EF
LS
A
B
P EF
Table 212.
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 - 42 9813/9050-1 25 - 42
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 213.
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 445.
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 - 43 9813/9050-1 25 - 43
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-45
25 - 44 9813/9050-1 25 - 44
00 - General
Introduction .................................................... 25-45 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-46 fluid flow in the steering system.
25 - 45 9813/9050-1 25 - 45
00 - General
Figure 446.
D E
C C
A
B
G D
G K J F
J
F E
Item Description
Table 214. H Steer valve
J Load sense port
Item Description
K Steering system relief
A Hydraulic steer unit valve
B Shock Valves (if in-
stalled)
C Check valve
D Left feed/ return port
E Right feed/ return port
F Valve inlet
G Return line
25 - 46 9813/9050-1 25 - 46
00 - General
Remove and Install

Remove 7. Put a label on the hoses to help installation.
8. Disconnect the hydraulic hoses from the steering
2. Follow all the general health and safety unit.
procedure. Refer to (PIL 01-03).
3. Discharge the hydraulic pressure. Refer to (PIL contamination.
30-00).
10. Mark the orientation of steering unit to the splined
4. Turn the steering wheel to the left and to the right shaft.
11. Remove the bolts from inside the cab. At the
5. Make sure that the steering wheel is in the same time, get an assistant to support the
straight ahead position. steering unit from under the machine.
6. Get access to the steer unit. Remove the front 12. Remove the steering unit.
panel from the cab.
Figure 447.
C
B
B Steering unit C Bolts (x 4)

D Splined shaft
Install 1.2. Make sure that the hoses are connected in

the correct positions.
1.3. If the hydraulic adaptors are removed make
sure that they are tightened to the correct
steps.
torque value.
1.1. Tighten the bolts to the correct torque value.
25 - 47 9813/9050-1 25 - 47
00 - General
Figure 448.
E Hydraulic adaptor 1 F Hydraulic adaptor 2
1.4. The steering unit is spring loaded to the

neutral position. Make sure that the steering
wheel is in the straight ahead position when
you connect the splined shaft.
1.5. Before you drive the machine, bleed the
system. Refer to (PIL 25-00).
1.6. If a new steering unit is installed then
the system relief valve must be tested for
correct pressure setting.
1.7. Check the hydraulic oil level and top up as

Item Nm
C 45
E 48
F 14
25 - 48 9813/9050-1 25 - 48
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-03 Manual Mode Valve ....................................................................................................... 25-51

25-09-06 Auto Mode Valve ............................................................................................................ 25-58
25 - 49 9813/9050-1 25 - 49
Notes:
25 - 50 9813/9050-1 25 - 50
09 - Mode Valve
03 - Manual Mode Valve
03 - Manual Mode Valve Remove and Install

Remove
2. Install the safety strut. Refer to (PIL 06-69).
30-00).
5. Turn the steering wheel to the left and to the right
several times to discharge the system pressure
fully.
6. Make sure that the steering wheel is in the
straight ahead position.
8. Disconnect the hydraulic hoses from the steer
mode valve.
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 - 51 9813/9050-1 25 - 51
09 - Mode Valve
Figure 449.
A C
A B
A
A Hoses B Bolts
C Steer mode valve
25 - 52 9813/9050-1 25 - 52
09 - Mode Valve
Figure 450.
D Steer mode selector control handle
25 - 53 9813/9050-1 25 - 53
09 - Mode Valve
Figure 451.
E E
E Nuts F Steer mode selector unit
Figure 452.
G A B
H C
A Spacer plates B Bolts

C Steer mode valve G Chassis side plate
H Washer
25 - 54 9813/9050-1 25 - 54
09 - Mode Valve
Install
steps.
1.1. Make sure that the hoses are installed in the
correct position.
1.2. Bleed the steering system. Refer to (PIL
25-00).
1.3. Install the two washers between the valve
block, spacer and the chassis side plate.
25 - 55 9813/9050-1 25 - 55
09 - Mode Valve
Consumables travel away from the valve) until they disengage

Description Part No. Size the operating cable thread.
JCB Threadlocker 4101/0250 0.01L 4. Remove the locknut 2 and disconnect the
and Sealer (Medium 4101/0251 0.05L operating cable from valve adaptor.
Strength)
5. Remove the screws 2 from the end cap 2.
Disassemble
6. Remove the locknut 3. Rotate the locknut 3 and
1. Remove the steer mode valve assembly from the the end cap 2 counterclockwise (so that the parts
machine. Refer to (PIL 25-09). travel away from the valve) until they disengage
the operating cable thread.
2. Remove the screws 1 from the end cap 1.
7. Disengage the operating cable from the steer
3. Remove the locknut 1. Rotate the locknut 1 and mode selector.
the end cap 1 counterclockwise (so that the parts
Figure 453.
H K
E
A
C D
A Screws 1 B End cap 1

C Locknut 1 D Locknut2
E Operating cable F Adaptor
G Screws 2 H End cap 2
J Locknut 3 K Steer mode selector
25 - 56 9813/9050-1 25 - 56
09 - Mode Valve
Assemble
following steps.
Figure 454.
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 454. 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 - 57 9813/9050-1 25 - 57
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 455. 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 216.
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 - 58 9813/9050-1 25 - 58
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-61
25 - 59 9813/9050-1 25 - 59
Notes:
25 - 60 9813/9050-1 25 - 60
12 - Column
00 - General
00 - General Figure 456.

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 - 61 9813/9050-1 25 - 61
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 - 62 9813/9050-1 25 - 62
15 - Proximity Switch
Contents Page No.
25-15-00 General ........................................................................................................................... 25-65
25 - 63 9813/9050-1 25 - 63
Notes:
25 - 64 9813/9050-1 25 - 64
00 - General
Introduction .................................................... 25-65 These are installed on machines with auto steer
Adjust ............................................................ 25-66 mode system or manual (indicated) mode system.
25 - 65 9813/9050-1 25 - 65
00 - General
Adjust Figure 458.
A
If the proximity switch is defective, replace it. Refer
to steering system- proximity switch, refer to (PIL
25-15).
For electrical operation and testing, refer to electrical

system- electronic diagnostic, refer to (PIL 33-57).
B
The proximity switch setting procedure is the same
for both the front and rear axles. Y
1. Align the wheels in the straight ahead position.

D
2. Check the alignment as shown in the figure. Set
the steering so that the dimension X is of the
specified value. D C
Figure 457.
A Target disc
B Proximity switch
X C Bracket
D Bolts
Y Distance between the sensor tip and the end of
the target disc
5. If the dimension is not correct, adjust the switch
as follows:
5.1. Loosen the bolts.
5.2. Move the bracket up or down to make
dimension Y correct.
5.3. Tighten the bolts.
5.4. Repeat the step 4 again.
X Wheel alignment dimension

3. Remove the proximity switch cover.
4. Measure the dimension Y between the sensor tip
and the edge of the target disc and make sure
that it is to the specified value.
25 - 66 9813/9050-1 25 - 66
00 - General
Remove and Install
Working Under the Machine Remove

Make the machine safe before getting beneath it. 1. Make the machine safe. Follow all the general
Make sure that any attachments on the machine are safety procedures. Refer to (PIL 01-03).
the ignition key, disconnect the battery. If the machine 2. Disconnect the harness electrical connector from
has wheels use blocks to prevent unintentional the switch electrical connector.
movement.
3. Remove the proximity switch cover.
The following procedure applies to each of the steer
4. Remove the bolt and nut that secure the
proximity switches on the front and rear axles.
proximity switch to the support bracket.
5. Remove the proximity switch from the support
bracket.
Figure 459.
C B
A Proximity switch B Nut

C Support bracket D Proximity switch electrical connector
25 - 67 9813/9050-1 25 - 67
00 - General
Install
Installation is the opposite of the removal procedure.
During the installation procedure do this below step
also.
1. Make sure to set the proximity switch air gap.
25 - 68 9813/9050-1 25 - 68
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-71
25 - 69 9813/9050-1 25 - 69
Notes:
25 - 70 9813/9050-1 25 - 70
00 - General

Check (Condition) .......................................... 25-71
Check Energiser Seals
Disassemble and Assemble .......................... 25-76 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 460.
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 461.
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 - 71 9813/9050-1 25 - 71
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 462.
25 - 72 9813/9050-1 25 - 72
00 - General
Remove and Install
10.5. Remove the adaptor 2.

Remove 10.6. Plug all the open ports and hoses to
11. At this point, if the power track rod is to be
2. Follow the general health and safety procedures dismantled, loosen the track rod link arms while
for the hydraulic system. Refer to (PIL 30-00). the track rod is still securely clamped. Refer to
3. Discharge the hydraulic pressure. Refer to (PIL steering system, Arm. Refer to (PIL 25-33).
30-00). 12. Remove the screw and the pin at each end
4. Turn the steering wheel to the left and to the right of the axle and separate the link arms from
several times to discharge the system pressure. their mounting points. Discard the two web seals
Make sure that the steering wheel is in the seated in the eye of each link arm.
straight ahead position. 13. Make alignment marks on the cylinder flange,
5. Before you start work, clean the area around the the end cover of the power track rod and on the
axle and the power track rod. housing flange of the axle.
6. Raise the front or the rear wheels from the 14. Remove the mounting screws 2 (x4).
ground with suitable lifting equipment. 15. If you work on the front axle, do the following
7. Block the chassis. steps:
8. Remove the front left or the rear right wheel as 15.1. Use suitable jacks to support both ends
applicable. of the axle and then remove the mounting
nuts from both ends. Leave the bolts in
9. If you work on the front axle, do the following position.
steps: 15.2. Lower the jack at the left end so that there
9.1. Put a label on the hoses to help installation. is sufficient room for removal of the power
track rod.
9.2. Disconnect hose 1 and hose 2 and then
remove the adaptor 1. 15.3. Use a soft-faced hammer to gently tap the
closed end of the track rod cylinder to the
9.3. Plug all the open ports and hoses to prevent left and out of its mounting.
contamination.
16. If you work on the rear axle, do the following
10. If you work on the rear axle, do the following steps:
steps:
16.1. Use a suitable jack to raise the left end of
10.1. Put a label on the hoses to help the axle so as to swivel the right end down
installation. to make room for removal of the power
10.2. Disconnect the pipe assembly from the track rod.
power track rod at the end point 1 and the 16.2. Use a soft-faced hammer to gently tap the
end point 2. closed end of the track rod cylinder to the
10.3. Remove the mounting screw 1. right and out of its mounting.
10.4. Remove the pipe assembly.
25 - 73 9813/9050-1 25 - 73
00 - General
Figure 463.
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 - 74 9813/9050-1 25 - 74
00 - General
Install
steps.
1.1. Apply grease and install the two new web
seals in each link arm eye. Make sure that
they are installed correctly and fully seated.
1.2. Apply grease to the machined external
shoulders of the power track rod. Install by
tapping with a soft-faced hammer on the
mounting flange.
1.3. Take care to align the marks made during
removal.
1.4. Check the steer proximity switch setting.
steering system. Refer to (PIL 25-00).

Item Description Nm
G Mounting screw 56
H Adaptor 2 56
J Screw 56
M Mounting screw 166
N Mounting nut 600
P Bolts 600
25 - 75 9813/9050-1 25 - 75
00 - General
Consumables 3. Remove the end cap and then pull the piston rod
Description Part No. Size assembly from the cylinder.
Cleaner/Degreaser 4104/1557 0.4L 4. Do not allow the piston rod to come into contact
- General purpose with the cylinder bore. The cylinder bore may be
solvent based parts damaged by careless dismantling.
cleaner
JCB Multi-Gasket 4102/1212 0.05L 5. Position the piston rod assembly on the bench in
place of the ram cylinder.
Use the alphabetical sequence shown on the
illustration as a guide to disassembly. Refer to Figure 6. Remove and discard the wear rings and the seal/
464. energising ring.
7. The piston head cannot be removed from the
Disassemble rod, if there is damage to the rod or piston head,
replace the complete assembly.
1. Fix the ram assembly on a locally manufactured
strip/ rebuild bench. 8. Carefully inspect the bore of the cylinder and the
piston rod outer diameter for scoring, nicks and
2. Remove the steering link arm 1 and the steering burrs. If damaged, install a new component.
link arm 2. Refer to steering system- track rod,
25 - 76 9813/9050-1 25 - 76
00 - General
Figure 464.
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 - 77 9813/9050-1 25 - 77
00 - General

F G E
H
E Wear ring 1
F Wear ring 2
G Seal
Figure 466. 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 466.
12. Make sure that the piston rod does not touch the
cylinder bore.
13. Engage the new piston head wear rings and
Assemble seals carefully into the cylinder.
1. Make sure all threads are free of grease, 14. If the piston head wear rings or the seals
hydraulic oil and sealant with the degreaser. are damaged during this stage, they must be
replaced.
purpose solvent based parts cleaner 15. When operating in conditions which are
consistently below freezing, it is recommended
2. Allow the degreaser to dry for 15 minutes and that the track rod is operated slowly to its full
then apply the sealant. extent in both directions before you start normal
Consumable: JCB Multi-Gasket working.
3. Make sure that the lubricants used during 16. Check the energiser seals. Refer to Front Track
assembly do not come into contact with the JCB Rod - Check Condition (PIL 25-18).
multi-gasket.
4. Install the piston rod seals and the wiper rings
correctly into the closed end of cylinder and into
the cover along with the cover seal.
5. Make sure that the energiser ring is not twisted.
6. If the installation is not correct, it may lead to
leakage of the hydraulic fluid between the two
sides of the power track rod and will cause
steering problems.
7. Make sure that three white marks are visible on
the outside diameter arrowed before install the
seal.Refer to Figure 467.
25 - 78 9813/9050-1 25 - 78
33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ........................................................................................................................... 25-81
25 - 79 9813/9050-1 25 - 79
Notes:
25 - 80 9813/9050-1 25 - 80
33 - Link Arm
00 - General
00 - General
Remove and Install
Consumables Figure 468.

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 468. and point2 and turn against each other until one
ball joint unscrews as shown. Refer to Figure
469.
3. For this explanation, assume the ball joint at
point1 is now loose, do as follows:
25 - 81 9813/9050-1 25 - 81
33 - Link Arm
00 - General
Figure 469.
A
B
A Point1 B Point2
25 - 82 9813/9050-1 25 - 82
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 470.
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 - 83 9813/9050-1 25 - 83
33 - Link Arm
00 - General
Figure 471.
X Distance1 Y Distance2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 84 9813/9050-1 25 - 84
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-06 Semi-Automatic Gearbox
27-06-00 General ............................................................................................................................. 27-7
27-06-06 Clutch - Reverse ............................................................................................................ 27-54
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-58
27-06-08 Clutch - Layshaft ............................................................................................................ 27-74
27-06-09 Clutch - Main Shaft ........................................................................................................ 27-83
27-06-11 Clutch - Forward (Input) ................................................................................................. 27-91
27-06-15 Solenoid Control Valve ................................................................................................. 27-101
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-106
27-06-24 Oil Pump ...................................................................................................................... 27-108
27-06-27 Speed Sensor .............................................................................................................. 27-110
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-116
27-06-33 Oil Temperature Sensor ............................................................................................... 27-119
27-06-39 Filter ............................................................................................................................. 27-124
27-06-40 Suction Strainer ............................................................................................................ 27-126
27-06-45 Piston Ring Seal .......................................................................................................... 27-128
27-06-47 Oil Seal ........................................................................................................................ 27-130
27-06-52 Driveshaft ..................................................................................................................... 27-132
27-06-54 Main Shaft .................................................................................................................... 27-133
27-06-56 Layshaft ........................................................................................................................ 27-136
27-06-57 Input Shaft .................................................................................................................... 27-137
27-06-58 Output Shaft ................................................................................................................. 27-138
27-06-81 Mount ........................................................................................................................... 27-145
27-06-85 Oil Feed Pipe ............................................................................................................... 27-146
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-147
27-06-90 Front Case ................................................................................................................... 27-148
27-06-91 Rear Case .................................................................................................................... 27-153
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-155
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-159
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-185
27-14-06 Control Valve ................................................................................................................ 27-193
27-14-09 Relief Valve .................................................................................................................. 27-195
27-20 Axle
27-20-00 General ......................................................................................................................... 27-199
27-20-15 Breather ........................................................................................................................ 27-221
27-20-81 Mount ........................................................................................................................... 27-222
9813/9050-1
2017-12-21
27-22 Drivehead
27-22-00 General ......................................................................................................................... 27-225
27-22-06 Crownwheel .................................................................................................................. 27-246
27-22-09 Pinion Gear .................................................................................................................. 27-248
27-24 Differential
27-24-00 General ......................................................................................................................... 27-251
27-27 Hub
27-27-00 General ......................................................................................................................... 27-263
27-27-66 Wheel Stud ................................................................................................................... 27-270
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-273
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-277
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-281
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-287
27-51-15 Shaft Hub Side ............................................................................................................. 27-289
9813/9050-1
2017-12-21
Acronyms Glossary
2WD Two Wheel Drive

LSD Limited Slip Differential
LSP Load Sense Pump
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PMV Pressure Maintenance Valve
PTFE Polytetrafluoroethylene
PTO Power Take-Off
RAS Rear Axle Stabilization
9813/9050-1
2017-12-21
Notes:
9813/9050-1
2017-12-21
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/9050-1 27 - 1
Notes:
27 - 2 9813/9050-1 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 9813/9050-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
Table 219. 531-70, 535-95 and 541-70

Item Feature
Transmission PS754
Front Axle SD 70 or 80 Trunnion mount, 3 piece, fixed or sway.
Front drive head 80 series 3 piece
Rear Axle SD 55 Trunnion mount, 1 piece
Rear drive head 55 series 1 piece
Front differential LSD or Maxtrac
(1)
Rear differential LSD or Maxtrac

(1)
Front hub 80 Series

Front swivels and drive shafts 55 Series
Front axle brakes 70 Series integral brakes
Rear swivels and drive shafts 55 Series
Rear axle brakes .
(1) If the LSD differential option is not installed, a JCB Maxtrac differential is installed.
27 - 4 9813/9050-1 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 472.
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 9813/9050-1 27 - 5
27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ............................................................................................................................. 27-7

27-06-06 Clutch - Reverse ............................................................................................................ 27-54
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-58
27-06-08 Clutch - Layshaft ............................................................................................................ 27-74
27-06-09 Clutch - Main Shaft ........................................................................................................ 27-83
27-06-11 Clutch - Forward (Input) ................................................................................................. 27-91
27-06-15 Solenoid Control Valve ................................................................................................. 27-101
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-106
27-06-24 Oil Pump ...................................................................................................................... 27-108
27-06-27 Speed Sensor .............................................................................................................. 27-110
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-116
27-06-33 Oil Temperature Sensor ............................................................................................... 27-119
27-06-39 Filter ............................................................................................................................. 27-124
27-06-45 Piston Ring Seal .......................................................................................................... 27-128
27-06-47 Oil Seal ........................................................................................................................ 27-130
27-06-52 Driveshaft ..................................................................................................................... 27-132
27-06-54 Main Shaft .................................................................................................................... 27-133
27-06-56 Layshaft ........................................................................................................................ 27-136
27-06-57 Input Shaft .................................................................................................................... 27-137
27-06-58 Output Shaft ................................................................................................................. 27-138
27-06-81 Mount ........................................................................................................................... 27-145
27-06-85 Oil Feed Pipe ............................................................................................................... 27-146
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-147
27-06-90 Front Case ................................................................................................................... 27-148
27-06-91 Rear Case .................................................................................................................... 27-153
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-155
27 - 6 9813/9050-1 27 - 6
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Introduction ...................................................... 27-7 Semi-automatic gearboxes are a hybrid form of
Technical Data ................................................. 27-8 transmission where an integrated control system
Component Identification ............................... 27-11 handles manipulation of the clutch automatically,
Operation ....................................................... 27-18 but the driver can still take manual control of gear
selection.
Fault-Finding .................................................. 27-26
Drain and Fill ................................................. 27-33 Many of these transmissions allow the driver to fully
Clean ............................................................. 27-34 delegate gear shifting choice to the control system,
Check (Condition) .......................................... 27-34 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
Check (Level) ................................................ 27-35 torque converter instead of a straight friction clutch
Check (Pressure) .......................................... 27-36 to manage the connection between the transmission
Remove and Install ....................................... 27-49 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.
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Technical Data
Table 220. 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) Limp Mode 4 (Repeating Error reading transmis-
beeps until ECU power sion speed
When applicable, the gearbox ECU provides is reset)
restricted or modified gearbox operation if faults are
Machine holds a gear If the ECU detects and
detected by the ECU. Typical 'limp mode' forms of
error with the speed
operation are shown here. Fault codes may also be
sensor while operating,
displayed on the instrument panel. For fault codes
it prevents autoshifting.
refer to (PIL 33-57-90).
On power up, the ECU will normally sound 3 beeps. Stall Speed Combinations
These beeps can be masked by other audible
warnings on start up. The tests carried out at the factory record the correct
engine r.p.m. (stall speed) when under maximum
Table 221. Gearbox 'Limp load from the transmission and hydraulic systems.
Modes' (Powershift Electronic Control).
The figures relate to tests conducted at an ambient
Mode Possible Reason temperature of 25°C (77.0°F) and barometric
Limp Mode 1 (2 beeps Internal 'setup data' pressure of 1bar (14.5psi)at sea level. The changes
at power up). ECU fault. in ambient temperature, pressure and humidity and
Machine autoshifts at If on power up the ECU fuel grade will affect engine power and hence the stall
different road speeds detects an internal fault figures.
than normal. with its 'set up' data, it
will revert to use of a de- For example, at 10,000 ft the power reduction of a
fault set of values. naturally aspirated engine could be 29% and for a
turbo engine 8%.
Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software. The figures apply to `bedded-in' engines, i.e. engines
Machine remains in neu- If on power up, the ECU that have done a minimum of 250 working hours.
tral at all times. detects an internal fault Therefore they should not be used for pre-delivery
with its 'core operating inspection (PDI) checks.
software' it will prevent
operation of the gear- All figures are recorded with the transmission oil
box. at 60°C (139.9°F) and the hydraulic oil at 55°C
Limp Mode 3 (Machine Error reading transmis- (130.9°F). Figures achieved should be within +/- 100
will not autoshift). sion speed. RPM (Revolutions Per Minute) from the figures given
in the table.
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.
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Table 222. 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 223. 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).
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Table 224. Oil Flow Rates

Flow Rates (in Flow Rate
neutral)
Cooler oil 1000 RPM 8–13
flow at 50°C
(121.9°F)
2000 RPM 19–25
Pump oil flow at 1000 RPM 11–15
50°C (121.9°F)
2000 RPM 22.5–29.5
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)).
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Figure 473.
Unit Identification
The gearbox serial number is stamped on the
unit identification plate as shown. When you make
an order for parts replacement, always quote the
details on the unit identification plate. In the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.
A Identification plate
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Main Component Identification
Figure 474. External components
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Item Description
13 Oil pump
Table 225.
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 - 13 9813/9050-1 27 - 13
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00 - General
Figure 475. 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 226.
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
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Item Description Item Description

10 Park brake caliper 18 Input shaft clutch as-
bracket sembly
11 Park brake caliper 19 Reverse shaft clutch as-
12 Output shaft support sembly
bearings (1) Permanent 4 wheel drive variants have a one-
13 Spacer piece shaft in place of the 2/4 wheel drive clutch
14 2/4 wheel drive clutch
(1) assembly.
15 Layshaft clutch assem- The internal component drawing is not a true
bly sectional view. It is drawn to show the main
16 Main shaft clutch as- components as clearly as possible
sembly
17 Output shaft
27 - 15 9813/9050-1 27 - 15
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Figure 476. Test Point
1 4
Test point Description

4 Forward high ratio clutch
Table 227.
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
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Test point Description Clutch Control Solenoids

8 Layshaft clutch pressure
Figure 477.
9 2/4 wheel drive clutch
pressure
3022
3021
3033
3041
3029
3040
Table 228.
Gear Clutches engaged Solenoids energised Refer to
Figure 477.
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
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Operation
which in turn energise the applicable gearbox control

Operation Overview solenoids.
The Powershift gearbox is an electro-hydraulic Joystick Gear Controls

transmission unit. Input from the engine is by
means of a torque converter. Gear shifting and Gear ratio selection can be controlled with the
direction selection are controlled by engaging and joystick ratio up (plus) and down (minus) buttons.
disengaging multi-disc clutch packs. Inputs from the buttons are connected to the
transmission ECU via the machine control ECU and
Electric solenoid valves divert pressurised oil the CANbus.
(provided by the gearbox oil pump) to the selected
clutch packs. A gearbox mounted ground speed sensor detects
the ground speed of the machine. Signals from the
Drive direction and gear ratio are selected by sensor are connected to the transmission ECU via
means of electrical control switches (typically a the machine control ECU and the CANbus. The ECU
steering column mounted lever and swivel switch). responds by preventing ratio selection if the machine
Inputs from control devices are connected to various ground speed is not within pre-set values.
ECU (Electronic Control Unit)s. The ECUs energise
the applicable electrical devices depending on the When the ratio up (plus) button is pressed the
machine status. The ECUs are connected to the transmission ECU selects the next (higher) gear
machine CAN (Controller Area Network)bus which ratio. When the ratio down (minus) button is pressed
enables integrated control of all the main machine the transmission ECU selects the next (lower) gear
systems. ratio
For ECU details refer to (PIL 33-45). Park brake on

Start up When the park brake is ON the park brake switch
state changes. Inputs from the switch are connected
Electrical interlocks prevent the engine being started, to the transmission ECU via the machine control
unless the transmission is set to neutral. ECU and the CANbus. The ECU selects Neutral
even if Forward or Reverse is selected. An audible
Drive Direction Control warning sounds.
A column switch controls the drive direction, forward, Transmission dump

neutral or reverse. Inputs from the switch are
connected to the transmission ECU via the CANbus The input from the transmission `dump' switch on the
which in turn energise the applicable gearbox control joystick is connected to the transmission ECU. When
solenoids. the switch is pressed the ECU selects Neutral even
if Forward or Reverse is selected.
Joystick Direction Controls
2/4 Wheel drive select
Drive direction can also be controlled with the joystick
F / N / R (Forward / Neutral / Reverse) direction A cab mounted switch controls 2 or 4 wheel drive
control switch. Inputs from the switch are connected selection. Inputs from the switch are connected to
to the transmission ECU via the joystick powerbase the machine control ECU which in turn energises
ECU and the CANbus. There is a logic control for the applicable gearbox control solenoid. The
drive direction selection. Selection of Forward or transmission automatically selects 4 wheel drive
Reverse with the column switch disables the joystick when the service brakes are applied.
direction control switch. Both the joystick and column
switch must first be set to Neutral before the joystick Transmission Oil Pressure and
direction control switch is enabled.
Temperature
Manual Gear Controls Oil pressure and temperature sensors are connected
to the machine instrumentation which displays the
A rotating barrel switch controls selection of the pressure and temperature status. Warning displays
gear ratios (1,2,3 or 4). Inputs from the switch are and fault codes are activated if the oil pressure or
connected to the transmission ECU via the CANbus temperature is not within pre-set values.
27 - 18 9813/9050-1 27 - 18
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00 - General
Drive paths Figure 480. 3rd gear forward
Forward A
Figure 478. 1st gear forward
F
A
Table 231.
Clutches engaged Solenoids energised
Forward low ratio (A) 3022
Table 229. Mainshaft (F) 3033
Forward low ratio (A) 3022 Figure 481. 4th gear forward
Layshaft (E) 3029
B
Figure 479. 2nd gear forward
F
B
Table 232.
Forward high ratio (B) 3021
Table 230. Mainshaft (F) 3033
Forward high ratio (B) 3021
Layshaft (E) 3029
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Reverse Figure 484. 3rd gear reverse
Figure 482. 1st gear reverse
C
C Table 235.
Table 233. Reverse low ratio (C) 3041
Mainshaft (F) 3033
Reverse low ratio (C) 3041 Figure 485. 4th gear reverse
Layshaft (E) 3029
Figure 483. 2nd gear reverse

F
Table 236.
D
Reverse high ratio (D) 3040
Mainshaft (F) 3033
Table 234.
Hydraulic operation and schematics
Reverse high ratio (D) 3040 The engine directly drives the oil pump through the
Layshaft (E) 3029 torque converter.
Oil from the pump is fed through an internal passage

via the filter to the PMV (Pressure Maintenance
Valve), which maintains pressure to the solenoid
valves for clutch selection. Excess oil from the
maintenance valve flows back through the case to
the torque converter. A relief valve controls pressure
in the converter and dumps oil from the converter line
back to the sump.
Oil from the torque converter flows out of the gearbox

to the external oil cooler (if installed) and again
27 - 20 9813/9050-1 27 - 20
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00 - General
comes back to the converter. Oil then flows through The reverse clutch assembly is also similar to the
internal oil ways providing lubrication for clutches forward clutch assembly. It contains two hydraulically
and bearings before it goes back to the gearbox operated clutches: one clutch gives a reverse low
sump. ratio drive and the other gives a reverse high ratio
drive. The reverse clutches are controlled by a
The torque converter is a fluid coupling bolted to three position solenoid valve. When the applicable
a drive plate which in turn is bolted to the engine solenoid is energised, pressurised oil is directed to
drive. As the engine starts to rotate, the converter either the reverse low (solenoid 3041) or reverse high
gives smooth power take off and gradually increases (solenoid 3040) clutch.
the torque transmitted. This torque is transferred
from the converter assembly to the clutch/gear Both the mainshaft and the layshaft assemblies have
assemblies through the input shaft on the forward a single clutch each. Both clutches are controlled
clutch assembly. by a three position solenoid valve. When energised,
solenoid 3029 directs pressurised oil to the layshaft
The forward clutch assembly contains two clutch and solenoid 3033 directs pressurised oil the
hydraulically operated clutches: one clutch gives a mainshaft clutch.
forward low ratio drive and the other gives a forward
high ratio drive. The clutches are controlled by a When a gear is selected through the control switch
three position solenoid valve. When the applicable in the cab, two clutches are always engaged. When
solenoid is energised, pressurised oil is directed to you select different pairs of clutches different gear
either the forward low (solenoid 3022) or forward high ratios are engaged. ECUs control the solenoids. All
(solenoid 3021) clutch. the clutches work on the same principle.
Figure 486.
K
U J Q
L
D C
V N
R
W P
B A
M
X
H
Y S1
F
S2 G S
Z 4
3
2
E
1
Table 237.
Item Description
A Forward low ratio clutch
B Forward high ratio clutch
C Reverse low ratio clutch
D Reverse high ratio clutch
E Layshaft assembly
27 - 21 9813/9050-1 27 - 21
27 - Driveline
00 - General
Item Description
F Mainshaft assembly
G Layshaft clutch
H Mainshaft clutch
J Pressure maintenance valve
K Relief valve
L Oil filter
M Forward clutch assembly
N Reverse clutch assembly
P Pump
Q Oil flows to the external oil cooler from the torque
converter
R External oil cooler
S Torque converter
T Oil flows back to the torque converter from the exter-
nal oil cooler
U Solenoid 3040
V Solenoid 3041
W Solenoid 3021
X Solenoid 3022
Y Solenoid 3029
Z Solenoid 3033
Forward and Reverse Clutch Operation The counter plates and friction plates are pressed
together by a hydraulically actuated piston. Drive
The forward and reverser clutch assembly transfers is then transmitted from the input shaft to the gear
drive from the input shaft to either gear 1 or gear 2 1. Clutch for gear 2 is disengaged and no drive is
depending on which of the two clutches is engaged, transmitted to gear 2 plate carrier. The gear is also
giving forward or reverse drive. free to rotate on the input shaft assembly.
When neither clutch is engaged, neutral is selected. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve. When
The clutches are of the wet, multi plate type. neutral is selected both solenoids are deactivated
and the flow of pressurised oil to the clutches is
The clutch housings and input shaft are a one piece blocked. The gear springs 1 and 2 move the pistons
assembly. The assembly is permanently driven by away from the clutch plates and oil from both pistons
the engine via the torque converter. is vented to the sump.
Clutch counter plates are also permanently driven When either forward or reverse is selected, the
via meshing teeth inside the clutch housings. Clutch solenoid control valve diverts pressurised oil via
friction plates are meshed with the gear plate cross drillings inside the input shaft to the appropriate
carriers. clutch piston in the unit. Pressure from the other
clutch is vented to the sump via the solenoid valve
In the diagram, clutch for gear 1 is engaged. spool. Oil is prevented from leaking by seals on the
pistons and ring seals on the input shaft.
27 - 22 9813/9050-1 27 - 22
27 - Driveline
00 - General
Figure 487.
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 - 23 9813/9050-1 27 - 23
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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 488.
D B E
A A1
3 2
1
A2 C
A Solenoid control valve A1 Solenoid 1

A2 Solenoid 2 B Clutch pack
C Piston D Springs
E Output yoke
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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 489.
D G B F E
A 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 F Actuating sleeve
G Pressure plate
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Fault-Finding
Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 238. Page 27-26
overheating.
Machine does not drive in any gear. Table 239. Page 27-27
Some gears fail to engage or lack power. Table 240. Page 27-28
Gearbox oil overheating. Table 241. Page 27-28
Noisy operation. Table 242. Page 27-29
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 243. Page 27-29
Cannot engage 2WD (Spring ON clutch). Table 244. Page 27-29
Gearbox oil contaminated with water. Table 245. Page 27-30
Consequential Faults (Gearbox faults caused typically by water Table 246. Page 27-30
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 249. Page 27-31
(Lock-up torque converter variants only).
Gear shifts fail to function normally- Sychroshuttle gearboxes only. Table 250. Page 27-31
Gear shifts fail to function normally or shifts occur at the incorrect road Table 251. Page 27-31
speed.
The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and Table 252. Page 27-31
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 238. Machine drives but lacks power in all gears. Gearbox oil may also be overheating.
Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Pressure maintenance valve defective. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the pressure maintenance valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the torque converter relief valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
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Cause Remedy
Oil cooler lines restricted or blocked. Internal Carry out oil pressure and flow tests. Refer to
blockage within the oil cooler matrix due to driveline- semi-automatic gearbox, refer to (PIL
contamination. 27-06).
Clear the restriction. Inspect the hose routing
and install new the hoses or oil cooler matrix as
applicable.
Faulty torque converter. Carry out torque converter stall tests to confirm stall
speeds are within specification. Refer to driveline-
Torque converter, refer to (PIL 27-14).
Remove the gearbox and install new the torque
converter. Note that the torque converter assembly is
a non serviceable item.
Failure of oil pump assembly. Carry out the oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect the oil pump for
signs of damage or excessive wear. Install new oil
pump as applicable.
Gearbox internal leakage fault. Carry out oil pressure and flow tests. Refer to
27-06).
Remove and disassemble the gearbox. Inspect all
components for signs of damage or excessive wear.
In particular, check the seals and install new as
applicable.
Table 239. Machine does not drive in any gear.

Cause Remedy
Park brake switch or transmission dump switch Check the function of the park brake switch and
defective. transmission dump switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Gear selector column switch defective. Check the function of the gear selector column
switch.
Clutch solenoid wiring defective Inspect the condition of the associated electrical
Low mainline oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new oil pump as
applicable.
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Table 240. 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 241. 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 - 28 9813/9050-1 27 - 28
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00 - General
Table 242. 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 243. 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 244. 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 - 29 9813/9050-1 27 - 29
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00 - General
Table 245. 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 246. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Pressurisation of gearbox casing. Dipstick blows out and oil escapes
from dipstick tube.
Cause Remedy
Water in the oil combined with heat from torque Replace or renew the dipstick.
converter causes steam. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Clutch failure due to friction lining separation.
Cause Remedy
Water ingress. Remove and dismantle gearbox. Inspect relevant
clutch components for signs of damage or excessive
wear. Install new as applicable.
Overheating transmission oil. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Badly worn or noisy bearings.
Cause Remedy
Water ingress. Remove and dismantle the gearbox. Inspect all
Install new components as applicable.
Insufficient lubrication. Drain the oil and flush the gearbox. Refer to
27-06).
Carry out oil pressure and flow tests. Refer to
27-06).
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Table 249. 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 250. Gear shifts fail to function normally- Sychroshuttle gearboxes only.
Cause Remedy
Cable shift mechanism faulty Adjust or replace gear shift cables as necessary.
Table 251. 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 252. 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 - 31 9813/9050-1 27 - 31
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Cause Remedy
Gearbox ECU defective. (In response to certain Use the ECU Diagnostics software to check the
faults the ECU will enter a `Limp Mode'. For a ECU inputs and outputs. Refer to electrical system-
detailed description of the Limp Modes, refer electronic diagnostic, refer to (PIL 33-57).
to `Service Procedures - Powershift Gearbox, Inspect the condition of the associated electrical
Electronic Control Unit'.) wiring, plugs and connectors for damage and check
Install new ECU. (The ECU is inherently reliable.
It is protected internally from electrical damage.
It is housed in a rugged case for protection from
mechanical damage and ingress of dirt and moisture.
Faults with associated systems are more likely to be
caused by wiring or other input and output device
failure. Before renewing the ECU make sure beyond
reasonable doubt that it is faulty.)
27 - 32 9813/9050-1 27 - 32
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Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30min
Transmission Oil and Filter
14. Allow the machine to cool then drain the
Refer to driveline, semi-automatic gearbox, Filter, transmission oil through the suction strainer
(PIL 27-06-39). aperture. Refer to (PIL 27-06-40).
15. Test the oil for contamination. If the oil is still
Transmission Oil Suction Strainer contaminated, repeat the flushing procedure
Refer to driveline, semi-automatic gearbox, Suction from step 3
Strainer, (PIL 27-06-40). 16. If the oil is clean:
Flushing the Transmission Oil 16.1. Replace the suction strainer. Refer to (PIL
27-06-40).
1. If the transmission oil has been contaminated
with water or incorrect oil types, the transmission 16.2. Install a new oil filter. Refer to (PIL
must be flushed to effectively remove the 27-06-39).
contaminated oil. 16.3. Fill the transmission with the correct grade
of fresh oil. Refer to (PIL 75-00)
2. Park the machine and make it safe.
16.4. Check the oil level and top up as required.
3. Drain the oil from the gearbox. Refer to (PIL Refer to (PIL 27-06-00).
27-06-40).
4. Remove the suction strainer. Refer to (PIL
27-06-40).
5. Clean the suction strainer and install. Refer to
(PIL 27-06-40).
6. Replace the oil filter. Note that the filter may be
remotely mounted on some installations. Refer to
(PIL 27-06-39).
7. Fill the transmission with the correct grade of
fresh oil. Refer to (PIL 75-00).
8. Check the oil level and top up as required. Refer
to (PIL 27-06-00).
9. Start the engine and run the machine until the
normal operating temperature is as specified.
Temperature: 50–100°C (121.9–211.9°F)
10. Stall the torque converter for the specified
duration. Refer to (PIL 27-14).
Duration: 5s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5min
12. Repeat step 10.
27 - 33 9813/9050-1 27 - 33
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00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
solvent based parts Strength)
cleaner
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 - 34 9813/9050-1 27 - 34
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00 - General
5.4. Re-assemble the pump. Check (Level)

Figure 490.
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 - 35 9813/9050-1 27 - 35
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 497. • 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 - 36 9813/9050-1 27 - 36
27 - Driveline
00 - General
Figure 491. Test points
A D
H
Item Description
F Reverse high ratio clutch
Table 253. 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 - 37 9813/9050-1 27 - 37
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Mainline pressure 2.1. A low reading can be caused by either

a faulty pressure maintenance valve or a
1. Stop the engine, connect a pressure gauge of the worn pump. Refer to Figure 492.
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 492.
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 492.
pressure gauge will show the main line pressure.
Refer to Figure 492. 4. Stop engine and remove the test gauge. Refer to
Figure 492.
27 - 38 9813/9050-1 27 - 38
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Figure 492. Pump flow test
A
L
X Y Z
P
Q
N
27 - 39 9813/9050-1 27 - 39
27 - Driveline
00 - General
Special Tool: Flowmeter (Qty.: 1)
Table 254. 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 492.
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 492.
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 492.
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 492.
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 492. 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 492. 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 493.
492.
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 492. 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 493.
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 492. a pump flow test. Refer to Figure 493.
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 493.
to the correct torque value. Refer to Figure 2.3. Low pressure could be caused by a faulty
492. pump or internal leakage. Refer to Figure
3.4. Type 'z': With the component parts 493.
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 493.
to Figure 492.
3.5. Connect the flowmeter to the flow and
return adapters (shown with arrows). Refer
to Figure 492.
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27 - Driveline
00 - General
Figure 493. Converter in, converter relief valve pressure tests

S
C Converter inlet and converter relief valve S Load valve

pressure test point
27 - 41 9813/9050-1 27 - 41
27 - Driveline
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Converter relief (safety valve) pressure does not indicate a fault. If necessary reset the
load valve and perform the test again, carefully
The purpose of the torque converter relief valve is watch the pressure gauge. Refer to Figure 493.
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 493.
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 493.
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 493.
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 493.
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 493. • 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 493. 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 494.
valve pressure setting. Refer to Figure 493.
2. Carefully remove the spring. Refer to Figure 494.
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 494.
27 - 42 9813/9050-1 27 - 42
27 - Driveline
00 - General
Figure 494. 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 494. 494.
5. Do not damage the spool and its seat. Refer to Duration: 1min
Figure 494.
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 494. 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 - 43 9813/9050-1 27 - 43
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 495.
converter out line. Refer to Figure 495.
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 495.
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 495.
Figure 495.
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 495.
in neutral. Refer to Figure 495.
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 495.
Figure 495. 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 - 44 9813/9050-1 27 - 44
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 495. 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 495. record the pressure readings. Refer to Refer to
Table 255.
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 495. 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 255.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 496. 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 255.
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 - 45 9813/9050-1 27 - 45
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Figure 496.
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 496.
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 496.
the specified to the mainline pressure test point.
Refer to Figure 496. 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 496.
to Figure 496.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 496.
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 496. the gauges is still greater than the specified
27 - 46 9813/9050-1 27 - 46
27 - Driveline
00 - General
value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 496. readings are different than the value
mentioned in step 7 then calibrate the
gauges and again do the check. Refer to
Figure 496.
27 - 47 9813/9050-1 27 - 47
27 - Driveline
00 - General
Figure 497. Transmission Technical Data Checklist
27 - 48 9813/9050-1 27 - 48
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 498.
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 - 49 9813/9050-1 27 - 49
27 - Driveline
00 - General
Figure 499.
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 - 50 9813/9050-1 27 - 50
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 - 51 9813/9050-1 27 - 51
27 - Driveline
00 - General
table lists all the service procedures for the gearbox.

Before following some of the procedures, remove For some procedures it is necessary to do other
the gearbox from its machine installation. Refer to procedures first, these are shown in the table.
the correct machine service documentation. The
Table 256. 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).
18 Main shaft Clutch - Disassemble. 11
Refer to (27-06-54).
19 Main shaft Clutch - Assemble. Re- -
fer to (27-06-54).
27 - 52 9813/9050-1 27 - 52
27 - Driveline
00 - General
Serial No. Procedure Name Do these procedures first

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.
27 - 53 9813/9050-1 27 - 53
27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse Introduction

Introduction .................................................... 27-54 A clutch is a mechanical device that engages and
Check (Condition) .......................................... 27-55 disengages drive, from driving shaft to driven shaft.
Check (Pressure) .......................................... 27-55
Remove and Install ....................................... 27-56 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 - 54 9813/9050-1 27 - 54
27 - Driveline
Check (Condition) Check (Pressure)

Special Tools
Carry out a visual inspection of the friction and Description Part No. Qty.
counter plates: Hand Pump Pressure 892/00223 1
Test
Counter plates Pressure Test Adaptor 993/59300 1
1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored 1. Assemble the 2 and 4 wheel drive clutch. Refer to
must be replaced with a new set. the relevant Clutch- Disassemble and Assemble
procedure (PIL 27-06).
Friction plates 2. Check the clutch pack end float and adjust
as required. Refer to the relevant Clutch -
1. The cross hatching should be clearly visible, Disassemble and Assemble procedure (PIL
plates that are not flat, have friction material 27-06).
damage or scoring must be replaced with a new
set. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
2. DO NOT mix old and new plates, if a plate is and 4 wheel drive clutch shaft as shown. Hold the
damaged or worn install a complete new set. adaptor in position with clamp.
3. Needle roller bearings should slide into position Special Tool: Pressure Test Adaptor (Qty.: 1)
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings. 4. Use the hand pump (892/00223) to pressurise
the clutch assembly until the gear can be turned
4. Take care when handling disc springs to avoid by hand. Note the pressure gauge reading. Do
marking or damage, which could result in stress not exceed the given value.
cracking. If in doubt install a new disc spring.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5. If the pressure gauge reading is between
the given values, then the clutch is operating
correctly and can be installed in the gearbox.
Pressure: 8.6–9.3bar (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 - 55 9813/9050-1 27 - 55
27 - Driveline
Figure 500. Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, main shaft
clutch and forward / input clutch are all part of the
main shaft assembly.
Refer to the main shaft remove and install procedure.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 56 9813/9050-1 27 - 56
27 - Driveline
Refer to Clutch-Input, Disassembly and Assembly

(PIL 27-06-11).
27 - 57 9813/9050-1 27 - 57
27 - Driveline
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Introduction

Component Identification ............................... 27-59 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-62
Check (Pressure) .......................................... 27-62 Each gear on the gearbox has an associated clutch
Disassemble and Assemble .......................... 27-64 When the solenoid is engaged fluid is applied to the
shaft.

27 - 58 9813/9050-1 27 - 58
27 - Driveline
For: PS750 MK4 ....................... Page 27-59

For: PS750 MK4 ....................... Page 27-60
(For: PS750 MK4)
Figure 501. 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)
U O-ring 2 (Shaft)
27 - 59 9813/9050-1 27 - 59
27 - Driveline
(For: PS750 MK4)
Figure 502. 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 - 60 9813/9050-1 27 - 60
27 - Driveline
Figure 503. S2 Spring ON

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16
1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
16 O-ring 1 17 O-ring 2
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve
22 Clutch drum 23 Shaft
27 - 61 9813/9050-1 27 - 61
27 - Driveline
Check (Condition) Check (Pressure)

Special Tools
Do a visual check of the friction and counter plates Description Part No. Qty.
and gears: 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 one. the relevant Clutch- Disassemble and Assemble
Friction plates 2. Check the clutch pack end float and adjust
as required. Refer to the relevant Clutch -
1. The lubrication slots should be clearly visible, Disassemble and Assemble procedure (PIL
plates that are not flat, have friction material 27-06).
one. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
2. Do not change individual 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
The piston consists of a small check valve. Visually by hand. Note the pressure gauge reading. Do
check the piston to make sure that the ball is in not exceed the given value.
place and that the seat is free from contamination. Pressure: 13.8bar (200.0psi)
If necessary clean the valve by blowing through with Special Tool: Hand Pump Pressure Test (Qty.: 1)
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat. 5. If the pressure gauge reading is between
the given values, then the clutch is operating
Gears correctly and can be installed in the gearbox.
Pressure: 8.6–9.3bar (124.6–134.8psi)
1. Check the gear teeth for wear, cracking or
damage. 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 - 62 9813/9050-1 27 - 62
27 - Driveline
Figure 504. Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, mainshaft
clutch and forward / input clutch are all part of the
mainshaft assembly.
Refer to the mainshaft remove and install procedure.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 63 9813/9050-1 27 - 63
27 - Driveline
For: PS750 MK4, Pressure ON

................................................... Page 27-64
For: PS750 MK4, S1, Spring ON
................................................... Page 27-67
For: PS750 MK4, S2, Spring ON
................................................... Page 27-70
(For: PS750 MK4, Pressure ON)

Special Tools
Hand Pump Pressure 892/00223 1
Test
Disassemble
Figure 505.
G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A
27 - 64 9813/9050-1 27 - 64
27 - Driveline

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 Figure 506.

replaced.
2. Carefully remove the piston ring seal.
2.1. Note: If the piston ring seal is damaged
or excessively worn then check for burrs
or damage on shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
3. With a puller or press, remove the 4WD gear and
splined hub, together with its bearing 2, needle
roller bearing and thrust washer 1.
4. Remove the thrust washer 2.
4.1. Note the thrust washer 1 and thrust washer
2 are not interchangeable. 9. Lift off the spring retaining plate.
5. Remove the circlip 1 that retains the friction and 10. Remove the spring and oil baffle.
counter plates.
11. Turn the assembly over and knock the clutch
6. Remove the pressure end plate and shim (If shaft on a piece of aluminium (or wood) to loosen
applicable). the piston.
7. Remove the friction plates and the counter 11.1. If the piston does not loosen, then hand
plates. pump air down the shaft oil inlet hole.
7.1. Keep them together in sets, do not mix the Special Tool: Hand Pump Pressure Test
plates with those from other clutches. (Qty.: 1)
8. Put the clutch assembly in a suitable press. Figure 507.
8.1. With a cut away tube compress the piston

spring and remove the circlip 2.
12. Remove the piston.

13. Remove and discard the piston O-ring 1.
27 - 65 9813/9050-1 27 - 65
27 - Driveline
14. Remove and discard the shaft O-ring 2. Figure 508.
Assemble
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 13. If it is necessary to adjust the end float to bring it
install the circlip 2. within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
7. Install one counter plate followed by one friction end plate, with either a shim or an extra counter
plate. plate between the retaining circlip 1 and the
pressure end plate.
7.1. Continue to install alternate counter and
friction plates, finishing with a friction plate. 14. Use an air line to check the operation of the
clutch.
8. Install the pressure end plate. Make sure the
chamfered face of the pressure end plate faces 15. Install the thrust washer 2.
the clutch pack.
16. Carefully align the teeth of the clutch plates with
9. Make sure that the teeth are not aligned with the a thin rod (or screwdriver) and install the 4WD
lubrication slots in the housing. gear and splined hub, needle roller bearings and
thrust washer 1.
10. Do not install the shim at this stage.
17. Apply gearbox oil on the clutch end bearing 2 and
11. Install the friction and counter plate retaining press the bearing onto the shaft to seat on the
circlip 1. thrust washer 1.
12. With a DTI (Dial Test Indicator) measure the end 18. Install the new piston ring seals.
float of the pressure end plate. The value should
be within the specified range.
Dimension: 1.9–2.5mm
27 - 66 9813/9050-1 27 - 66
27 - Driveline
(For: PS750 MK4, S1, Spring ON)
Disassemble
Figure 509.
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 - 67 9813/9050-1 27 - 67
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 510.
6.1. Keep them together in sets, do not mix the
plates with those from other clutches.
7. Remove the clutch drum retaining circlip 2 and
support washer.
8. Remove the clutch drum and the actuating
sleeve.
9. Remove the disc spring 2.
10. Remove the piston and its spring steel ring.
11. Remove and discard the piston O-ring 1 and O-
ring 2.
CAUTION! The spring (or springs) apply
12. If necessary, remove the piston housing. The
considerable force. Make sure you take care to
piston housing is a press fit on the shaft.
avoid damage or injury.
Assemble 14. Use a suitable press to compress the disc spring
and install the circlip 1.
1. Lubricate the shaft.
15. Use levers to remove free play.
2. Install the piston housing by pressing the shaft
squarely into the housing (make sure the housing
is securely supported).
3. Install the O-ring 1 and O-ring 2 onto the piston.
4. Lubricate the piston with oil and press fully into
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 - 68 9813/9050-1 27 - 68
27 - Driveline
Figure 511. 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 - 69 9813/9050-1 27 - 69
27 - Driveline
(For: PS750 MK4, S2, Spring ON)
Disassemble
Figure 512.
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
9 Disc spring 1 (x4) 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
27 - 70 9813/9050-1 27 - 70
27 - Driveline
21 Actuating sleeve 22 Clutch drum

23 Shaft
1. Carefully remove the piston ring seal from the Figure 513.
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 514.
6. Remove the thrust washer 2.
7. Use a suitable press on the output end of the
shaft and push the clutch drum with its related
bearing 2, thrust washer 3, piston housing, and
actuating sleeve.
8. Remove the disc springs 2.
18 19
9. Remove the piston and its spring steel ring.
18 Piston
10. Remove and discard the piston O-ring 1 and O- 19 Spring steel ring
ring 2.
5. Use a suitable press to assemble the shaft to the
Assemble piston housing and clutch drum as follows:
1. Install the needle roller bearing 1 and needle 5.1. Place the thrust washer 3 on the press.
roller bearing 2 to the 4WD gear in the correct Arrange the press so that the shaft can
orientation. pass through the thrust washer a sufficient
distance during assembly.
1.1. One end of the bearing has a rounded 5.2. Put the piston housing and piston assembly
profile and the other end has a flat profile. centrally on the thrust washer.
5.3. Put the disc spring 2 in position.
27 - 71 9813/9050-1 27 - 71
27 - Driveline
Figure 515. 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 516.
Figure 518.
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 517. 7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
Figure 519.
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 - 72 9813/9050-1 27 - 72
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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 520. 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.

avoid damage or injury.
12. Use a suitable press to compress the disc springs

1 and install the retaining circlip.
13. Use levers to remove the free play.
Figure 521.
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08 - Clutch - Layshaft
08 - Clutch - Layshaft Introduction

Check (Condition) .......................................... 27-77
Calibrate ........................................................ 27-77 Each gear on the gearbox has an associated clutch
shaft.

27 - 74 9813/9050-1 27 - 74
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Figure 522.
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 - 75 9813/9050-1 27 - 75
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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 - 76 9813/9050-1 27 - 76
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Check (Condition) Calibrate
Do a visual check of the friction and counter plates: End float measurement
Counter plates 1. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate.
that are not flat, worn or heavily marked or scored 2. The end float should be within the specified limit.
must be replaced with a new one. Dimension: 1.9–2.5mm
Friction plates Figure 523.
1. The cross hatching should be clearly visible,

plates that are not flat, have friction material
one.
2. Do not change individual plates, if a plate is A
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
the cage has been distorted install new bearings.
The piston consists of a small check valve. Visually

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
it can damage the valve seat.
A DTI
3. If the end float is more than the specified value
then install 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.
4. Use an air line to check the operation of the
clutch.
27 - 77 9813/9050-1 27 - 77
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Remove and Install
The layshaft clutch, 2WD / 4WD clutch, reverse

clutch, mainshaft clutch and forward / input clutch are
all part of the mainshaft assembly.

27 - 78 9813/9050-1 27 - 78
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Disassemble
Figure 524.
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 - 79 9813/9050-1 27 - 79
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C 4 wheel drive transfer gear D Taper roller bearing 2

E Piston housing F Spring retaining plate
G Spring H Oil baffle
J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
N Thrust washer 1 P Thrust bearing 1
Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
1. Carefully remove the piston ring seals. 11. Remove the thin thrust washer 2 and thrust
bearing 2.
1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 12. Remove the circlip 2 that retains the friction
grooves. If necessary remove burrs with a plates and counter plates.
fine grade abrasion paper and oil.
13. Remove the outer pressure end plate and shim
2. Remove the taper roller bearing 1 with a suitable (if installed).
puller and press.
14. Remove the friction plates and the counter
2.1. This bearing would not normally be plates.
removed unless it was damaged. It is
permissible to use a standard bearing 14.1. Keep them together in sets, do not mix the
puller, although damage to the bearing cage plates with those from other clutches.
may be incurred which will require a new
bearing. 15. Remove the inner pressure end plate.
3. From the opposite side of the shaft, use a 16. Remove the piston.
suitable puller to remove the 4WD transfer gear 17. Remove and discard the O-ring 3 from the piston.
(if applicable) and the taper roller bearing 2.
3.1. The gear and bearing 1 are under pressure Assemble
from the spring, make sure you proceed
with caution. 1. Install the O-ring 3 onto the piston.
3.2. Make sure to remove the thrust washer 2. 2. Lubricate the piston with oil and press fully into
3.3. Make a record of the orientation of the gear
for ease during assembly. 3. Install the inner pressure end plate. Make sure
3.4. The 2 wheel drive machines have a spacer that the teeth are not aligned with the lubrication
installed instead of a gear. slots in the housing.
4. Lift off the piston housing complete with clutch 3.1. Note: The inner pressure end plate is 4 mm
pack. (0.157 in) thick and should not be confused
with the outer pressure end plate which is
5. Lift off the spring retaining plate. either 6 mm (0.23 in) or 6.5 mm (0.25 in)
thick.
6. Remove the spring and the oil baffle.
4. Install one friction plate followed by one counter
7. Remove and discard the O-ring 1 and O-ring 2 plate.
from the shaft.
4.1. Continue to install alternate friction and
8. Remove the circlip 1. counter plates, finishing with a friction plate.
9. Remove the gear and the splined hub together 5. Install the outer pressure plate.
with the thrust washer 1, thrust bearing 1, and
thin thrust washer 1. 5.1. Make sure that the flatter of the two faces is
installed outermost. It will face against the
10. Remove the two needle roller bearing retaining circlip 2 when this is installed.
assemblies.
27 - 80 9813/9050-1 27 - 80
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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 526.
Figure 525.
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.
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21.3. Use an air line to check the operation of

the clutch.
22. Apply gearbox oil onto the taper roller bearing 1
and install the bearing onto the shaft.
23. Install the new piston ring seals.
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09 - Clutch - Main Shaft
09 - Clutch - Main Shaft Introduction

Check (Condition) .......................................... 27-86
Remove and Install ....................................... 27-86 Each gear on the gearbox has an associated clutch
When the solenoid is engaged fluid is applied to the
shaft.

27 - 83 9813/9050-1 27 - 83
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Figure 527.
M
N
P J
K
L
Q
G
B
A
27 - 84 9813/9050-1 27 - 84
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Table 257.
Item Description
A Piston ring seals
B Taper roller bearing 1
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
N Piston
P O-ring 1 (Piston)
Q O-ring 2 (Shaft)
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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).
must be replaced with a new one.
Friction plates
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material
one.
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
the cage has been distorted install new bearings.
The piston consists of a small check valve. Visually

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
it can damage the valve seat.
27 - 86 9813/9050-1 27 - 86
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Special Tools
Hand Pump Pressure 892/00223 1
Test
27 - 87 9813/9050-1 27 - 87
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Disassemble
Figure 528.
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 - 88 9813/9050-1 27 - 88
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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 530.
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
7. Put the clutch assembly in a suitable press.
1. Install the new O-ring 1 onto the piston.
spring and then remove the circlip 2. 2. Install the new O-ring 2 onto the shaft.
Figure 529. 3. Lubricate the piston with oil and press fully into
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.
friction plates, finishing with a friction plate.
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 - 89 9813/9050-1 27 - 89
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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.
Figure 531.
13. If it is necessary to adjust the end float to bring it

within tolerance, there is a choice of installing a
end plate, with either a shim or an extra counter
plate between the retaining circlip 1 and the
pressure end plate.
14. Use an airline to check the operation of the
clutch.
15. Apply gearbox oil to the taper roller bearings 1
and 2.
16. Install the bearings onto the shaft.
17. Install new piston ring seals.
27 - 90 9813/9050-1 27 - 90
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11 - Clutch - Forward (Input)
11 - Clutch - Forward (Input) Introduction

Clean ............................................................. 27-94
Check (Condition) .......................................... 27-94 Each gear on the gearbox has an associated clutch
shaft.

27 - 91 9813/9050-1 27 - 91
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Figure 532.
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
Table 258.
Item Description
A Piston ring seal 1
B Clutch end bearing
C Gear
D Needle roller thrust bearing 1
27 - 92 9813/9050-1 27 - 92
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Item Description
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 - 93 9813/9050-1 27 - 93
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Consumables
Description Part No. Size Carry out a visual inspection of the friction and
Surface Cleaning Fluid 4103/1204 1L counter plates:
1. Carefully remove all traces of gasket or gasket Counter plates

compound from the front and rear case mating
faces. 1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
1.1. Use a gasket removal product such as must be replaced with a new set.
Loctite Chisel when you remove the gasket
compound. Friction plates
1.2. Make sure that the mating faces are not 1. The cross hatching should be clearly visible,
damaged. plates that are not flat, have friction material
1.3. Clean the mating faces with a fine damage or scoring must be replaced with a new
carborundum paper. set.
1.4. Use a solvent cleaner and a clean cloth to 2. DO NOT mix old and new plates, if a plate is
finally remove all traces of oil or debris. damaged or worn install a complete new set.
Consumable: Surface Cleaning Fluid 3. Needle roller bearings should slide into position
2. Use a suitable degreasing agent to clean the freely, do not bend or distort the cage to install. If
inside of the case. the cage has been distorted install new bearings.
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
cracking. If in doubt install a new disc spring.
27 - 94 9813/9050-1 27 - 94
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Remove and Install
The layshaft clutch, 2WD / 4WD clutch, reverse

all part of the mainshaft assembly.

27 - 95 9813/9050-1 27 - 95
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Special Tools Description Part No. Qty.

Description Part No. Qty. Spring Compressor 892/00916 1
Hand Pump Pressure 892/00223 1 Tool
Test
27 - 96 9813/9050-1 27 - 96
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Disassemble
Figure 533.
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 - 97 9813/9050-1 27 - 97
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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 534.

1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft
grooves. If necessary remove burrs with a
fine grade abrasion paper and oil.
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.
Special Tool: Hand Pump Pressure Test
10. Put the clutch assembly in a suitable press. (Qty.: 1)
spring and then remove the circlip 2.
27 - 98 9813/9050-1 27 - 98
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Figure 535. 8. Install one counter plate followed by one friction

plate.
friction plates, finishing with a friction plate.
9. Install the pressure end plate. Make sure the
chamfered face of the pressure end plate faces
the clutch pack.
10. Make sure that the teeth are not aligned with the
lubrication slots in the housing.
12. Install the friction and counter plate retaining
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 536.

remove the piston ring seals 2.
18. Remove the bearing 2 with a suitable puller.
19. Remove the thrust bearing 3, thick thrust washer
2 and thin thrust washer 3.
20. Remove the gear and splined hub 2 assembly
with the needle roller bearing 2.
21. Do the steps 5 to 16 to disassemble the clutch
assembly.
Assemble
14. If it is necessary to adjust the end float to bring it
1. Install the new O-ring 1 onto the piston. within tolerance, there is a choice of installing a
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.
install the circlip 2.
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 - 99 9813/9050-1 27 - 99
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22. To assemble the opposite clutch do the steps 1

to 19.
23. Carefully align the teeth of the clutch plates using
a thin rod (or screwdriver) and install the gear and
splined hub 2.
24. Install the needle roller bearing 2.
25. Install the thrust bearing 3, thick washer 2, and
thin washer 3.
install the gear and bearing 2 onto the shaft.
27. Install the new piston ring seals 2.
27 - 100 9813/9050-1 27 - 100

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15 - Solenoid Control Valve
15 - Solenoid Control Valve Introduction

Introduction .................................................. 27-101 The solenoid control valves provides the switching
Check (Condition) ........................................ 27-102 for forward drive and reverse drive to select the
Remove and Install ..................................... 27-102 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 - 101 9813/9050-1 27 - 101

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Consumables
If damage to any component or distortion of the Description Part No. Size
spool is evident the complete valve assembly must JCB Transmission Fluid 4000/2601 5L
be renewed. Great care should be taken when EP SAE 30
dismantling and assembling the valve to avoid the 4000/2605 20L
following: 4000/2603 200L
• Contamination There are two types of solenoid installed.

• Damage to spools
• Damage to seal grooves Solenoid valve - nut retained - this has a nut securing
the solenoid coil to the stem.
Any of the above may result in possible problems
with the operation of the valve. Solenoid valve - bolt retained - the solenoid is
enclosed in a metal casing and the casing is bolted
to the transmission housing.
Solenoid Valve - Nut retained

The procedure for the solenoid control valves is
the same. The following procedure is for one valve.
The gearbox shown has three solenoid valves, other
gearbox variants may contain a different quantity of
valves.
Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector (if
installed) at the solenoid coil 1 and coil 2.
3. Record the position of the solenoid coil electrical
connectors on the valve stem.
4. Clean the area around the solenoid valves. Do
not allow particles of grit to fall into the gearbox..
5. Remove the nut, coil 1, spacer and coil 2. Make
sure that you record the orientation of the spacer
for correct installation.
6. Clean the area around the valve stem and the
gearbox case to prevent contamination of the
gearbox. Plug all the open ports and hoses to
7. Remove the valve stem from the gearbox case.
27 - 102 9813/9050-1 27 - 102

27 - Driveline
Figure 537. gauze is defective, replace the valve with a new

one.
4. Inspect the O-ring seals for damage. Refer to
Check Condition (PIL 27-06-15).
5. Put some clean gearbox oil on the O-ring seals.
Consumable: JCB Transmission Fluid EP SAE
30
6. Use an extended socket to tighten the valve stem
to the correct torque value. Refer to Table 259.
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 259.
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 - 103 9813/9050-1 27 - 103

27 - Driveline

Item Nm
L F 6
J 27
K L 6
N
K Electrical harness connector
L Retaining bolts
M Valve
N O-ring seals
Install
steps.
2. Replace the O-ring seals.
3. Put some clean gearbox oil on the O-ring seals.
Consumable: JCB Transmission Fluid EP SAE
30
4. Install the solenoid in the correct orientation.
Refer to Table 259.
27 - 104 9813/9050-1 27 - 104

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Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due
to a fault in the system.
The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.
27 - 105 9813/9050-1 27 - 105

27 - Driveline
21 - Pressure Maintenance Valve (PMV)
21 - Pressure Maintenance Valve

(PMV)
Remove and Install
2. Do not allow particles of grit to fall into the

Remove gearbox.
1. Clean the area around the valve and the gearbox 3. Remove the plug then the sealing washer, the
case. spring and the valve spool.
Figure 539.
B
C
D
A Plug B Sealing washer

C Spring D Valve spool
27 - 106 9813/9050-1 27 - 106

27 - Driveline
21 - Pressure Maintenance Valve (PMV)
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
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27 - Driveline
24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) ........................................ 27-108
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 540.
A
B
C
A Screw
B Oil seal
C Pump housing
4. Make sure that the seal housing is not damaged.
5. Install a new seal.
6. Install the seal the correct way around. Push the
seal flush with the front of the housing.
7. Assemble the pump again.
8. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.
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27 - Driveline
24 - Oil Pump
Remove and Install 5. Install the bolts together with the new sealing
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 261. Torque Values

Item Nm
1. Clean the area around the pump. Do not allow
any dirt or contamination to fall into the gearbox. A 28
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 541.
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.
(Medium Strength)
27 - 109 9813/9050-1 27 - 109

27 - Driveline
27 - Speed Sensor
27 - Speed Sensor Introduction

Introduction .................................................. 27-110 The sensor sends a varying frequency signal to
Component Identification ............................. 27-111 the Transmission ECU to determine the current
Operation ..................................................... 27-112 rotational speed of the input shaft or torque
Diagram ....................................................... 27-113 converter. The ECU uses the input shaft speed to
determine the slippage across the torque converter
Remove and Install ..................................... 27-114 and potentially to determine the rate of slippage
across the clutches. This information is vital to
regulate the application of the torque converter lock-
up clutch smoothly and effectively.
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27 - Driveline
27 - Speed Sensor
Figure 542. Location
A
A Ground speed sensor
Wires and Connectors
Figure 543. 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 - 111 9813/9050-1 27 - 111

27 - Driveline
27 - Speed Sensor
Operation
Machines with PS766 and PS750 transmission have

a Ground Speed Sensor and an Input Speed Sensor.
Machines with PS750 transmission only use the

Ground Speed Sensor.
Ground Speed Sensor Operation

The ground speed sensor is a magnetic induction
type. The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The ground speed sensor installation senses the

rotation of the gearbox output gear.
The speed sensor incorporates two sensor elements

and a dual output signal to enable diagnosis if there
is a disagreement between the two sensor outputs.
Input Speed Sensor Operation

The input speed sensor is a magnetic induction type.
The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The input speed sensor senses the rotation of the

gearbox input shaft via the reverse clutch driven
gear.
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27 - Driveline
27 - Speed Sensor
Diagram
3 Signal A - output (white)

Figure 544. Ground Speed 4 Signal B - power (orange)
Sensor Internal Schematic 5 Signal B- earth (brown)
1 6 Signal B - output (yellow)
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 545. 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
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27 - Driveline
27 - Speed Sensor
Remove and Install
4. Remove the screw 1.

Speed sensors are installed depending on the
machine application. The gearbox has provision for 5. Remove the speed sensor 1 from the housing.
two speed sensors.
Install
Speed sensor 1 1. Installation is the opposite of the removal
procedure. At the time of installation do the
Remove following steps.
1. If connected, disconnect the speed sensor 2. If the O-ring 1 is damaged replace it with a new
electrical connector. one.
2. Clean the area around the speed sensor. 3. Install the screw 1.
3. Do not allow particles of grit to fall into the 4. Tighten the screw 1 to the correct torque value.
gearbox.
Figure 546.
B
A
G B
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27 - Speed Sensor
Table 262.
Item Description
A Speed sensor 1
B Speed sensor 2
C Screw 1
D O-ring 1
E Screw 2
F O-ring 2
G Shims or spacers
Speed sensor 2
Remove
1. If connected, disconnect the speed sensor
2. Clean the area around the speed sensor.
gearbox.
4. Remove the screw 2.
5. Remove the speed sensor 2 from the housing.
6. If installed remove the shims or the spacers with
the sensor 2.
Install
1. Installation is the opposite of the removal
following steps.
2. If the O-ring 2 is damaged replace it with a new
one.
3. If the spacers or the shims were removed replace
them correctly.
4. The speed sensor may be damaged or fail to
operate correctly if it is not at the correct distance
inside the housing.
5. Install the screw 2.
6. Tighten the screw 2 to the correct torque value.

Item Description Nm
C Screw 1 28
E Screw 2 12
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30 - Oil Pressure Sensor
30 - Oil Pressure Sensor Introduction

Introduction .................................................. 27-116 The transmission pressure sensor is a form of switch
Component Identification ............................. 27-117 that closes an electrical contact when a certain
Remove and Install ..................................... 27-117 set pressure has been reached on its input. The
switch may be designed to make contact either on a
pressure rise or on a pressure fall.
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Component Identification Remove and Install

Remove
1. Clean off all debris, dirt and grit from around the
pressure switch.
A
2. There must be no signs of debris, dirt or grit
inside the gearbox.
3. Remove the pressure switch and discard the
sealing washer.
4. Put caps on all the open ports of the gearbox.
Figure 549.
A Transmission Oil Pressure Switch

Figure 548. Wires and Connectors
A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch
A Pressure switch
B Sealing washer
Install
1. Installation is the opposite of the removal
following steps.
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2. The oil pressure switch is non serviceable. If it is

faulty or damaged, it must be replaced with new
one.
4. Tighten the pressure switch to the correct torque
value.

Item Description Nm
A Pressure switch 16
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27 - Driveline
33 - Oil Temperature Sensor
33 - Oil Temperature Sensor Introduction

Introduction .................................................. 27-119 The transmission oil temperature sensor sends
Technical Data ............................................. 27-120 an analog signal to the instrument panel ECU
Component Identification ............................. 27-121 (Electronic Control Unit) to warn if the transmission
Remove and Install ..................................... 27-123 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 - 119 9813/9050-1 27 - 119

27 - Driveline
Technical Data
Table 265. 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
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27 - Driveline
B A
A Transmission Oil Temperature Sender B Transmission Oil Cooler
27 - 121 9813/9050-1 27 - 121

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Figure 551. Wires and Connectors
2 1
1 2
Figure 552.
ECU
A Transmission ECU (Electronic Control Unit)

B Transmission Oil Temperature Sender
27 - 122 9813/9050-1 27 - 122

27 - Driveline
Remove and Install
Remove
Figure 553.
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). 4. Tighten the sender to the correct torque value.
Refer to Table 266.
2. Access to the transmission oil cooler is made
easier if the engine cover base is removed. Refer Table 266. Torque Values
to (PIL 06-06-06).
Item Nm
3. Clean off all debris, dirt and grit from around the B 27
sender.
4. Disconnect the harness electrical connector from
the sender.
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.
2. The sender is non serviceable. If it is faulty or
damaged, it must be replaced with new one.
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27 - Driveline
39 - Filter
39 - Filter Introduction
Introduction .................................................. 27-124 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-125 contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.
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27 - Driveline
39 - Filter
Remove and Install Consumable: JCB Transmission Fluid EP SAE

30
Special Tools
Description Part No. Qty. 2. Screw the filter on until it just contacts the filter
head.
Oil Filter Removal Tool 892/00292 1
3. Turn the filter at least another 3/4 of a turn.
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20L
4000/2603 200L
For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).
Remove
1. Clean the area around the filter. Do not allow
particles of grit to fall into the gearbox.
2. If required, use a strap wrench to loosen the oil
filter.
Special Tool: Oil Filter Removal Tool (Qty.: 1)
3. Remove and discard the filter.
Figure 554.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
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27 - Driveline
40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................. 27-126 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-127 large and coarse particles entering the transmission
system.
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27 - Driveline
Remove and Install Table 267. Torque Values

Item Nm
Consumables
Description Part No. Size B 12
Strength)
Remove
1. Clean the area around the strainer. Do not allow
2. Place a container, of suitable size beneath the
suction strainer. Remove the bolts. Remove the
strainer and the gasket. Allow the oil to drain into
the container. Be aware that the oil may be hot.
Refer to Gearbox, Drain and Fill (PIL 27-06).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 555.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
2. Apply JCB Threadlocker and Sealer to the
threads of the bolts. Tighten the bolts to the
(Medium Strength)
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27 - Driveline
45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................. 27-128 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-129 the outer diameter of a piston
27 - 128 9813/9050-1 27 - 128

27 - Driveline
45 - Piston Ring Seal
Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Assemble procedure (PIL 27-06).
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 556.
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 557.
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 - 129 9813/9050-1 27 - 129

27 - Driveline
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................. 27-130 Oil seals close spaces between components in
Remove and Install ..................................... 27-131 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.
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27 - Driveline
47 - Oil Seal

1. Make sure that the oil seal interface on the yoke
Remove is clean and free from wear or damage.
1. Bend back the stake nut locking ring. 2. Install a new oil seal. Locate the seal in the
position shown, the seal does not locate to the
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
3. Lubricate the lips of the oil seal.
3. Remove the oil seal. Do not damage the seal
housing. 4. Install the yoke, refer to Gearbox, Yoke- Remove
and Install (27-06-95).
Figure 558.
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 - 131 9813/9050-1 27 - 131

27 - Driveline
52 - Driveshaft
52 - Driveshaft
Introduction
The driveshaft is a mechanical component for

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.
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27 - Driveline
54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-133 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-134 and transmits the power to other components in the
Remove and Install ..................................... 27-134 gearbox.
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 133 9813/9050-1 27 - 133

27 - Driveline
54 - Main Shaft

1. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
Remove
or damage is evident, the components must be 1. Carefully lift out the clutch/shaft assemblies in the
renewed. following order.
2. Make sure that all oil way cross drillings are clear 1.1. Layshaft clutch assembly.
and free from debris. Blocked oil ways are a
common cause of bearing failure. If necessary 1.2. 2/4 wheel drive clutch or the permanent
use an air line to blow through the oil ways. 4WD (Four Wheel Drive) shaft, as
applicable.
Figure 559.
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.
Clutch Disassemble and Assemble

Procedures
For detailed disassemble and assemble procedures
refer to the following procedures:
• Reverse clutch - refer to (PIL 27-06-06)
27 - 134 9813/9050-1 27 - 134

27 - Driveline
54 - Main Shaft
• 2WD (Two Wheel Drive) / 4WD clutch - refer to 3. Install the correct bearing outer cups 2 to the
(PIL 27-06-07) clutch shaft bearings.
• Layshaft clutch - refer to (PIL 27-06-08)
• 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 560.
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
2.3. With the help of an assistant slightly raise
and tilt the input clutch and main shaft
clutch, install the reverse clutch.
2.4. Install the 2/4 wheel drive clutch or
permanent 4WD shaft, as applicable.
2.5. Install the layshaft clutch.
27 - 135 9813/9050-1 27 - 135

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 - 136 9813/9050-1 27 - 136

27 - Driveline
57 - Input Shaft
57 - Input Shaft
Introduction
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 137 9813/9050-1 27 - 137

27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-138 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-139 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-140 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 - 138 9813/9050-1 27 - 138

27 - Driveline
58 - Output Shaft
Calibrate
Refer to the individual Remove and Install tasks of

the Output Shaft for the calibration procedure.
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27 - Driveline
58 - Output Shaft
Remove and Install

Setting Tool Kit 892/00918 1 B
A
Spacer Kit 921/52600 1
End Float Setting Tool 993/70100 1
Kit
(10-100Nm) D
Remove H E
Before removing the output shaft and its bearings

remove all the clutch assemblies. J
1. Remove the output shaft as follows: Refer to

Figure 561. K
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).
1.4. Remove the output shaft.
1.5. Remove and discard the oil seal.
1.6. Remove the outer taper roller bearing.
F
1.7. Remove the spacer and keep for assembly.
1.8. Use a suitable puller to remove the output
shaft inner bearing. G
C
1.9. If required, the park brake bracket can
be removed at this stage. Before removal,
mark the position of the bracket with respect
to the case.
1.10. Note: Due to different ratio options, some A Brake disc
gearboxes may have a larger diameter B Output shaft nut
output gear. When you remove the output C Output shaft
shaft the gear may touch the gearbox D Oil seal
housing, preventing removal. Refer to E Outer taper roller bearing
Section- Output Shaft Removal- Larger F Spacer
Diameter Gears within this procedure. G Inner taper roller bearing
H Bolt 1
J Park brake bracket
K Rear case
Install
1. If removed, the park brake bracket must be
installed at this stage as follows: Refer to Figure
562.
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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 563. 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 564.
Special Tool: Setting Tool Kit (Qty.: 1)
27 - 141 9813/9050-1 27 - 141

27 - Driveline
58 - Output Shaft
3.2. Tighten the service tool nut to the correct Figure 565.
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 564.
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
269.
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 565. 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 566.
27 - 142 9813/9050-1 27 - 142

27 - Driveline
58 - Output Shaft
Figure 566. 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 269. 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 - 143 9813/9050-1 27 - 143

27 - Driveline
58 - Output Shaft
Figure 567.
C C
1
2
B
1 Output shaft
2 Taper rollers
3 Bearing outer cup
A Gear
B Position 1
C Spacers
Note: If the output shaft is being removed after initial

assembly, typically to set the end float, take extreme
care to avoid damage to the bearing outer cup and
inner cup and taper rollers. Use only soft spacers
such as aluminium, Do not use hardened steel items
such as screwdrivers.
If the bearing is damaged a new bearing MUST be

installed. The tolerance difference between the new
bearings is expected to be less than the difference
between the solid spacer sizes so changing a
bearing should not affect the end float.
27 - 144 9813/9050-1 27 - 144

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 - 145 9813/9050-1 27 - 145

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 568.
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 - 146 9813/9050-1 27 - 146

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 569.
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 - 147 9813/9050-1 27 - 147

27 - Driveline
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-148
Check (Condition) ........................................ 27-149
Remove and Install ..................................... 27-149 - 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.
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27 - Driveline
90 - Front Case

JCB Threadlocker 4101/0250 0.01L JCB Multi-Gasket 4102/1212 0.05L
Strength) Before removal
1. If the gearbox cases are to be renewed, be Before splitting the front and rear case do the
sure to install blanking plugs and adaptors as following procedures.
required. Inspect the original cases and identify
the blanking plug and adaptor positions. Transfer • Remove the oil filter. Refer to (PIL 27-06-39).
the plugs and adaptors to the new cases. Apply
JCB Threadlocker and Sealer to the threads • Remove the suction strainer. Refer to (PIL
before installation. 27-06-40)
Consumable: JCB Threadlocker and Sealer • Remove the solenoid control valves. Refer to
(Medium Strength) (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 - 149 9813/9050-1 27 - 149

27 - Driveline
90 - Front Case
Figure 570. 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 572.
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 571.
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 - 150 9813/9050-1 27 - 150

27 - Driveline
90 - Front Case
Before installation Figure 574.

• 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 573.
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.
Consumable: JCB Multi-Gasket
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 - 151 9813/9050-1 27 - 151

27 - Driveline
90 - Front Case
Figure 575.
E Case fixing screws (x22)

F Rear case
G Front case
5. If necessary rotate the output shaft a small
amount to align the splines.
6. Apply sealant to the threads of the case fixing
bolts and install them.
After installation
Install the external oil feed pipe.

Item Description Nm
E Case fixing screws 56
27 - 152 9813/9050-1 27 - 152

27 - Driveline
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-153 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-154
27 - 153 9813/9050-1 27 - 153

27 - Driveline
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).
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27 - Driveline
95 - Coupling Yoke 4WD
95 - Coupling Yoke 4WD Introduction

Introduction .................................................. 27-155 The drive yoke is an important component of a
Remove and Install ..................................... 27-156 driveshaft assembly. The drive yoke assembly allows
a driveshaft or PTO (Power Take-Off) to flex or slip
with their given application. The drive yoke is also
essential for allowing u-joints to rotate properly with
the driveshaft.
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27 - Driveline
Special Tools
Drive Coupling 892/00812 1
Spanner
Remove
1. Bend back the stake nut locking ring.
2. Clean the area around the yoke. Do not allow
3. Use service tool 892/00812 to hold the yoke and
at the same time undo the nut. The nut is very
tight, the help of an assistant will be required.
Discard the nut.
Special Tool: Drive Coupling Spanner (Qty.: 1)
4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
the seal housing.
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
Install
1. Make sure that the oil seal interface on the yoke
is clean and free from wear or damage.
2. If necessary install a new oil seal. Locate the seal
in the position shown, the seal does not locate to
the back of the housing.
3. Lubricate the lips of the oil seal.
4. Install the yoke.
5. Install the stepped washer the correct way
around with the plan face facing the stake nut as
shown.
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27 - Driveline
6. Install a NEW stake nut. Tighten to the correct

torque value.
7. Stake the nut to the shaft using a square ended
staking tool, as shown.

Item Nm
B 400
27 - 157 9813/9050-1 27 - 157

27 - Driveline
12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-159
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27 - Driveline
00 - General
Introduction .................................................. 27-159 The transfer gearbox is a system of gears used in
Component Identification ............................. 27-160 4WD (Four Wheel Drive) vehicles, which transfers
Clean ........................................................... 27-163 torque from the transmission to the front and rear
Check (Condition) ........................................ 27-163 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Calibrate ...................................................... 27-164 wheels.
Disassemble and Assemble ........................ 27-173 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 - 159 9813/9050-1 27 - 159

27 - Driveline
00 - General
order for parts replacement, always give the details

Unit Identification mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
The gearbox serial number is stamped on the unit stamped on the gear, and the number of teeth.
identification plate as shown. When you make an
27 - 160 9813/9050-1 27 - 160

27 - Driveline
00 - General
Figure 577. 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 - 161 9813/9050-1 27 - 161

27 - Driveline
00 - General
Table 275.
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 - 162 9813/9050-1 27 - 162

27 - Driveline
00 - General

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 - 163 9813/9050-1 27 - 163

27 - Driveline
00 - General
Calibrate
Figure 578.
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 - 164 9813/9050-1 27 - 164

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 580.
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 579.
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 276. 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 - 165 9813/9050-1 27 - 165

27 - Driveline
00 - General
Figure 581. Table 276. 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 582.
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 582.
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 - 166 9813/9050-1 27 - 166

27 - Driveline
00 - General
2. With the gearbox under load, rotate the gears in Figure 584.
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
583. ) in mesh with the bevel gear do the
following:
Figure 583.
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 584. ) 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 - 167 9813/9050-1 27 - 167

27 - Driveline
00 - General
Method B
Figure 585.
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 277. 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 585.
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.
277. and Refer to Table 278.. When you note down Table 278. 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 277. AK Pinion assembly deviation 17
AL Pinion gear deviation +60
AP
(1)
=77
27 - 168 9813/9050-1 27 - 168

27 - Driveline
00 - General
Item Description Devia- Figure 586.

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
279.
Table 279.
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 280.
Table 280.
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 587.

deviations. Refer to Table 281.
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 281. - 27
27 - 169 9813/9050-1 27 - 169

27 - Driveline
00 - General
Table 281.
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 587.
If the case deviation markings are not visible it will Figure 588.
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 282.
Old = 40.65
New = 40.32
Result = -0.33
Table 283.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Difference = +0.1
Add difference from Refer to Table = -0.33
282.
Result = -0.23
27 - 170 9813/9050-1 27 - 170

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 589.
A Flywheel housing bolts
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27 - Driveline
00 - General
Install
removal procedure.

Item Nm
A 70
27 - 172 9813/9050-1 27 - 172

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 590.
suitable wooden blocks to securely support the
assembly.
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken. Wash the
exterior of the gearbox assembly, refer to Transfer
Gearbox-Clean (PIL 27-12).
Make sure you note the orientation of the mounting

bushes if their replacement is required. Use a
suitable tube to press the outer steel ring of the
bushes during removal/installation of the mounting
bushes. Make sure the new bushes are installed in
their correct orientation and are positioned properly
in the housing bosses.
Disassemble the gear assembly as follows (For X

Machines before 2011).
1. Remove the pinion drive gear assembly. 1.10. Remove the bearing cups from the pinion
gear housing.
1.1. Remove the bolts 1 that attach the
pinion drive gear assembly to the gearbox 1.11. Put a suitable drift through the two holes
housing. in the pinion gear and then remove the
bearing2 from the gear.
1.2. If necessary, use a jacking bolt in the tapped
extraction holes on the pinion gear housing. 2. Remove the bevel gear assembly.
1.3. Remove the shim set 1 and put a label as 2.1. Remove the bolts 2 that attach the bevel
'for use with the pinion gear assembly.' gear assembly to the gearbox housing.
1.4. Use a reaction block to hold the gear 2.2. If necessary, use a jacking bolt in the tapped
assembly in a vice. extraction holes on the bevel gear housing.
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27 - Driveline
00 - General
2.3. Remove the shim set 2 and put a label as Figure 591.
'for use with the bevel gear assembly.'
2.4. Use a reaction block to hold the gear
assembly in a vice.
Special Tool: Reaction Block Fixture (Qty.:
1)
2.5. With a heavy duty socket of the specified
value, remove the stake nut 2.
Dimension: 46mm
Special Tool: Heavy Duty Socket 46mm A/
F (Qty.: 1)
2.6. Remove the washer, drive flange 1, and the
O-ring 3.
2.7. Remove the bevel gear. Make sure you also
remove the bearing 3 and spacer 3.
X
2.8. Remove the triple-lip seal 2 and the O-ring
4.
2.10. Remove the bearing cups from the bevel
2.9. Important: If the bearings or the gear gear housing.
assembly is to be replaced, measure and
record the dimension as shown below. 2.11. Put a suitable drift through the two holes
Make sure you use suitable measuring in the pinion gear and then remove the
equipment with an accuracy of the specified bearing 4 from the gear.
value.
Dimension: 0.01mm
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27 - Driveline
00 - General
Figure 592. Gearbox (Before 2011)

AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1

C Pinion gear housing D Extraction holes
E Shim set 1 F Nut 1
G Spacer 1 H O-ring 1
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00 - General
J Pinion gear K Bearing 1

L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange 1 Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
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27 - Driveline
00 - General
Assemble Figure 593.
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 594.
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 592.
Torque: 0.5–1.5N·m 3. Assemble the bevel gear assembly (for
2.11. Remove the nut 1 and the spacer 1. machines before 2011).
2.12. Install the new O-ring 1. 3.1. Check the bevel gear assembly end float.
2.13. Install a new triple lip seal 1 with a 3.2. Press the inner bearing 4 onto the bevel
suitable mandrel. Make sure that the seal gear.
is installed correctly in its housing.
3.3. Install the spacer 3 selected in step 3.1.
2.14. Carefully install the spacer 1 inside the
triple lip seal 1. Make sure that the outer 3.4. Install the pinion gear and the bearing 4 into
lip of the seal is against the housing. the bevel gear housing.
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27 - Driveline
00 - General
3.5. Install the inner bearing 3 onto the bevel 3.18. Do not stake the nut 2 at this stage.
gear.
3.19. Measure the rolling torque. Make sure
3.6. Use the reaction block to hold the bevel the rolling torque is between the specified
gear assembly in a vice. value.
Special Tool: Reaction Block Fixture (Qty.: Torque: 0.5–2.5N·m
1)
3.20. Excessive rolling torque indicates an
3.7. Install the drive flange 1, washer, and the incorrectly installed seal.
nut 2.
3.21. For figure, Refer to Figure 592.
3.8. Tighten the nut 2 to the correct torque value
with a socket of the specified dimension. Table 285. Torques (Before 2011)
Dimension: 46mm Item Torque
3.9. Do not stake the nut 2 at this stage. B 85
F 300
3.10. Measure the bearing rolling torque. Make
sure the rolling torque is between the S 85
specified value. W 300
Torque: 0.5–1.5N·m
Machines (After 2011)
3.11. Remove the nut 2, washer, and the drive
flange 1. Disassemble
3.12. Install the new O-ring 3.
Disassemble the gear assembly as follows (for
3.13. Install a new triple lip seal 2 with a machines after 2011).
suitable mandrel. Make sure that the seal
is installed correctly in its housing. 1. Remove the bolted bevel gear assembly.
3.14. Carefully install the drive flange 1 inside 1.1. Remove the screws that attach the adaptor
the triple lip seal 2. Make sure that the to the drive flange.
outer lip of the seal is against the housing.
1.2. Remove the adaptor.
Figure 595.
assembly in a vice.
1)
1.4. Remove the set screw.
1.5. Remove the drive flange.
1.6. Remove the pinion gear.
1.7. Remove the triple lip seal and the O-ring 2.
3.15. Use the reaction block to hold the 1.8. Remove the O-ring 1.
assembly in the vice.
1.9. Remove the bearing and spacer.
1) 1.10. Put a suitable drift through the two holes
in the pinion gear and then remove the
3.16. Install the washer and the nut 2. bearing 8 from the gear.
3.17. Tighten the nut 2 to the correct torque
value with a socket of the specified
dimension.
Dimension: 46mm
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27 - Driveline
00 - General
Figure 596. 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 597.
assembly in a vice.
1)
1.2. Remove the stake nut.
1.3. Remove the pinion gear from the bearing
carrier.
1.4. Remove the triple lip seal 3 and the O-ring
5.
1.5. Remove the O-ring 6.
1.6. Remove the bearing 6 and spacer 5.
1.7. Put a suitable drift through the two holes
in the pinion gear and then remove the
bearing 6 from the gear.
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00 - General
Figure 597. Bevel Gear Assembly (Nut) AM Spacer 4

AN Stake nut 3
AP O-ring 6
AQ O-ring 5
Make sure you do not discard any component at this

stage.
Inspect the gearbox assembly. Refer to (PIL 27-12).
AN
AM
AQ
AL
AK
AP
AJ
AH
AG
AG Pinion gear 2
AH Bearing 6
AJ Spacer 5
AK Bearing 5
AL Triple lip seal 3
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00 - General
Figure 598. 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.
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27 - Driveline
00 - General
1.3. Pack the cavity between the seal lips with 1.17. Excessive rolling torque indicates an
the correct grease before assembly. incorrectly installed seal. Renew the seal
if it is damaged.
1.4. Select a bearing spacer to achieve the
specified preload. 1.18. Install the adaptor. Tighten the fastenings
to the correct torque. Refer to (PIL 72).
1.5. Press the bearings into the bearing carrier 2. Assemble bevel pinion drive gear (nut). (For
Make sure you install the spacer. Refer to machines after 2011). Refer to Figure 597.
Figure 598. and Refer to Figure 597.
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 599. 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
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 600.
1.12. If the seal drag is within limits, tighten the
setscrew to the specified torque value.
Torque: 395N·m
the rolling torque is between the specified
value.
1.14. Use the reaction block to hold the bevel
2.10. Install the O-ring 6.
1.15. Install the set screw and tighten it to the
specified torque value. 2.11. Use the reaction block to hold the bevel
Torque: 395N·m
1.16. Measure the rolling torque. Make sure 1)
value. 2.12. Take up the free play on the stake nut. Do
not stake the nut.
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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 601.
3. Install the bevel gear assemblies into the

gearbox case. Tighten the bolts to the correct
torque value.
4. Measure the correct thickness required for the
bevel gear assembly shim sets 1 and 2.
5. Important: Correct gear meshing and backlash
settings are essential for the reliable operation of
the gearbox. The settings are obtained by means
of variable shim stacks. Three methods of shim
selection are used which depends on the parts
replaced during assembly:
5.1. Method A: Assembly using all the original
components.
5.2. Method B: Assembly using complete
new gear/bearing assemblies or gearbox
casing.
5.3. Method C: Shim pack thickness can be
calculated by comparing relevant sizes of
old and replacement components and then
adjusting the shim pack accordingly. This
method must be used when you replace the
taper roller bearings. It can also be of use if
some deviation markings are not visible.
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27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ......................................................................................................................... 27-185

27-14-06 Control Valve ................................................................................................................ 27-193
27-14-09 Relief Valve .................................................................................................................. 27-195
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Introduction .................................................. 27-185 The torque converter is a type of fluid coupling that
Component Identification ............................. 27-186 is used to transfer rotating power from the engine to
Operation ..................................................... 27-186 a rotating driven load.
Check (Operation) ....................................... 27-187
The torque converter normally takes the place of
Remove and Install ..................................... 27-191 a mechanical clutch in a vehicle with an automatic
transmission, allowing the load to be separated from
the power source.
It is usually located between the engine flywheel and

the transmission.
The key characteristic of a torque converter is its

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.
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27 - Driveline
00 - General

Figure 602. The torque converter is similar to a fluid coupling,
which utilises the centrifugal force exerted in the
transmission oil to transmit power from the engine to
D the gearbox. It multiplies the torque from the engine
and functions as a combined clutch and infinitely
variable reduction gearbox.
The torque converter is enclosed in a casing and

consists of three basic parts, the impeller, reaction
member and turbine.
A
The impeller is driven by the engine.
B The reaction member does not rotate. Its hub
engages with a splined tube on the gearbox oil pump
and is held stationary.
The turbine is engaged with the splined end of the

G C gearbox input shaft.
The impeller driven by the engine, forms one set

of shaped blades, it can be likened to a centrifugal
pump imparting energy to the transmission oil. This
F E energy is transferred to another set of shaped
blades, which form the turbine. The turbine is
connected to the gearbox and converts the energy
back to a mechanical torque.
H
When the impeller is rotating faster than the turbine,
the fixed reaction member causes some of the
energy in the oil to be transferred back to the impeller.
This has the effect of multiplying the torque available.
When the impeller (input) is running much faster

than the turbine (output) there is a substantial
circulation of transmission oil around the blades. The
oil circulation is maximum when the turbine (output)
is stalled, and is almost zero when the impeller and
turbine speeds are equal i.e. the ratio is near 1:1.
If the turbine (output) is stalled whilst the impeller
(input) is revolving, all the power is dissipated as
A Impeller heat.
B Turbine
C Reaction member Because of the absence of a direct mechanical
D Drive plate (engine driven bevel gearbox) connection between the engine and the gearbox,
E Drive to gearbox input shaft the flexibility of the torque converter drive greatly
F Spline location for reaction member reduces wear on the transmission, absorbing shocks
G Direct drive from the engine to the gearbox oil and torsional vibration from the engine. The engine
pump cannot be stalled due to overload, as the fluid
H Direction of oil flow coupling slips.
For illustration refer to Component Identification (PIL

27-14-00).
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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 603.
The purpose of the stall test is to check the The check list will help the engineer to identify the
performance of the transmission by stalling the cause of a gearbox fault, and if required, can be sent
to the JCB Technical Service Team via e-mail.
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27 - Driveline
00 - General
Figure 603.
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27 - Driveline
00 - General
Procedure 4. When fully engaged, the park brake electrically

disconnects the transmission drive. This
The purpose of the stall test is to check the prevents the machine from being driven with
performance of the transmission by `stalling' the the park brake on. Therefore, so that we can
torque converter. This is the point at which, due to complete the test, move the park brake lever
torque applied by the engine, the torque converter fractionally forward until the warning light is just
stops transmitting drive to the gearbox. The engine extinguished.
speed at which `stalling' occurs is compared to
speeds recorded for a machine in normal condition. 5. Hold the lever in this position for the duration of
Abnormal stall speed results can be used to identify the test.
possible faults as follows: 6. Do not move the lever too far forward, otherwise
the park brake will not be fully operational.
1. Poor engine performance
7. Do not disconnect the switch at the park brake.
2. Faulty torque converter
8. Select the 1st speed forward drive and open
3. Faulty gearbox hydraulic clutches
throttle fully. Record the engine speed from the
4. Faulty torque converter relief valve tachometer.
5. Transmission hydraulic leaks 9. Repeat the test in reverse drive.
6. Faulty hydraulic system relief valves 10. Repeat the test with the machine in each
configuration as described in the stall data tables.
For normal stall speed values refer to driveline- semi- Refer to driveline- semi-automatic gearbox, refer
automatic gearbox, refer to (PIL 27-06). to (PIL 27-06).
Do not stall the converter for longer than 10 seconds 11. For the machines with powershift gearboxes,
or the transmission fluid will overheat. Make sure repeat the test in 2nd and 3rd gears in both
that the oil level is correct and at normal operating forward and reverse drive.
temperature.
12. All recorded readings should be as specified.
If the machine is installed with a variflow hydraulic Refer to driveline- semi-automatic gearbox, (PIL
pump, make sure that the hydraulic oil temperature is 27-06).
above 50°C (121.9°F). Also make sure that the valve
block LSRV (Load Sense Relief Valve) pressure and Interpreting the Test Results
the variflow pump Delta P pressure are set correctly.
If all the engine speeds are below the stated figures
Before completing the following test, remove the either the engine is losing power and should be
transmission dipstick. If there is any sign of serviced/ overhauled or the torque converter reaction
smoke emitting from the dipstick tube stop the member clutch is slipping. To check the engine,
test immediately and dismantle the transmission for select neutral, open throttle fully and operate a
servicing. hydraulic service to 'blow off' the main relief valve.
Engine speed should fall to slightly below the
1. Check all engine fluid levels. Run the engine at maximum governed speed. Refer to (PIL 15-00). If
maximum speed and check the no load speed. engine speed is correct the torque converter reaction
Refer to Engine, General, General, Technical member clutch is slipping.
Data, (PIL 15-00-00).
If all the engine speeds are higher than the stated
2. Make sure that the engine and transmission are figures in all gears the torque converter safety relief
at normal working temperature (the transmission valve may be faulty. Alternatively there may be
oil must be above the specified temperature). internal oil leakage.
Run engine at maximum speed and check the
engine speed is correct (High Idle/ maximum If the engine speeds are higher than the stated
governed speed). Refer to engine- general, refer figures in some gears, check the transmission for
to (PIL 15-00). clutch slippage or internal leakage.
The example given below shows how the results can
3. Apply the park brake and foot brake firmly. be used to isolate a suspect clutch.
If necessary, set the machine against a fixed
obstruction.
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27 - Driveline
00 - General
Table 286.
Stall Test Results- 4 Speed Powershift
Gear Clutches engaged
Forward RPM (Revolutions Reverse RPM
Per Minute)
1st T, Z 1990 W, Z 1980
2nd U, Z 2060 V, Z 1975
3rd T, Y 1985 W, Y 1990
In the example shown, the engine speed is

abnormally high when 2nd gear forward drive is
selected, indicating a slipping clutch, possibly U or
Z. We can now use the results to determine which
clutch is at fault.
As per the details from the table, there is no problem

with clutch Z since it is engaged in other gears,
the stall speeds for those gears are normal. This
indicates that the clutch U is slipping.
Clutches may slip for several reasons. Hydraulic

leakage is possible and this can be confirmed by
carrying out a pressure test. Refer to driveline- semi-
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27 - Driveline
00 - General
Remove and Install
Consumables 2. Remove the gearbox. Refer to (PIL 27-06).

3. Prise out the access panel from the bevel
JCB Threadlocker 4101/0250 0.01L gearbox torque converter housing.
Strength) 4. Rotate the engine so as to gain access to the
torque converter retaining bolts (x4).
Remove
5. Support the torque converter. Loosen and
1. Due to the configuration of the engine and the remove the bolts (x4). Remove the torque
transmission mounting system, we recommend converter.
to remove the engine and the transmission as a
full assembly.
Figure 604.
D
F
B
A Access panel B Retaining bolt

C Drive plate D Spigot
E Bolts F DTI (Dial Test Indicator)
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27 - Driveline
00 - General
Install
steps.
1.1. Make sure that the drive plate and the
torque converter mating faces are perfectly
clean.
1.2. If removed, make sure that the drive plate
mating faces are clean and free from burrs
before you install it over the spigot on the
drive flange.
1.3. Install the bolts with JCB Threadlocker and
Sealer. Tighten to the correct torque value.
(Medium Strength)
1.4. Make sure that there are no burrs on the
torque converter spigot or to any of the
mating faces adjacent to the drive plate.
1.5. Install the torque converter spigot on the
recess in the bevel box output shaft.
1.6. Install a DTI.
1.7. Rotate the torque converter and measure
the run out of the drive shaft. Make sure that
the run out does not exceed the specified
value.

Item Nm
B 46
E 28
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27 - Driveline
06 - Control Valve
06 - Control Valve Figure 605.

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.
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27 - Driveline
06 - Control Valve
6. Install the pipe and tighten the nuts to the correct

torque value.

Item Nm
A 56
D 9
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27 - Driveline
09 - Relief Valve
09 - Relief Valve
Remove and Install

Remove gearbox.
1. Clean the area around the valve and the gearbox 3. Remove the plug, sealing washer, spring and the
case. poppet.
Figure 606.
B
C
A Plug B Sealing washer

C Spring D Poppet
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27 - Driveline
09 - Relief Valve
Install
At the time of installation do the following step.

Item Description Nm
A Plug 56
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27 - Driveline
20 - Axle
20 - Axle
Contents Page No.
27-20-00 General ......................................................................................................................... 27-199

27-20-15 Breather ........................................................................................................................ 27-221
27-20-81 Mount ........................................................................................................................... 27-222
27 - 197 9813/9050-1 27 - 197

Notes:
27 - 198 9813/9050-1 27 - 198

27 - Driveline
20 - Axle
00 - General

Technical Data ............................................. 27-199 For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD], Front ............................. Page 27-199
For: 531-70 [5AA], 535-95 [5AB], 541-70
Drain and Fill ............................................... 27-205 [5AD], Rear ............................. Page 27-199
Check (Level) .............................................. 27-208
Remove and Install ..................................... 27-209 (For: 531-70 [5AA], 535-95 [5AB], 541-70
Disassemble and Assemble ........................ 27-216 [5AD], Front)
Front Axle
Table 290. SD70 3 Piece Steer Drive Axle
Designations
Hubs 80 Series
Hub swivels and drive 55 Series
shafts
Drive head 80 Series 3 piece
Brakes 70 Series Integral
Brakes (3 piece axles)
Type JCB spiral bevel input
with epicyclic hub reduc-
tion
Brakes Oil immersed multi-plate
discs, located in centre
section
Steering Steer rams
(For: 531-70 [5AA], 535-95 [5AB], 541-70

[5AD], Rear)
Rear Axle
Table 291. SD55 1 Piece Steer Drive Axle
Designations
Hubs 55 Series
Hub swivels and drive 55 Series
shafts
Drive head 55 Series 1 piece
Type JCB spiral bevel input
with epicyclic hub reduc-
tion
Steering Steer rams
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20 - Axle
00 - General
For: 70/80-Series, Front .......... Page 27-200 The axle consists of a centre casing (drivehead) and
For: 55-Series, 70-Series ........ Page 27-200 two axle arms and swivel wheel hubs.
For: 70/80-Series, Rear ........... Page 27-201 The drivehead houses the differential gearing and
For: 55-Series ......................... Page 27-204 two oil immersed disc brake units. The axle arms
house the driveshafts. Specially shaped spider gears
(For: 70/80-Series, Front) in the differential provide torque proportioning, which
make sure drive power will be kept on one wheel if
the other is slipping. The wheel hubs are connected
3 Piece Axle to the driveshafts through universal joints which drive
sun-and-planet gears inside the hubs.
The illustration shows a typical 3 piece steer drive
front axle. The drive yoke, pinion, crownwheel and differential
unit are all components of the drivehead.
Figure 607.
C D N
M L
E H F
A
B
A Yoke connection to propshaft (axle input) B Pinion

C Crownwheel D Differential unit
E Driveshaft F Universal coupling
G Reduction gear hub H Steer swivel trunnion bearings
L Inboard oil-immersed multi-plate disc brake M Brake actuating piston
pack
N Hydraulic brake lines
SD55 1 Piece Steer Drive Axle

(For: 55-Series, 70-Series)
The illustration shows a typical steer drive rear axle.
SD80 3 Piece Steer Drive Axle- Integral The axle has a single piece case which houses the
Brakes differential and half shafts. The rear axle is pivot
mounted to the chassis.
For SD80 3 piece steer axle, refer to (PIL 20-00).
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20 - Axle
00 - General
Figure 608.
A B
E
F
G
J
K
C
D
L
A Yoke connection to propshaft B Pinion

E Drive shaft F Universal coupling
J Axle pivot K Oil fill and level plug
L Oil drain plug
The axle has a single-piece casing which houses the

(For: 70/80-Series, Rear) differential and driveshafts.
The axle is mounted to the chassis with a pivot pin to

1 Piece Axle allow the machine to sway.
The illustration shows a typical 1 piece steer drive
rear axle.
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20 - Axle
00 - General
Figure 609.
A B
F
G
J
K
C
D
E
H

J Axle pivot K Oil filler / level plug
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20 - Axle
00 - General
3 Piece Axle house the driveshafts. Specially shaped spider gears

in the differential provide torque proportioning, which
The illustration shows a typical 3 piece steer drive make sure drive power will be kept on one wheel if
rear axle. the other is slipping. The wheel hubs are connected
to the driveshafts through universal joints which drive
The axle consists of a centre casing (drivehead) and sun-and-planet gears inside the hubs.
two axle arms and swivel wheel hubs.
The drive yoke, pinion, crownwheel and differential
The drivehead houses the differential gearing and unit are all components of the drivehead.
two oil immersed disc brake units. The axle arms
Figure 610.
C D N
M L
E H F
A
B

L Inboard oil-immersed multi-plate disc brake M Brake actuating piston
pack
N Hydraulic brake lines
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00 - General
(For: 55-Series)
Figure 611. SD55 1 Piece Steer Drive Axle
A B
F E
J
K
D
C
A Yoke connection to propshaft B Pinion

E Drive shaft F Universal coupling
J Axle pivot K Oil fill and level plug
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20 - Axle
00 - General
Drain and Fill
axle for your machine. Refer to Figure 612.

(For: 55-Series, 70/80-Series) and Refer to Figure 613.
Notice: The oil level must be checked with the 1.2. Then make sure you identify the correct
machine level, otherwise a false indication of the plug for your machine.
amount of oil will be given. 1.3. Then use the related torque information for
Notice: It is not recommended that the machine the drain plug. Refer to Table 292. and Refer
be driven with the axle partially filled with oil. to Table 293.
2. Remove the hexagonal fill/level plug with its
Remove sealing washer (if installed) or the tapered plug.
1. Make the machine safe. Refer to (PIL 01-03). 3. Fill with the specified oil until oil is level with the
bottom of the hole. Refer to (PIL 75-00).
2. Get access to the axle drain plug.
4. Clean the fill/level plug.
3. Clean the area around the drain plug.
5. Install the fill/level plug with its sealing washer (if
4. Drain the oil. installed) or the tapered plug.
4.1. Place a container of suitable size beneath 6. Tighten the fill/level plug to the correct torque
drain plug to catch the oil. value.
4.2. Remove the hexagonal drain plug and its 6.1. To Make sure you use the correct torque
washer (if installed) or the tapered plug. tightening information, identify the correct
Allow oil to drain out. Wipe it clean (metallic axle for your machine. Refer to Figure 612.
particles should be carefully removed). and Refer to Figure 613.
6.2. Then make sure you identify the correct
Install plug for your machine.
1. Install the drain plug (and sealing washer- if 6.3. Then use the related torque information for
installed), tighten to the correct torque. the fill/level plug. Refer to Table 292. and
Refer to Table 293.
1.1. To Make sure you use the correct torque
tightening information, identify the correct
Figure 612. JCB Axle (Inboard Brakes)
C
A
B
C
A Axle fill/level plug B Axle drain plug

C Hub drain plug
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20 - Axle
00 - General
Figure 613. JCB Axle (Braked Hubs)

F
D
E
D Axle fill/level plug E Axle drain plug

F Hub drain plug
Figure 614. Hexagonal Plug and Seal- Figure 615. Taper Plug (January 2011 Onwards)
ing Washer (Prior to January 2011)
Table 292. JCB Axles With Inboard Brakes

Function of Plug Installed Description Torque (Nm)
Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80
Table 293. Axles With Braked Hubs

Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
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20 - Axle
00 - General

Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80
Also refer to hub, general, drain and refill, (PIL

27-00).
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00 - General
Check (Level)
Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
Notice: It is not recommended that the machine
be driven with the axle partially filled with oil.

2. Get access to the axle fill/level plug.
3. Clean the area around the fill/level plug.
4. Remove the plug with its sealing washer.
5. Make sure the oil is level with the bottom of the
hole.
6. If necessary add the correct new oil. Refer to (PIL
75-00).
7. Clean the fill/level plug.
8. Install the plug with its sealing washer.
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00 - General
Remove and Install
For: 70-Series, 80-Series, Front 2. Install the safety strut. Refer to (PIL 06-69).
................................................. Page 27-209
For: 55 Series (1 Piece Axle), 55-Series, 3. Shims may have been installed on the axle
Rear ........................................ Page 27-211 mounts. Make sure to note the position and
quantity of these shims before removal. There
For: 80 Series (3 Piece Axle), 80-Series,
Rear ........................................ Page 27-213 may be an uneven number of shims on each side
of the axle as they are used to adjust the machine
height and make it level.
(For: 70-Series, 80-Series, Front)
4. Make sure to collect the shims and replace them
Consumables in the correct position when you replace the axle.
Special HP Grease 4003/2017 0.4kg 5. If installed, remove the front stabilisers. Refer to
(PIL 06-42-00).
4003/2006 12.5kg
4003/2005 50kg 6. Remove the bolt 1 and disconnect the propshaft
coupling from the axle.
Raised Machine
7. Disconnect the hydraulic feed hoses from the
Never position yourself or any part of your body steer rams (one hose on each ram). Cap the
under a raised machine which is not correctly open ports and hoses to prevent contamination.
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be 8. Loosen the front road wheel retaining nuts then
killed. raise and support the front end of the machine
WARNING! A raised and badly supported machine on support stands or blocks positioned under the
can fall on you. Position the machine on a firm, level chassis. Refer to (PIL 27-29.
surface before raising one end. Ensure the other 9. Remove the front road wheels.
end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine 10. If installed, remove the front fenders. Refer to
when working under it. Disconnect the battery, to (PIL 06-54).
beneath it. 11. Disconnect the brake hose. Cap the open ports
and hoses to prevent contamination.
WARNING! Before disconnecting any propshaft,
make sure you block both sides of all wheels to 12. Remove the bolt 2 and then remove the pivot pin
prevent machine movement. The park brake will 1.
become ineffective or may only operate on 2 wheels
(depending on machine specification). 13. Support the axle on a trolley jack.
Remove 14. Remove the bolt 3 and then remove the pivot pin
2.
15. Remove the axle from the machine.
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20 - Axle
00 - General
Figure 616. SD80 Pivot sway axle
A B
F
C
Install
Table 294. 1. The installation procedure is the opposite of the
Item Description removal procedure. Additionally do the following
steps.
A Bolt 1
B Hydraulic feed hoses 1.1. Install the road wheels. Refer to (PIL 27-29).
C Brake hose 1.2. Tighten the bolt 2 and bolt 3 to the correct
D Bolt 2 torque value.
E Pivot pin 1 1.3. Make sure that you bleed the brake system.
F Bolt 3 Refer to (PIL 24-00).
G Pivot pin 2, Axle pivot 1.4. Make sure that you bleed the steering
1.5. Make sure that you re-phase the steering
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20 - Axle
00 - General
1.6. Apply grease on the axle pivot. Refer to (PIL 6. Remove the rear fenders (if installed).
75-06-00).
7. Slacken off the rear road wheel retaining nuts
Consumable: Special HP Grease and then raise and support the rear end of the
machine on axle stands or blocks positioned
Table 295. Torque Values under the chassis. Remove the rear road wheels.
Item Description Nm Refer to (PIL 27-30).
G Pivot pin 2 118
8. Support the axle on a trolley jack.
9. Remove the bolt 2 securing the axle pivot pin and
(For: 55 Series (1 Piece Axle), 55-Series, the drive out the pivot pin towards the rear of the
Rear) machine.
10. Lower the axle away from the mounting yoke and
SD55 1 Piece Steer Drive Axle remove from the machine.
Remove Install
1. Make the machine safe. Refer to (PIL 01-03). 1. The installation procedure is the opposite of the
2. Install the safety strut. Refer to (PIL 06-69). steps.
3. Follow the general health and safety procedures. 1.1. Install the road wheels and do the tightness
Refer to (PIL 01-03). checks. Refer to (PIL 27-30).
4. Remove the bolts 1 and disconnect the propshaft 2. Before you drive the machine, do the following
coupling from the axle. Refer to (PIL 27-48). steps.
5. Disconnect and install caps on the hydraulic feed
hoses to the steer rams (one hose on each ram).
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20 - Axle
00 - General
Figure 617. SD55 1 Piece Steer Drive Axle
A Bolt 1 B Hydraulic feed hose

C Bolt 2 D Axle pivot pin
2.1. Bleed the steering system. Refer to (PIL 2.3. Put grease in the axle pivot. Refer to (PIL
25-00). 25-00).
2.2. Re-phase the steering system. Refer to (PIL
25-00).
Table 296. Torques table

Item Nm
C 118
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20 - Axle
00 - General
(For: 80 Series (3 Piece Axle), 80-Series, 11.1. The axle pivot pin has a cut out on one
Rear) end to allow it to clear the crownwheel
during removal or installation. During pin
removal, make sure that the cut out is
SD80 3 Piece Steer Drive Axle- Integral aligned with the crownwheel. If you do not
Brakes align the pivot pin, the pin will damage the
crownwheel.
Remove
Figure 618.
1. Make the machine safe. Refer to (PIL 01-03). B
4. Remove the bolts 1 and disconnect the propshaft
coupling from the axle. Refer to (PIL 27-48). A
5. Disconnect and install the caps on the hydraulic

feed hoses to the steer rams (one hose on each
ram).
6. Slacken off the rear road wheel retaining nuts C
and then raise and support the rear end of the
machine on axle stands or blocks positioned A 5/8 UNF Thread
under the chassis. Remove the rear road wheels. B Rear axle pivot pin
Refer to (PIL 27-30). C Cutout
7. Remove the rear fenders (if installed). Refer to 12. Lower the axle away from the mounting yoke and
(PIL 06-54). remove from the machine.
8. Disconnect the brake hose. Install caps on the Install

open connections.
9. Support the axle on a trolley jack. removal procedure. Additionally do the following
steps.
10. Remove the bolt 2 and take out the right side
RAS (Rear Axle Stabilization) ram pivot pin. 1.1. Install new seals on the pivot pin.
Repeat the procedure for the left side RAS ram 1.2. Make sure the axle pivot pin cut out is
pivot. correctly aligned to allow it to pass the
11. Remove the bolt 3 securing the axle pivot pin crownwheel.
and remove the pivot pin towards the rear of the 1.3. Install the road wheels. Refer to (PIL 27-29).
machine.
2. Before you drive the machine do the following
steps.
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20 - Axle
00 - General
Figure 619. SD80 3 Piece Steer Drive Axle- Integral Brakes
C
B
D
F
G
A Bolt 1 B Hydraulic feed hose

C Brake hose D Bolt 2
E RAS ram pivot pin F Bolt 3
G Axle pivot pin
27 - 214 9813/9050-1 27 - 214

27 - Driveline
20 - Axle
00 - General
2.1. Bleed the brake system. Refer to (PIL 2.3. Re-phase the steering system. Refer to (PIL
24-03). 25-00).
2.2. Bleed the steering system. Refer to (PIL 2.4. Put grease in the axle pivot. Refer to (PIL
25-00). 25-00).
Table 297. Torques table

Item Nm
F 118
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20 - Axle
00 - General
For: 70-Series, 80 Series (3 Piece Axle) 10. Scoring of the counter plates to a certain limit is
................................................. Page 27-216 permissible.
For: 55 Series (1 Piece Axle) ... Page 27-220
11. Install a new brake pack, if it is damaged.
(For: 70-Series, 80 Series (3 Piece Axle)) 12. Make sure that you do not install new plates
individually.
Consumables
Description Part No. Size 13. Remove all the three reaction pins and check
JCB Gear Oil HP 4000/0505 20L them for damage.
4000/0503 200L 14. In the controlled retraction piston type, If new
JCB Multi-Gasket 4102/1212 0.05L brake and friction plates are installed then a new
JCB Threadlocker 4101/0250 0.01L brake back off pin 1 and tension bushes also
and Sealer (Medium 4101/0251 0.05L need to be installed. Failure to do so could result
Strength) in the brake being permanently on.
Disassembly Brake piston and seals- Controlled

retraction type
It is recommended that axle must be removed from
the machine while you disassemble the rear axle Make sure that only one side at a time is
brake. disassembled to prevent damage to the bearings and
preserve the crownwheel and the backlash settings.
Before you disassemble the rear axle brakes, it is
mandatory to mark the components for alignment Before you remove the brake housing and the piston
and to identify the right hand and left hand side, to assembly make sure that you support the differential
make sure that it is correctly assembled at the time with the driveshaft or any other suitable support.
of assembly.
1. Mark the brake piston housing and the
drivehead.
Brake pack
2. Remove the capscrews.
1. Use a heavy duty (6 point) socket to remove the
bolt 1. 3. Remove the brake housing and the piston
assembly.
2. Carefully remove the axle arm from the
drivehead. 4. Make sure that you do not turn the nut, if it is
turned then the bearing pre-load needs to be
3. If necessary, tap the case with a soft faced
reset.
hammer and remove all traces of the old sealant
from the mating faces. 5. Remove the six reaction pin assemblies.
4. The brake pack consist of five friction plates and 5.1. Remove the circlip 2.
six counter plates. There are two counter plates,
one at each end of the brake pack, which are not 5.2. Remove the back off pins 1.
attached to the plate carrier. 5.3. Remove the tension bushes and the spring
1.
5. If it is necessary to install the plates again
then make a note of their position and correct 6. Remove the brake piston from the brake housing.
orientation.
7. Remove and discard the seal 1 and seal 2.
6. Remove the circlip 1.
8. Check the housing bore for damage and scoring.
7. If it is necessary to install the brake pack again
then make a note of their original position before 9. Nicks or cuts in the seals may be the reason for
you remove them. loss of brake fluid.
8. The wear limit of friction plates is to the depth of
the cross hatching.
9. Check all plates for flatness and damage.
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27 - Driveline
20 - Axle
00 - General
Brake Piston and Seals- Positive retraction 4. Make sure that you do not turn the nut, if it is
type turned then the bearing pre-load needs to be
reset.
Make sure that only one side at a time is
disassembled to prevent damage to the bearings and 5. Remove the six reaction pin assemblies.
do the preservation procedure for the crownwheel 5.1. Remove the back off pins 2.
and the backlash settings.
5.2. Remove the spring 2.
Before you remove the brake housing and the piston
assembly make sure that you support the differential 6. Remove the brake piston from the brake housing.
with the driveshaft or any other suitable support.
7. Remove and discard both the seal 1 and seal 2.
1. Mark the brake piston housing and the 8. Check the housing bore for damage and scoring.
drivehead.
9. Nicks or cuts in the seals may be the reason for
2. Remove the capscrews. loss of brake fluid.
3. Remove the brake housing and the piston
assembly.
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20 - Axle
00 - General
Figure 620.
E J
L
K
M
N Q R
T
B
B
C D
Item Description
Table 298. D Circlip 1
Item Description E Reaction pin
A Bolt 1 F Support for differential
B Counter plate G Brake piston housing
C Plate carrier H Capscrew
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20 - Axle
00 - General
Item Description Brake piston and seals- Positive retraction

J Nut type
K Circlip 2 1. Remove all traces of the old sealant from the
L Back off pin 1 mating faces of the drivehead and the brake
M Tension bush piston housing.
N Spring 1
2. Install a new seal 1 and seal 2. Make sure that
P Brake piston they are seated squarely in their grooves.
Q Seal 1
R Seal 2 3. Carefully push the piston all the way into the
housing. Make sure that the brake back off holes
S Back off pin 2 are aligned with the housing.
T Spring 2
U Cross hatching 4. Apply sealant to the threads of the back off pin 2.
Install the spring 2 over the back off pin 2. Screw
V Oil flow holes the back off pin 2 into the brake piston.
W Drivehead housing
(Medium Strength)
Assemble
5. Apply JCB multigasket to the drivehead mating
Brake piston and seals- Controlled surface and then install the brake piston housing
retraction type assembly. Make sure that they are aligned
against the marking, made at the time of
1. Remove all traces of the old sealant from the disassembly.
mating faces of the drivehead and the brake
piston housing.
6. Install the capscrews, tighten the capscrews to
2. Install a new seal 1 and seal 2. Make sure that
they are seated squarely in their grooves.
7. Remove the differential support.
3. Apply sealant to the threads of the back off pin 1.
Screw the back off pin 1 into the brake piston.
Brake pack
(Medium Strength) 1. In the controlled retraction piston type, If new
brake and friction plates are installed then a new
4. Carefully push the piston all the way into the brake back off pin 1 and tension bushes also
housing. Make sure that the brake back off holes need to be installed. Failure to do so could result
are aligned with the housing. in the brake being permanently on.
5. Install the spring 1 over the back off pin 1. 2. Assemble the five friction plates and six counter
plates onto the brake carrier. If the original brake
6. Put the tension bush over the back off pin 1. pack is reinstalled then return the plates to their
7. Use a suitable tool to drive the tension bush onto original positions.
the back off pin 1, use a soft faced hammer until 3. Soak the new friction plates in JCB Special Gear
the circlip 2 is installed. Oil before assembly.
8. Apply JCB multigasket to the drivehead mating Consumable: JCB Gear Oil HP
surface and then install the brake piston housing
assembly. Make sure that they are aligned 4. Install the circlip 1.
against the marking, made at the time of
disassembly. 5. At the time of assembly of the brake packs, the oil
flow holes must be aligned with each other when
Consumable: JCB Multi-Gasket installed to the brake pack carrier.
9. Install the capscrews, tighten the screws to the 6. Put the three reaction pins into their grooves and
correct torque value.Refer to Table 299. lubricate them.
10. Remove the differential support. 7. Push the pins fully into their location holes in the
housing. Makes sure they stay in place.
8. Install one counter plate into the housing,
lubricate it and then the other counter plate.
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20 - Axle
00 - General
9. If the old counter plates are re installed then put Consumable: JCB Threadlocker and Sealer
them into their original position. (Medium Strength)
10. Fully press the brake pack in the housing. 13. Put the axle arm on to the drivehead. Make sure
it is aligned correctly.
11. Apply JCB multigasket to the mating surface of
the drive head. 14. Install the bolts 1 and tighten the bolt to the
12. Apply threadlocker and sealer to the bolt thread. 14.1. Check the grade of the installed bolt and
make sure you tighten them to the correct
torque.Refer to Table 299.
Table 299. Torques

Item Torque
If the bolt 1 is 8.8 grade 244
If the bolt 1 is 12.9 grade 400
Item H (capscrew) 56
(For: 55 Series (1 Piece Axle))

This axle is a 1 piece assembly. No disassemble
procedure is required.
To remove the internal components refer to the

applicable sections.
For drive head components refer to (PIL 27-22).
For differential components refer to (PIL 27-24).
For hub and components refer to (PIL 27-27).
For drive shaft components refer to (PIL 27-51).
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15 - Breather
15 - Breather
Check (Condition)
Breathers are installed to axles to release the If the breather is dislodged or removed, make sure
pressure build up due to braking and prolonged that it is installed again with the hole pointing towards
roading. the wheel.
If the breathers are blocked, there can be oil leakage Make sure that the breather is installed on the
past seals and brake problems due to pressure opposite side of the crownwheel (in less turbulent oil
build up. Most of the axles are have long stem type areas) to avoid oil seepage.
breather.
Make sure that the plug is installed on the
Make sure that there is sufficient clearance around crownwheel side.
the breather.
Figure 621.
A Long stem breather B Plug

C Hole
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27 - Driveline
20 - Axle
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 - 222 9813/9050-1 27 - 222

27 - Driveline
22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-00 General ......................................................................................................................... 27-225

27-22-06 Crownwheel .................................................................................................................. 27-246
27-22-09 Pinion Gear .................................................................................................................. 27-248
27 - 223 9813/9050-1 27 - 223

Notes:
27 - 224 9813/9050-1 27 - 224

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22 - Drivehead
00 - General
Introduction .................................................. 27-225 The axle drivehead transmits drive from the input
Component Identification ............................. 27-226 coupling yoke to the driveshafts through the
Disassemble and Assemble ........................ 27-233 differential unit.
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22 - Drivehead
00 - General
For: 55 Series (1 Piece Axle) ... Page 27-226 Figure 623.

For: 80 Series (3 Piece Axle) ... Page 27-229
Unit Identification
The axle serial number is stamped on the unit
mentioned on the unit identification plate. In the case
Figure 622.
27 - 226 9813/9050-1 27 - 226

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22 - Drivehead
00 - General
Figure 624.
4 5
2 3 6 7 8
Item Description
5 Bevel gears
Table 300.
6 Side nut locking pin
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
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22 - Drivehead
00 - General
Location Drawing (448/00040)
Figure 625.
15 10
14
12
13
1
2
11
3
4
5
Item Description
Table 301. 4 Spacer
Item Description 5 Bearing (taper roller)
1 Drivehead carrier 6 Pinion seal
2 Bearing (taper roller) 7 Coupling yoke
3 Shim 8 Stake nut
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00 - General
Item Description Figure 626.

10 Bolt-Verbus Ripp
11 Crown wheel and pinion
assembly
12 Bearing (taper roller)
13 Side nut
15 Differential assembly
A

Unit Identification Figure 627.

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22 - Drivehead
00 - General
Figure 628.
4 5
2 6 3 7 8
Item Description
5 Bevel gears
Table 302.
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
27 - 230 9813/9050-1 27 - 230

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22 - Drivehead
00 - General
Location Drawing (450/00019, 450/00023)
Figure 629.
10 11 15 27 1 21
24
25
13
26
12
31 33
32
34
16
29
28 2
30
3
4
6
5
7
7
8
Item Description
Table 303. 8 Stake nut
10 Bolt Verbus-ripp
Item Description
11 Crownwheel and pinion
1 Housing assembly
2 Bearing (taper roller) 12 Bearing (taper roller)
3 Shim 13 Side nut
4 Spacer 15 Differential assembly
5 Bearing (taper roller) 16 Brake piston housing
6 Pinion seal 21 Dowel
7 Coupling yoke
27 - 231 9813/9050-1 27 - 231

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22 - Drivehead
00 - General
Item Description
24 Brake piston
25 O-Ring
26 O-Ring
27 Drain plug
28 Spring
29 Pin (brake back-off)
30 Flanged bush
33 Spring
34 Pin (brake back-off)
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For: 55 Series (1 Piece Axle) ... Page 27-233 7. Remove the bearing outer race 1 and bearing
For: 80 Series (3 Piece Axle) ... Page 27-238 outer race 2 from the drivehead carrier bores.
8. Drive off the taper roller bearing cone 1 from the
(For: 55 Series (1 Piece Axle)) crownwheel differential case half.
Special Tools 9. Remove the differential assembly from the
Description Part No. Qty. carrier.
Spanner 10. Mark the position of the drive yoke on the splined
shaft.
Setting Tool Kit 892/00918 1
Spacer Kit 921/52600 1 11. Use the special tool to prevent the drive yoke
Spacer Kit 921/53300 1 from rotating and remove the pinion nut.
Torque Wrench 993/70111 1 Special Tool: Drive Coupling Spanner (Qty.: 1)
(10-100Nm)
Support Bracket 997/11000 1 12. Remove the drive yoke.
13. Remove the pinion shaft from the drivehead
Consumables carrier.
JCB Multi-Gasket 4102/1212 0.05L 14. Prise the pinion oil seal out of the bore.
JCB Threadlocker 4101/0250 0.01L 15. Remove the pinion tail bearing.
Strength) 16. If necessary, remove the bearing outer race 3.
17. If necessary, remove the bearing cup from
Disassembly the opposite side of the drivehead carrier and
remove the pinion shims.
The drivehead consists of the drivehead carrier
and pinion assembly, and the differential unit. A 18. Remove the spacer and the taper roller bearing
separate disassembly procedure is given for each cone 3 from the pinion.
sub assembly.
Disassemble the differential unit (If
Disassemble the Drivehead Carrier necessary)
1. Drain the oil from the axle centre case. 1. For LSD (Limited Slip Differential) Refer to Front
2. Completely remove both hub assemblies with the Differential, Disassemble and Assemble.
driveshafts. 2. Remove the differential assembly retaining bolt
3. Mark the installation position of the drivehead and separate the case half 1 and case half 2.
carrier with respect to the axle case. 3. Remove the side gears and the thrust washer 1
4. Remove the drivehead carrier retaining bolt and (2 off each).
then remove the drivehead carrier from the axle 4. Remove the bevel gears and thrust washer 2 (4
case. off each) from the trunnion pins.
5. Clean the drivehead carrier and axle case mating 5. Remove the taper roller bearing cone 2 from the
faces. differential case half.
6. Pull out the tension pin 1 and tension pin 2, and 6. Remove the Verbus-ripp bolts.
remove the castellated nut 1 and castellated nut
2. 7. Remove the crownwheel from the differential
case half.
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00 - General
Figure 630.
D K L
T
M
Q
G E C
P
R W N
S
F
H J
V
A
B
AG
U
AD
AE
Z
AF
AC
AB
AA
X Y
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27 - Driveline
22 - Drivehead
00 - General
housing halves are also matched. Do not use

unmatched halves.
Table 304.
Item Description Assemble the differential unit (if necessary)
A Drivehead carrier retain- 1. For LSD Refer to Front Differential, Disassemble
ing bolt and Assemble.
B Drivehead carrier
C Tension pin 1 2. Assemble the trunnion pin, bevel gear 1 and the
bevel gear 2 then the thrust washer 1 and thrust
D Tension pin 2 washer 2 into differential half case 2.
E Castellated nut 1
F Castellated nut 2 3. Put the differential half case 1 onto the half case
2. Make sure you align them properly.
G Bearing outer race 1
H Bearing outer race 2 4. Apply sealant to the differential assembly
J Taper roller bearing retaining bolt and then install it.
cone 1 Consumable: JCB Threadlocker and Sealer
K Differential assembly (Medium Strength)
L Differential assembly re-
taining bolt 5. Tighten the bolt to the correct torque value.
M Case half 1 6. Check the gears for free rotation.
N Case half 2
7. Use new Verbus-ripp bolts to install the
P Side gear
crownwheel.
Q Thrust washer 1
R Bevel gear 8. Tighten the bolt to the correct torque value. Refer
S Thrust washer 2 to table1.
T Taper roller bearing Assemble the drivehead carrier
cone 2
U Verbus-ripp bolt 1. Measure the correct thickness for the seam.
V Crownwheel Refer to Front Drivehead, Pinion Gear- Calibrate.
W Trunnion pin Refer to: PIL 27-22-09.
X Pinion nut
2. Install the shim behind the new bearing cup.
Y Drive yoke
Z Pinion shaft 3. Install the new pinion head bearing cone onto the
AA Pinion oil seal pinion.
AB Pinion tail bearing 4. Install the pinion and bearings into the drivehead
AC Bearing outer race 3 case.
AD Bearing cup
5. Install the largest available solid spacer (14.20
AE Drive pinion shim mm).
AF Spacer
AG Taper roller bearing
cone 3 6. Apply a coat of oil and then install the pinion tail
bearing.
Assembly 7. Do not install the oil seal at this stage.
The procedure below refers to the following aspects 8. Install the special tool sleeve and the special
of the drivehead assembly, which are covered pinion shaft adaptor from the setting kit.
separately in detail.
Special Tool: Setting Tool Kit (Qty.: 1)
• Pinion depth setting
• Crownwheel and pinion meshing 9. Tighten the adaptor to the correct torque value.
10. Make sure that the pinion is free to rotate and
Both the crownwheel and pinion and the bevel gear
there is end float, this will prevent any damage
1 and bevel gear 2 are matched and should be
to the bearing. If the pinion is not free to rotate
replaced as a set, if any of their components are
or there is no end float at this stage check the
damaged or excessively worn. The two differential
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27 - Driveline
22 - Drivehead
00 - General
bearing is installed properly. Also check that the Figure 632.

correct size spacer is installed.
11. Use two (M10x30) nuts and bolts to install the
special bracket on the drivehead housing.
Special Tool: Support Bracket (Qty.: 1) AN
Figure 631.
AM
AL
AJ
AK
AH
AM DTI
AN Torque wrench
16. Set the torque wrench to the specified value and
measure the end float while you rotate the shaft.
Torque: 35N·m
1)
AH Special tool sleeve
AJ Adaptor 17. To select the right size spacer do the following
AK Special bracket steps. Refer to Table 307.
AL Support pillar 17.1. Subtract the end float obtained in step
12. Install the special support pillar on the bracket so 16 from the solid spacer thickness value
that the fork end engages with the adaptor. (14.20 mm).
17.2. Subtract 0.04mm to allow for theoretical
13. Make sure that the fork is centrally located on the bearing tolerance and pre-load.
adaptor.
17.3. The result is the size of spacer to be
14. If necessary, align the bracket again. installed from the solid spacer setting kit.
15. Install a DTI (Dial Test Indicator). Make sure that Special Tool: Spacer Kit (Qty.: 1)
the DTI is mounted on the drivehead and not on 17.4. If there is no spacer of this size, then install
the bracket. the next nearest size spacer.
18. Remove the sleeve and the temporary spacer.
19. Install the correct size spacer from the solid
spacer setting kit.
20. Make sure that you do not damage the outer
bearing.
21. Again install the sleeve and then install the
adaptor.
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22. Tighten the adaptor to the correct torque value, 41. Measure the backlash between the crownwheel
to protect against bearing damage while spacer and the pinion and it should be within the
selection is verified making sure the pinion is free specified limit.
to rotate. Length/Dimension/Distance: 0.17–0.28mm
23. Check there is no end float and the pinion is free 42. When altering the backlash adjust both the
to turn smoothly by hand. castellated nut in equal amounts.
24. Remove the adaptor and then install the nut. 43. When the backlash and pre-load are both
25. Make sure that the rolling torque is less than 2.0 correct, install the tension pin 1 and tension pin 2.
Nm, if the rolling torque exceeds 2.0 Nm, then 44. Check the tooth marks to verify that the
check that the shaft is assembled correctly or not. crownwheel and the pinion are set correctly.
26. If the pinion is not free to rotate, check the correct 45. Apply JCB Multigasket to the mating faces of the
size spacer has been installed. drivehead carrier and the axle case.
27. If the rolling torque measured at step 25 is Consumable: JCB Multi-Gasket
too high, install the next larger size spacer. If
the rolling torque is too low, install the next 46. Install the drivehead carrier to the axle case with
smallest size spacer. If a correct spacer is not the crownwheel towards the short driveshaft.
available from the range, check that drivehead is
assembled correctly. 47. Install the drivehead carrier retaining bolts.
28. Remove the adaptor and the sleeve. 48. Tighten the bolt to the correct torque value.
29. Lubricate the seal lips and then install the new 49. Reassemble both driveshafts and hub
oil seals. assemblies.
30. Install the coupling yoke and the new stake nut.
Table 305. Torque Settings (55 Series)
31. Gradually tighten the stake nut up to the specified Item Description Nm
torque value, while occasionally rotating the
coupling yoke. A Drivehead carri- 98
er retaining bolt
Torque: 250N·m U Verbus-ripp bolt 94
32. If the correct size spacer is selected then the
pinion rolling torque should with in the specified
limit. Table 306. Torque Settings (70 and 80 Series)
Torque: 2.3–3.4N·m Item Description Nm

A Drive head car- 166
33. The nut tightening torque value can be increased rier retaining
to a maximum of 300 Nm but the pinion rolling bolt
torque does not exceed the maximum of 3.4 Nm. U 'Verbus Ripp' 200
bolt
34. Finally stake the nut into the slot.
35. Install the differential assembly onto the
drivehead carrier. Table 307. Spacer Selection Example
Value
(1)
36. Push the taper roller bearing onto the spigot of

the differential half case2. Temporary spacer size 14.20
Subtract end float 0.25
37. Install the bearing outer race 1 and bearing outer Total 13.95
race 2.
Subtract tolerance and 0.04
38. Install the castellated nut 1 and castellated nut 2 preload
to the drivehead carrier. Result 13.91
39. Do not install the tension pin 1 and tension pin 2 Use next smallest spac- 13.90
at this stage. er
(1) All the values are in millimetre (mm).
40. Adjust the castellated nut to give an increase in
input pinion rolling torque of between 1.36 and
2.5 Nm more than that specified in Step25.
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00 - General
Table 308. Torque Values Figure 633.

Item Description Nm
L Differential assembly 46
AB AA
retaining bolt
AJ Adaptor 50

Special Tools
Spanner
Setting Tool Kit 892/00918 1
Shim Kit 921/01900 1
Spacer Kit 921/53400 1
(10-100Nm)
AA Park brake disc
Support Bracket 997/11000 1 AB Flange spanner
Consumables 2. Remove the pinion nut.
Figure 634.
JCB Multi-Gasket 4102/1212 0.05L
JCB Threadlocker 4101/0250 0.01L AC AE
Strength)
Disassembly
When the drivehead is installed on the machine it
cannot be disassembled. It is recommended that you
remove the complete axle. Refer to Brakes and Hub
and Driveshaft for axle arm removal procedure.
The crownwheel and the pinion are matched and

should be replaced as a pair, if either of them are
damaged or excessively worn.
AC Coupling yoke
The two differential case halves are also matched as AE Drive coupling spanner
are the differential side gears and planet gears, do
not use unmatched halves or gears. 3. As applicable, use a flange spanner or a drive
coupling spanner to remove the brake disc.
1. The drivehead pinion may be installed with either Special Tool: Flange Spanner (Qty.: 1)
a park brake disc or a coupling yoke, depending Special Tool: Drive Coupling Spanner (Qty.: 1)
on the axle application.
4. In a drivehead with the park brake disc, the
brake caliper bracket is orientated differently
depending on the axle application.Refer to
Figure 635.
5. Make sure that you mark the bracket and the
drivehead case before you remove the bracket.
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Figure 635. 12. Move the differential side nut locking pin to do the
adjustment on assembly. Refer to Figure 637.
AF AG Figure 637.
C Differential side nut locking pin

AF Brake caliper bracket
AG Brake caliper bracket mounting bolt 13. Remove the other brake piston housing only if
damaged, but it is mandatory to remove the
6. Remove and discard the brake caliper mounting locking pin (to allow for side load adjustment on
bracket bolts. Refer to Figure 635. assembly). Refer to Figure 637.
7. Remove the brake caliper mounting bracket. 14. Lift out the crownwheel and differential assembly.
Refer to Figure 635. Refer to Figure 638.
8. Place the drivehead with the crownwheel at the Figure 638.

top. Refer to Figure 636.
9. Mark the drivehead case to show the crownwheel D
position. Refer to Figure 636.
Figure 636.
B A
D Crownwheel and differential assembly

15. If it is necessary to remove the brake piston
housings, mark the crownwheel end of the
A Capscrew drivehead case to make sure that the assembly
B Brake piston housing is returned to its original position. Refer to Figure
638.
10. Mark the brake piston housing and the
drivehead. Refer to Figure 636. 16. Use a soft faced hammer to hit the pinion end
shaft until the pinion is free from its front bearing
11. Remove the capscrews and then remove the and then remove the pinion. Refer to Figure 639.
brake piston housing. Refer to Figure 636.
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17. Remove the pinion seal and the outer bearing 23. Remove the inner bearing cone. Refer to Figure
cone. Refer to Figure 639. 640.
18. If necessary, drive out the pinion inner bearing 24. Disassembly of the differential unit. Refer to
cup and shims. Refer to Figure 639. Figure 641.
Figure 639. 24.1. Remove the bolts.
24.2. Lift off the top half housing.
H
Figure 641.
J
E M
G Q
N
F
S
E Pinion P
F Pinion seal
G Outer bearing cone
H Inner bearing cup
J Shim
19. Discard the shims. Refer to Figure 639.
20. If necessary, Do the step to 18 remove the outer
bearing cup. Refer to Figure 639.
21. There are no shims for the outer bearing cup.
Refer to Figure 639. M Bolt
N Top half housing
22. Remove the pinion spacer. Refer to Figure 640. P Spherical washer
Q Differential bearing cone
Figure 640. S Differential gear
24.3. Remove the differential gears and the
K L spherical washers.
24.4. Remove the differential bearing cones.
Assembly
Axles not installed with the park brake discs feature
have a different type of drivehead case to those
illustrated. Differences in assembly procedure are
given as necessary.
1. If necessary, install a new crownwheel to the

differential case half.
K Bearing cone 2. Install the crownwheel retaining bolt.

L Pinion spacer
3. Tighten the bolt to the specified torque value.
Torque: 200N·m
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22 - Drivehead
00 - General
4. Assemble the differential gear and the spherical Figure 643.

washers into the bottom half of the differential
housing. Refer to Figure 642.
K L
5. Install the differential bearing cones. Refer to
Figure 642.
Figure 642.
Q
N K Bearing cone
L Pinion spacer
11. Install the inner bearing cup with the necessary
thickness of the shim to give correct pinion depth.
S Refer to Front Drivehead, Pinion Gear- Calibrate
(PIL 27-22-09). Refer to Figure 644.
P
12. Select the shims from the shim kit. Refer to
Figure 644.
Special Tool: Shim Kit (Qty.: 1)
13. Use a puller tool to make sure that the inner
bearing cup is installed in square. Do not use a
hammer. Refer to Figure 644.
14. Install the outer bearing cup. Refer to Figure 644.
M Bolt 15. Put the pinion into its bore. Refer to Figure 644.
N Top half housing Figure 644.
P Spherical washer
Q Differential bearing cone
S Differential gear H
6. Put the top half of the differential housing on to J

the differential and make sure that you align it
correctly. Refer to Figure 642. E
7. Apply sealant to the threads of the bolts and then
install them. Refer to Figure 642.
(Medium Strength)
8. Tighten the bolt to the correct torque value. Refer G
to Figure 642.
F
9. Check the gears for free rotation. Refer to Figure
642.
10. Install the pinion inner bearing cone and the
largest available spacer (14.20mm). Refer to E Pinion
Figure 643. F Pinion seal
G Outer bearing cone
H Inner bearing cup
J Shim
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00 - General
16. Before you put the pinion into the bore, make 25. Make sure that the correct size spacer is
sure that it is matched with the crownwheel. installed. Refer to Figure 645.
26. Use two bolts (M10x30) to install the special
17. The code numbers etched on the pinion end bracket to the drivehead housing. Refer to Figure
face and the crownwheel perimeter should be the 645.
same. Refer to Figure 644. Special Tool: Support Bracket (Qty.: 1)
18. Install the pinion outer bearing cone. Refer to 27. Install the special tool support pillar to the bracket
Figure 644. so that the fork end engages in the adaptor. Refer
19. Do not install the oil seal at this stage. Refer to to Figure 646.
Figure 644.
28. Make sure that the fork is centrally located on the
20. Install the special tool sleeve and the special adaptor. Refer to Figure 646.
pinion shaft adaptor. Refer to Figure 645.
29. If necessary, align the bracket again. Refer to
Special Tool: Setting Tool Kit (Qty.: 1) Figure 646.
21. Tighten the adaptor to the correct torque value. Figure 646.
22. Make sure that the pinion is free to rotate and Z
there is end float. Refer to Figure 645.
Figure 645. Y
X
U
X Support pillar
Y DTI
W Z Torque wrench
30. Install a DTI. Refer to Figure 646.
1
T Pinion shaft adaptor 31. Make sure that the DTI is installed on the
U Special tool sleeve drivehead not on the bracket. Refer to Figure
V Special bracket 646.
W Bolt (M10x30)
32. Set the torque wrench to the specified value and
23. End float will prevent the bearing from damage. measure the end float while you rotate the shaft.
Refer to Figure 645. Refer to Figure 646.
24. If the pinion is not free to rotate or there is no end Torque: 35N·m
float at this stage check the bearing is installed Special Tool: Torque Wrench (10-100Nm) (Qty.:
correctly. Refer to Figure 645. 1)
33. Correct size solid spacer selection. Refer to
Figure 646.
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00 - General
33.1. To select the correct size spacer, subtract Figure 647.

the end float obtained at step 32 from the
solid spacer size (14.20 mm). AC AH
33.2. Also subtract 0.04 mm to allow for
theoretical bearing tolerance and pre-load. AA
33.3. The result is the size of spacer to be
installed from the solid spacer kit.
AG
33.4. If there is no spacer of this size, install the
next nearest size spacer from the spacer
kit. T
AJ
34. Remove the sleeve and the temporary spacer.
U
AF
35. When you remove the temporary spacer make
sure that the outer bearing is not damaged. Refer
to Figure 647.
36. Install the correct size spacer from the solid
spacer setting kit. Refer to Figure 647.
37. Install the sleeve. Refer to Figure 647.
38. Tighten the adaptor to the specified value, to
protect against bearing damage while spacer T Pinion shaft adaptor
selection is verified and make sure that the pinion U Special tool sleeve
is free to rotate. Refer to Figure 647. AA Park brake disc
AC Coupling yoke
Torque: 50N·m
AF Brake caliper bracket
39. Check there is no end float and the pinion is free AG Brake caliper bracket mounting bolt
to turn smoothly by hand. Refer to Figure 647. AH Stake nut
AJ Oil seal
40. Remove the adaptor and install the stake nut.
Refer to Figure 647. 41. Check that rolling torque is less than 2.0 Nm. If
the rolling torque exceeds 2.0 Nm, check that the
shaft is assembled correctly. Refer to Figure 647.
42. If the pinion is not free to rotate then check the
correct size spacer is installed or not. Refer to
Figure 647.
43. If the rolling torque measured at step 41 is too
high then install the next largest size spacer. If
the rolling torque is too low then install the next
smallest size spacer. Refer to Figure 647.
44. If a correct spacer is not available from the range,
check that drivehead is assembled correctly.
45. Remove the stake nut and the sleeve. Refer to
Figure 647.
46. Lubricate the seal lips and then install the new oil
seal. Refer to Figure 647.
47. Drivehead with park brake disc. Refer to Figure
647.
47.1. Put the brake caliper bracket on the
drivehead case correctly.
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27 - Driveline
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00 - General
47.2. Apply sealant to the new brake caliper 49. Gradually tighten the stake nut up to the specified
mounting bracket bolts and install them. limit, occasionally rotate the coupling yoke or the
brake disc.
47.3. Tighten the bolts to the correct torque
value. 50. If the correct size spacer is selected, the rolling
47.4. Install the brake disc and a new stake nut. torque should be within the specified torque
value including the seal drag.
47.5. Install the drive coupling spanner. Refer to
Figure 648. Torque: 2.3–3.4N·m
Special Tool: Drive Coupling Spanner 51. The stake nut tightening can be increased to a
(Qty.: 1) maximum value, if the pinion rolling torque does
not exceed the maximum of 3.4 Nm. Maximum
Figure 648. torque values for M30 stake nut and M24 stake
nut are mentioned below.
AB AA 51.1. M24 Stake nut.

Torque: 300N·m
51.2. M30 Stake nut.
Torque: 370N·m
52. Finally stake the nut into the slot.
53. If the brake piston housing is removed then install
one at the opposite end to the crownwheel.
54. Apply JCB Multigasket to the drivehead mating
face, then install the brake piston housing.
55. Make sure that the mark made between the
drivehead and the brake piston housing at the
time of disassembly is aligned. Refer to Figure
AA Park brake disc 651.
AB Flange spanner
56. Then install the crownwheel and differential
48. Drivehead with coupling yoke. assembly into the drivehead. Refer to Figure 650.
48.1. Install the coupling yoke and a new stake Figure 650.
nut. Refer to Figure 647.
48.2. Locate the flange spanner. Refer to Figure
649. D
Special Tool: Flange Spanner (Qty.: 1)
Figure 649.
AC AE
D Crownwheel and differential assembly

AC Coupling yoke
AE Drive coupling spanner
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00 - General
57. Install the other side brake piston housing onto correctly. Refer to Front Drivehead, Crownwheel-
the drivehead. Refer to Figure 651. Check(Operation) (PIL 27-22-06).
58. Install the capscrews. Refer to Figure 651. 66. To measure the backlash, use a magnet drilled
and tapped 6 mm to accept a length of rod
Figure 651. threaded 6 mm on one end. Put the magnet
between the crownwheel locking bolts.
C
Figure 652.
AD
B A
Table 309. Spacer selection example

A Capscrew Value
(1)
B Brake piston housing

C Side nut locking pin Temporary spacer size 14.20
AD Differential side nut Subtract end float 0.25
Total 13.95
59. Tighten the capscrews to the correct torque
value. Refer to Figure 651. Subtract tolerance and 0.04
pre-load
60. Adjust the differential side nuts to give a bearing Result 13.91
pre-load of the specified value. Refer to Figure Use next smallest spac- 13.90
651. er
Torque: 1.13–2.26N·m (1) All the values are in millimetre (mm).
61. Measure the pre-load by taking another rolling Table 310. Torque Values
torque reading and subtracting the torque figure
measured at step 50. The difference is the Item Description Nm
bearing pre-load. Refer to Figure 651. M Bolt 56
T Pinion shaft adaptor 50
62. Measure the crownwheel backlash, it should be
within the specified limit. Refer to Figure 651. AG Brake caliper mounting bolt 166
A Capscrew 56
AH Stake nut 250
63. Adjust the differential side nuts by equal amounts
when you change the backlash. Refer to Figure
651.
64. When the backlash and pre-load are both
correct, install the side nut locking pins. Refer to
Figure 651.
65. Check the tooth mark to make sure
that the crownwheel and pinion are set
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27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-246 A crown wheel is a rotating gear wheel with teeth set
Check (Operation) ....................................... 27-247 at right angles to its plane, it is usually matched with a
pinion gear that meshes with the crown wheel. They
are mainly used in vehicles to maintain a forward
movement.
27 - 246 9813/9050-1 27 - 246

27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Operation) Figure 655.
Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking
three of the pinion teeth with engineers marking
compound and rotating the pinion. The marking will
then be transferred to the crown wheel teeth.
1. Correct tooth marking.

Figure 653.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 654.
3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.
27 - 247 9813/9050-1 27 - 247

27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear Introduction

Introduction .................................................. 27-248 A pinion gear is a small gear that meshes with a
Calibrate ...................................................... 27-249 larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.
27 - 248 9813/9050-1 27 - 248

27 - Driveline
22 - Drivehead
09 - Pinion Gear
Calibrate the bearing before measurement. Make sure

that the bearing cup is square and measure
and record the height. The bearing cups and
(For: 55-Series, 70/80-Series) rollers are matched sets. Always keep the
bearing assemblies together. Make sure that you
Special Tools measure only the inner bearing.
Shim Kit 921/M0229 1 Figure 658.
Pinion Depth Setting E

Determine the pinion depth setting shim size as
follows: E Inner bearing height
1. Note the deviation figure etched on the pinion
Shim Size Calculation Example
and the deviation figure on the drivehead
housing. Both figures are in units of 0.01 mm. Table 311. Calculation 1.
Note: The pinion depth may be etched on the Actual Drivehead Case Size
gear face or on the rear of a gear tooth.
Item Typical Fig- Description
Special Tool: Shim Kit (Qty.: 1) ures
Figure 656. A 187.6 mm Nominal drive-
head case size,
D fixed at the fac-
tory
B -0.14 mm Drivehead
case deviation,
marked on the
case
Sum of A and B 187.46 mm Actual drive-
head case size
Table 312. Calculation 2. -

Actual Pinion and Bearing Size
Item Typical Fig- Description
ures
C 150.0 mm Nominal pinion
D Pinion depth length, fixed at
the factory
Figure 657. D 0.10 mm Pinion devia-
tion, marked on
the pinion
E 36.6 mm Bearing size, in-
ner pinion bear-
ing
Sum of C, D 186.70 mm Actual pinion
and E and bearing
size
Table 313. Calculation 3. Shim

Size = Calculation 1 - Calculation 2
Typical Figures Description
187.46 - 186.70 = Select the nearest shim
0.76mm size from the shim kit.
B Deviation figure
2. Assemble the pinion inner bearing and its
cup on a flat surface. Lightly oil and rotate
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27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-251
27 - 250 9813/9050-1 27 - 250

27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-251 A differential is a particular type of simple planetary
Component Identification ............................. 27-253 gear train.
Check (Condition) ........................................ 27-255
Disassemble and Assemble ........................ 27-256 The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational

velocity of the input shaft is the average of the
rotational velocity of the output shafts under normal
traction conditions. Therefore, increasing the speed
of one output shaft will decrease the speed of the
other output shaft.
The problem is an open differential always tries to

balance the torque. It means that if the spider gears
are pushing on both drive gears and one of them
offers lots of resistance and the other side offers no
resistance then it will try to find a balance where both
sides are receiving almost no torque at all. All the
rotational energy is guided to the side with the least
resistance. In the end, that side spins very fast and
the pressure on each drive gear is the same. Almost
no torque is needed to spin one wheel, and since
the open differential always sends the same amount
of torque to both output shafts, almost no torque is
going to the other side as well.
Limited Slip Differential (LSD)

In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
27 - 251 9813/9050-1 27 - 251

27 - Driveline
24 - Differential
00 - General
2. More predictable handling at the limits of grip.
This type behaves as an open differential unless one

wheel begins to spin and exceeds that threshold.
The LSD will remain open unless enough torque is
applied to cause one wheel to lose traction and spin,
at which point it will engage.
An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.
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27 - Driveline
24 - Differential
00 - General
For: Limited Slip Differential (LSD)

................................................. Page 27-253
For: Max-Trac .......................... Page 27-254
(For: Limited Slip Differential (LSD))
Figure 659. Limited Slip Differential (LSD)
E
F
H
J
K
N P
A M
G K
C J
H
G
A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers
27 - 253 9813/9050-1 27 - 253

27 - Driveline
24 - Differential
00 - General
(For: Max-Trac)
Figure 660. JCB Maxtrac Differential
E C
B
D
A Capscrews
B Side gears
C Thrust washers
D Bevel gears
E Spherical washers
F Differential bearing cones
27 - 254 9813/9050-1 27 - 254

27 - Driveline
24 - Differential
00 - General
Check (Condition)
(For: Limited Slip Differential (LSD))

1. For JCB axles only: measure and note the
thickness of the friction plates, the result must not
be less than the specified dimension.
Dimension: 1.25mm
2. Check the condition of the friction material, which
should be even over both surfaces. If in doubt,
discard the set (friction and counter plates).
27 - 255 9813/9050-1 27 - 255

27 - Driveline
24 - Differential
00 - General
For: 55-Series, 80-Series, Front, Limited Slip 2. Remove the crownwheel.

Differential (LSD) ..................... Page 27-256
For: Front, Max-Trac, Rear ...... Page 27-259 3. Put marks on the two halves of the differential
housing before disassembly to make sure of
correct assembly.
(For: 55-Series, 80-Series, Front, Limited
Slip Differential (LSD)) 4. Remove the capscrews.
The numerical sequence shown on the illustration is 5. Disengage the two halves of the differential and
intended as a guide for disassembly. remove the following components:
5.1. Trunnion pins.
The number of friction and counter plates shown in
the illustration is typical only. The actual number of 5.2. Side gears.
plates is determined by the axle variant. 5.3. Bevel gears.
Important: The crownwheel and pinion are matched 5.4. Spherical washers.
and should be renewed as a pair if either one is
damaged or excessively worn. The two halves of 5.5. Pressure plates.
the differential housing are also matched as are the 5.6. Counter plates.
differential side gears and bevel gears, do not use
unmatched halves or gears. 5.7. Friction plates.
5.8. Shims.
Disassemble
6. Make a note of the relative positions of the
1. Use a heavy duty socket to remove the verbus- friction plates, counter plates and spacers before
ripp bolts. Discard the bolts. disassembly, they must be installed in the same
positions.
Figure 661. Limited Slip Differential (LSD)
E
F
H
J
K
N P
A M
G K
C J
H
G
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27 - Driveline
24 - Differential
00 - General
A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers
27 - 257 9813/9050-1 27 - 257

27 - Driveline
24 - Differential
00 - General
Assembly 1.6. Thrust washers.
1. Install the following components into the 2. Do not install the shims at this stage.
crownwheel half of the differential assembly:
3. Align the two halves of the differential assembly
1.1. Trunnion pins. with the bolts. Make sure that the marks made
during disassembly are aligned.
1.2. Side gears with pressure plates.
4. Use a DTI (Dial Test Indicator) (or feeler gauges),
1.3. Counter plates.
with two screwdrivers or suitable levers, gently
1.4. Friction plates. apply pressure to prise the side gear away from
the trunnion pins.
1.5. Bevel gears.
Figure 662.
5. Measure and record the end float of the side assembled differential as this is only an
gear. initial setting figure which allows for bedding
in.
6. Turn the differential assembly over and repeat
steps 4 and 5 for the second side gear. 8.2. Select the minimum number of shims to
give the correct thickness.
7. Disassemble the differential assembly.
9. Do the steps 4 to 6 again.
8. Add shims to give an end float between the
specified range. 10. If the end float is correct, tighten bolts to the
11. Install the crownwheel with new verbus-ripp
8.1. Shimming must be carried out whenever bolts.
the differential is dismantled, however, the
end float 0.1 and 0.2 mm (0.004 and 12. Tighten the verbus-ripp bolts to the correct torque
0.008 in) can be exceeded on previously value.
27 - 258 9813/9050-1 27 - 258

27 - Driveline
24 - Differential
00 - General

Item Nm
1
(1)
94
1
(2)
200
3 56
(1) The torque value is applicable for the 55 Series drivehead.
(2) The torque value is applicable for the 80 Series drivehead.
Figure 663.
(For: Front, Max-Trac, Rear)
Consumables
A
Strength)
F
The crownwheel and pinion are matched and should
be replaced as a pair if either one is damaged or
excessively worn.
The two halves of the differential housing are also

matched as are the differential side gears and bevel E C
gears. Do not use unmatched halves or gears.
B
If it is necessary to install a new crownwheel to the
D
differential unit, then install it and torque tighten the
crownwheel retaining bolts to the specified torque
value.94N·m
Disassembly
1. Before you disassemble match-mark the two
halves of the differential housing for the correct
assembly. A Capscrews
B Side gears
2. Remove the capscrews. C Thrust washers
D Bevel gears
3. Disengage the two halves of the differential E Spherical washers
housing. F Differential bearing cones
4. Remove the side gears, thrust washers, bevel
gears and spherical washers. Assembly
5. Remove the differential bearing cones. 1. Assemble the side gears, thrust washers,
bevel gears and spherical washers into the
crownwheel half of the differential housing.
2. Position the top half housing onto the differential.
2.1. Make sure that they are aligned with
the match mark made at the time of
disassembly.
2.2. Apply sealant to the threads of capscrews
and install them.
(Medium Strength)
2.3. Tighten the capscrews to the correct torque
value.
27 - 259 9813/9050-1 27 - 259

27 - Driveline
24 - Differential
00 - General
3. Check the gears for free rotation.

4. Install the differential bearing cones.

Item Description Nm
A Capscrews 46
27 - 260 9813/9050-1 27 - 260

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-263

27-27-66 Wheel Stud ................................................................................................................... 27-270
27 - 261 9813/9050-1 27 - 261

Notes:
27 - 262 9813/9050-1 27 - 262

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-263 The hub is the part of the axle where the wheel
Component Identification ............................. 27-264 is mounted and where the axle shaft (if installed)
Drain and Fill ............................................... 27-266 passes through.
Calibrate ...................................................... 27-269
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 - 263 9813/9050-1 27 - 263

27 - Driveline
27 - Hub
00 - General

(For: 55-Series, 70-Series)
Figure 666.
Unit Identification
G H
of gear replacements, always check the part number A
Figure 664. B
K
A D
E L
Figure 665. F M
Table 316.
Item no Description
A Annulus ring
B Planet gear assembly
(x3)
C Thrust pad
D Sun gear
E Planet gear carrier
F Wheel stud (x5)
G Bearing carrier
A Identification plate H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)
27 - 264 9813/9050-1 27 - 264

27 - Driveline
27 - Hub
00 - General
Sectional Drawing
Figure 667.
13 10 7 11 5 3 4 57 1
12
14
8 18
16
15
17
20
19
23
26 9 22 24 25
Item no Description
Table 317. 17 Thrust pad
Item no Description 18 Driveshaft
1 Swivel hub 19 Sun gear
3 Bearing (taper roller) 20 Circlip (external)
4 Oil seal 22 O-ring
5 Bearing carrier 23 Drain plug
7 Annulus carrier 24 Bearing
8 Dowels 25 Oil seal
9 Bolt Verbus-ripp 26 Spacer (55 Series hub
only)
10 Annulus ring
57 Cover plate
11 Circlip (internal)
12 Planet gear
13 Planetary hub carrier
14 Bearing
15 Circlip (L-shaped)
16 Circlip (external)
27 - 265 9813/9050-1 27 - 265

27 - Driveline
27 - Hub
00 - General
Drain and Fill
4. Apply the park brake.

(For: 55-Series, 70/80-Series) 5. Set the transmission to the neutral position.
Check the hub oil level of one wheel at a time. 6. Lower the attachments to the ground.
Complete the steps below to check the hub oil.
8. Clean the area around the hub plug.
2. Set the machine level with the wheels above the
ground. 9. Remove the hub plug.
2.1. Use suitable lifting equipment to lift the 10. Check the oil level of the hub.
machine axles to the same level.
10.1. The hub oil level must be level with the
3. Set the hub oil level mark to the horizontal bottom surface of the plug hole.
position.
10.2. If necessary, add the correct axle oil. Refer
3.1. Turn the wheel manually to get the hub oil to (PIL 75).
level mark to the horizontal position.
11. Clean the plug before you install it.
3.2. The specified tolerance is permitted above
or below the oil level mark horizontal 12. Install the hub plug and tighten to the correct
position. torque.
Length/Dimension/Distance: 5mm 12.1. To Make sure you use the correct torque
tightening information, identify the correct
Figure 668. axle for your machine. Refer to Figure 669.
A and Refer to Figure 670.
12.2. Make sure you identify the correct plug
B for your machine. Then use the related
torque information. Refer to Figure 671.
and Refer to Figure 672.
D C
A Wheel
B Hub
C Plug
D Level mark
E Tolerance 5mm
27 - 266 9813/9050-1 27 - 266

27 - Driveline
27 - Hub
00 - General
Figure 669. JCB Axles With Inboard Brakes (If installed)
A
B
A Axle drain plug 1 location
Table 318. JCB Axles With Inboard Brakes

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 1 with hexagonal Taper plug (3/4 in NPSF) 50
head and bonded washer
Axle drain plug 1 with tapered plug Taper plug (3/4 in BSP) 80
Figure 670. JCB Axles With Braked Hubs (If installed)

D
D Drain plug E Axle drain plug 2 location
Table 319. Axles With Braked Hubs

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 2 with hexagonal Plug (M22) 37.5
head and bonded washer
Axle drain plug 2 with tapered plug Taper plug (3/4 in BSP) 80
Figure 671. Hexagonal Head Plug and

Bonded Washer (Prior to January 2011)
27 - 267 9813/9050-1 27 - 267

27 - Driveline
27 - Hub
00 - General
Figure 672. Taper Plug (If in-

stalled) (January 2011 Onwards)
27 - 268 9813/9050-1 27 - 268

27 - Driveline
27 - Hub
00 - General
Calibrate
Refer to the relevant Disassemble and Assemble

27 - 269 9813/9050-1 27 - 269

27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 674.

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 673.
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 - 270 9813/9050-1 27 - 270

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-273
27 - 271 9813/9050-1 27 - 271

Notes:
27 - 272 9813/9050-1 27 - 272

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-273 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-274 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-274 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 - 273 9813/9050-1 27 - 273

27 - Driveline
29 - Wheel
00 - General
Health and Safety Remove and Install

WARNING If, for whatever reason, a wheel stud WARNING Whenever a wheel has been
is renewed, all the studs for that wheel must be changed, check the nut torques every two hours.
changed as a set, since the remaining studs may When the nuts stay tight for 8h, the interval for
have been damaged. checking can revert to the period stated in the
servicing schedule.
WARNING Wheels and tyres are heavy. Take
care when lifting or moving them. Store with care DANGER Run flat inserts may be installed in the
to ensure that they cannot fall and cause injury. rear wheels. These must remain installed to the
rear wheels to ensure machine stability is not
WARNING An exploding tyre can kill. Inflated
compromised in the event of a deflated tyre.
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the Make sure that all tyres are inflated to the correct
tyres. Do not cut or weld the rims. Use a tyre/ pressure and have run flat inserts as required.
wheel specialist for all repair work. Where run flat inserts have been specified for use,
WARNING Deflate the tyre you wish to change ensure that replacement wheels also have run flat
before removing the wheel from the machine. inserts to ensure the machine stability.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner Remove (One Wheel)
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Wheels installed with semi-solid tyres 2. Follow the general health and safety procedures.
are heavy. Removing and installing them requires Refer to (PIL 01-03).
special equipment and training. Have the work
carried out by your JCB dealer or a tyre specialist. 3. Put chocks 1 under the rear wheels.
WARNING Do not install pneumatic tyres on a 4. Loosen the five wheel nuts by half a turn.
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If 5. Put a jack under the axle arm. Use the correct
you are unsure of the correct specification for jack.
your machine, contact your local JCB dealer or a
6. Use the jack to lift the machine until the front
trained specialist.
wheel is off the ground.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the 7. Put chocks 2 under the axle arm.
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre. 8. Hold the wheel and remove the wheel nuts.
Make sure that all tyres are inflated to the correct 9. Remove the wheel.
pressure and have run flat inserts as required.
Where run flat inserts have been specified for use,
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
27 - 274 9813/9050-1 27 - 274

27 - Driveline
29 - Wheel
00 - General
Figure 675.
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 680N·m
27 - 275 9813/9050-1 27 - 275

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-277
27 - 276 9813/9050-1 27 - 276

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-277 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-278 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-278 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 - 277 9813/9050-1 27 - 277

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 - 278 9813/9050-1 27 - 278

27 - Driveline
33 - Tyre
00 - General
Figure 676.
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 - 279 9813/9050-1 27 - 279

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-281
27 - 280 9813/9050-1 27 - 280

27 - Driveline
47 - Propshaft
00 - General

Check (Condition) ........................................ 27-281 1. Make the machine safe. Refer to (PIL 01-03).
Lubricate ...................................................... 27-282
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 - 281 9813/9050-1 27 - 281

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 - 282 9813/9050-1 27 - 282

27 - Driveline
47 - Propshaft
00 - General
Remove and Install

Strength)
Special MPL-EP 4003/1501 0.4kg
Grease 4003/1506 12.5kg
4003/1510 50kg
WARNING Before disconnecting any propshaft,

make sure you block both sides of all wheels B
to prevent machine movement. The park brake
will become ineffective or may only operate on 2
wheels (depending on machine specification). C
Remove
1. Make the machine safe with the lift arm
raised. Refer to (PIL 01-03). Install the lift arm
maintenance strut, refer to (PIL 06-69). A
2. Remove the central access panels. refer to (PIL A Bolts 1
06-06). B Bolts 2
C Strap
3. Put marks on both propshaft companion flanges
and the sliding joints before removal to help 4.2. Remove the nuts and the bolts 1 to
during the replacement procedure. disconnect the propshaft coupling from the
transmission.
4. Machines without RAS (Rear Axle Stabilization):
4.3. Remove the bolts 2 and straps to
4.1. Support the propshaft. disconnect the propshaft form the axles.
5. Machines with RAS:
5.1. Support the auxiliary speed sensor plate.
5.2. Support the propshaft.
5.3. Remove the bolts 1 to disconnect the
propshaft coupling from the transmission.
5.4. Remove the auxiliary speed sensor plates
from behind the park brake disc.
5.5. Remove the bolts 2 and straps to
disconnect the propshaft coupling from the
axle.
Consumable: Special MPL-EP Grease
27 - 283 9813/9050-1 27 - 283

27 - Driveline
47 - Propshaft
00 - General
Figure 678.
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 679.
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 679.
the case of a shaft being replaced use the
manufacturer's alignment markings.
2. Apply sealant to the threads of all the flange
bolts.
(Medium Strength)
27 - 284 9813/9050-1 27 - 284

27 - Driveline
47 - Propshaft
00 - General
Figure 679.
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 - 285 9813/9050-1 27 - 285

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-287

27-51-15 Shaft Hub Side ............................................................................................................. 27-289
27 - 286 9813/9050-1 27 - 286

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-287 The driveshaft is a mechanical component for
Check (Condition) ........................................ 27-288 transmitting torque and rotation, usually used to
Lubricate ...................................................... 27-288 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 - 287 9813/9050-1 27 - 287

27 - Driveline
51 - Driveshaft
00 - General
Check (Condition) Lubricate
(For: 55-Series, 70/80-Series) (For: 55-Series, 70/80-Series)

1. Make the machine safe. Refer to (PIL01-03). 1. Make the machine safe. Refer to (PIL 01-03).
2. Check the joint for damage, cracks or play. 2. Make sure you have the correct grease. Refer to
(PIL 75-00).
3. Renew any defective component as needed.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
driveshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
4. Remove any excess grease.
27 - 288 9813/9050-1 27 - 288

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
15 - Shaft Hub Side 7. Measure the gap at the top trunnion and subtract
1 mm (0.040 in) to give the shim thickness
(bearing pre-load). Refer to Figure 681.
Remove and Install
Figure 681. Measuring the top trunnion gap
(For: 55-Series)
Consumables
Strength)
Calibrate
Previous axles had a shim installed under the top
trunnion. The shim controls the bearing pre-load.
When you assemble, select the correct thickness

shim and check the bearing pre-load as follows:
1. Locate the hub swivel and install the bottom

trunnion. 8. Remove the top trunnion and install the correct
shim.
2. Apply JCB Threadlocker to the bottom trunnion
bolts. 9. Install the top trunnion.
Consumable: JCB Threadlocker and Sealer 10. Apply JCB Threadlocker to the top trunnion bolts.
(Medium Strength)
3. Tighten the bolts to the specified torque value. (Medium Strength)
Torque: 98N·m 11. Tighten the bolts to the specified torque value.
4. Install the top trunnion and finger tighten the top Torque: 98N·m
trunnion bolts.
12. Check that the spring balance reading which
5. Attach a spring balance to the track rod swivel should be 4.5 kgf (10lbf) more than the reading
and note the reading. Refer to Figure 680. mentioned in the step 5.
Figure 680. Measuring the swivel turning force Table 322. Example of
shim thickness calculation
Gap 1.55mm
Subtract 1mm
Shim Thickness 0.55mm
6. Tighten the top trunnion bolts to stop end float

but not the bearing pre-load, so that there is no
increase in the spring balance reading.
27 - 289 9813/9050-1 27 - 289

Notes:
27 - 290 9813/9050-1 27 - 290

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-09 Levelling System ............................................................................................................ 30-29
30-00-49 Schematic Symbols ........................................................................................................ 30-34
30-00-50 Schematic Circuit ........................................................................................................... 30-38
30-03 Tank
30-03-00 General ......................................................................................................................... 30-119
30-04 Filter
30-04-00 General ......................................................................................................................... 30-127
30-04-03 Main .............................................................................................................................. 30-128
30-04-09 Return Line ................................................................................................................... 30-130
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-134
30-11 Gear Pump
30-11-00 General ......................................................................................................................... 30-137
30-12 Variable Displacement Pump
30-12-00 General ......................................................................................................................... 30-149
30-15 Cylinder / Ram
30-15-00 General ......................................................................................................................... 30-159
30-15-06 Lift Arm ......................................................................................................................... 30-171
30-15-07 Lift Extension ................................................................................................................ 30-177
30-15-08 Lift Compensating ........................................................................................................ 30-183
30-15-11 Lift Arm Crowd ............................................................................................................. 30-186
30-15-34 Steering ........................................................................................................................ 30-193
30-15-63 Sway ............................................................................................................................. 30-196
30-15-99 Seal Kit ......................................................................................................................... 30-199
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-203
30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-207
30-21 Oil Cooler
30-21-00 General ......................................................................................................................... 30-215
30-51 Lift Arm Control Valve Block
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-219
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-220
30-51-21 Load Sense Relief Valve .............................................................................................. 30-223
30-51-24 Flow Regulator ............................................................................................................. 30-225
30-53 Servo System Control Valve Block
30-53-00 General ......................................................................................................................... 30-229
30-53-27 Pressure Compensator Valve ...................................................................................... 30-245
30-53-36 Load Hold Check Valve ............................................................................................... 30-246
9813/9050-1
2017-12-21
30-53-80 Spool ............................................................................................................................ 30-247
30-54 Parallel Circuit Control Valve Block
30-54-00 General ......................................................................................................................... 30-251
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-277
30-60-12 Electro Proportional Control ......................................................................................... 30-279
30-60-15 Joystick ......................................................................................................................... 30-292
30-60-27 Auxiliary Circuit ............................................................................................................ 30-296
30-60-82 Sway ............................................................................................................................. 30-297
30-60-90 Flow Regulator ............................................................................................................. 30-301
30-61 Counterbalance Valve
30-61-00 General ......................................................................................................................... 30-303
30-61-06 Lift Arm ......................................................................................................................... 30-308
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-313
30-70 Pilot Pressure Supply Valve
30-70-00 General ......................................................................................................................... 30-317
30-93 Hose
30-93-00 General ......................................................................................................................... 30-321
30-93-03 Lift Arm ......................................................................................................................... 30-329
30-96 Pipe
30-96-03 Lift Arm ......................................................................................................................... 30-331
30-97 Connectors
30-97-03 Quick Release Coupling .............................................................................................. 30-333
30-97-09 Adaptor ......................................................................................................................... 30-335
30-97-24 Push Lock Fitting ......................................................................................................... 30-337
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-338
9813/9050-1
2017-12-21
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
PWM Pulse Width Modulation
QRC Quick Release Coupling
SAE Society of Automotive Engineers
SRS Smooth Ride System
TBV Trailer Brake Valve
9813/9050-1
2017-12-21
Notes:
9813/9050-1
2017-12-21
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-09 Levelling System ............................................................................................................ 30-29
30-00-49 Schematic Symbols ........................................................................................................ 30-34
30-00-50 Schematic Circuit ........................................................................................................... 30-38
30 - 1 9813/9050-1 30 - 1
Notes:
30 - 2 9813/9050-1 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3
Health and Safety ........................................... 30-4
Technical Data ................................................. 30-4
Operation ....................................................... 30-11
Operation (Hydraulic) .................................... 30-17
Diagram ......................................................... 30-18
Fault-Finding .................................................. 30-21
Clean ............................................................. 30-23
Check (Level) ................................................ 30-24
Check (Pressure) .......................................... 30-25
Table 323. Valve Block and Pump Options

Machine Valve Block Options Hydraulic Pump Op-
tions
531-70 Manual lever Electro servo Gear
30 - 3 9813/9050-1 30 - 3
00 - General
00 - General

Hydraulic Pressure For: 535-95 [5AB] ........................ Page 30-4
For: 541-70 [5AD] ....................... Page 30-5
Before connecting or removing any hydraulic hose, For: 531-70 [5AA] ........................ Page 30-7
hose line must be vented. Make sure the hose (For: 535-95 [5AB])
removing hoses. Make sure the machine cannot be Gear Pump Machines
WARNING! Fine jets of fluid at high pressure can Double Pump Machines
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. Table 324. System Pressures (Gear
Pump- 2 Section) EN15000 Multi Lever
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot. Circuit Restriction Relief Valve
Setting
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use Neutral Circuit Pressure lim- 240bar
the machine if a hose or hose fixture is damaged. ited by main (3,478.2psi)
valve block
Notice: Using incorrect fluid could damage the MRV (Main Re-
system. See Fluids, Capacities and Lubricants for lief Valve)
the correct fluid. The fluid can harm your skin. Wear
Neutral Circuit Fan Motor Cir- 230bar
rubber gloves. Cover cuts or grazes.
cuit limited by (3,333.3psi)
Notice: Do not allow dirt to enter the system. Before the ARV (Aux-
disconnecting any part of the system, thoroughly iliary Relief
clean around the connection. When a component Valve)
has been disconnected, always install protective Neutral Circuit Trailer Brake 150bar
caps and plugs to prevent dirt ingress.Failure to Circuit limited (2,173.9psi)
follow these instructions will lead to dirt entering the by the ARV to
system. Dirt in the system will seriously damage
Neutral Circuit Sway Circuit 220bar
the systems components and could be expensive to
limited by the (3,188.4psi)
repair.
ARV to
CAUTION! The temperature of the hydraulic oil will Lift End The lift circuit is 240bar
be high soon after stopping the machine. Wait until it limited to MRV (3,478.2psi)
cools before beginning maintenance. pressure
Notice: Using incorrect fluid could damage the Lift End The extension 240bar
system. See Fluids, Capacities and Lubricants for circuit is limited (3,478.2psi)
the correct fluid. The fluid can harm your skin. Wear to MRV pres-
rubber gloves. Cover cuts or grazes. sure
Lift End The tilt circuit is 240bar
limited to MRV (3,478.2psi)
pressure dur-
ing normal op-
eration and
the parallel lift
function when
the tilt ram end
stops is limited
by 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 - 4 9813/9050-1 30 - 4
00 - General
00 - General
Triple Pump Machines Circuit Restriction Relief Valve

Setting
Neutral Circuit Sway Circuit 220bar
Table 325. System Pressures (Gear
Pump- 3 Section) EN15000 Single Lever
ARV to
Circuit Restriction Relief Valve Lift End The lift circuit is 240bar
Setting limited to MRV (3,478.2psi)
Neutral Circuit Pressure limited 240bar pressure
by main valve (3,478.2psi) Lift End The extension 240bar
block MRV circuit is limited (3,478.2psi)
Neutral Circuit Fan Motor Cir- 230bar to MRV pres-
cuit limited by (3,333.3psi) sure
the ARV Lift End The tilt circuit is 240bar
Neutral Circuit Trailer Brake 150bar limited to MRV (3,478.2psi)
Circuit limited (2,173.9psi) pressure dur-
by the ARV to ing normal op-
Neutral Circuit Sway Circuit 220bar eration and
limited by the (3,188.4psi) the parallel lift
ARV to function when
the tilt ram end
Lift End The lift circuit is 240bar
stops is limited
by ARV to
pressure
Lift End The extension 240bar
circuit is limit- (3,478.2psi)
ARV to
ed to the MRV
pressure Steer Circuit Steer circuit is 190bar
ARV to
limited to MRV- (3,478.2psi)
pressure dur-
ing normal op-
eration and
the parallel lift (For: 541-70 [5AD])
function when
the tilt ram end Gear Pump Machines
stops is limited
by the ARV to Double Pump Machines
ARV to Table 327. System Pressures (Gear
Pump- 2 Section) EN15000 Multi Lever
limited by the (2,753.6psi) Circuit Restriction Relief Valve
ARV to Setting
Neutral Circuit Pressure limited 260bar
Variable Pump Machines by main valve (3,768.1psi)
block MRV
Table 326. System Pressures (Variable Pump) cuit limited by (3,333.3psi)
Circuit Restriction Relief Valve the ARV
Setting Neutral Circuit Trailer Brake 150bar
Neutral Circuit Pressure limited 240bar Circuit limited (2,173.9psi)
by main valve (3,478.2psi) by the ARV
block MRV Neutral Circuit Sway Circuit 220bar
Neutral Circuit Fan Motor Cir- 230bar limited by the (3,188.4psi)
cuit limited by (3,333.3psi) ARV
the ARV Lift End Pressure limited 260bar
Neutral Circuit Trailer Brake 150bar by main valve (3,768.1psi)
Circuit limited (2,173.9psi) block MRV set
by the ARV to at
30 - 5 9813/9050-1 30 - 5
00 - General
00 - General
Circuit Restriction Relief Valve Circuit Restriction Relief Valve

Setting Setting
Lift End Pressure limited 260bar Auxiliaries / Auxiliary circuit 220bar
by main valve (3,768.1psi) Hitch is limited by the (3,188.4psi)
block MRV set ARV to
at Steer Circuit Steer circuit is 190bar
Lift End The tilt circuit is 138bar limited by the (2,753.6psi)
limited to MRV (2,000.0psi) ARV to
pressure dur-
ing normal op- Variable Pump Machines
eration and
the parallel lift
A536-70L Machine (Not Agri Plus / Super /
function when
the tilt ram end Xtra)
stops is limited
by the ARV to Table 329. System Pressures (Variable
Auxiliaries / Auxiliary circuit 220bar Pump) Not Agri Plus / Super / Xtra)
ARV to Circuit Restriction Relief Valve
Setting
limited by the (2,753.6psi) Neutral Circuit Pressure limited 260bar
ARV to by main valve (3,768.1psi)
block MRV
Triple Pump Machines Neutral Circuit Fan Motor Cir- 230bar
cuit limited by (3,333.3psi)
the ARV
Table 328. System Pressures (Gear
Neutral Circuit Trailer Brake 150bar
Pump- 3 Section) EN15000 Single Lever
Circuit limited (2,173.9psi)
Circuit Restriction Relief Valve by the ARV
Setting Neutral Circuit Sway Circuit 220bar
Neutral Circuit Pressure limited 260bar limited by the (3,188.4psi)
by main valve (3,768.1psi) ARV
block MRV Lift End The lift circuit is 260bar
Neutral Circuit Fan Motor Cir- 230bar limited to MRV (3,768.1psi)
cuit limited by (3,333.3psi) pressure
the ARV Lift End The extension 260bar
Neutral Circuit Trailer Brake 150bar circuit is limited (3,768.1psi)
Circuit limited (2,173.9psi) to MRV pres-
by the ARV sure
Neutral Circuit Sway Circuit 220bar Lift End The tilt circuit is 140bar
limited by the (3,188.4psi) limited to MRV (2,029.0psi)
ARV pressure dur-
Lift End The lift circuit is 260bar ing normal op-
limited to MRV (3,768.1psi) eration and
pressure the parallel lift
Lift End The extension 260bar function when
circuit is limited (3,768.1psi) the tilt ram end
to MRV pres- stops is limited
sure by the ARV to
Lift End The tilt circuit is 138bar Auxiliaries / Auxiliary circuit 220bar
limited to MRV (2,000.0psi) Hitch is limited by the (3,188.4psi)
pressure dur- ARV to
ing normal op- Steer Circuit Steer circuit is 190bar
eration and limited by the (2,753.6psi)
the parallel lift ARV to
function when
the tilt ram end
stops is limited
by the ARV to
30 - 6 9813/9050-1 30 - 6
00 - General
00 - General
A536-70L Machine Agri Plus / Super Circuit Restriction Relief Valve

Setting
Table 330. System Pressures
(Variable Pump) Agri Plus / Super
Circuit Restriction Relief Valve pressure
Setting Lift End The extension 260bar
Neutral Circuit Pressure limited 260bar circuit is limited (3,768.1psi)
by main valve (3,768.1psi) to MRV pres-
block MRV sure
Neutral Circuit Fan Motor Cir- 230bar Lift End The tilt circuit is 200bar
cuit limited by (3,333.3psi) limited to MRV (2,898.5psi)
the ARV pressure dur-
Neutral Circuit Trailer Brake 150bar ing normal op-
Circuit limited (2,173.9psi) eration and
by the ARV the parallel lift
Neutral Circuit Sway Circuit 220bar function when
limited by the (3,188.4psi) the tilt ram end
ARV stops is limited
by the ARV to
limited to MRV (3,768.1psi) Auxiliaries / Auxiliary circuit 220bar
pressure Hitch is limited by the (3,188.4psi)
ARV to
Lift End The extension 260bar
circuit is limited (3,768.1psi) Steer Circuit Steer circuit is 198bar
to MRV pres- limited by the (2,869.6psi)
sure ARV to
pressure dur- (For: 531-70 [5AA])
ing normal op-
eration and Valve 25/411600 Mechanical Lever
the parallel lift Control, (Non SRS).
function when
the tilt ram end Figure 682.
stops is limited F
by the ARV to
ARV to B
ARV to A
1 2 3 4
A536-70L Machine Agri Xtra
Table 331. System Pressures
(Variable Pump) Agri Xtra
Circuit Restriction Relief Valve
Setting C
Neutral Circuit Pressure limited 260bar
by main valve (3,768.1psi)
block MRV
D
cuit limited by (3,333.3psi) E
ARV
1 Lift spool (double acting)
Neutral Circuit Trailer Brake 150bar 2 Extend spool (double acting)
Circuit limited (2,173.9psi) 3 Tilt spool (double acting)
by the ARV 4 Auxiliary spool (double acting)
- - - A Port A
30 - 7 9813/9050-1 30 - 7
00 - General
00 - General
B Port B
C Top outlet section
D Linkage assemby
E MRV position
F Top inlet
Table 332.
MRV pressure 241.3bar (3,497.1psi)
Valve 25/407900 Mechanical Single Lever

Control, (Non SRS).
Figure 683.
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 333.
MRV pressure 241.3bar (3,497.1psi)
30 - 8 9813/9050-1 30 - 8
00 - General
00 - General
Figure 684.
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

B Control valve Parallel valve
Table 334.
block block
Item Description Notes C Hydraulic oil fil- Positioned in
A Pump assembly Two or three ter the return line
section to tank
gearpump D Hydraulic tank -
A1 Pump section 1 - E Fan motor Driven by pump
A2 Pump section 2 - section 2
A3 Pump section 3 -
30 - 9 9813/9050-1 30 - 9
00 - General
00 - General

F Hydraulic oil Oil from pump
cooler section 2 flows
through the oil
cooler
G Single lever -
control
30 - 10 9813/9050-1 30 - 10
00 - General
00 - General
Operation
cooling fan hydraulic motor. On sway machines a

Hydraulic pump changeover valve switches oil supply between the
sway ram service and the fan motor.
Oil is drawn from the hydraulic tank by the hydraulic
pump assembly. The pump assembly is mounted on Some smaller machines may have a hydraulic pump
the rear of the bevel gearbox and is driven by the with only two sections, in this case the larger pump
engine. section 1 has the integral priority valve, and operates
in the same way as section 2.
The pump has three sections, Oil from the larger
pump section 1 flows direct to the control valve block. In neutral circuit conditions (i.e. no service selected),
Pump section 2 has an integral priority valve which the oil flows through the control valve block neutral
always gives priority demand to the steer circuit. gallery into the return or exhaust line and back to the
With the steering in the straight ahead position (i.e. tank through an in-tank filter.
with no steering demand), oil from pump section 2
flows through the priority valve and joins with the flow Some machine variants also have a hydraulic oil
from pump section 1 to feed the control valve block. cooler in the return line from the fan hydraulic motor,
Pump section 3 is dedicated to driving the cooling to cool the system hydraulic oil as it is continually
fan. Oil from pump section 3 flows directly to the circulated around the cooling fan circuit.
30 - 11 9813/9050-1 30 - 11
00 - General
00 - General
Figure 685.
G H
C
J
A
E
Q
A1 A2 A3
K N
L P
M
Item Description
Table 335. 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 336. 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 9813/9050-1 30 - 12
00 - General
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Item Description spools. A third lever operates the auxiliary service

N Return to tank spool. The levers operate the spools via mechanical
linkages. For machines with stabilisers two more
P Oil from pump section 3 levers are installed to operate the stabiliser service
spools (6 spool control valve).
Control valve block
Single lever control
The control valve block controls the boom hydraulic
services. For machines with stabilisers, the valve has Machines with single lever control use a lever which
two more spools to control the stabiliser hydraulic moves in two axis and operates two service spools
services. via mechanical linkages. Buttons on the control lever
operate solenoid valves on the remaining two spools.
When the control valve spools are actuated, oil from
the pump passes into the service ports, operating the
relevant hydraulic ram.
Parallel lift
The parallel lift system is used to make sure that
The control valve contains MRV (Main Relief Valve)
when the boom raise/lower or extend/retract services
and ARV (Auxiliary Relief Valve). These valves
are operated, the forks remain parallel to the ground.
prevent the hydraulic pressure increasing to a
level which would cause damage to the hydraulic
components and pipework. Boom regenerative valve (3 stage
booms)
The control valve block inlet section also includes
valves which are used for the LLMC (Longitudinal The regenerative valve is installed to the outer
Load Moment Control) system. extension ram to increase the speed of the boom
during the extend cycle, under light load conditions.
Dual lever control Hydraulic oil is displaced from the rod side of the
inner extension ram to supplement the pump flow to
Machines with dual lever control use two control the head side of the outer extension ram. The speed
levers for operation of the three loader service of the extending boom is increased.
Figure 686.
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 9813/9050-1 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 687.
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 9813/9050-1 30 - 14
00 - General
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Figure 688.
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 689.
U1
V
Y
U
Z
30 - 15 9813/9050-1 30 - 15
00 - General
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Z Check valve
30 - 16 9813/9050-1 30 - 16
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Operation (Hydraulic) and leakage and can lead to major problems. The
main contaminants can be classified as follows:
The hydraulic system is a power transmission system 1. Solid Particles - Sand, fibres, metallic particles,
that uses the force of flowing liquids to transmit power welding scale, sealing materials and wear
to specific components in a machine. particles etc.
To help you trace specific hydraulic problems to a 2. Liquid - Usually water and incompatible oils and
faulty unit (valve, actuator, ram etc.), refer to Fault greases.
finding. Refer to: PIL 30-00-00.
3. Gases - Air, sulphur dioxide etc. which can create
Once you have traced the faulty unit, refer to corrosive compounds if dissolved in the fluid.
the relevant section for removal, disassembly and
checking instructions. These contaminants can appear during
manufacture, assembly and operation.
To help identify circuits, valves, rams etc. mentioned
in the fault finding procedures. Refer to the hydraulic
schematic diagrams. Refer to: PIL 30-00-50.
• Before you begin fault finding, read the Health

and Safety Information. Refer to: PIL 30-00-00.
• Make simple checks before you remove or
disassemble a major component.
• Make sure that the hydraulic fluid is at the
correct working temperature 50°C (121.9°F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
and Hydraulic System - Clean. Refer to: PIL
30-00-00.
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
30 - 17 9813/9050-1 30 - 17
00 - General
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Diagram
Neutral
Figure 690.
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 337. Colour codes
for oil flow and pressure AD Servo
AE Load sense line
AA Full Pressure
AB Neutral
30 - 18 9813/9050-1 30 - 18
00 - General
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One service operated
Figure 691.
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 9813/9050-1 30 - 19
00 - General
00 - General
Main system pressure relief
Figure 692.
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 9813/9050-1 30 - 20
00 - General
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Fault-Finding
Fault
One service fails, or is slow to operate. Table 340. Page 30-21
The engine tends to stall when hydraulics are under load. Table 341. Page 30-21
Forks creep down Table 342. Page 30-22
Parallel lift faulty Table 343. Page 30-22
Ram creep Table 344. Page 30-22
Table 340. 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 341. 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 9813/9050-1 30 - 21
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Table 342. 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 343. 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 344. 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 9813/9050-1 30 - 22
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00 - General
Clean • Red Blood Cell = 8 microns (0.008 mm,

0.000315 in)
Special Tools • Human Hair = 70 microns (0.07 mm, 0.00275
Description Part No. Qty. in)
Hydraulic Flushing Rig 892/01255 1 • Grain of Salt = 100 microns (0.1 mm, 0.00394
in)
Cleaning Operation The smallest particle visible to the naked eye is
40 microns (0.00157) approximately. Standards will
The purpose of cleaning oil is to remove often be quoted to ISO (International Standards
contaminants of all types and sludge by filtering Organisation) for which literature can be obtained.
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
manual.
Procedure
1. Connect the Hydraulic flushing rig in place of the
hydraulic filter.
Special Tool: Hydraulic Flushing Rig (Qty.: 1)
2. Run the system for sufficient time to pump all the
hydraulic fluid through the unit.
3. Disconnect the cleaning unit and reconnect the
filter.
4. Top up the system with clean hydraulic fluid as
required.
Figure 693.
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 - 23 9813/9050-1 30 - 23
00 - General
00 - General
Check (Level)
2. Machines may be installed with a sight tube or a
dipstick for hydraulic fluid level display.
Machines with a Sight Tube

1. Look at the hydraulic fluid in the sight tube. If
the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
2. The level of hydraulic fluid should be between the
two marks on the sight tube.
3. If necessary, add the recommended hydraulic
fluid:
3.1. Discharge the pressure from the hydraulic
tank. Refer to (PIL 30-00).
3.2. Get safe access to the hydraulic filler port.
3.3. Use a suitable container to add the
hydraulic fluid through the filler port.
3.4. Check the level of hydraulic fluid.
Machines with a Dipstick

1. Open the rear cover if installed. Refer to (PIL
06-06-14).
2. Discharge the pressure from the hydraulic tank.
3. Get access to the hydraulic dipstick / breather.
Remove the dipstick from the hydraulic tank.
4. If the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
5. Check the hydraulic oil level. The level of
hydraulic fluid should be between the two marks
on the dipstick
6. If necessary, add the recommended hydraulic
fluid:
6.1. Get safe access to the hydraulic filler port.
6.2. Use a suitable container to add the
hydraulic fluid through the filler port.
6.3. Check the level of hydraulic fluid.
30 - 24 9813/9050-1 30 - 24
00 - General
00 - General
Check (Pressure)
Special Tools Figure 695. Test Point (Typical Triple Pump)

Digital Hydraulic 998/11051 1
Pressure Test Kit
Testing MRV Pressure

30-00).
3. Connect the digital hydraulic pressure test kit to
the pressure test point.
A
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1)
4. Start the engine and bring the hydraulic system
to the specified working temperature. A Pressure test point
Testing ARV's Set Lower than the MRV
5. Select the lift arm lower service and hold the ram
fully closed. 1. Make the machine safe. Refer to (PIL 01-03).
6. Gradually increase the engine speed to 2200 2. Discharge the hydraulic pressure. Refer to (PIL
RPM (Revolutions Per Minute) while checking 30-00).
the maximum gauge reading. Refer to (PIL
30-00). 3. Connect the digital pressure test kit to the
pressure test point.
Figure 694. 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
A Pressure test point
30 - 25 9813/9050-1 30 - 25
00 - General
00 - General
Figure 696. 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 698. , Refer to
Figure 697. Test Point (Typical Triple Pump)
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 - 26 9813/9050-1 30 - 26
00 - General
00 - General
Figure 698. Tilt ram hose at the rear lift arm bulkhead bracket
A Hose B Connector
Figure 699. Tilt ram hose forward of the lift arm pivot
A Hose B Connector
30 - 27 9813/9050-1 30 - 27
00 - General
00 - General
Figure 700. Tilt ram hose on the displacement ram hose, lift arm underside
A Hose B Connector
30 - 28 9813/9050-1 30 - 28
00 - General
09 - Levelling System
Operation
Table 345. 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 701. 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 - 29 9813/9050-1 30 - 29
00 - General
Figure 702.
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 - 30 9813/9050-1 30 - 30
00 - General
Figure 703.
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 - 31 9813/9050-1 30 - 31
00 - General
Figure 704. 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 705.
Q
J
R H
S
G
K
L
P
F N

30 - 32 9813/9050-1 30 - 32
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 706.
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 - 33 9813/9050-1 30 - 33
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-34 Complex hydraulic components and circuits can
Diagram ......................................................... 30-35 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 - 34 9813/9050-1 30 - 34
00 - General
Diagram Table 349. Directional control valves

Symbol Description
Used to enclose sever-
Table 346. 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 347. 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 348. 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 - 35 9813/9050-1 30 - 35
00 - General
Table 350. 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 351. 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 - 36 9813/9050-1 30 - 36
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 - 37 9813/9050-1 30 - 37
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-38 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-39 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 - 38 9813/9050-1 30 - 38
00 - General
Diagram
For: 531-70 [5AA], 535-95 [5AB], 541-70

[5AD] ......................................... Page 30-39
For: 535-95 [5AB] .................... Page 30-112
(For: 531-70 [5AA], 535-95 [5AB], 541-70 [5AD])
Figure 707. Parallel Dual Lever Control 334/L1242-9 (531-70)............................................. Page 30-41
Figure 708. Parallel Dual Lever Control 334/L1244-10 (535-95)........................................... Page 30-47
Figure 709. Parallel Dual Lever Control 334/L1243-10 (541-70, 536-70).............................. Page 30-53
Figure 710. Parallel Single Lever Control 334/L1247-10 (531-70)......................................... Page 30-59
Figure 711. Parallel Single Lever Control 334/L1245-13 (535-95)......................................... Page 30-65
Figure 712. Parallel Single Lever Control 334/L1246-11 (536-70, 541-70)............................ Page 30-71
Figure 713. LSP Electro Servo (S1) 334/L7029-7 (531-70, 536-70, 541-70)......................... Page 30-77
Figure 714. LSP Electro Servo (S2) 333/G4103-9 (531-70).................................................. Page 30-83
Figure 715. LSP Electro Servo (S2) 333/G4105-11 (535-95).................................................Page 30-89
Figure 716. LSP Electro Servo (S2) 333/G4102-8 (536-60).................................................. Page 30-95
Figure 717. LSP Electro Servo (S2) 333/G1967-8 (536-70, 541-70)................................... Page 30-101
Figure 718. LSP Electro Servo (S4) 332/H1323-14 (550-80)...............................................Page 30-107
Specification Variants- Hydraulic 536-60 Machines
Schematics
1. LSP Electro Servo Control (S2), Refer to Figure
716.
531-70 Machines
1. Parallel Lever Dual Control (P1), Refer to Figure 536-70, 541-70 Machines
707.
1. Parallel Lever Dual Control (P2), Refer to Figure
2. Parallel Lever Single Control (P6), Refer to 709.
Figure 710.
2. Parallel Lever Single Control (P5), Refer to
3. LSP Electro Servo Control (S1), Refer to Figure Figure 712.
713.
4. LSP Electro Servo Control (S2), Refer to Figure 713.
714.
717.
535-95 Machines
1. Parallel Lever Dual Control (P3), Refer to Figure 550-80 Machines
708.
2. Parallel Lever Single Control (P4), Refer to 718.
Figure 711.
715.
30 - 39 9813/9050-1 30 - 39
Notes:
30 - 40 9813/9050-1 30 - 40
00 - General
Page 30-42 Figure 707. Parallel Dual Lever

Control 334/L1242-9 (531-70) Page 30-43
J
J
J
A J
J
B
E
F
G
H
30 - 41 9813/9050-1 30 - 41
00 - General
Page Page
30-42 30-43
Figure 707. (Part 1 of 2)
Page 30-43
D
G
H
30 - 42 9813/9050-1 30 - 42
00 - General
Page Page
30-42 30-43
J
J
J
A J
J
B
C
Page 30-42
E
F
G
H
30 - 43 9813/9050-1 30 - 43
00 - General
Note The schematic shows the sway option. On

non sway machines the pump flow goes
directly to the fan motor.
Table 352. Parallel Dual Lever Control 334/L1242-9 (531-70)

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
5 Hydraulic control valve
8 Poppet valve - 2 port SRS (Smooth Ride System) - 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
30 - 44 9813/9050-1 30 - 44
00 - General

61 Sway cylinder Sway
62 Check valve - low leak Sway
63 Pilot piston Sway
64 Restrictor Sway
65 Check valve
30 - 45 9813/9050-1 30 - 45
Notes:
30 - 46 9813/9050-1 30 - 46
00 - General

Control 334/L1244-10 (535-95) Page 30-49
J
J J
J
A
J
B K
C
L
F
E
G
H
30 - 47 9813/9050-1 30 - 47
00 - General
Page Page
30-48 30-49
Page 30-49
D
F
E
G
H
30 - 48 9813/9050-1 30 - 48
00 - General
Page Page
30-48 30-49
J
J J
J
J
K
Page 30-48
30 - 49 9813/9050-1 30 - 49
00 - General
Note The schematic shows sway or trailer Note On non sway/trailer brakes machines the
brake options. pump flow goes direct to the fan motor
Note When sway and trailer brakes are
combined then: Port N (TBV (Trailer Brake
Valve)) to port P (sway), Port F (sway) to
fan feed, Port R (TBV) tees in to port T
(sway)
Table 353. Parallel Dual Lever Control 334/L1244-10 (535-95)

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
F MRV
G Compensator valve
K Make up valve detail
L Regen valve
ble pump
7 Trailer brake valve
8 Poppet valve - 2 port SRS - rod side drain
14 Inner extend cylinder Extend
15 Outer extend cylinder Extend
17 Hitch cylinder
30 Counterbalance cartridge SRS lift
31 Counterbalance cartridge Tilt and extend
33 Counterbalance cartridge Extend outer
breather
39 Cartridge Extend outer
30 - 50 9813/9050-1 30 - 50
00 - General

51 Accumulator SRS
52 Accumulator SRS
53 Accumulator Trailer brake
60 Sway valve Sway
64 Restrictor Sway
65 Vented counterbalance valve Extend outer
67 Make up valve Extend
68 Check valve
30 - 51 9813/9050-1 30 - 51
Notes:
30 - 52 9813/9050-1 30 - 52
00 - General

Control 334/L1243-10 (541-70, 536-70) Page 30-55
J
J
J
A J
J
B
F
E
G
H
30 - 53 9813/9050-1 30 - 53
00 - General
Page Page
30-54 30-55
Page 30-55
D
G
H
30 - 54 9813/9050-1 30 - 54
00 - General
Page Page
30-54 30-55
J
J
J
A J
J
B
C
Page 30-54
F
E
G
H
30 - 55 9813/9050-1 30 - 55
00 - General

non sway machines, the pump flow goes
direct to the fan motor.
Table 354. Parallel Dual Lever Control 334/L1243-10 (541-70, 536-70)

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
F MRV
G Compensator valve
ble pump
30 Counterbalance valve Lift
breather
51 Accumulator SRS
52 Accumulator SRS
60 Sway valve Sway
30 - 56 9813/9050-1 30 - 56
00 - General

64 Restrictor Sway
65 Check valve
Schematics- Parallel System with Single Lever Controls
30 - 57 9813/9050-1 30 - 57
Notes:
30 - 58 9813/9050-1 30 - 58
00 - General
Page 30-60 Figure 710. Parallel Single Lever

Control 334/L1247-10 (531-70) Page 30-61
J
J
J
J
J J
J
A
F
E
G
H
30 - 59 9813/9050-1 30 - 59
00 - General
Page Page
30-60 30-61
Page 30-61
D
30 - 60 9813/9050-1 30 - 60
00 - General
Page Page
30-60 30-61
J
J
J
J
J J
J
A
C
Page 30-60
F
E
G
H
30 - 61 9813/9050-1 30 - 61
00 - General

direct to the fan motor
Table 355. Parallel Single Lever Control 334/L1247-10 (531-70)

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
breather
51 Accumulator SRS
52 Accumulator SRS
30 - 62 9813/9050-1 30 - 62
00 - General

58 Bi-directional check valve AG tyre option
59 Check valve
30 - 63 9813/9050-1 30 - 63
Notes:
30 - 64 9813/9050-1 30 - 64
00 - General

Control 334/L1245-13 (535-95) Page 30-67
J J
J
A
K
B
L
C
F
E
G
H
30 - 65 9813/9050-1 30 - 65
00 - General
Page Page
30-66 30-67
Page 30-67
D
F
E
G
H
30 - 66 9813/9050-1 30 - 66
00 - General
Page Page
30-66 30-67
J J
L
Page 30-66
30 - 67 9813/9050-1 30 - 67
00 - General

Table 356. Parallel Single Lever Control 334/L1245-13 (535-95)

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
K Make up valve detail
L Regen valve
pump
14 Inner extend cylinder Extend
15 Outer extend cylinder Extend
17 Hitch cylinder
30 Counterbalance cartridge SRS Lift
31 Counterbalance cartridge Tilt and Extend
33 Counterbalance cartridge Extend outer
breather
30 - 68 9813/9050-1 30 - 68
00 - General

51 Accumulator SRS
52 Accumulator SRS
65 Vented counterbalance valve Extend outer
67 Make up valve Extend
68 Check valve
30 - 69 9813/9050-1 30 - 69
Notes:
30 - 70 9813/9050-1 30 - 70
00 - General

Control 334/L1246-11 (536-70, 541-70) Page 30-73
J
J
J
J
J
A
E F
G
H
30 - 71 9813/9050-1 30 - 71
00 - General
Page Page
30-72 30-73
Page 30-73
D
G
H
30 - 72 9813/9050-1 30 - 72
00 - General
Page Page
30-72 30-73
J
J
J
J
J
A
C
Page 30-72
E F
G
H
30 - 73 9813/9050-1 30 - 73
00 - General

Table 357. Parallel Single Lever Control 334/L1246-11 (536-70, 541-70)

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
pump
5 Hydraulic control valve EN 15000
17 Hitch cylinder
breather
51 Accumulator SRS
52 Accumulator SRS
30 - 74 9813/9050-1 30 - 74
00 - General

59 Check valve
Schematics- LSP Electro Servo System (S1)
30 - 75 9813/9050-1 30 - 75
Notes:
30 - 76 9813/9050-1 30 - 76
00 - General
Page 30-78 Figure 713. LSP Electro Servo (S1)

334/L7029-7 (531-70, 536-70, 541-70) Page 30-79
H
H
H
H
H
A
B
H
C
D
30 - 77 9813/9050-1 30 - 77
00 - General
Page Page
30-78 30-79
A
B
C
D
Page 30-79
30 - 78 9813/9050-1 30 - 78
00 - General
Page Page
30-78 30-79
H
H
H
H
H
A
B
H
C
D
G
Page 30-78
30 - 79 9813/9050-1 30 - 79
00 - General
Table 358. LSP Electro Servo (S1) 334/L7029-7 (531-70, 536-70, 541-70)
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
5 Servo system control 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 - 80 9813/9050-1 30 - 80
00 - General

40 Fan motor - 11cc 81–93kW
42 Variable fan motor - 19cc 55kW
43 Check valve
44 Check valve
30 - 81 9813/9050-1 30 - 81
Notes:
30 - 82 9813/9050-1 30 - 82
00 - General
Page 30-84 Figure 714. LSP Electro Servo

(S2) 333/G4103-9 (531-70) Page 30-85
D
E E
E
E
E
30 - 83 9813/9050-1 30 - 83
00 - General
Page Page
30-84 30-85
Page 30-85
D
30 - 84 9813/9050-1 30 - 84
00 - General
Page Page
30-84 30-85
C
Page 30-84
D
E E
E
E
E
30 - 85 9813/9050-1 30 - 85
00 - General
Table 359. LSP Electro Servo (S2) 333/G4103-9 (531-70)

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
250 Hydraulic oil cooler
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 - 86 9813/9050-1 30 - 86
00 - General

420 Accumulator SRS
430 Check valve
30 - 87 9813/9050-1 30 - 87
Notes:
30 - 88 9813/9050-1 30 - 88
00 - General

(S2) 333/G4105-11 (535-95) Page 30-91
C
F
F
D E
F E
E
E
E
E
30 - 89 9813/9050-1 30 - 89
00 - General
Page Page
30-90 30-91
Page 30-91
D
30 - 90 9813/9050-1 30 - 90
00 - General
Page Page
30-90 30-91
C
F
Page 30-90
D E
F E
E
E
E
E
30 - 91 9813/9050-1 30 - 91
00 - General

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release couplings
F Make up valve detail view
power control
30 Make-up valve Inner extend
40 Cartridge Outer extend
100 Lift cylinder SRS SRS Lift
140 Inner extend cylinder
150 Outer extend cylinder
160 Steering power track rod
200 Check valve
240 Vented Counterbalance Valve Outer extend
260 Hydraulic oil cooler -t4
320 Counterbalance cartridge Inner extend
330 Counterbalance cartridge Outer extend
340 Counterbalance valve - SRS
breather
390 Cartridge Outer extend
400 Variable fan motor 11cc 81–93kW
30 - 92 9813/9050-1 30 - 92
00 - General

430 Accumulator SRS
440 Sway valve Sway
460 Accumulator SRS
490 Check valve
30 - 93 9813/9050-1 30 - 93
Notes:
30 - 94 9813/9050-1 30 - 94
00 - General

(S2) 333/G4102-8 (536-60) Page 30-97
B
A
C
D
F
H
G
H H
H
H
H
H
30 - 95 9813/9050-1 30 - 95
00 - General
Page Page
30-96 30-97
C
D
Page 30-97
G
30 - 96 9813/9050-1 30 - 96
00 - General
Page Page
30-96 30-97
B
A
C
D
F
H
Page 30-96
G
H H
H
H
H
H
30 - 97 9813/9050-1 30 - 97
00 - General

A Steer priority valve
B Flow regulator valve
C LSRV
D Lift spool
E Tilt spool
F Extend spool
G Auxiliary spool
H Quick release couplings
ment
ment - power control
90 Lift valve Non SRS - 536-60
170 Hitch cylinder
200 Fan motor - 11cc 81–93kW
230 Check valve
260 Hydraulic oil cooler Combination - T4
280 Accumulator SRS
290 Accumulator SRS
300 Counterbalance valve Lift and extend
340 Lift valve SRS - 536-60
breather
30 - 98 9813/9050-1 30 - 98
00 - General

390 Check valve
30 - 99 9813/9050-1 30 - 99
Notes:
30 - 100 9813/9050-1 30 - 100

00 - General

(S2) 333/G1967-8 (536-70, 541-70) Page 30-103
C
E
E
D
E
E E
E
E
30 - 101 9813/9050-1 30 - 101

00 - General
Page Page
30-102 30-103
Page 30-103
C
30 - 102 9813/9050-1 30 - 102

00 - General
Page Page
30-102 30-103
B
Page 30-102
C
E
E
D
E
E E
E
E
30 - 103 9813/9050-1 30 - 103

00 - General
Table 362. LSP Electro Servo (S2) 333/G1967-8 (536-70, 541-70)

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release connectors
power control
90 Counterbalance valve - SRS
100 Lift cylinder SRS Lift
200 Check valve
230 Accumulator SRS
240 Sway valve Sway
260 Hydraulic oil cooler t4
320 Counterbalance valve Extend
330 Steer control valve Orbitrol
breather
400 Fan motor 11cc 81–93kW
30 - 104 9813/9050-1 30 - 104

00 - General

410 Variable speed fan motor - revers- 81–108kW
ing
420 Accumulator SRS
430 Check valve
30 - 105 9813/9050-1 30 - 105

Notes:
30 - 106 9813/9050-1 30 - 106

00 - General

(S4) 332/H1323-14 (550-80) Page 30-109
340
410
415
330
280
60 60
70
370 320 70
375
380 250
90 420
385 N 40
390 M
P 80
400 60
70
Q
120 90
140
R
310 130 130
350 150
430
170
S 160
T
360
U
190
30 180
U 200
U
180 U
10
U
290 280
300 180
U
240 U 220
20
210
50
270
230
H
90 E B
L
C G
I
H A J
D F
30 - 107 9813/9050-1 30 - 107

00 - General
Page Page
30-108 30-109
410
415
280
370 320
375
380 250
385 N 40
390 M
P
400
R
350 310
430
S
Page 30-109
T
360
30
10
290 280
300
20
50
270
H
90 E B
L
C G
I
H A J
D F
30 - 108 9813/9050-1 30 - 108

00 - General
Page Page
30-108 30-109
340
330
60 60
70
70
90 420
N 40
M
P 80
60
70
120 90
140
130 130
150
170
160
Page 30-108
U
190
180
U 200
U
180 U
U
180
U
240 U 220
210
230
30 - 109 9813/9050-1 30 - 109

00 - General
Table 363. LSP Electro Servo (S4) 332/H1323-14 (550-80)

A-L Tank ports
M Steer priority valve
N Flow regulator valve
P LSRV
Q Lift spool
R Tilt spool
S Extend spool
T Auxiliary spool
U Quick release couplings
10 Hydraulic oil filler cap Tank
ment
60 Dual counterbalance valve Lift cylinder
70 Lift cylinder
80 SRS manifold
90 Pressure transducer SRS and brake
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
190 Ball valve Rear
200 Hitch cylinder
210 Ball valve Carriage
240 Accumulator Servo
260 Auto steer mode valve
270 Brake charge valve
280 Pressure transducer Brake charge pressure
290 Accumulator Brake
300 Power brake valve
310 Trailer brake valve If installed
320 Sway valve
330 Sway cylinder
340 Check valve - low leak
350 Variable fan motor
370 Axle - front - pad mount 213 - Standard 38°
30 - 110 9813/9050-1 30 - 110

00 - General

375 Axle - front - pad mount 213 - LSD (Limited Slip Differen-
tial)38°
380 Axle - front - pad mount 213 - Standard 32°
385 Axle - front - pad mount 213 - LSD32°
390 Axle - front - trunnion mount 213 - Standard 38°
400 Axle - front - trunnion mount 213 - LSD38°
410 Axle - rear - trunnion mount 223 - Standard 38°
415 Axle - rear - trunnion mount 223 - Standard 32°
420 Manifold Auto SRS 550 and 560
430 Check valve
30 - 111 9813/9050-1 30 - 111

00 - General
(For: 535-95 [5AB])

Figure 719. DTVT Transmission 400/G4301 issue 3 (sheet 1 of 1)..................................... Page 30-113
30 - 112 9813/9050-1 30 - 112

00 - General
Page 30-114 Figure 719. DTVT Transmission

400/G4301 issue 3 (sheet 1 of 1) Page 30-115
30 - 113 9813/9050-1 30 - 113

00 - General
Page Page
30-114 30-115
Page 30-115
30 - 114 9813/9050-1 30 - 114

00 - General
Page Page
30-114 30-115

Page 30-114
30 - 115 9813/9050-1 30 - 115

00 - General
Item Description
310 Counter balance car-
Table 364.
tridge
Item Description 320 Counter balance car-
10 Variable power pump- tridge
19cc gear 330 Steer valve + shocks
20 Power brake valve 340 Accumulator 0.24L5bar
30 Variable fan motor (72.5psi)
40 Priority accumulator 350 Check adaptor G1/4A -
charging valve 7/16 SAE
50 Valve block 5AB AG 360 6 way solenoid change
electric over valve
60 Pilot valve 370 Hydraulic oil filler cap
70 DTVT (Dual Technology 380 Pressure transducer
Variable Transmission) 400 Check valve and body
transmission assembly
80 Poppet valve assembly- 410 Oil cooler fluid to fluid
2 port
420 Oil cooler and brackets
90 Pilot operated counter
430 Outer extension ram 100
balance valve- lift ram-
x 60
SRS
440 Counter balance car-
100 Lift arm SRS 120 x 70
tridge
P492
450 Cartridge
120 Tilt ram 130 x 75
460 Vented counterbalance
130 Displacement ram 70 x
valve
40
470 Cartridge
140 Inner extension ram 80 x
50 P33 480 Assembly make-up
valve 1" UNF
160 Power track rod
170 Hitch ram
180 Ram- hydraulic pin lock-
ing
190 Ball valve
200 Suction strainer
210 Suction strainer
220 Return filter
230 Accumulator 30.3bar
(439.1psi)
240 Accumulator 25bar
(362.3psi)
250 Cooling pack- 81 kw
P414
260 Bi-directional check
valve
270 Quick release coupling
06 male - 6 SAE (Soci-
ety of Automotive Engi-
neers)
280 Quick release coupling
06 female - 6 SAE
290 Steer mode valve
300 Accumulator 12bar
(173.9psi)
30 - 116 9813/9050-1 30 - 116

03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ......................................................................................................................... 30-119

30 - 117 9813/9050-1 30 - 117

Notes:
30 - 118 9813/9050-1 30 - 118

03 - Tank
00 - General
Introduction .................................................. 30-119 The hydraulic tank holds excess hydraulic oil to
Drain and Fill ............................................... 30-120 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 - 119 9813/9050-1 30 - 119

03 - Tank
00 - General
Drain and Fill
4. Drain the hydraulic tank.

Remove 4.1. Clean the area around cover plate and the
1. Make the machine safe. Refer to (PIL 01-03). drain plug below the tank.
4.2. Put a suitable size container below the drain
2. Open the rear cover (if installed). Refer to (PIL plug.
06-06-14).
4.3. Remove drain plug and allow the hydraulic
3. Discharge the hydraulic pressure from the oil to drain.
Figure 720.
A Hydraulic tank drain plug
30 - 120 9813/9050-1 30 - 120

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 - 121 9813/9050-1 30 - 121

03 - Tank
12 - Suction Strainer Introduction

Introduction .................................................. 30-122 The suction strainer is a component used for trapping
Remove and Install ..................................... 30-123 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 - 122 9813/9050-1 30 - 122

03 - Tank
Remove and Install
6. Carefully lower the cover plate away from the

Remove machine.
1. Make the machine safe. Refer to (PIL 01-03). 7. Discard the gasket.
2. Open the rear cover (if installed). Refer to (PIL 8. Remove the strainer.
06-06-14).
8.1. Use a spanner of the specified size-
3. Discharge the hydraulic pressure. Refer to (PIL measured across the flats - to remove the
30-00). strainer.
4. Drain the hydraulic tank.
8.2. Carefully remove the strainer from pipe.
4.1. Clean the area around cover plate and the
drain plug below the tank. 9. Use a suitable cleaning fluid to clean the suction
strainer at every applicable service interval.
plug. 10. Make sure that the strainer is free from
4.3. Remove drain plug and allow the hydraulic contamination. If the strainer is defective replace
oil to drain. 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 - 123 9813/9050-1 30 - 123

03 - Tank
Figure 721.
B D C
A Suction strainer B Cover plate

C Drain plug D Bolts
E Gasket
30 - 124 9813/9050-1 30 - 124

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 - 125 9813/9050-1 30 - 125

04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ......................................................................................................................... 30-127

30-04-03 Main .............................................................................................................................. 30-128
30-04-09 Return Line ................................................................................................................... 30-130
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-134
30 - 126 9813/9050-1 30 - 126

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 - 127 9813/9050-1 30 - 127

04 - Filter
03 - Main
03 - Main Figure 722.
Remove and Install

CAUTION When the strainer is removed, oil will
gush out. Keep to one side when you remove the
strainer.
Canister Type Filter
Remove
The canister filter is installed under the chassis,
located to the rear of the front axle.
1. Make the machine safe with the lift arm lowered,

2. Discharge the hydraulic system pressure. Refer
to (PIL 30-00).
A Canister filter
3. Clean the area around the filter body. C Seal
4. Place a container of suitable size beneath the 4.1. Run the engine for a few minutes.
machine to catch the oil.
4.2. Make the machine safe.
5. From under the machine, unscrew and remove 4.3. Check for leaks at the filter.
the element. The element will contain hydraulic
fluid; keep your face clear of spilling fluid.
Oil Filter (Hydraulic Oil Tank, Top
Install Mounting)
1. Install the new element. Remove

1.1. Clean the mating faces on the new element 1. Make the machine safe with the lift arm raised,
and filter holder. refer to (PIL 01-03).
1.2. Smear the seal with clean new hydraulic 2. Open rear cover. Refer to (PIL 06-06).
fluid.
1.3. Screw the new element in place, hand-tight 3. Discharge the hydraulic system pressure. Refer
only. to (PIL 30-00).
2. Check oil level and replenish as required through 4. Clean the top of the tank around the filter.
filler. Refer to (PIL 30-00). 5. Either disconnect the hose or undo clip to enable
3. Install the filler cap. cover plate removal.
4. Check for leaks: 6. Remove the element assembly:

6.1. Remove the screws. Remove the cover
plate and gasket, discard the gasket.
6.2. Remove the spring.
6.3. Hold the handle and pull the element
assembly from the hydraulic tank.
7. Remove the element from its canister:
7.1. Hold the canister.
7.2. Hold the handle and rotate the element the
specified angle counter clockwise.
Angle: 90°
30 - 128 9813/9050-1 30 - 128

04 - Filter
03 - Main
7.3. Pull on handle, the element should separate H Seal 1

from its canister. Discard the old element. J Seal 2
K Hose
7.4. Remove and discard the seal.
7.5. Clean the inside of canister.
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.
1.5. Install the spring and gasket.
1.6. Install the cover plate and tighten the
screws.
2. Check oil level and replenish as required through
filler.
4. Close the rear cover.
Figure 723.
A Screws
B Cover plate
C Gasket
D Spring
E Handle
F Canister
G Element
30 - 129 9813/9050-1 30 - 129

04 - Filter
09 - Return Line
09 - Return Line
Remove and Install
For: 535-95 [5AB] .................... Page 30-130 4. Drain the hydraulic tank.
For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD] ....................................... Page 30-131 4.1. Clean the area around cover plate and the
drain plug below the tank.
(For: 535-95 [5AB]) 4.2. Put a suitable size container below the drain
plug.
Special Tools
4.3. Remove drain plug and allow the hydraulic
oil to drain.
Special Spanner (117 332/G2160 1
mm) 5. Hold the cover plate and remove the bolts.
WARNING Personal injury can result from being 6. Carefully lower the cover plate away from the
struck by parts propelled by a released spring machine.
force. Make sure to wear all necessary protective
equipment. Follow the recommended procedure 7. Discard the gasket.
and use all recommended tools to release the 8. Remove the filter element.
spring force.
8.1. Use a spanner to remove the filter element.
Remove 8.2. Carefully remove the filter from pipe.
1. Make the machine safe. Refer to (PIL 01-03). 8.3. Make sure you hold the filter tightly. When
you remove the filter from the return pipe,
2. Open the rear cover (if installed). Refer to (PIL the spring 2 can cause the filter to move
06-06-14). suddenly.
3. Discharge the hydraulic pressure from the

Figure 724.
G
K
E
L
B D C
30 - 130 9813/9050-1 30 - 130

04 - Filter
09 - Return Line
Table 367.
Item Description
B Cover plate
C Drain plug
D Bolts
E Gasket
F Filter element
G Pipe
H Spring 2
J Spring 1
K Spanner
L Distance between handle and ratchet.
Install Table 368. Torque Values

Item Description Nm
1. Install a new filter element.
C Drain plug 122
1.1. Screw the filter onto the pipe by hand. D Bolt 9.9
1.2. Make sure you install spring 2 together with
the filter.
(For: 531-70 [5AA], 535-95 [5AB], 541-70
1.3. Use the correct special spanner together
with a torque wrench and extension. [5AD])
Because the torque wrench handle is Special Tools
extended by the spanner care must be used Description Part No. Qty.
to obtain the correct torque on the filter.
Special Spanner (66 332/F2828 1
Special Tool: Special Spanner (117 mm) mm)
(Qty.: 1)
1.4. Set the torque wrench to the specified WARNING Personal injury can result from being
value. struck by parts propelled by a released spring
force. Make sure to wear all necessary protective
Torque: 33N·m equipment. Follow the recommended procedure
1.5. Operate the wrench, holding the handle at and use all recommended tools to release the
a specified distance from the ratchet. spring force.
Distance: 300mm
Remove
1.6. Torque tighten the filter.
2. Open the rear cover (if installed). Refer to (PIL
3. Install the cover plate and secure the cover plate 06-06-14).
with the bolts.
4. Tighten the bolts to the correct torque value. system. Refer to (PIL 30-00).
5. Install the drain plug and tighten the drain plug to 4. Drain the hydraulic tank.
4.1. Clean the area around cover plate and the
6. Fill the hydraulic system to the correct oil level. drain plug below the tank.
7. Install the filler cap. plug.
8. Close the rear cover (if installed). 4.3. Remove drain plug and allow the hydraulic
oil to drain.
5. Hold the cover plate and remove the bolts.
30 - 131 9813/9050-1 30 - 131

04 - Filter
09 - Return Line
6. Carefully lower the cover plate away from the 8.1. Use a spanner to remove the filter element.
machine.
8.2. Carefully remove the filter from pipe.
7. Discard the gasket. 8.3. Make sure you hold the filter tightly. When
you remove the filter from the return pipe,
8. Remove the filter element.
the spring 2 can cause the filter to move
suddenly.
Figure 725.
G
K
E
L
B D C
Table 369.
Item Description
B Cover plate
C Drain plug
D Bolts
E Gasket
F Filter element
G Pipe
H Spring 2
J Spring 1
K Spanner
L Distance between handle and ratchet.
Install extended by the spanner care must be used

to obtain the correct torque on the filter.
1. Install a new filter element.
Special Tool: Special Spanner (66 mm)
1.1. Screw the filter onto the pipe by hand. (Qty.: 1)
1.2. Make sure you install spring 2 together with 1.4. Set the torque wrench to the specified
the filter. value.
1.3. Use the correct special spanner together Torque: 33N·m
with a torque wrench and extension.
Because the torque wrench handle is
30 - 132 9813/9050-1 30 - 132

04 - Filter
09 - Return Line
1.5. Operate the wrench, holding the handle at

a specified distance from the ratchet.
Distance: 300mm
1.6. Torque tighten the filter.
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 - 133 9813/9050-1 30 - 133

04 - Filter
60 - Pilot Pressure Supply Main
60 - Pilot Pressure Supply Main Figure 728.
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 726.
Figure 726.
E Servo pilot pressure valve - Old
Figure 729.
A Cab side panel

4. Identify the servo pilot pressure valve under the
cab. Refer to Figure 727.
F Servo pilot pressure valve - New
Figure 727.
7. Unscrew and remove the filter cartridge. Be
aware that there could be some residual
hydraulic pressure. Refer to Figure 730.
B Servo pilot pressure valve

5. Discharge the hydraulic pressure .
Refer to: PIL 30.
6. Refer to Refer to Figure 728. and Refer to Figure
729. for old and new servo pilot pressure valves.
30 - 134 9813/9050-1 30 - 134

04 - Filter
60 - Pilot Pressure Supply Main
Figure 730.
G Filter cartridge location

8. Clean the filter cartridge. Refer to Figure 731.
Figure 731.
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.
Pressure: 30bar (434.8psi)
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 - 135 9813/9050-1 30 - 135

11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ......................................................................................................................... 30-137
30 - 136 9813/9050-1 30 - 136

11 - Gear Pump
00 - General

Technical Data ............................................. 30-137 For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD] ....................................... Page 30-137
For: 531-70 [5AA], 535-95 [5AB], 541-70
Operation ..................................................... 30-140 [5AD] ....................................... Page 30-138
Diagram ....................................................... 30-141
Check (Pressure) ........................................ 30-142 (For: 531-70 [5AA], 535-95 [5AB], 541-70
Remove and Install ..................................... 30-145 [5AD])
The pump installed on your machine will be one of
two types:
2 Section (Double pump)
Table 371. 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
Maximum pressure- port 200 (2,898.5)
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 372. Triple Pump

Mounting Gearbox
ment per RPM- Main
services pump (mount-
ing flange end)
fan pump
fan pump
30 - 137 9813/9050-1 30 - 137

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
Maximum pressure- port 265 (3,840.6) Table 378.
EF
Maximum pressure- port 200 (2,898.5) Theoretical displace- Value
P ment
Maximum speed 2500 RPM Main services pump 45 cc/rev
(mounting flange end)
Cooling fan pump 16 cc/rev
Weight 34.1kg
(1) At 2200 RPM and system pressure (90% min Table 379.
displacement). Flow at 2200RPM and Value
system pressure (90%
min. displacement)
(For: 531-70 [5AA], 535-95 [5AB], 541-70
Main services pump TBA
[5AD]) (mounting flange end)
Depending on the specification of your machine, the Cooling fan pump TBA
following pumps may be installed: Table 380.
Minimum pressure Value
Two section double pump (1)
Port EF 260bar (3,768.1psi)
Table 373. Port P 180bar (2,608.7psi)
Type Double gear pump
Mounting Gearbox Three section triple pump (3)
Direction of rotation Anti-clockwise Table 381.
Type Triple gear pump
Mounting Gearbox
Weight 22.7kg
Direction of rotation Anti-clockwise
Table 374. Maximum speed 2500RPM
Theoretical displace- Value Minimum speed 500RPM
ment Weight 34.1kg
Main services pump 36 cc/rev
Table 382.
(mounting flange end)
Cooling fan pump 16 cc/rev Theoretical displace- Value
ment
Table 375. Main services pump 36 cc/rev
Flow at 2200RPM and Value (mounting flange end)
system pressure (90% Steering pump 19 cc/rev
min. displacement) Cooling fan pump 16 cc/rev
Main services pump 71.3L/min
(mounting flange end) Table 383.
Cooling fan pump 31.7L/min Flow at 2200RPM and Value
system pressure (90%
Table 376. min. displacement)
Minimum pressure Value Main services pump 71.3L/min
Port EF 265bar (3,840.6psi) (mounting flange end)
Port P 200bar (2,898.5psi) Steering pump 37.6L/min
Cooling fan pump 31.7L/min
Two section double pump (2) Table 384.
Table 377. Minimum pressure Value
Type Gear pump Port EF 265bar (3,840.6psi)
Mounting Gearbox Port P 200bar (2,898.5psi)
30 - 138 9813/9050-1 30 - 138

11 - Gear Pump
00 - General
Figure 732. Typical Double Pump
D
C
Figure 733. Typical Triple Pump
A
D
B
C
A Main services section
B Steering section (if fitted)
C Cooling fan section
D Steering priority valve
30 - 139 9813/9050-1 30 - 139

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 734.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
Table 385. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 140 9813/9050-1 30 - 140

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 735.
LS P EF F G
C A
B
Item Description
Table 386. 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 387. Port details

Item Description
F Fan and pilot valve feed
G Test point
P Pump main output
30 - 141 9813/9050-1 30 - 141

11 - Gear Pump
00 - General
Check (Pressure) Figure 737.
Special Tools
Flowmeter 892/00229 1 D
Load Valve 892/00270 1
Digital Hydraulic 998/11051 1
Pressure Test Kit
Double pump
The gear pump assembly has isolated sections that
supply hydraulic oil to the main services circuits, to
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health D Hose 1
and safety information. Refer to (PIL 30-00).
5. Connect the flow meter, digital pressure test kit
3. Discharge the hydraulic pressure. Refer to (PIL and a load valve into the discharge line from the
30-00). cooling fan pump as follows:
Figure 736. 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 738.
C A
A Flowmeter
B Pressure gauge
C Load valve
4. Connect the flowmeter, digital pressure test kit E
and a load valve into the discharge line from the
main service pump as follows:
Special Tool: Load Valve (Qty.: 1)
Special Tool: Flowmeter (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1) E Hose 2
4.1. Disconnect the hose 1 from the pump. 6. Make sure that the load valve and the flowmeter
4.2. Install the flow meter and the load valve is installed in the correct way with the direction
between the hose 1 and the pump 1. arrow pointing away from the pump.
7. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
30 - 142 9813/9050-1 30 - 142

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 740.
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 739.
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 - 143 9813/9050-1 30 - 143

11 - Gear Pump
00 - General
Figure 741. 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 743.
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 742.
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 - 144 9813/9050-1 30 - 144

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 745. 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 744. 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 - 145 9813/9050-1 30 - 145

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.
1.10. 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 - 146 9813/9050-1 30 - 146

12 - Variable Displacement Pump
Contents Page No.
30-12-00 General ......................................................................................................................... 30-149
30 - 147 9813/9050-1 30 - 147

Notes:
30 - 148 9813/9050-1 30 - 148

00 - General
Introduction .................................................. 30-149 The most common variable displacement pump used
Technical Data ............................................. 30-150 in vehicle technology is the axial piston pump. This
Component Identification ............................. 30-151 pump has several pistons in cylinders arranged
Operation ..................................................... 30-152 parallel to each other and rotating around a central
shaft. A swashplate at one end is connected to the
Remove and Install ..................................... 30-154 pistons. As the pistons rotate, the angle of the plate
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 - 149 9813/9050-1 30 - 149

00 - General
Technical Data
are mounted together inline on the gearbox. Refer

Your machine is installed with a double pump. One to component identification, (PIL 30-00) and gear
pump is a gear type (for the cooling fan) and one is pump, (PIL 30-11).
a variable piston type (for the main services). They
Variable Pump (Main Services)

Table 389.
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 - 150 9813/9050-1 30 - 150

00 - General
Figure 746.
G1
F1
G
F
A
J
H
B
A
E D
K L
L
C
Item Description
J Swash plate control
Table 390.
spring
Item Description K Swash plate
A Drive shaft. Driven from L Axial pistons
the bevel gearbox
B Inlet (suction) port
C Outlet port
D Separate gearpump
(cooling fan circuit) dri-
ven by drive shaft
E Hydraulic control valve
F Pressure cut off safety
valve spool
F1 Pressure cut off safety
valve adjuster cover (not
adjustable)
G Flow compensator valve
spool
G1 Flow compensator valve
adjuster cover (not ad-
justable)
H Swash control piston
30 - 151 9813/9050-1 30 - 151

00 - General
Operation
controlled via the swash control piston. The piston

The hydraulic services pump is a variable varies the angle of the tilting swash plate, which
displacement axial piston pump, which uses the alters the displacement (stroke) of the pistons. This
swash plate design principle. has the effect of changing the hydraulic oil flow in the
system.
Rotation of the input drive shaft produces linear
movement of the axial pistons. The pump output is
Figure 747.
Item Description
LS Load sense line
Table 391.
P Operating pressure
Item Description
A Swashplate The swash control piston is controlled by two
B Spring1 systems, as follows.
C Piston
• The flow compensator valve. The valve is
D Compensator spool actuated by load sense hydraulic pressure. This
E Spring2 system controls the pump in response to the
F Spring3 demands of the hydraulic services.
G Pressure cut-off spool • The hydraulic control valve operates to make
sure that the torque required to turn the
X Solenoid valve
30 - 152 9813/9050-1 30 - 152

00 - General
pump does not exceed the maximum engine Pressure cut-off valve
torque range. Two types of valve are installed
depending on the machine variant. The pressure cut-off valve is a secondary safety
device to limit the maximum operating pressure
Pump control thereby protect the pump from over pressurisation.
If the pump operating pressure (i.e. main system
The pump output flow and operating pressure are pressure) ever reaches the setting of the valve
controlled by varying the angle of the tilting swash spring3, the pressure cut-off spool will be pushed to
plate. The swashplate is moved in one direction the left, this in turn, increases the control pressure
by the force of the spring1, and in the opposite acting on the swash control piston, which decreases
direction by control pressure (orange) acting behind the angle of the swash plate, and reduces the pump
the swash control piston. The control pressure is output flow to minimum. While the pressure cut-off
derived from the pump operating pressure (red) valve is operating the pump will remain hydraulically
by the action of the flow compensator spool. The stalled i.e. maintaining maximum operating pressure
flow compensator spool regulates the angle of the at minimum flow.
swashplate automatically in response to changes in
the hydraulic load sense pressure (yellow) from the Hydraulic variable control solenoid valve
hydraulic service. (HVCS)
Flow compensator valve The proportional solenoid valve is part of the HVCS
(Hydraulic Variable Control Solenoid Valve). The
When a hydraulic service is operated, boom lift for system automatically adjusts the pump performance
example, a pressure signal (demand) is generated (power curve characteristic) to limit the hydraulic
in the load sense line (LS) from the control valve power available to the hydraulic services under
block. The increase in the load sense pressure, conditions of high engine load or high hydraulic fluid
combined with the force of the spring2 pushes the temperature.
flow compensator spool to the right, this in turn,
allows some control pressure (orange) acting on the The solenoid valve is controlled by a current
swash control piston to vent back to tank via the case signal output from an ECU (Electronic Control
drain (green). The force of the spring1 increases the Unit). The solenoid valve works as a separate
angle of the swashplate and the pump output flow pressure regulating valve and increases the control
increases proportionally. pressure acting on the swash control piston by a
set amount, according to the valve current signal.
When the output flow is enough to satisfy the Because the control pressure is regulated by the
flow demanded by the service, the pump operating solenoid valve independently (down stream) of the
pressure (red) increases sufficiently to start to move flow compensator spool, this means that when it
the service ram. The increase in the pump operating is operating, it will alter the way that the pump
pressure pushes the flow compensator spool back swashplate normally responds to changes in the
to the left, against the force of the spring2 and hydraulic load sense pressure.
hydraulic load sense pressure; this in turn increases
the control pressure acting on the swash control In this way, the hydraulic power curve of the pump
piston, which decreases the angle of the swash plate can be adjusted electrically by the current signal from
against the force of spring1. As the swash plate angle the ECU.
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 - 153 9813/9050-1 30 - 153

00 - General
Remove and Install
Consumables 4. Disconnect the outlet hose from the fan pump.

5. Disconnect the electrical connector 1 from the
JCB Threadlocker and 4101/0550 0.01L pump control solenoid.
Sealer (High Strength) 4101/0552 0.2L
6. Disconnect the electrical connector 2 from the
Working Under the Machine hydraulic fluid temperature switch.
Make the machine safe before getting beneath it. 7. Remove the clips and disconnect the suction
Make sure that any attachments on the machine are hose from the pump inlet manifold.
the ignition key, disconnect the battery. If the machine 8. 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.
9. Remove flange bolts and remove the outlet hose
Hydraulic Pressure from the pump body.
Before connecting or removing any hydraulic hose, 10. Plug the open port and cap the hose to prevent
residual hydraulic pressure trapped in the service loss of fluid and ingress of dirt.
11. Disconnect the load sense hose from the pump.
Plug the open port and cap the hose to prevent
removing hoses. Make sure the engine cannot be
loss of fluid and ingress of dirt.
12. Disconnect the case drain hose from the pump.
The fan pump is bolted to the variflow pump. This Plug the open port and cap the hose to prevent
procedure describes removing the variflow pump and loss of fluid and ingress of dirt.
fan pump as one unit.
CAUTION! This component is heavy. It must only
Before you remove the pump, make sure the exterior be removed or handled using a suitable lifting
of the pump and working area is thoroughly cleaned method and device.
and free of possible sources of contamination.
13. Make sure you use a sling around the pump
Remove assembly.
1. Make the machine safe. Refer to (PIL 01-03). 14. With the pump correctly supported, remove the
mounting bolts and carefully remove the pump
2. Discharge the hydraulic pressure. Refer to (PIL from the gearbox.
30-00).
Two bolts are hexagon head and other two are
3. Drain the hydraulic fluid from the hydraulic tank caphead bolts. Record the position of the bolts for
into a suitable clean container. correct installation.
30 - 154 9813/9050-1 30 - 154

00 - General
Figure 748.
H K J
Item Description
Table 392. 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 - 155 9813/9050-1 30 - 155

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
before installation.
2. Install new O-ring seals to the pump to gearbox
case mating face and inlet and outlet hose
flanges.
3. Lubricate the O-rings with clean hydraulic fluid.
4. Apply sealant to the flange bolts and tighten the
bolts to the correct torque value.
(High Strength)
5. Remove the cap and fill the pump case with clean
hydraulic fluid. Install the cap.
6. Reconnect the hydraulic hoses and suction hose
to the pump.
7. Connect the electrical connectors with the
hydraulic fluid temperature switch and the pump
control solenoid.
8. Fill the hydraulic tank to the correct level with
clean hydraulic fluid. Refer to (PIL 30-00).
9. Loosen cap and allow any trapped air to escape
from the pump body and drain hose. Tighten the
cap.

Item Value
J
(1)
87N·m
J
(2)
97N·m
K
(1)
84N·m
K
(2)
84–92N·m
(1) 550-80 machines only.
(2) Other machines.
30 - 156 9813/9050-1 30 - 156

15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ......................................................................................................................... 30-159

30-15-06 Lift Arm ......................................................................................................................... 30-171
30-15-07 Lift Extension ................................................................................................................ 30-177
30-15-08 Lift Compensating ........................................................................................................ 30-183
30-15-11 Lift Arm Crowd ............................................................................................................. 30-186
30-15-34 Steering ........................................................................................................................ 30-193
30-15-63 Sway ............................................................................................................................. 30-196
30-15-99 Seal Kit ......................................................................................................................... 30-199
30 - 157 9813/9050-1 30 - 157

Notes:
30 - 158 9813/9050-1 30 - 158

15 - Cylinder / Ram
00 - General
Introduction .................................................. 30-159 A hydraulic cylinder ram is a mechanical actuator
Health and Safety ........................................ 30-160 that is used to give a single directional force
Technical Data ............................................. 30-162 through a single action stroke. It is used in many
Operation ..................................................... 30-163 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Check (Condition) ........................................ 30-166 consists of a cylinder barrel, in which a piston
Disassemble and Assemble ........................ 30-167 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 - 159 9813/9050-1 30 - 159

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.
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 - 160 9813/9050-1 30 - 160

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 - 161 9813/9050-1 30 - 161

15 - Cylinder / Ram
00 - General
Technical Data
Table 394. Cycle Times (Seconds)

Opera- 526-56 531-70 535-95 536-60 536-70 536-70 541-70 550-80 560-80
tion Agri, Agri, Agri, Agri, Agri, LP Agri, Agri, Agri Agri
Agri Agri Agri Agri Agri Agri Agri Plus, Plus,
Plus Plus, Plus, Plus, Plus, Plus, Plus, Agri Su- Agri Su-
Agri Su- Agri Su- Agri Su- Agri Su- Agri Su- Agri Su- per per
per, Agri per per per, Agri per per, Agri
Pro Pro Pro
Lift 5.2 4.5 5.6 5.7 5.0 5.0 5 7.4 7.4
Lower 3.8 5.7 6.3 5.7 5.2 5.2 5.2 5.9 8.3
Extend 4.5 6.7 9.4 5.9 6.7 6.7 6.7 8.3 8.3
Retract 2.4 5 10 4.8 5.0 5.0 5 5.9 5.9
Shovel 2.6 2.9 1.9 2.7 2.9 2.9 3.5 2.8 2.8
dump
Shovel 3.1 2.3 2.5 2.1 2.3 2.3 2.9 3.0 3.0
crowd
All measurements taken with the machine at normal

operating temperature.
30 - 162 9813/9050-1 30 - 162

15 - Cylinder / Ram
00 - General
Operation
Ram- Cylinder end

(For: 531-70 [5AA], 541-70 [5AD])
A restrictor probe installed to the end of the cylinder,
aligns with a groove in the piston rod.
Ram end damping
As the ram closes to full retract, the probe engages
When you operate the lift and extension rams, it can with the groove in the piston rod, the damping effect
cause a shake when the ram is at full travel. This is caused as the orifice plate seats on the face of
could cause load instability and operator discomfort. the piston rod counterbore. The holes in the probe
control the speed of the ram by restricting the flow of
oil at a gradual rate until the ram is fully closed.
Figure 749. 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 - 163 9813/9050-1 30 - 163

15 - Cylinder / Ram
00 - General
Figure 750. 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 - 164 9813/9050-1 30 - 164

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 751.
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 752.
R S
R O-ring
S Extrusion ring
30 - 165 9813/9050-1 30 - 165

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 - 166 9813/9050-1 30 - 166

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 - 167 9813/9050-1 30 - 167

15 - Cylinder / Ram
00 - General
Figure 754.
T S
R
U
F
A
G
J
H
E
K
L
C B
D
Q
P
N
Table 395.
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 - 168 9813/9050-1 30 - 168

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 396.. 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 396.. 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 - 169 9813/9050-1 30 - 169

15 - Cylinder / Ram
00 - General
Figure 755.
AH
AJ
AH Diameter
AJ Depth
Table 396. 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 - 170 9813/9050-1 30 - 170

15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm Bleed

Bleed ........................................................... 30-171
(For: 535-95 [5AB])
Bleed Procedure
Whenever a hydraulic component is removed or
disconnected from the lift arm extension circuit, the
circuit must be bled to make sure that any residual
air is removed.
During the following procedure, it is important that

the inner ram is not allowed to extend more than the
outer ram, to prevent damage to the inner ram and
auxiliary feed and return hoses.
1. Park the machine and make it safe. Refer to (PIL

01-03).
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to the horizontal position.
5. Assemble a suitable bleed hose, fitted with a
male quick release coupling (QRC) and female
quick release coupling.
6. Make sure that the male quick release coupling is
connected to the straight swivel end of the hose.
For bleed hose specification, refer to Refer to
Table 398.
Figure 756.
B A
C
A Bleed hose
B Male quick release coupling
C Female quick release coupling
7. Attach the bleed hose assembly to the male quick
release coupling on the top extension hose.
30 - 171 9813/9050-1 30 - 171

15 - Cylinder / Ram
06 - Lift Arm
B D
D Outer ram
12. If the inner ram extends during this sequence,
B Male quick release coupling deselect the auxiliary service. Operate the retract
service to fully retract the inner ram before
8. Connect the other end of the bleed hose
continuing to extend the outer ram with the
assembly to the female quick release coupling on
correct tank line auxiliary service.
the lift arm nose.
13. With the outer ram fully extended, and the inner
9. Put the hose beneath the lift arm so that it does
ram fully retracted, fully retract the outer ram
not entangle when the lift arm is extended or
using the lift arm retract and auxiliary service
retracted.
together. Use the auxiliary service in the opposite
Figure 758. direction to provide an additional pressure feed
during the retract function.
14. Make sure that the hoses are located correctly in
the roller assembly at the base of the lift arm.
CAUTION! Allow the hydraulic fluid temperature

to cool before removing the hydraulic tank filler
cap. Open the cap slowly to prevent oil being
forced out of the filler neck.
C
15. Release the hydraulic pressure. Refer to
hydraulic system- general, refer to (PIL 30-00).
16. Check the hydraulic fluid level. Refer to hydraulic
system- general, refer to (PIL 30-00.
A
17. Install the hydraulic tank filler cap again.
A Bleed hose
C Female quick release coupling
10. Start the engine. Operate the lift arm service to
fully retract the inner and outer lift arm sections.
11. Slowly operate the lift arm extend and auxiliary
service together until the outer ram is fully
extended. Make sure that the auxiliary service
selected provides a return to tank for the outer
ram so that the inner ram does not extend.
30 - 172 9813/9050-1 30 - 172

15 - Cylinder / Ram
06 - Lift Arm
Figure 760.
E
F
E Roller assembly
F Hydraulic tank filler cap
18. Detach the bleed hose assembly from the quick
release couplings on the machine.
19. On completion, extend and retract the lift arm
fully five times while checking that the lift arm
sections open and close fully together. Inspect
the hydraulic connections and check for leaks.
20. If the lift arm sections do not open and close fully
together, repeat the bleeding procedure.
21. If the lift arm sections do not open and close fully
together after repeating the bleeding procedure,
refer to hydraulic system fault finding, refer to
(PIL 30-00).
Table 398. Bleed Hose Specification

Length (Approx.) 6,300mm
Bore 9.5mm
Pressure rating High (Suitable for
240bar (3,478.2psi) op-
erating pressure)
30 - 173 9813/9050-1 30 - 173

15 - Cylinder / Ram
06 - Lift Arm
Remove and Install
Special Tools 6. If installed, disconnect the remote greasing pipe.

Figure 762.

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 761. 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 - 174 9813/9050-1 30 - 174

15 - Cylinder / Ram
06 - Lift Arm
Figure 763. 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 - 175 9813/9050-1 30 - 175

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 - 176 9813/9050-1 30 - 176

15 - Cylinder / Ram
07 - Lift Extension
07 - Lift Extension
Remove and Install
For: 531-70 [5AA], 541-70 [5AD] 8. Disconnect the extension ram hydraulic hoses.
................................................. Page 30-177
For: 531-70 [5AA], 535-95 [5AB], 541-70 9. Plug all the open ports and hoses to prevent
[5AD] ....................................... Page 30-178 contamination.
10. For 531-70 and 541-70 machines, to gain access
(For: 531-70 [5AA], 541-70 [5AD]) to the extension ram, remove the displacement
ram.
Remove 11. Remove the nut and bolt, then remove the
1. Remove any attachments installed on the extension ram pivot pin far enough so that you
carriage. can remove the displacement ram easily.
2. Extend the lift arm sufficiently to gain access to 11.1. Remember that the extension ram pivot
the extension ram rod end pivot pin 1. pin is also the main pivot for the lift arm.
11.2. Make sure you use a dummy pivot pin to
3. Lower the lift arm to the ground. drive out the extension ram pivot pin so the
4. Discharge the hydraulic pressure from the other side of the lift arm is supported.
CAUTION! This component is heavy. It must only
5. Make the machine safe. Refer to (PIL 01-03). be removed or handled using a suitable lifting
method and device.
6. Remove the capscrew, lock plate and then
remove the extension ram rod end pivot pin. 12. Use suitable lifting equipment to remove the
extension ram from the lift arm.
Figure 764. 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 - 177 9813/9050-1 30 - 177

15 - Cylinder / Ram
07 - Lift Extension
Install 2. Make the machine safe. Refer to (PIL 01-03).
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. Apply the correct grease to the pivot pins. system. Refer to (PIL 30-00).
5. Operate the controls back and forth several times
1.2. Install the bolts and tighten to the correct to discharge the residual hydraulic pressure from
torque value. Refer to (PIL 72-00). the system.
6. Put label on the hoses to help installation.
(For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD]) 7. Disconnect and plug feed hose 1, feed hose 2,
carry over hose 1 and carry over hose 2.
Consumables
Description Part No. Size 8. Plug all the open ports and hoses to prevent
contamination.
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 4101/0552 0.2L 9. Remove the restraining strap.
CAUTION This component is heavy. It must only 10. Support the extension ram.
method and device. 11. Remove the nut and bolt, then remove the pivot
1 from the cylinder end.
Outer ram 12. Remove the snap ring and then remove the pivot
2 from the rod end.
Remove 13. Remove the ram from the machine.
1. Fully retract and lower the lift arm to the ground.
30 - 178 9813/9050-1 30 - 178

15 - Cylinder / Ram
07 - Lift Extension
Figure 765. Machines with 3 Stage Lift Arm - Outer Ram
H
E
A
B J
F
A Feed hose 1 B Feed hose 2

C Carry over hose 1 D Carry over hose 2
E Restraining strap F Pivot 1
G Nut and bolt H Pivot 2
J Snap ring
30 - 179 9813/9050-1 30 - 179

15 - Cylinder / Ram
07 - Lift Extension
Install section must be kept equal to avoid damage

to the internal hoses.
removal procedure. Additionally do the following 6. Lower the lift arm to align the inner ram rear pivot
steps. pin with the access holes in the chassis.
1.1. Grease the pivot pins. Refer to (PIL 06-30). 7. Stop the engine and remove the ignition key.
1.2. Bleed the lift arm extension hydraulic circuit. 8. Remove the hydraulic tank filler cap and operate
the lift arm extend and retract controls to
Inner ram discharge residual pressure.
Remove 9. Open the cover at the rear of the lift arm to gain
access to the hose guides and roller assembly.
1. Make sure you follow the procedure. Failure to
10. Release the hydraulic breather tube from the
do so may damage the internal ram and auxiliary
chassis and tie it clear of the rear of the lift arm.
feed hoses.
11. Remove bolts 2 and remove the lift arm roller
2. Park the machine on firm level ground. Apply the
assembly.
park brake and remove the carriage.
12. Remove bolts 3 and remove the hose guide.
3. Raise the lift arm to just above the horizontal.
Extend the lift arm to gain access to the front pivot 13. Disconnect the hoses from the rear of the
pin. extension cylinder. Plug the open ports and mark
the connections.
4. Remove the bolt 1. Use a suitable drift to knock
the pin through the lift arm. 14. Remove the bolts 4 (x2) that secure the guide on
the hose tray.
5. Raise the lift arm and operate the retract control
to slowly retract the extension ram. The inner 15. Support the ram.
lift arm section should retract with the hydraulic
cylinder under its own weight. 16. Use a suitable drift to remove the bolt 5 and
knock the pivot pin through the lift arm. Note the
5.1. If the inner lift arm section will not retract location of the spacers.
under its own weight, lower the lift arm and
carefully push the lift arm against an outside 17. Use suitable lifting equipment to remove the ram
force (for example, another machine). from the lift arm.
5.2. The length of the inner and intermediate 18. Make sure that the hoses inside the lift arm are
lift arm sections protruding from the outer not damaged.
30 - 180 9813/9050-1 30 - 180

15 - Cylinder / Ram
07 - Lift Extension
Figure 766.
D
A
A Pivot pin B Bolt 1

C Access hole D Hydraulic breather tube
30 - 181 9813/9050-1 30 - 181

15 - Cylinder / Ram
07 - Lift Extension
Figure 767. If a new cylinder is to be installed, transfer the

hose tray to the new cylinder.
2. Position the cylinder inside the inner lift arm.
3. Grease the rear pivot pin. Refer to (PIL 06-30).
E
4. Install the pin and secure it with bolt 5.
5. Operate the extend control to slowly extend the
cylinder and push out the inner lift arm section.
6. Release the control when the front pivot pin is
visible.
7. Make sure the length of the inner and
C intermediate lift arm sections protruding from the
outer section are kept equal to avoid damaging
the internal hoses.
G
F 8. Grease the front pivot pin. Refer to (PIL 06-30).
E Bolts 2 9. Align the bush on the rod end of the cylinder with
F Bolts 3 the lift arm. Install the pin and secure it with bolt 1.
G Hose guide
10. Connect hoses at the rear of the extension
Figure 768. cylinder. Install the guide to the hose tray, roller
assembly and hose guide.
J 11. Tension the hoses equally by pivoting the roller

assembly. Make sure that the lift arm hoses are
installed over the rollers without being stretched.
12. Apply sealant and tighten the bolt 2 to the correct
torque value.
(High Strength)
13. Secure the breather tube and fill the hydraulic
tank. Refer to (PIL 30-00).
14. Bleed the lift arm extension hydraulic circuit.
L
H
K
H Hoses
J Bolts 4
K Bolt 5
L Pin
M Spacers
Install
1. Make sure that the head side and rod side
bushes are aligned before installing the cylinder.
30 - 182 9813/9050-1 30 - 182

15 - Cylinder / Ram
08 - Lift Compensating
Remove and Install
4. Lower the lift arm and the carriage to the ground.

(For: 531-70 [5AA], 541-70 [5AD]) 5. Discharge the hydraulic pressure. Refer to (PIL
Special Tools 30-00).
7. Disconnect the hydraulic hoses.
Consumables
Description Part No. Size 8. Plug all the open hoses and ports to prevent
Special MPL-EP 4003/1501 0.4kg contamination.
Grease 4003/1506 12.5kg 9. Support the displacement ram.
4003/1510 50kg
10. Remove the lock bolt/nut and washers (if
CAUTION This component is heavy. It must only 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
of the displacement ram. Retract the lift arm fully. 13. Remove the pivot pin 2 from the cylinder end with
Support the front end of the lift arm. the slide hammer kit.
2. Make the machine safe. Refer to (PIL 01-03). 14. Remove the ram from the machine.

30 - 183 9813/9050-1 30 - 183

15 - Cylinder / Ram
Figure 769.
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 - 184 9813/9050-1 30 - 184

15 - Cylinder / Ram
Install
steps.
1.1. Put grease on the ram pivot pins.
1.2. Check the hydraulic fluid level and top up as
30 - 185 9813/9050-1 30 - 185

15 - Cylinder / Ram
11 - Lift Arm Crowd
11 - Lift Arm Crowd Bleed

Bleed ........................................................... 30-186 1. Make the machine safe. Refer to (PIL 01-03).
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to a convenient height to access
the tilt ram.
30-00).
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 - 186 9813/9050-1 30 - 186

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 770.
A Locknut
B Screw

Item Description Nm
A Locknut 12
B Screw 15
30 - 187 9813/9050-1 30 - 187

15 - Cylinder / Ram
11 - Lift Arm Crowd
Remove and Install
For: 531-70 [5AA], 541-70 [5AD] 6. Follow the general health and safety procedures.
................................................. Page 30-188 Refer to (PIL 01-03).
For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD] ....................................... Page 30-190 7. Discharge the hydraulic pressure from the
(For: 531-70 [5AA], 541-70 [5AD]) 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
CAUTION This component is heavy. It must only 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 - 188 9813/9050-1 30 - 188

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 771.
C D
A F
Install
Table 400. 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 - 189 9813/9050-1 30 - 189

15 - Cylinder / Ram
11 - Lift Arm Crowd
(For: 531-70 [5AA], 535-95 [5AB], 541-70 7. Remove the lift arm nose cover (if installed).
[5AD]) 8. Put a label on the hoses to help installation.
Special Tools
9. Disconnect the tilt ram hydraulic hoses.
Slide Hammer Kit 993/68100 1 10. Plug all the open ports and hoses to prevent
contamination.
Remove 11. Support the tilt ram.
1. Remove any attachments from the carriage. 12. Remove the recessed capscrew.
2. Extend the lift arm approximately to the specified 13. Use the slide hammer kit to remove the pivot pin
limit. 1 from the rod end.
Length: 600mm Special Tool: Slide Hammer Kit (Qty.: 1)
3. Lower the lift arm onto a suitable support so that 14. Remove the nut and bolt and washers (if
the carriage is clear of the ground. installed).
4. Make the machine safe. Refer to (PIL 01-03). 15. Use the slide hammer kit to remove the pivot pin
5. Follow the general health and safety procedure. 2 from the cylinder end.
Refer to (PIL 01-03). Special Tool: Slide Hammer Kit (Qty.: 1)
6. Discharge the hydraulic pressure from the 16. Remove the ram from the machine.
30 - 190 9813/9050-1 30 - 190

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 772.
A Capscrew B Pivot pin 1

C Tilt ram hydraulic hoses D Bolt
E Pivot pin 2
30 - 191 9813/9050-1 30 - 191

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 - 192 9813/9050-1 30 - 192

15 - Cylinder / Ram
34 - Steering
34 - Steering Remove and Install

Remove and Install ..................................... 30-193 Working Under the Machine
Disassemble and Assemble ........................ 30-195 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 773.
B
C
A
A Hoses B Screws
C Pins
30 - 193 9813/9050-1 30 - 193

15 - Cylinder / Ram
34 - Steering
Install
steps.
1.1. Tighten the screws to the correct torque
value.
steering system. Refer to (PIL 25-00).

Item Description Nm
B Screws 56
30 - 194 9813/9050-1 30 - 194

15 - Cylinder / Ram
34 - Steering
Refer to Hydraulic system, cylinder ram, general (PIL

30-15-00).
30 - 195 9813/9050-1 30 - 195

15 - Cylinder / Ram
63 - Sway
63 - Sway Bleed
Bleed ........................................................... 30-196 Communications
Remove and Install ..................................... 30-197 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
5. Start the engine.
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 - 196 9813/9050-1 30 - 196

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 Consumables
Length: 6.5mm Description Part No. Size
Special HP Grease 4003/2017 0.4kg
9. Start the engine. 4003/2006 12.5kg
10. Operate the sway lever to sway the machine fully 4003/2005 50kg
to the operator's left side.
11. Hold the lever in this position. be removed or handled using a suitable lifting
method and device.
12. Make sure that the air is removed completely
through the bleed valve.
Remove
13. Return the control lever to the neutral position.
14. Tighten the bleed valve immediately to prevent
air entering the circuit. 2. Lower the lift arm and the carriage to the ground.
Figure 774. 3. Follow the general health and safety procedures.
30-00).
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.
6. Support the chassis on both sides of the
machine.
A
7. Put a label on each hose to help installation.
8. Disconnect the sway hydraulic hoses.
contamination.
A Bleed valve
10. Support the sway ram.
15. Operate the sway ram fully in both directions 10
times. 11. Remove the nut and bolt 1.
16. Repeat steps 7 to 17. 12. Remove the pivot pin 1 from the cylinder end.
17. Stop the engine and remove the ignition key. 13. Attach suitable lifting equipment to the cylinder
end of the ram. Support the ram.
18. Check the hydraulic fluid level and top up as
required. Refer to (PIL 30-00). 14. Remove nut and bolt 2.
15. Remove the pivot pin 2 from rod end.
16. Remove the ram from the machine.
30 - 197 9813/9050-1 30 - 197

15 - Cylinder / Ram
63 - Sway
Figure 775.
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 - 198 9813/9050-1 30 - 198

15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 776.
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 777.
(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 778.
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 - 199 9813/9050-1 30 - 199

15 - Cylinder / Ram
99 - Seal Kit
Figure 779. 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 781.
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 780.
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 782.
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 - 200 9813/9050-1 30 - 200

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 783.
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 - 201 9813/9050-1 30 - 201

18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-203

30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-207
30 - 202 9813/9050-1 30 - 202

18 - Accumulator
00 - General
Introduction .................................................. 30-203 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-204 reservoir used to store hydraulic fluid, the non-
Component Identification ............................. 30-204 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ........................... 30-205 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 - 203 9813/9050-1 30 - 203

18 - Accumulator
00 - General
Health and Safety Component Identification

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 784.
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 - 204 9813/9050-1 30 - 204

18 - Accumulator
00 - General
Discharge and Pressurise Figure 785.
Special Tools
Accumulator Charging 892/01042 1 B
Kit (Diaphragm)
Accumulator Charging 892/01043 1 A
J
Adaptor
WARNING You must vent all the hydraulic

pressure from the accumulators before
C
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 - 205 9813/9050-1 30 - 205

18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 786.

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 - 206 9813/9050-1 30 - 206

18 - Accumulator
06 - Smooth Ride System (SRS)
06 - Smooth Ride System (SRS) Technical Data

Technical Data ............................................. 30-207 For: 531-70 [5AA], 541-70 [5AD]
................................................. Page 30-207
Preparation .................................................. 30-208
For: 535-95 [5AB] .................... Page 30-207
Discharge and Pressurise ........................... 30-209
(For: 531-70 [5AA], 541-70 [5AD])

Table 402.
Charging gas Air free dry nitrogen
Accumulator capacity 1L
Accumulator weight 4.4kg
Table 403. Accumulator charge pressure

Accumulator Value
Accumulator1 10.3bar (149.3psi)
Accumulator2 20bar (289.9psi)
(For: 535-95 [5AB])

Table 404.
Charging gas Air free dry nitrogen
Accumulator capacity 1L
Accumulator weight 4.4kg
Table 405. Accumulator charge pressure

Accumulator Value
30 - 207 9813/9050-1 30 - 207

18 - Accumulator
Preparation Figure 788. 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 787. Large plate
30 - 208 9813/9050-1 30 - 208

18 - Accumulator
Discharge and Pressurise

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 790.
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 - 209 9813/9050-1 30 - 209

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 - 210 9813/9050-1 30 - 210

18 - Accumulator
Remove and Install
WARNING You must vent all the hydraulic Per Minute). The the accumulators will discharge
pressure from the accumulators before during this period.
4. With the engine still running and manual SRS
mode is active, use the lifting equipment to lift the
Remove boom. Do not use the hydraulic lift service.
1. Make the machine safe. Refer to (PIL 01-03). 5. Install the safety strut. Refer to (PIL 06-69).
2. Switch SRS (Smooth Ride System) to manual 6. Loosen the nuts (x4).
mode, make sure the right hand console is
indicating that manual mode is selected. Lift the 7. Disconnect the hydraulic connections and plug
boom. the ends.
3. Use the control lever to lower the boom and 8. Remove the nuts and washers (x4) and remove
keep the lever in down position for 3 minutes the 'U' clamps (x2).
while the engine is run at 1000 RPM (Revolutions
9. Remove the accumulators from their mounting
brackets.
Figure 791.
C
C
B A
A Hydraulic connections B Nuts (x4)

C 'U' clamps D Accumulators
E Washers (x4)
30 - 211 9813/9050-1 30 - 211

18 - Accumulator
Install
steps.
1.1. Check the accumulator nitrogen pre-charge
1.2. Operate the machines hydraulic system.
Check for correct operation and leaks.
1.3. Fill the hydraulic system with the
recommended hydraulic fluid. Refer to (PIL
30-00).
It is not possible to disassemble the accumulators.

You can only 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 - 212 9813/9050-1 30 - 212

21 - Oil Cooler
21 - Oil Cooler
Contents Page No.
30-21-00 General ......................................................................................................................... 30-215
30 - 213 9813/9050-1 30 - 213

Notes:
30 - 214 9813/9050-1 30 - 214

21 - Oil Cooler
00 - General
00 - General Component Identification

Figure 792.
A B
A Hydraulic oil cooler matrix B Transmission oil cooler matrix
30 - 215 9813/9050-1 30 - 215

21 - Oil Cooler
00 - General
Remove and Install
4. Open the engine cover. Refer to (PIL 06-06).

The hydraulic oil cooler is a combination cooler. The
right hand side is used for transmission oil cooling 5. If installed, remove the fuel cooler.
and the left hand side is used for hydraulic oil cooling.
If the transmission or hydraulic oil cooler has failed 6. If installed, remove the air conditioning
the complete unit must be replaced. condenser. Refer to (PIL 12-15).
7. Disconnect the hydraulic and transmission hoses
Remove from the matrix, at the 4 couplings.
1. Make the machine safe. Refer to (PIL 01-03). 8. Support the matrix.
2. If the engine is hot let it cool for the specified time. 9. Remove the bolts.
Duration: 1h 10. Remove the matrix from the machine.
system. Refer to health and safety (PIL 30-00)
Figure 793.
A A C
A Bolts B Matrix
C Couplings (x4)
30 - 216 9813/9050-1 30 - 216

21 - Oil Cooler
00 - General
Install
steps.
1.1. Check the hydraulic fluid level. Refer to (PIL
30-00).
1.2. Check the transmission oil level.
1.3. When the installation procedure is complete
start the engine and check for fuel leaks.
30 - 217 9813/9050-1 30 - 217

51 - Lift Arm Control Valve Block
Contents Page No.

30-51-21 Load Sense Relief Valve .............................................................................................. 30-223
30-51-24 Flow Regulator ............................................................................................................. 30-225
30 - 218 9813/9050-1 30 - 218

03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Figure 795.

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 794.
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 - 219 9813/9050-1 30 - 219

06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-220 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-221 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 - 220 9813/9050-1 30 - 220

Operation Figure 797. 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 796. Valve at rest
EX Exhaust gallery
Anti-cavitation mode
When a service is operated in such a way that low
pressure, or cavitation, exists in the service line, the
relatively high pressure oil in the exhaust gallery acts
on the lower poppet and flows into the service gallery
to make up the deficiency.
Figure 798. Anti-cavitation mode

EX
S Service gallery
EX Exhaust gallery
Poppet opens
The setting of the ARV is exceeded by the service EX
pressure which causes the poppet to rise against
spring force allowing the pressure to be released into
the exhaust gallery. S
S Service gallery
EX Exhaust gallery
30 - 221 9813/9050-1 30 - 221

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.
Consumable: JCB Hydraulic Fluid OP 46
1.4. If necessary, adjust the ARV pressure
setting. Refer to (PIL 30-00).

Item Description Nm
E Valve assembly 70
30 - 222 9813/9050-1 30 - 222

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 800.
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 - 223 9813/9050-1 30 - 223

21 - Load Sense Relief Valve
Table 407. 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 - 224 9813/9050-1 30 - 224

24 - Flow Regulator
24 - Flow Regulator Check (Condition)

Check (Condition) ........................................ 30-225
Inspection
1. Examine the valve components for scratches,
pitting, corrosion or any other damage.
2. Clean the filter gauze installed in the end of the
valve body.
3. If any part other than the O-rings are damaged,
replace the entire valve.
Figure 801.
A Filler gauze
30 - 225 9813/9050-1 30 - 225

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
correct orientation.
2. Carefully remove the shims, the spring and the
piston. Table 408. 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 802.
A Top plug
B Shims
C Spring
D Piston
E Filter gauze
F Valve body
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. When assembling do the following steps also:
2.1. Clean the valve components in the correct
solvent.
30 - 226 9813/9050-1 30 - 226

53 - Servo System Control Valve Block
Contents Page No.
30-53-00 General ......................................................................................................................... 30-229

30-53-27 Pressure Compensator Valve ...................................................................................... 30-245
30-53-80 Spool ............................................................................................................................ 30-247
30 - 227 9813/9050-1 30 - 227

Notes:
30 - 228 9813/9050-1 30 - 228

00 - General

Technical Data ............................................. 30-229 For: 531-70 [5AA] .................... Page 30-229
Fault-Finding ................................................ 30-234 For: 535-95 [5AB] .................... Page 30-231
Remove and Install ..................................... 30-237 For: 541-70 [5AD] .................... Page 30-231
(For: 531-70 [5AA])
Load Sense Pressure System (Agri, Agi-

Plus, Agri-Super Machines)
Depending on the specification of your machine,
alternative valves may be installed. Refer to (PIL
30-54-00).
Figure 803. 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 409.
Type Spool, load sense- pressure
compensated, double acting
spools
Spool 1 Boom lift & low- Integral propor-
er service tional electro
servo pilot oper-
ated
Spool 2 Carriage tilt ser- Integral propor-
vice tional electro
servo pilot oper-
ated
30 - 229 9813/9050-1 30 - 229

00 - General
Spool 3 Boom extend & Integral propor- Table 411.

retract Service tional electro Type Spool, load sense- pressure
servo pilot oper- compensated, double acting
ated spools
Spool 4 Auxiliary ser- Integral propor- Spool 1 Auxiliary ser- Integral propor-
vice tional electro vice tional electro
servo pilot oper- servo pilot oper-
ated ated
The maximum auxiliary service flow available is up Spool 2 Carriage tilt ser- Integral propor-
to 95L/min with 'manual' thumb wheel operation, and vice tional electro
up to 65L/min with 'constant' operation selected. servo pilot oper-
ated
Table 410. Relief valve pressures Spool 3 Boom extend & Integral propor-
retract Service tional electro
Item Value servo pilot oper-
LSRV
(1)
260bar (3,768.1psi) ated
ARV (Auxiliary Relief - Spool 4 Boom lift & low- Integral propor-
Valve) er 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 275bar (3,985.5psi) The maximum auxiliary service flow available is up
Carriage tilt ram head 140bar (2,029.0psi) to 95L/min with 'manual' thumb wheel operation, and
side up to 65L/min with 'constant' operation selected.
(1) Before you check the Load Sense relief valve
pressure, allow the hydraulic system to warm up to Table 412. Relief valve pressures
50°C (121.9°F) to make sure an accurate reading. Item Value
Be sure to identify the machine variant correctly. 240bar (3,478.2psi)
LSRV
(1)
ARV -
Load Sense Pressure System (Agri-Extra
Machines) Auxiliary ram rod side 220bar (3,188.4psi)
Auxiliary ram head side 220bar (3,188.4psi)
Figure 804. 4 Spool control valve block Carriage tilt ram rod side 275bar (3,985.5psi)
A B E Carriage tilt ram head 200bar (2,898.5psi)
side
pressure, allow the hydraulic system to warm up to
50°C (121.9°F) to make sure the reading is accurate.
Make sure you identify the machine variant correctly.
D
A LSRV
C Auxiliary ram head side
D Carriage tilt ram rod side
E Carriage tilt ram head side
30 - 230 9813/9050-1 30 - 230

00 - General
(For: 535-95 [5AB]) Table 414. Relief valve pressures

Item Value
Load Sense Pressure System (Agri, Agri- LSRV
(1)
240bar (3,478.2psi)
Plus, Agri-Super Machines) ARV -
Figure 805. 4 Spool control valve block Auxiliary ram rod side 220bar (3,188.4psi)
F Auxiliary ram head side 220bar (3,188.4psi)
B
C Carriage tilt ram rod side 250bar (3,623.2psi)
Carriage tilt ram head 240bar (3,478.2psi)
side
B4 A4 (1) Before you check the Load Sense relief valve
B3 A3 50°C (121.9°F) to make sure an accurate reading.
Be sure to identify the machine variant correctly.
B2 A2
B1 A1 (For: 541-70 [5AD])

LS
D E Load Sense Pressure System (Agri, Agri-

Plus, Agri-Super Machines)
P
T
G A Depending on the specification of your machine,

A LSRV 30-54-00).
C Auxiliary ram head side Figure 806. 4 Spool control valve block
D Carriage tilt ram head side
F
E Carriage tilt ram rod side B
F Flushing valve C
G Steer priority valve
B4 A4
Table 413.
Type 4 Spool, load sense- pressure B3 A3
compensated, double acting
spools B2 A2
Spool 1 Lift arm raise & Integral propor-

lower service tional electro B1 A1
servo pilot oper- LS
ated D P E
T
vice tional electro

servo pilot oper- G A
ated A LSRV
Spool 3 Lift arm extend Integral propor- B Auxiliary ram rod side
& retract ser- tional electro C Auxiliary ram head side
vice servo pilot oper- D Carriage tilt ram rod side
ated E Carriage tilt ram head side
Spool 4 Auxiliary ser- Integral propor- F Flushing valve
vice tional electro G Steer priority valve
servo pilot oper-
ated Table 415.
Type Spool, load sense- pressure
The maximum auxiliary service flow available is up compensated, double acting
to 95L/min with 'manual' thumb wheel operation, and spools
up to 65L/min with 'constant' operation selected. Spool 1 Lift arm raise & Integral propor-
lower service tional electro
servo pilot oper-
ated
30 - 231 9813/9050-1 30 - 231

00 - General
Spool 2 Carriage tilt ser- Integral propor- Load Sense Pressure System (Agri-Extra
vice tional electro Machines)
servo pilot oper-
ated Figure 807. 4 Spool control valve block
Spool 3 Lift arm extend Integral propor- A B E
& 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. C
Table 416. Relief valve pressures

Item Value
LSRV
(1)
260bar (3,768.1psi)
ARV - D
Auxiliary ram rod side 220bar (3,188.4psi) A LSRV
Auxiliary ram head side 220bar (3,188.4psi) B Auxiliary ram rod side
Carriage tilt ram rod side 275bar (3,985.5psi) C Auxiliary ram head side
Carriage tilt ram head 140bar (2,029.0psi) D Carriage tilt ram rod side
side E Carriage tilt ram head side
(1) Before you check the Load Sense relief valve Table 417.
50°C (121.9°F) to make sure an accurate reading. Type 4 Spool, load sense- pressure
Be sure to identify the machine variant correctly. compensated, double acting
spools
Spool 1 Auxiliary ser- Integral propor-
vice tional electro
servo pilot oper-
ated
vice tional electro
servo pilot oper-
ated
Spool 3 Boom extend & Integral propor-
retract Service tional electro
servo pilot oper-
ated
Spool 4 Boom lift & low- Integral propor-
er service 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.

Item Value
LSRV
(1)
260bar (3,768.1psi)
ARV -
Auxiliary ram rod side 220bar (3,188.4psi)
30 - 232 9813/9050-1 30 - 232

00 - General
Item Value
Carriage tilt ram rod side 275bar (3,985.5psi)
side
50°C (121.9°F) to make sure an accurate reading.
Be sure to identify the machine variant correctly.
30 - 233 9813/9050-1 30 - 233

00 - General
Fault-Finding
Fault
All services lack power Table 419. Page 30-234
All services slow to operate Table 420. Page 30-235
The system pressure is too high Table 421. Page 30-235
A service stays selected Table 422. Page 30-235
System isolation not working Table 423. Page 30-236
All services inoperative Table 424. Page 30-236
Low flow from auxiliary service Table 425. Page 30-236
Lift arm operation is "Fierce" Table 426. Page 30-236
Servo operated spool services slow to operate or low auxiliary flow (The Table 427. Page 30-236
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 419. 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 - 234 9813/9050-1 30 - 234

00 - General
Table 420. 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 421. 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 422. 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 - 235 9813/9050-1 30 - 235

00 - General
Table 423. 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 424. 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 425. 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 426. 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 427. 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 - 236 9813/9050-1 30 - 236

00 - General
Remove and Install
For: 531-70 [5AA], 535-95 [5AB], 541-70 Remove

[5AD] ....................................... Page 30-237
For: 531-70 [5AA], 541-70 [5AD] 1. Make the machine safe with the lift arm raised.
................................................. Page 30-238 Refer to (PIL 01-03).
(For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD]) 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
be removed or handled using a suitable lifting 4. Remove the hydraulic filler cap.
method and device.
5. Mark and disconnect the hoses and pipes from
the valve assembly.
Incorrect handling will result in permanent damage to
the valve assembly. The valve block should be lifted 6. Mark and disconnect the electrical connectors
by holding the ends of the valve body, not the electric from the valve block solenoids.
solenoids.
7. With the valve block correctly supported, remove
the mounting bolts. Carefully lift the valve block
away from the bracket and clear of the machine.
Figure 808.
A
A Mounting bolts B Valve block

C Valve block solenoids D Bracket
30 - 237 9813/9050-1 30 - 237

00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe with the lift arm raised.
removal procedure. Additionally do the following Refer to (PIL 01-03).
steps.
Check for correct operation and leaks. 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
recommended hydraulic fluid as necessary. 4. Remove the hydraulic filler cap.
5. Remove the valve cover panels.
1.3. After installation check the MRV (Main
Relief Valve) and the ARV (Auxiliary Relief 6. Put labels on the hoses to help installation.
Valve) pressures. Refer to (PIL 30-00).
7. Disconnect the hoses and pipes from the valve
assembly.
(For: 531-70 [5AA], 541-70 [5AD])
CAUTION This component is heavy. It must only contamination.
method and device. 9. Mark and disconnect the electrical connectors
from the valve block solenoids.
The valve assembly should be handled correctly as 10. With the valve block suitably supported, remove
it can be permanently damaged. The valve block the mounting bolts. Carefully lift the valve block
should be lifted by holding the ends of the valve body, and move away from the machine.
not the electric solenoids.
30 - 238 9813/9050-1 30 - 238

00 - General
Figure 809.
A
H
G
J
C H F H B

recommended hydraulic fluid as necessary.
Table 428. Refer to (PIL 30-00).
Item Description 1.3. After installation, check the MRV and ARV
A Mounting bolts pressures. Refer to (PIL 30-00).
B Valve block solenoids
C Adaptor 1
D Adaptor 2 Item Description Adaptor to Hose to
valve adaptor or
E Adaptor 3
adaptor to
F Adaptor 4 adaptor
G Adaptor 5 C Adaptor 1 27N·m 33–40N·m
H Adaptor 6 D Adaptor 2 48N·m 33–40N·m
J Adaptor 7 E Adaptor 3 122N·m 58–65N·m
K Adaptor 8 F Adaptor 4 122N·m 84–92N·m
G Adaptor 5 48N·m 44–50N·m
Install H Adaptor 6 27N·m 24–27N·m
1. The installation procedure is the opposite of the J Adaptor 7 200N·m 115–126N·m
removal procedure. Additionally do the following and 44–
steps. 50N·m
K Adaptor 8 - 24–27N·m
30 - 239 9813/9050-1 30 - 239

00 - General
Take care when you disassemble and assemble the

(For: 531-70 [5AA], 541-70 [5AD]) valve. Make sure you do not damage to seals and
seal grooves. Damage or contamination can cause
Consumables problems with valve operation.
JCB Hydraulic Fluid OP 4002/2001 5L Disassemble
46 4002/2005 20L
1. Remove the valve block from the machine. Refer
4002/2003 200L to (PIL 30-53-00).
Sealer (High Strength) 4101/0552 0.2L 2. Remove the tie rod nuts (x4).
3. Carefully disconnect and remove the outlet
The valve block is a 'sectional' type, which is
section.
made up of a number of separate sections. Make
sure you note the location of all components when 4. If the outlet section is to be replaced, remove and
you disassemble. Although some components may keep the tie rods.
appear to be identical, they are not interchangeable,
for example service spools are two different types. 5. Disconnect and remove the remaining service
Make sure that components are assembled in their sections and the inlet section.
original positions.
Figure 810.
B L
C
N N
M
H R
Q H N N
P
H
J
D
K
H
Q
K
A E
A Tie rod nuts B Inlet section

C Auxiliary section D Tilt section
E Lift / lower section F Outlet section
G Tie rods H Load hold check valves
J Pressure compensator valves K Service spool (Electrically operated)
L LSRV (Load Sense Relief Valve) M Flow regulator valve
30 - 240 9813/9050-1 30 - 240

00 - General
N ARV (Auxiliary Relief Valve) P Steer priority valve

Q Spool activation solenoids R Shuttle valve
30 - 241 9813/9050-1 30 - 241

00 - General
Assembly
following steps.
1.1. Clean the valve components in an
applicable solvent. Make sure that the
mating faces of the valve sections are fully
clean before assembly.
1.2. Replace the O-rings located between the
valve sections. Install the O-rings correctly.
1.3. Apply lubricant on all the parts before
assembly. Make sure that all the parts move
freely.
Consumable: JCB Hydraulic Fluid OP 46
1.4. Apply sealant to the tie rods before you
assemble them.
(High Strength)
1.5. Screw the tie rods into the inlet section until
they are tight.
1.6. Unscrew the tie rods for one turn.
1.7. Once the valve block is fully assembled
these rods may be adjusted to allow
sufficient thread for the tie rod nuts to
tighten.
1.8. Tighten the tie rod nuts to the correct torque
value.

Item Description Nm
A Tie rod nuts 35
30 - 242 9813/9050-1 30 - 242

Introduction
30 - 243 9813/9050-1 30 - 243

Introduction
30 - 244 9813/9050-1 30 - 244

27 - Pressure Compensator Valve
27 - Pressure Compensator Valve
Operation
Pressure Compensation (Flowshare) When one or more services are selected, the
pressure compensator valve detects the service
Each service spool incorporates a pressure generating the highest pressure and allows the pump
compensator valve. When services are operated to deliver oil at sufficient pressure to move the load.
simultaneously the system ensures consistent The load hold check valve prevents the load falling
operating speed for all services, even when the limit back if the load pressure is greater than the pump
of the hydraulic pump performance is approached. pressure.
The oil from the main hydraulic pump arrives at The closed centre design ensures consistent service
the inlet gallery. When the relevant service spool operation regardless of load.
is selected, the spool moves against the force of
the centring spring. This allows the oil flow to move For information about service spool and pressure
the required service. When the service spool is de- compensator valve operation, refer to hydraulic
selected, the centring spring returns the spool to the system- lift arm control valve block, refer to (PIL
neutral position. 30-51).
Figure 811.
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 - 245 9813/9050-1 30 - 245

36 - Load Hold Check Valve
36 - Load Hold Check Valve 1. The installation procedure is the opposite of the
steps.
Consumables applicable solvent.
Cleaner/Degreaser 4104/1557 0.4L purpose solvent based parts cleaner
- General purpose
solvent based parts 1.2. Lubricate the parts with hydraulic fluid
cleaner before assembly.
JCB Hydraulic Fluid HP 4002/0801 5L Consumable: JCB Hydraulic Fluid HP 46
46 4002/0805 20L 1.3. Make sure that all the parts move freely.
4002/0803 200L
Remove Item Description Nm
D Load hold check valve plug 15
3. Remove the valve block from the machine.
4. Remove the ARV (Auxiliary Relief Valve)
assembly.
5. Remove the LHCV (Load Hold Check Valve)
from the valve block section.
6. Remove the spring and the poppet.
Figure 812.
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 - 246 9813/9050-1 30 - 246

80 - Spool
80 - Spool Adjust
Adjust .......................................................... 30-247
(For: 531-70 [5AA], 541-70 [5AD])
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 813.
A Stop screw
B Locknut
30 - 247 9813/9050-1 30 - 247

80 - Spool
3. Remove the cover plate screws.

(For: 531-70 [5AA], 541-70 [5AD]) 4. Remove the housing and the O-ring from the
Consumables valve block.
5. Hold the spool assembly in a vice using the spool
Cleaner/Degreaser 4104/1557 0.4L clamp.
- General purpose
solvent based parts 6. Remove the spool end screw, the centering
cleaner spring, the spring retainers and the spring cup.
JCB Hydraulic Fluid HP 4002/0801 5L If necessary pre-heat the spool to the specified
46 4002/0805 20L temperature in an oven or with a heat gun to
remove the spool end.
4002/0803 200L
Disassemble 7. Carefully remove the spool from the valve body.
1. Remove the solenoid assembly. When you remove the O-rings and seals, use a
Refer to: PIL 33-86-00. rounded tool that will not cause damage to the seal
grooves. Discard all the O-rings and back-up rings.
2. Remove the mounting screws and the mounting Do not use worn or damaged items.
plate.
Figure 814.
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 - 248 9813/9050-1 30 - 248

80 - Spool
Figure 815. 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.
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 - 249 9813/9050-1 30 - 249

54 - Parallel Circuit Control Valve Block
Contents Page No.
30-54-00 General ......................................................................................................................... 30-251

30 - 250 9813/9050-1 30 - 250

00 - General

Technical Data ............................................. 30-251 For: 531-70 [5AA] .................... Page 30-251
Component Identification ............................. 30-255 For: 535-95 [5AB] .................... Page 30-252
Operation ..................................................... 30-257 For: 541-70 [5AD] .................... Page 30-253
Fault-Finding ................................................ 30-260
Adjust .......................................................... 30-261 (For: 531-70 [5AA])
Single lever control
30-53-00).
Table 433. 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)
side
30 - 251 9813/9050-1 30 - 251

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
Table 435. (For: 535-95 [5AB])

Pilot pressure range: Value
(machines with single Single lever control
lever controls)
All machines 10–30bar (144.9– alternative valves may be installed. Refer to (PIL
434.8psi) 30-53-00).
Dual lever control Table 438. 4 Spool, parallel

Table 436. 4 Spool, parallel Spool 1 Lift arm raise & Manually oper-
service, double acting spools lower service ated
Spool 1 Lift arm raise & Manually oper- Spool 2 Carriage tilt ser- Manually oper-
lower service ated vice ated
Spool 2 Lift arm extend Manually oper- Spool 3 Lift arm extend Solenoid, servo
& retract ser- ated & retract ser- pilot operated
vice vice
Spool 3 Carriage tilt ser- Manually oper- Spool 4 Auxiliary ser- Solenoid, servo
vice ated vice pilot operated
Spool 4 Auxiliary ser- Manually oper-
vice ated
Table 437. Relief valve pressures Relief valve Pressure value

MRV 240bar (3,478.2psi)
ARV -
MRV 240bar (3,478.2psi)
ARV -
Carriage tilt ram rod side 276bar (4,000.0psi) side
side
30 - 252 9813/9050-1 30 - 252

00 - General

A D A D
4 B A 4 B A
3 B A 3 B A
2 B A 2 B A
1 B A 1 B A
B C 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 440.
(For: 541-70 [5AD])
(machines with single
lever controls) Single lever control
All machines 10–30bar (144.9– Depending on the specification of your machine,
434.8psi) alternative valves may be installed. Refer to (PIL
30-53-00).
Dual lever control
service, double acting spools Spool 1 Lift arm raise & Manually oper-
lower service ated
lower service ated Spool 2 Carriage tilt ser- Manually oper-
vice ated
Spool 2 Lift arm extend Manually oper-
& retract ser- ated Spool 3 Lift arm extend Solenoid, servo
vice & retract ser- pilot operated
vice
vice ated Spool 4 Auxiliary ser- Solenoid, servo
vice pilot operated
vice ated
Relief valve Pressure value MRV 260bar (3,768.1psi)
MRV 240bar (3,478.2psi) ARV -
ARV - Auxiliary ram rod side 220bar (3,188.4psi)
Auxiliary ram rod side 220bar (3,188.4psi) Auxiliary ram head side 220bar (3,188.4psi)
Auxiliary ram head side 220bar (3,188.4psi) Carriage tilt ram rod side 276bar (4,000.0psi)
Carriage tilt ram rod side 250bar (3,623.2psi) Carriage tilt ram head 138bar (2,000.0psi)
Carriage tilt ram head 240bar (3,478.2psi) side
side
30 - 253 9813/9050-1 30 - 253

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 445.
(machines with single
lever controls)
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
vice ated

MRV 260bar (3,768.1psi)
ARV -
side
30 - 254 9813/9050-1 30 - 254

00 - General
(For: 531-70 [5AA], 535-95 [5AB])
Machines with dual lever controls
Figure 822.
B
A
C D
H G
Item Description
F Hydraulic cooling fan
Table 448.
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 - 255 9813/9050-1 30 - 255

00 - General
Machines with single lever controls
Figure 823.
B
A
C D E
J
H
K
M
Table 449.
Item Description
A Hydraulic tank
B Control valve
C Steer pump
D Fan supply pump
E Main hydraulic supply
pump
F Sway ram
G Hydraulic cooling fan
motor pipework
H Trailer brake valve
J Sway valve
K Hydraulic cooling fan
motor case drain line
L Steer return line
M Trailer brake coupling
30 - 256 9813/9050-1 30 - 256

00 - General
Operation Figure 825. 4 Spool Control Valve

(Dual Lever Control) Schematic
4 Spool Control Valve (Dual Lever

Control)
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 B J
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
B H
Figure 824. 4 Spool Control
Valve (Dual Lever Control)
E E
E E
A
G
J B
B A
H
B A
E G A
B A F
E B
F
B A
T C
A Service port 1
B Service port 2
C Inlet port
E ARV (Auxiliary Relief Valve)
F Spool 1
G Spool 2
H Spool 3
J Spool 4 T C
T Tank port A Service port 1
B Service port 2
The oil from the pump enters the control valve at C Inlet port
the inlet port, passing the adjustable MRV (Main D MRV
Relief Valve). As the spool 1, spool 2, spool 3 and E ARV
spool 4, are in neutral, the oil passes round their F Spool 1
central waists, the spool lands preventing the oil G Spool 2
from entering the service ports. On reaching the end H Spool 3
housing, the oil enters the exhaust gallery and is J Spool 4
discharged back to the tank. The control valve also T Tank port
incorporates adjustable ARV's.
30 - 257 9813/9050-1 30 - 257

00 - General
4 Spool Control Valve (Single Lever Figure 827. 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 826. 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 - 258 9813/9050-1 30 - 258

00 - General
K Pressure reduction valve

L Accumulator attachment port
T Tank port
30 - 259 9813/9050-1 30 - 259

00 - General
Fault-Finding
Fault
Lack of power at all hydraulic functions Table 450. Page 30-260
All mechanically operated hydraulic services slow to operate Table 451. Page 30-260
All solenoid/servo operated hydraulic services slow to operate Table 452. Page 30-260
Is the machine experiencing boom extend or retract problems? Table 453. Page 30-260
Bleed air from the hydraulic cylinders - is it OK now? Table 454. Page 30-260
Table 450. 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 451. 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 452. 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 453. Is the machine experiencing boom extend or retract problems?

Cause Remedy
YES = Go to Table 5, NO = done
Table 454. Bleed air from the hydraulic cylinders - is it OK now?

Cause Remedy
YES = Done, NO = Go to Table 6
30 - 260 9813/9050-1 30 - 260

00 - General
Adjust 6.1. Use the control lever to move and hold the
spool in the position.
Communications 6.2. Measure spool displacement 2.
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 455. Manual Spool Displacement
understood by everybody. Worksites can be noisy, do
not rely on spoken commands. Displacement Measurement
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
assembly. Adjustment
1. Make the machine safe with the lift arm raised. Spool displacement is influenced by the control lever
Refer to (PIL 01-03). linkage. Check, adjust and replace if necessary. If
sufficient adjustment can not be achieved it may be
2. Install the safety strut. Refer to (PIL 06-69). necessary to replace the spool assembly
3. Follow the general health and safety procedure.

30-00).
5. Check the spool displacement 1.
Figure 828.
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.
6. Check spool displacement 2.
30 - 261 9813/9050-1 30 - 261

00 - General
Remove and Install
7. Put a label on each hose to help installation.

Remove and Install (P1) 8. Disconnect the hydraulic hoses.
be removed or handled using a suitable lifting 9. Plug all the open ports and hoses to prevent
method and device. contamination.
10. Remove the securing clip and pin.
Remove
11. Disconnect the control lever rod from the spool
1. Make the machine safe. Refer to (PIL 01-03). end.
2. Follow the general health and safety procedures. 12. Repeat step 7 and step 8 for other control
Refer to (PIL 01-03). linkages.
3. Install the safety strut. Refer to (PIL 06-69). 13. Put a label on the electrical connectors to help
installation.
4. Follow the hydraulic safety procedures. Refer to
(PIL 30-00). 14. Disconnect all electrical connectors to the valve
block sensors.
30-00). 15. After you support the valve block properly,
remove the mounting screws. Carefully lift the
6. Remove the cab side cover (if installed) to get valve block away from the bracket and clear of
access to the valve block. Refer to (PIL 06-06). the machine.
30 - 262 9813/9050-1 30 - 262

00 - General
Figure 829.
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 - 263 9813/9050-1 30 - 263

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.
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 - 264 9813/9050-1 30 - 264

00 - General
Figure 830.
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 - 265 9813/9050-1 30 - 265

00 - General
Install
steps.
1.1. After you install, check the operation of the
mechanical control linkages. Operate the
control levers. Make sure that the lever
travel is the same in both directions. To
adjust the levers, remove the locknuts at
each end of the control rod. Turn the
rod to increase or decrease the length as
necessary. Tighten locknuts.
1.3. Check and fill the hydraulic system with the
recommended hydraulic fluid as necessary.
1.4. After installation, check the ARV and MRV
30 - 266 9813/9050-1 30 - 266

00 - General
Consumables Great care should be taken when you disassemble

Description Part No. Size and assemble a valve to avoid the following:
JCB Hydraulic Fluid HP 4002/0801 5L
46 • Contamination.
4002/0805 20L • Damage to spools.
4002/0803 200L • Damage to seal grooves.
Sealer (High Strength) 4101/0552 0.2L Any of the above may result in possible problems
with the operation of the valve.
Valve Block Sections Disassemble
Some valve sections and components are omitted 1. Remove the valve block from the machine.
from the figure for illustration purposes.
The valve block is a sectional type, which is made up 2. Remove the tie rod nuts.
of a number of separate sections. The illustration is
intended as a guide to identify the components. 3. Carefully separate and remove the outlet section
followed by the remaining service sections. If the
Be sure to note the location of all components when inlet section is to be replaced, remove and retain
you disassemble. Although some components may the tie rods.
appear to be identical, they are not interchangeable.
Make sure that components are assembled in their
original positions.
30 - 267 9813/9050-1 30 - 267

00 - General
Figure 831.
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 - 268 9813/9050-1 30 - 268

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 - 269 9813/9050-1 30 - 269

00 - General
Assemble
following steps.
1.1. Make sure that the mating faces of the
valve sections are thoroughly clean before
assembly.
1.2. Renew the seals located between the valve
sections. Make sure that 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 nut 1 and
nut 2. Tighten the nuts to the correct torque
value in the sequence 1, 2, 3 and then 1
again to the specified torque value.
(High Strength)

Item Description Nm
J Nut 1 40
K Nut 2 27
30 - 270 9813/9050-1 30 - 270

03 - Main Relief Valve (MRV) Introduction

Introduction .................................................. 30-271 Refer to (PIL 30-51-03).
30 - 271 9813/9050-1 30 - 271


The MRV (Main Relief Valve) is not serviceable. removal procedure. Additionally do the following
Replace the complete valve if it is defective. steps.
Remove 1.1. Replace all the O-rings.

1.2. Lubricate the parts with JCB hydraulic fluid
1. Make the machine safe. Refer to (PIL 01-03). before assembling.
2. Discharge the hydraulic pressure. Refer to (PIL 1.3. Tighten the valve to the specified torque
30-00). value.
3. Remove the valve assembly from the valve 1.4. Adjust the pressure setting as required.
block.
4. Remove the O-rings. Item Description Nm
4.1. When you remove the O-rings and seals, A Valve assembly 20
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 832.
A Valve assembly
30 - 272 9813/9050-1 30 - 272

06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-273 Refer to (PIL 30-51-06).
30 - 273 9813/9050-1 30 - 273

The ARV (Auxiliary Relief Valve) is not serviceable.

Replace the valve if it is defective.
Remove
1. Make the machine safe. Refer to (PIL 01-03)
30-00). A

block.
4. Remove the O-rings.
4.1. When you remove the O-rings and seals,
use a rounded tool that will not cause any
damage to the seal grooves.
4.2. Discard all the O-rings.
4.3. Do not use worn or damaged items.
A Valve assembly
Install
steps.
1.1. Replace all the O-rings.
1.2. Lubricate the parts with JCB hydraulic fluid
before assembling.
1.3. Tighten the valve assembly to the specified
torque value.
1.4. Adjust the pressure setting as required.

Item Description Nm
A Valve assembly 20
30 - 274 9813/9050-1 30 - 274

39 - Load Hold Check Valve
39 - Load Hold Check Valve Figure 834.
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
is engaged. Disconnect the battery to prevent the
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 - 275 9813/9050-1 30 - 275

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-277

30-60-12 Electro Proportional Control ......................................................................................... 30-279
30-60-15 Joystick ......................................................................................................................... 30-292
30-60-27 Auxiliary Circuit ............................................................................................................ 30-296
30-60-82 Sway ............................................................................................................................. 30-297
30-60-90 Flow Regulator ............................................................................................................. 30-301
30 - 276 9813/9050-1 30 - 276

00 - General
00 - General
Introduction
Flow Control Valves Figure 838.
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 835.
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 836. 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 840.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 277 9813/9050-1 30 - 277

00 - General
Figure 841. 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 - 278 9813/9050-1 30 - 278

12 - Electro Proportional Control
12 - Electro Proportional Control Operation

Operation ..................................................... 30-279
Diagram ....................................................... 30-291
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 - 279 9813/9050-1 30 - 279

Figure 842.
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 - 280 9813/9050-1 30 - 280

Figure 843.
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 - 281 9813/9050-1 30 - 281

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 844. 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 - 282 9813/9050-1 30 - 282

Figure 845.
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 - 283 9813/9050-1 30 - 283

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 846.
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 - 284 9813/9050-1 30 - 284

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 - 285 9813/9050-1 30 - 285

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 847.
IGN +VE
A Secondary fuse B Front/rear auxiliary changeover switch

C Front/rear auxiliary changeover solenoid
30 - 286 9813/9050-1 30 - 286

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 848.
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 - 287 9813/9050-1 30 - 287

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 849.
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 - 288 9813/9050-1 30 - 288

K Proportional control valve solenoid- auxiliary A

service
30 - 289 9813/9050-1 30 - 289

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 850.
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 - 290 9813/9050-1 30 - 290

Diagram
pressure flows to the proportional solenoid valves at

Oil from the hydraulic pump flows to the pilot each service spool.
pressure control valve via internal filters. Oil at pilot
Figure 851.
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 460. Hydraulic Connection Colour Key

A Oil at servo pressure
30 - 291 9813/9050-1 30 - 291

15 - Joystick
15 - Joystick Operation
Operation ..................................................... 30-292 For details of operation for Electro Proportional
Fault-Finding ................................................ 30-293 Controls refer to (PIL 30-60-12).
30 - 292 9813/9050-1 30 - 292

15 - Joystick
Fault-Finding Remove and Install

For related fault finding information refer to (PIL
30-00). Remove and Install (P1)
Machines with an electronic instruments system will
log some system faults as a fault code. These fault Remove
codes can be accessed with the correct diagnostics
software tool, using a laptop computer connected to The control lever and the attached powerbase is a
the machine CAN system. Refer to (PIL 33-57). non serviceable part. If it is faulty, it must be renewed.

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.
5. Lift away the arm rest and the trim assembly.
6. Remove the screws 1.
7. Remove the gaiter collar.
8. Remove the screws 2 and lift the control
lever and power base assembly to access the
electrical connectors.
9. Put label on the electrical connectors for correct
installation.
10. Disconnect the electrical connectors.
11. Remove the control lever from the housing.
30 - 293 9813/9050-1 30 - 293

15 - Joystick
Figure 852. 3. Prise the screw cover from the armrest.

4. Remove the screws and washers 1.
A
5. Lift away the arm rest.
B
6. Remove the rear screws and washers 2.
7. Remove front screws and washers 3.
8. Remove the gaiter collar.
C
9. Remove the pod top cover until you can access
J
the switch electrical connectors.
10. Put label on the electrical connectors for correct
installation.
H 11. Disconnect the switch connectors.
12. Disconnect the electrical connector 1, electrical
connector 2 and the electrical connector 3.
13. Remove the control lever from the pod.
D
14. Remove the screws 4.
15. Remove the control lever and the power base
assembly.
E
A Arm rest
B Screw cover
C Trim assembly
D Control lever
E Screws 1
F Housing
G Screws 2
H Gaiter collar
J Screws 3
Install
removal procedure.
Remove and Install (P2)

Remove
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.

2. Release the hydraulic pressure. Refer to (PIL
30-00).
30 - 294 9813/9050-1 30 - 294

15 - Joystick
Figure 853. Disassemble and Assemble
Do not attempt to dismantle the joystick. If the joystick

is defective, a new unit must be installed.
B
C Externally facing seals, port adaptors, gaiters and
joystick handles may be replaced if the correct parts
C are available and the correct cleanliness procedures
A are followed.
M G
M H H
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 - 295 9813/9050-1 30 - 295

27 - Auxiliary Circuit
27 - Auxiliary Circuit
Discharge and Pressurise
Refer to discharge and pressurise, (PIL 30-00).
30 - 296 9813/9050-1 30 - 296

82 - Sway
82 - Sway Operation (Hydraulic)

Operation (Hydraulic) .................................. 30-297 The schematic diagrams show an overview of the
Remove and Install ..................................... 30-299 system. For machine specific schematics, refer to
The engine cooling fan hydraulic oil supply is also

used to operate the sway system when installed.
When the sway system is operated, the supply to the
engine cooling fan is diverted to the sway system.
The hydraulic fan does not operate while the sway
system is in use. The sway ram will stay in position
until the switch is operated.
Later machines have a pressure relief valve installed.

For details of the valve pressures, refer to the
Operation of the switch energises the sway/fan

selection solenoid and the sway direction control
solenoid in the sway/fan changeover valve. The
sway/fan selection solenoid diverts the fan hydraulic
supply to feed the sway system. The sway direction
control solenoid is a double acting solenoid which
controls the direction of the supply to the correct side
of the sway ram.
A proximity switch located on the lift arm operates

when the lift arm is at an angle of 10° or higher.
The proximity switch prevents the sway relay from
energising and operating the sway system solenoid
until the lift arm is lowered.
Figure 854. Sway Switch Not Operated
T F P
D
30 - 297 9813/9050-1 30 - 297

82 - Sway
Figure 855. Right Sway Switch Operated Figure 856. Left Sway Switch Operated
C
C B
A
A
T F P D
T F P
D
Table 461.
A Sway/Fan selection solenoid
B Sway direction control solenoid
C Sway ram
D Pressure relief valve
F Fan hydraulic supply
P Pump hydraulic supply
T Tank return
30 - 298 9813/9050-1 30 - 298

82 - Sway
WARNING A raised and badly supported

machine can fall on you. Position the machine
on a firm, level surface before raising one end. A
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks B
to support the machine when working under it.
Disconnect the battery, to prevent the machine C
being started while you are beneath it.
Remove
1. Make the machine safe with the lift arm raised.
2. Install the safety strut. Refer to (PIL 06-69). D
4. Put labels on the hydraulic hoses to help
installation.
contamination.
7. Disconnect the electrical connector from the E E
stabiliser sway/fan selector solenoid.
A Bracket
8. Disconnect the electrical connectors from the B Sway/fan selector solenoid
sway direction control solenoids. C Sway direction control solenoids
D Sway/fan valve
9. Make a note of the route of the harness. E Bolts
10. Remove the harness retaining clips. Figure 858. Typical Sway Valve Harness
11. Support the sway/fan valve.
12. Release the bolts and remove the sway/fan valve F
from the bracket.
F Harness retaining clips

G Harness
30 - 299 9813/9050-1 30 - 299

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 - 300 9813/9050-1 30 - 300

90 - Flow Regulator
90 - Flow Regulator
Introduction
30 - 301 9813/9050-1 30 - 301

61 - Counterbalance Valve
Contents Page No.
30-61-00 General ......................................................................................................................... 30-303

30-61-06 Lift Arm ......................................................................................................................... 30-308
30 - 302 9813/9050-1 30 - 302

00 - General
Introduction .................................................. 30-303
Operation ..................................................... 30-304
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 - 303 9813/9050-1 30 - 303

00 - General
Operation
To prevent this, counterbalance valves are installed

The extend and tilt ram circuits have a to make sure that, only the pressure of flow from the
counterbalance valve. control valve spool will move the lift arm or carriage
and the weight will not affect it. Therefore when the
When there is a load on the carriage, the weight of lift/lower or crowd/dump services are not operated,
the load could cause the lift arm to lower or dump. the valve is closed effectively locking the ram in
This would be dangerous as the load may lower position regardless of load.
suddenly or fall off the carriage.
Component Location
Figure 859.
A Extend ram counterbalance valve B Tilt ram counterbalance valve
30 - 304 9813/9050-1 30 - 304

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 860. Typical Valve Schematics
A B
A Extend counterbalance valve B Tilt counterbalance valve
30 - 305 9813/9050-1 30 - 305

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 861. 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 861.
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 862. 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 862.
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 863. remains closed.
Pressure is supplied to extend the ram. The check
30 - 306 9813/9050-1 30 - 306

00 - General
Figure 863.
D
A
B
+
C
Electrical Operation
There are no electrical devices used in this system.
30 - 307 9813/9050-1 30 - 307

06 - Lift Arm
06 - Lift Arm
Operation
If the pressure in the circuit is less than 10bar

The counter balance valve is used to hold the lift (144.9psi) and the crowd and lift service operate at
arm in position and for it not to lower under its own the same time, the hydraulic ECU (Electronic Control
weight. Refer to hydraulic system- counterbalance Unit) deselects the crowd service. This allows the
valve, refer to (PIL 30-61). pressure to increase in the lift ram circuit.
When you operate the crowd and lift arm raise When the pressure in the circuit raises to more than
hydraulic services, there are rare occasions when 20bar (289.9psi) the hydraulic ECU responds by
the flow may divert through the displacement ram restoring normal operation of the crowd service.
circuit and cause the lift arm to raise under the power
of the displacement ram. On machines with SRS (Smooth Ride System), the
SRS pressure transducer is used. For information
Pressure monitoring of the lift ram full bore (rod about the SRS system, refer to hydraulic system-
end) maintains a minimum pressure ensuring correct general, refer to (PIL 30-00).
operation of the lift arm service. A pressure
transducer is installed in the full bore (rod end) side On machines without the SRS, a pressure transducer
of the lift arm circuit. is installed.
Component Location
Figure 864.
30 - 308 9813/9050-1 30 - 308

06 - Lift Arm
A Pressure transducer B Lift ram
30 - 309 9813/9050-1 30 - 309

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 865.
1 4 4 1
2 3 3 2
30 - 310 9813/9050-1 30 - 310

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-313
30 - 311 9813/9050-1 30 - 311

Notes:
30 - 312 9813/9050-1 30 - 312

00 - General
Introduction .................................................. 30-313 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-314 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 313 9813/9050-1 30 - 313

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 - 314 9813/9050-1 30 - 314

00 - General
Figure 866.
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 - 315 9813/9050-1 30 - 315

70 - Pilot Pressure Supply Valve
Contents Page No.
30-70-00 General ......................................................................................................................... 30-317
30 - 316 9813/9050-1 30 - 316

00 - General
00 - General
Check (Pressure)
1. Turn the ignition key switch to on, but do not start

Hydraulic Pressure
the engine.
Before connecting or removing any hydraulic hose, 2. Discharge the hydraulic pressure from the
residual hydraulic pressure trapped in the service system. Refer to (PIL 30-00).
service line has been vented before connecting or 3. Separate the hose from the filter and install tee-
removing hoses. Make sure the engine cannot be piece between the them.
Figure 867.
A Hose B Filter
C Tee-piece D Pressure gauge
30 - 317 9813/9050-1 30 - 317

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 - 318 9813/9050-1 30 - 318

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-321

30-93-03 Lift Arm ......................................................................................................................... 30-329
30 - 319 9813/9050-1 30 - 319

Notes:
30 - 320 9813/9050-1 30 - 320

93 - Hose
00 - General
Introduction .................................................. 30-321 Hydraulic hoses are used to connect different
Component Identification ............................. 30-322 components in the hydraulic circuit. The hoses
Disconnect and Connect ............................. 30-327 are graded by pressure, temperature, and fluid
Check (Condition) ........................................ 30-328 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 - 321 9813/9050-1 30 - 321

93 - Hose
00 - General
For: 531-70 [5AA], 535-95 [5AB], 541-70

[5AD] ....................................... Page 30-322
For: 531-70 [5AA], 541-70 [5AD]
................................................. Page 30-324
(For: 531-70 [5AA], 535-95 [5AB], 541-70 [5AD])
Figure 868. Neutral Circuit Layout
30 - 322 9813/9050-1 30 - 322

93 - Hose
00 - General
Figure 869.
Item Description
90 Hose 3/8 BSP
Table 462.
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 - 323 9813/9050-1 30 - 323

93 - Hose
00 - General
(For: 531-70 [5AA], 541-70 [5AD])
Figure 870.
30 - 324 9813/9050-1 30 - 324

93 - Hose
00 - General
Figure 871.
Item Description
Table 463. 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 - 325 9813/9050-1 30 - 325

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 - 326 9813/9050-1 30 - 326

93 - Hose
00 - General
Disconnect and Connect Figure 874.
Some attachments are hydraulically powered. The

following procedures show how to connect and
disconnect the hydraulic hoses safely.
Connecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Check the hoses and adaptors for damage. 5. Check for leaks:
4. Connect the hoses: 5.1. Start the machine.
4.1. Make sure that the hose is not twisted. 5.2. Operate the related controls to increase the
Pressure applied to a twisted hose can pressure in the hydraulic system.
cause the hose to fail or the connections to 5.3. Stop the machine then remove the key.
loosen.
5.4. Check for indications of leakage at the hose
Figure 872. connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Disconnect the hoses.
4.2. Make sure that the hose does not touch 4. Check the hoses and adaptors for damage.
hot parts. High ambient temperatures can
cause the hose to fail. 5. If necessary, install the blanking caps.
4.3. Make sure that the hose does not touch 6. Check for leaks:
parts which can rub or cause abrasion.
6.1. Start the machine.
4.4. Use the hose clamps (where possible) to
support long hose runs and keep the hoses 6.2. Operate the related controls to increase the
away from moving parts, etc. pressure in the hydraulic system.
Figure 873. 6.3. Stop the machine then remove the key.
6.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
4.5. To allow for length changes when the hose

is pressurised, do not clamp at the bend.
The curve absorbs the change.
30 - 327 9813/9050-1 30 - 327

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 - 328 9813/9050-1 30 - 328

93 - Hose
03 - Lift Arm
03 - Lift Arm
Technical Data
Refer to hydraulic system, hose, lift arm, component

identification (PIL 30-93-03).
30 - 329 9813/9050-1 30 - 329

96 - Pipe
96 - Pipe
Contents Page No.
30-96-03 Lift Arm ......................................................................................................................... 30-331
30 - 330 9813/9050-1 30 - 330

96 - Pipe
03 - Lift Arm
03 - Lift Arm
Refer to component identification, (PIL 30-93-03).
30 - 331 9813/9050-1 30 - 331

97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling .............................................................................................. 30-333

30-97-09 Adaptor ......................................................................................................................... 30-335
30-97-24 Push Lock Fitting ......................................................................................................... 30-337
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-338
30 - 332 9813/9050-1 30 - 332

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-333 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-334 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 875.
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 - 333 9813/9050-1 30 - 333

97 - Connectors
03 - Quick Release Coupling
• Periodically lubricate the internal locking balls Disconnect and Connect

on the female half of the coupling with silicone
grease.
Some attachments are hydraulically powered. The
Essential Don'ts following procedures show how to connect and
disconnect the hydraulic hoses safely.
• Never try to reconnect using a damaged half
coupling as this will destroy the seals in the
mating half and necessitate replacement of Connect
both halves. 1. Make the machine safe.
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this Refer to: PIL 01-03.
will distort the sleeve and prevent connection
and disconnection. 2. Discharge the hydraulic pressure.
• Never try to turn the sleeve when the coupling is Refer to: PIL 30-00-00.
disconnected as this will cause the locking ball
to jam under the locking sleeve and damage the 3. Wipe the two faces of the male and female
coupling. couplings and make sure they are clean.
• Never try to strip the coupling down, there are
no user serviceable parts. If the coupling is 4. Make sure that the ball in the female coupling is
damaged it must be replaced with a new one. located in one of its slots.
• Never hit the centre poppet of the coupling to 5. Connect the male coupling into the female
try and release the locked in pressure. This can coupling.
cause irreparable damage to the coupling and
serious injury. 6. Where applicable, rotate the sleeve half a turn
• When connecting the couplings, never clamp and make sure that the locking ball does not align
on the sleeve of the female or nose of the male, with the slot.
this will cause distortion and/or damage.
• Never subject the couplings to external forces, Disconnect
especially side load. This can decrease the life
of the coupling or cause failure. 1. Make the machine safe.
• Never allow the torsional forces transmitted
from the hoses to unscrew/screw together the Refer to: PIL 01-03.
couplings.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in Refer to: PIL 30-00-00.
the line unless the coupling type is specifically
designed to do so. 3. Where applicable, align the slot with the ball.
4. Pull back the sleeve to release the coupling.
Figure 876.
C D E
C Ball
D Slot
E Sleeve
30 - 334 9813/9050-1 30 - 334

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-335 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-336 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 877.
A O-ring seal
B Locknut
C Washer
30 - 335 9813/9050-1 30 - 335

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 878.
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 - 336 9813/9050-1 30 - 336

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 880.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 337 9813/9050-1 30 - 337

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 881.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 338 9813/9050-1 30 - 338

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 ................................................................................................................... 33-242
33-03 Battery
33-03-00 General ......................................................................................................................... 33-247
33-03-03 Isolator Switch .............................................................................................................. 33-258
33-06 Battery Cable
33-06-00 General ......................................................................................................................... 33-261
33-06-12 Earth Strap ................................................................................................................... 33-263
33-09 Power Distribution
33-09-00 General ......................................................................................................................... 33-267
33-09-03 Fuse ............................................................................................................................. 33-269
33-09-06 Relay ............................................................................................................................ 33-270
33-12 Harness
33-12-00 General ......................................................................................................................... 33-273
33-12-04 Chassis ......................................................................................................................... 33-286
33-12-06 Lift Arm ......................................................................................................................... 33-310
33-12-09 Engine .......................................................................................................................... 33-341
33-12-12 Operator Station ........................................................................................................... 33-359
33-12-14 Sway ............................................................................................................................. 33-381
33-12-15 Front Console ............................................................................................................... 33-387
33-12-22 Armrest ......................................................................................................................... 33-412
33-12-30 Gearbox ........................................................................................................................ 33-424
33-12-34 Trailer ........................................................................................................................... 33-435
33-12-36 Work Lights .................................................................................................................. 33-438
33-12-39 Road Lights .................................................................................................................. 33-450
33-12-46 Immobiliser ................................................................................................................... 33-455
33-12-58 Heater ........................................................................................................................... 33-461
33-15 Alarm
33-15-03 Reverse Warning .......................................................................................................... 33-465
33-21 Immobiliser
33-21-00 General ......................................................................................................................... 33-467
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-469
33-24-10 Hourmeter .................................................................................................................... 33-473
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................... 33-475
33-27-51 Hydraulic Flow .............................................................................................................. 33-477
33-33 Console Switch
33-33-04 Direction Indicators ...................................................................................................... 33-483
33-40 Bulb
9813/9050-1
2017-12-22
33-40-00 General ......................................................................................................................... 33-495
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-499
33-45-01 Instrument Panel .......................................................................................................... 33-502
33-45-06 Engine .......................................................................................................................... 33-509
33-45-09 Gearbox ........................................................................................................................ 33-513
33-45-24 Servo ............................................................................................................................ 33-523
33-45-36 Hydraulic ...................................................................................................................... 33-529
33-48 Entertainment
33-48-03 Radio ............................................................................................................................ 33-541
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-545
33-51-03 Socket .......................................................................................................................... 33-546
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-549
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-551
33-57-03 Servicemaster .............................................................................................................. 33-555
33-57-90 Fault Codes .................................................................................................................. 33-621
33-66 Load Motion Control System
33-66-00 General ......................................................................................................................... 33-663
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-673
33-84-15 Transmission Oil Temperature ..................................................................................... 33-674
33-84-41 Lift Arm ......................................................................................................................... 33-675
33-84-51 Rear Axle ..................................................................................................................... 33-676
33-84-72 Chassis ......................................................................................................................... 33-680
9813/9050-1
2017-12-22
Acronyms Glossary
2WD Two Wheel Drive

4WS Four Wheel Steer
AWS All Wheel Steer
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
LCD Liquid Crystal Display
LED Light Emitting Diode
LLMC Longitudinal Load Moment Control
LLMI Longitudinal Load Moment Indicator
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
OEM Original Equipment Manufacturer
PWM Pulse Width Modulation
RAS Rear Axle Stabilization
SCR Selective Catalytic Reduction
SRS Smooth Ride System
USB Universal Serial Bus
VIN Vehicle Identification Number
WIF Water in Fuel
9813/9050-1
2017-12-22
Notes:
9813/9050-1
2017-12-22
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................... 33-242
33 - 1 9813/9050-1 33 - 1
Notes:
33 - 2 9813/9050-1 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 9813/9050-1 33 - 3
00 - General
Health and Safety

Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the
alternator before arc-welding on the machine or
attached implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result in
irreparable damage to these components.
Parts of the machine are made from cast iron, welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to
the same component that is being welded to avoid
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the
part being welded no more than 0.6m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9813/9050-1 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 465. Page 33-5
General Relay Fault Table 466. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 467. Page 33-6
ECM Faults Table 468. Page 33-6
Table 465. Battery Fault

Cause Remedy
Battery Voltage Switch on the ignition key and check the battery
voltage with a multimeter. If the terminal voltage of
the battery is below 9 Volt or above 16 Volt, charge
or replace the battery.
Battery Connection Fault Disconnect the electrical connection from the battery.
Check for signs of corrosion or contamination in the
battery terminals, clean the terminals. Repair as
necessary.
If no fault is found proceed to ECM (Engine Control
Module) Connection Faulty.
ECM Connection Faulty Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
necessary.
Check the resistance between the vehicle chassis
ground and ECM ground, if the resistance is high
repair the ECM ground.
If no fault is found proceed to 'Battery Charge Circuit
Fault'.
Battery Charge Circuit Fault Check the battery charge circuit, if the circuit is found
faulty repair as necessary.
Table 466. 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 9813/9050-1 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 467. 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 468. 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 9813/9050-1 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 9813/9050-1 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 9813/9050-1 33 - 8
Figure 882.
/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 9813/9050-1 33 - 9
Figure 883. 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 9813/9050-1 33 - 10
Diagram
For: 535-95 [5AB] ...................... Page 33-11

For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD] ....................................... Page 33-141
For: 531-70 [5AA], 535-95 [5AB], 541-70
[5AD], JCB Tier 4F Elec 430 Engine 4 Cyl
................................................. Page 33-222
(For: 535-95 [5AB])

Figure 884. Battery and Primary Fuses 160/B4268 Issue 2- Sheet 2.................................... Page 33-13
Figure 885. Ignition and Secondary Fuses 160/B4268 Issue 2- Sheet 3............................... Page 33-17
Figure 886. Engine Fuses and Starter 160/B4268 Issue 2- Sheet 4......................................Page 33-21
Figure 887. Engine- ECU and Sensors 160/B4268 Issue 2- Sheet 5.................................... Page 33-25
Figure 888. Engine- After Treatment 160/B4268 Issue 2- Sheet 6........................................ Page 33-29
Figure 889. PS750 Transmission 160/B4268 Issue 2- Sheet 7............................................. Page 33-33
Figure 890. Livelink and Immobiliser 160/B4268 Issue 2- Sheet 8........................................ Page 33-37
Figure 891. Instruments 160/B4268 Issue 2- Sheet 9............................................................Page 33-41
Figure 892. Roadlights 160/B4268 Issue 2- Sheet 10........................................................... Page 33-45
Figure 893. Directional Indicators 160/B4268 Issue 2- Sheet 11........................................... Page 33-49
Figure 894. Worklights 160/B4268 Issue 2- Sheet 12............................................................Page 33-53
Figure 895. Wiper Motors 160/B4268 Issue 2- Sheet 13....................................................... Page 33-57
Figure 896. HVAC 160/B4268 Issue 2- Sheet 14.................................................................. Page 33-61
Figure 897. In Cab Entertainment 160/B4268 Issue 2- Sheet 15.......................................... Page 33-65
Figure 898. Reverse Fan 160/B4268 Issue 2- Sheet 16........................................................Page 33-69
Figure 899. CAN BUS Architecture 160/B4268 Issue 2- Sheet 17........................................ Page 33-73
Figure 900. CAN BUS Engine 160/B4268 Issue 2- Sheet 18................................................ Page 33-77
Figure 901. Switch Illumination 160/B4268 Issue 2- Sheet 19...............................................Page 33-81
Figure 902. Ground Panel 160/B4268 Issue 2- Sheet 20...................................................... Page 33-85
Figure 903. Ground Chassis 160/B4268 Issue 2- Sheet 21...................................................Page 33-89
Figure 904. Transmission ECU 160/B4268 Issue 2- Sheet 22...............................................Page 33-93
Figure 905. Hydraulic ECU 160/B4268 Issue 2- Sheet 23.....................................................Page 33-97
Figure 906. Pin Lock 160/B4268 Issue 2- Sheet 24............................................................ Page 33-101
Figure 907. Hitch Harness 160/B4268 Issue 2- Sheet 25....................................................Page 33-105
Figure 908. Steer Mode 160/B4268 Issue 2- Sheet 26........................................................Page 33-109
Figure 909. Park Brake and Auto/Man 160/B4268 Issue 2- Sheet 27................................. Page 33-113
Figure 910. SRS 160/B4268 Issue 2- Sheet 28...................................................................Page 33-117
Figure 911. LLMI 160/B4268 Issue 2- Sheet 29.................................................................. Page 33-121
Figure 912. Footbrake Dump 160/B4268 Issue 2- Sheet 30................................................Page 33-125
Figure 913. Valve Block 160/B4268 Issue 2- Sheet 31........................................................Page 33-129
Figure 914. Joystick and Sway Isolation 160/B4268 Issue 2- Sheet 32...............................Page 33-133
Figure 915. E-Stop 160/B4268 Issue 2- Sheet 33............................................................... Page 33-137
33 - 11 9813/9050-1 33 - 11
Notes:
33 - 12 9813/9050-1 33 - 12
Page 33-14 Figure 884. Battery and Primary

Fuses 160/B4268 Issue 2- Sheet 2 Page 33-15
1 2 3 4 5 6 7 8
F
F
95.00 mm² RED TO

/4.F5 TO STARTER MOTOR
C033
E
E
C/D A/B
PRIMARY FUSE
TO FUSE /3.D4 TO 4.00 mm² 200D B/2 50A 50A B/2 4.00 mm² 200A TO
/3.F1 TO IGNITION SWITCH
5 3
P002:11 -P046 -P045 P043:1
TO IGNITION RELAYS 3&4 /3.C1 TO 4.00 mm² 200C A/2 50A 50A A/2 4.00 mm² 202B TO
/3.D1 TO IGNITION RELAYS 1&2
4 2
SPLICE SP26 SPLICE SP35
1
FUSE LINK BOX BLUE FUSE LINK BOX GREY
-B001
M6
D
D
16.00 mm² RED

ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm² RED
M8 -S1
M8 -CS1
16.00 mm² RED

20.00 mm² RED
M10
M10
M8
-C001
-C002
-C002
-B002
M10
G/H E/F
M6
CHASSIS GROUND -P047 -P048
2 4
1
10.00 mm² BLACK TO
/6.F3 TO PURGE HOLD RELAY FUSE TO FUSE /3.B4 TO 4.00 mm² 200F A/2 50A 50A A/2 4.00 mm² 200G TO
/3.B1 TO IGNITION RELAY 6
C001 P003:11 SPLICE SP30
3 5
TO IGNITION RELAY 5 /3.B1 4.00 mm² 200E B/2 50A 50A B/2 4.00 mm² 319
/4.B1 TO ENGINE SUPPLY
C
TO TO
SPLICE SP15 P093:1

C
10.00 mm² BLACK TO
/6.F3 TO PURGE HOLD RELAY FUSE LINK BOX GREY 2 FUSE LINK BOX BLUE 2
C003 PRIMARY FUSE
20.00 mm² RED TO

/4.D4 TO GRID HEATER FUSE
CS1:1
B
B
A
A
1 2 3 4 5 6 7 8
33 - 13 9813/9050-1 33 - 13
Page Page
33-14 33-15

1 2 3 4
95.00 mm² RED TO

/4.F5 TO STARTER MOTOR
C033
TO FUSE /3.D4 TO 4.00 mm² 200D B/2

5
P002:11 -P046
TO IGNITION RELAYS 3&4 /3.C1 TO 4.00 mm² 200C A/2
4
SPLICE SP26
FUSE LINK BOX BLUE
ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm² RED
M8
M8 -CS1 20.00 mm² RED
M10
M10
M8
Page 33-15
-C001
-C002
-C002
M10
CHASSIS GROUND -P047

2
10.00 mm² BLACK TO
/6.F3 TO PURGE HOLD RELAY FUSE TO FUSE /3.B4 TO 4.00 mm² 200F A/2
C001 P003:11
3
TO IGNITION RELAY 5 /3.B1 4.00 mm² 200E B/2
C
TO
SPLICE SP15
10.00 mm² BLACK TO
/6.F3 TO PURGE HOLD RELAY FUSE LINK BOX GREY 2
C003
20.00 mm² RED TO

/4.D4 TO GRID HEATER FUSE
CS1:1
1 2 3 4
33 - 14 9813/9050-1 33 - 14
Page Page
33-14 33-15

5 6 7 8
TO STARTER MOTOR
C/D A/B
PRIMARY FUSE
4.00 mm² 200D B/2 50A 50A B/2 4.00 mm² 200A TO
/3.F1 TO IGNITION SWITCH
5 3
-P046 -P045 P043:1
4.00 mm² 200C A/2 50A 50A A/2 4.00 mm² 202B TO
/3.D1 TO IGNITION RELAYS 1&2
4 2
SPLICE SP35
1
FUSE LINK BOX BLUE FUSE LINK BOX GREY

-B001
M6
D
16.00 mm² RED
25.00 mm² RED

-S1
16.00 mm² RED
Page 33-14
-B002
G/H E/F
M6
-P047 -P048
2 4
1
4.00 mm² 200F A/2 50A 50A A/2 4.00 mm² 200G TO
/3.B1 TO IGNITION RELAY 6
SPLICE SP30
3 5
4.00 mm² 200E B/2 50A 50A B/2 4.00 mm² 319 TO
/4.B1 TO ENGINE SUPPLY
P093:1
FUSE LINK BOX GREY 2 FUSE LINK BOX BLUE 2 C
PRIMARY FUSE
TO GRID HEATER FUSE
5 6 7 8
33 - 15 9813/9050-1 33 - 15
33 - 16 9813/9050-1 33 - 16
Page 33-18 Figure 885. Ignition and Secondary

Fuses 160/B4268 Issue 2- Sheet 3 Page 33-19
1 2 3 4 5 6 7 8
FROM PRIMARY FUSE B /2.D6 4.00 mm² 200A

F
FROM
P045:B
F
IGNITION SWITCH
-P001 -P004
III START
HEAT
FUSE BOX A FUSE BOX D

PRE
0 OFF
I ON
-P043 -P044
II
1 5
/23.E1 C045 / P039:C8
4.00 mm² 200AB 4.00 mm² 200AA 4.00 mm² 001A 4.00 mm² 001A 1 5A 2 1.00 mm² 100 4.00 mm² 201G 1 20A 2 2.00 mm² 203 TO
-SP51 2 6 4.00 mm² 014 1 31

-P039
3
/4.F1 TO NEUTRAL START RELAY FROM NEUTRAL START /4.F2 TO ENGINE SUPPLY
4.00 mm² 004B 4.00 mm² 004 4.00 mm² 842A 3 30A 4 4.00 mm² 842 3 3A 4 2.00 mm² 3711 A8/84
TO FROM TO
/4.F3
4 -SP52 P010:1 P010:2 2 P093:2 32
8
/14.E4 TO HEATED GLASS /6.B1 TO NOx SENSOR RELAY
4.00 mm² 015B 5 5A 6 2.00 mm² 150 TO
5 10A 6 1.50 mm² 300NX TO
9 3 P054:1 33 P101:1
7
/25.D3 FRONT/REAR AUX SW /11.C3 TO HAZARD SWITCH
7 10A 8 1.50 mm² 114 TO
7 3A 8 1.00 mm² 300 TO
4 P017:2 34 P020:5
/6.B1 HOSE HEATER RELAY /9.C3 TO INSTRUMENT V+
9 5A 10 1.00 mm² 1100A TO
9 15A 10 1.00 mm² 301E TO
5 P101:3 35 SPLICE SP40 / P071

TO
/4.E1 TO REMOTE START RELAY FROM REMOTE START RELAY /4.E2 FROM 4.00 mm² 004A
P119:1 P119:2
/5.C1 TO ENGINE POD CON /6.B1 TO SCR ECU /22.E5 TO 07/11 CONNECTOR 2
11 3A 12 1.00 mm² 107B 1.00 mm² 1100 4.00 mm² 011G 11 3A 12 1.00 mm² 100TR
E
TO TO TO
6 C032:5 / P039:E7 C010E:22 / P199:9 36 P070:1

E
/14.C1 TO HEATER CON /8.D1 TO LIVE LINK RELAY
1.00 mm² 100 4.00 mm² 010B 13 30A 14 2.00 mm² 102 TO
13 5A 14 1.00 mm² 110LL TO
7 P033:3 37 P013:1
-P006 TO BRAKE LIGHT RELAY /29.E4 TO LLMI
15 10A 16 1.00 mm² 108 15 3A 16 1.00 mm² 101A
TO
/10.F5 TO
IGNITION RELAY 1 8 P011:1 38 P042-A

4
/27.D1 TO PARKBRAKE SW /9.E3 TO INSTRUMENT CLUSTER J1
17 3A 18 1.00 mm² 107PB TO
17 3A 18 1.00 mm² 106 TO
4.00 mm² 200B 1 2 4.00 mm² 015B 9 RC012:3 / P049:10 39 P071:2 FROM
/29.C1
TO COLUMN SWITCH RH 1.00 mm² 107SP
/15.C2 SEAT PRESSURE SW /8.D4 TO IMMOBILISER RELAY C032-3
19 3A 20 1.00 mm² 104 19 5A 20 1.00 mm² Y
TO
/11.B1 TO TO
-SP20 3 5 10 P038:14 RC012:1 / P049:14 40 P101:6

0.75 mm² 100J 0.75 mm² 601HB TO
/20.F4 TO GROUND 1.00 mm² 155EC FROM
/23.D5
SPLICE SP3 C017-15
-P039 -C001
1.50 mm² 155 F9/84 F9/84 1.50 mm² 155
-P006 -SC6
IGNITION RELAY 2 C081-1
1.00 mm² 155B
9
TO
/16.D7
-P002 -P005
FROM PRIMARY FUSE A /2.D6 4.00 mm² 202B 4.00 mm² 203B 6 7 4.00 mm² 010B FUSE BOX B FUSE BOX E 1.00 mm² 155C C081-4
/16.D7
FROM
TO
P045:A -SP35
8 10 COLUMN SWITCH RH
/20.F4 TO GROUND /14.D4 TO ROOF AC FANS RELAY /10.B4 TO DIPPED BEAM
0.75 mm² 100B 0.75 mm² 601EK 4.00 mm² 013C 1 25A 2 2.00 mm² 116 2.00 mm² 833 1 15A 2 1.50 mm² 834
TO TO
/10.B3 FROM TO
P038:9
D SPLICE SP3 11 P015:6 41 SPLICE SP18
3 20A 4 2.00 mm² 133 TO
/13.D3 TO WIPER PARK
COLUMN SWITCH RH
/10.B3 FROM 2.00 mm² 836 3 20A 4 2.00 mm² 838 TO
/10.B4 TO MAIN BEAM
D
-P007 12 SPLICE SP16 P038:13 42 SPLICE SP19
IGNITION RELAY 3 HEADLIGHT SWITCH
/13.B2 TO WIPER /19.C3 TO SIDE LIGHTS
5 15A 6 1.50 mm² 110 2.00 mm² 942D 5 7.5A 6 1.50 mm² 829E
TO
/10.C3 FROM TO
4 13 SPLICE SP33 SPLICE SP22 43 SPICE SP7

1 2 HEADLIGHT SWITCH
/14.C2 TO AC RELAY /10.C4 TO SIDE LIGHTS
4.00 mm² 201C 4.00 mm² 013C 4.00 mm² 012CA 7 20A 8 2.00 mm² 997 2.00 mm² 942E 7 5A 8 0.75 mm² 830
TO
/10.C3 FROM TO
14 P015:1 SPLICE SP22 44 P039:E2

3 5 HEADLIGHT SWITCH
/20.F4 TO GROUND /15.B3 TO MOBILE PHONE /10.F3 TO FOG LIGHT SWITCH
0.75 mm² 100H 0.75 mm² 601HL 9 15A 10 1.50 mm² 119 1.00 mm² 832B 9 3A 10 1.00 mm² 905
TO TO
/10.C3 FROM TO
15 P056:1 SPLICE SP21 45 P023:2

FROM PRIMARY FUSE D /2.D4 4.00 mm² 200D 11 5A 12 2.00 mm² 3100A
/6.D1 TO TANK HARNESS 1.00 mm² 601LL 11 5A 12 1.00 mm² 601L
/8.C4 TO LIVE LINK TO HEATED SEAT
FROM TO TO
ADDITIONAL FUSES P046:B 16 C199:1 46 2.00 mm² 151 P068:9

/14.F3 RC002:1 / P049:7
TO
/12.D3 TO FRONT WORKLIGHT RELAY

13 25A 14 2.00 mm² 308 4.00 mm² 014 13 20A 14 2.00 mm² 151B
TO
/14.E3 TO FACE FAN
TO
17 P012:1 47
P051:1
/5.F5 TO DAILY CHECKS /12.B1 TO BEACON SWITCH /11.E5 TO TRAILER DI RELAYS
4.00 mm² 203C 1 20A 2 1.00 mm² 300RDM TO
15 7.5A 16 1.00 mm² 310 TO 4.00 mm² 202E 15 20A 16 1.50 mm² 275 TO
P137:1 18 P028:2 48 SPLICE SP25

-P132
/22.D5 TO 07/11 VBATT /6.D1 TO HOSE HEATER RELAY
17 10A 18 1.50 mm² 300TR TO
17 20A 18 2.00 mm² 300HH TO
-SP66 1.00 mm² SPLICE SP38 49 P009:1

/5.F5 TO DAILY CHECKS
1 20A 2 1.00 mm² 100EX 100RDM TO 19
P137:8 301 -SP27 1.00 mm² 301J
/12.C3 BOOM WORK LIGHTS RELAY /12.A1 TO INTERIOR LIGHT
19 25A 20 2.00 mm² 312 19 10A 20 1.00 mm²
C -P131 TO TO
P011:6 50 RC010:1 / P049:9

1.00 mm² 100WBL TO
/13.C6 TO WASHER BOTTLE LEVEL 20
C
-P007 C001:1 / P135:1
4.00 mm² 012CB 1.00 mm² 301F TO
/15.E2 TO RADIO
IGNITION RELAY 4 LIVE LINK PERM GROUND P058:2
9 -P113 M10
1.00 mm² Y TO
/8.D5 TO IMMOBILISER
FROM PRIMARY FUSE C /2.D4 4.00 mm² 200C 4.00 mm² 202C 6 7 4.00 mm² 012C P066:7
FROM
P046:A -SP26 -SP53 1.00 mm² 301M TO

/17.D1 TO DIAG CONNECTOR
8 10 P073:B
0.75 mm² 100G 0.75 mm² 601HK TO
/20.F4 TO GROUND -P003
SPLICE SP3 FUSE BOX C
1.00 mm² 109E
/31.C2 TO
C062-2
/10.C5 TO REVERSE ALARM RELAY TO LIVE LINK RELAY
4.00 mm² 202E 4.00 mm² 017E 1 10A 2 1.50 mm² 109RA 1.00 mm² 100LL
TO TO
/8.C1
21 P010:6 1.00 mm² 109TD P013:3
/7.B5 TO
-P008 C061-1
/15.A3 TO AUXILLIARY CONNECTOR
3 5A 4 1.00 mm² 121 TO
IGNITION RELAY 5 P065:1 C002-15

22
/5.D7 FROM 1.00 mm² 109SS 0.75 mm² 100QA TO
/12.C1 TO ITALIAN HEADLIGHTS
4 5 3A 6 P126:1
FROM PRIMARY FUSE F /2.C4 1 2
FROM 4.00 mm² 200E 4.00 mm² 201E 4.00 mm² 017E 23 1.00 mm² 109CS TO
/7.B1 TO COLUMN SWITCH L/H
P047:B -SP15 SP65 / P037
/15.E2 RADIO TO INFO BUTTON SWITCH
7 10A 8 1.00 mm² 181 0.75 mm² 100K
TO TO
/9.E7
3 5 P058:1 P063:2
0.75 mm² 100F 0.75 mm² 601JJ TO
/20.F4 TO GROUND 24 -P039 -C001
SPLICE SP3 9 10
B 5A 1.00 mm² 109 D2/84 D2/84 1.00 mm² 109 1.00 mm² 109
25
/30.F2 TO
1.00 mm² 109FB -SC2 1.00 mm² 100ISO TO
/6.F1 TO PURGE HOLD RELAY B
4.00 mm² 201G FROM PRIMARY FUSE E 4.00 mm² 200F 11 5A 12 1.00 mm² 299LL TO LIVE LINK C027-2 P013:3
/2.C4 FROM TO
/8.D2
P047:A 26 P068:4 1.00 mm² 109LM
/29.F4 TO
-P008 C025-4
/12.C3 TO REAR WORKLIGHT RELAY /16.D2 TO REVERSE FAN SWITCH
13 25A 14 2.00 mm² 309 TO 1.00 mm² 100P TO
IGNITION RELAY 6 27 P012:6 P061:2

9 15 10A 16 2.00 mm² 307 TO HEADLIGHT SWITCH
TO
/10.C1
FROM PRIMARY FUSE G /2.C6 6 7 P024:2
FROM 4.00 mm² 200G 4.00 mm² 202G 4.00 mm² 011G 28 1.00 mm² 100RH TO
/24.E3 TO PIN LOCK SWITCH 0.75 mm² 100D TO
/10.C1 TO HEADLIGHT SWITCH
P048:A -SP30 P114:2 P024:8
/10.C1 TO ROADLIGHT RELAY
17 20A 18 2.00 mm² 306 TO
8 10 P013:6
0.75 mm² 100A 0.75 mm² 601X TO
/20.F4 TO GROUND 29 0.75 mm² 100M TO
/22.B3 TO FOUR WHEEL DRIVE SWITCH
SPLICE SP3 P027:2
/10.B1 TO COLUMN SWITCH R/H /10.C1 TO ROADLIGHT RELAY
19 25A 20 2.00 mm² 304A TO 0.75 mm² 100C TO
P038:4 P013:8
30 0.75 mm² 100J TO
/10.F5 TO BRAKE LIGHT RELAY
P011:3
2.00 mm² 304B TO
/7.C1 TO COLUMN SWITCH L/H
P037:11 0.50 mm² 106C TO CENTER CLUSTER
TO
/9.A5
P040:20
0.75 mm² 100H TO
/4.F1 TO NEUTRAL START RELAY
P010:3
A
A
1 2 3 4 5 6 7 8
33 - 17 9813/9050-1 33 - 17
Page Page
33-18 33-19
Figure 885. (Part

1 1 of 2) 2 3 4
FROM PRIMARY FUSE B /2.D6 4.00 mm² 200A

F
FROM
P045:B
IGNITION SWITCH
-P001
III START
HEAT
FUSE BOX A
PRE
0 OFF
I ON
-P043 -P044
II
4.00 mm² 200AB 4.00 mm² 200AA 1 5 4.00 mm² 001A 4.00 mm² 001A 1 5A 2 1.00 mm² 100
-SP51 2 6 4.00 mm² 014 1
3
/4.F1 TO NEUTRAL START RELAY FROM NEUTRAL START /4.F2
4.00 mm² 004B 4.00 mm² 004 4.00 mm² 842A 3 30A 4 4.00 mm² 842
TO FROM TO
/4.F3
4 -SP52 P010:1 P010:2 2
8 4.00 mm² 015B 5 5A 6 2.00 mm² 150 TO
/14.E4
9 3
7 7 10A 8
4
9 5A 10
5
TO
/4.E1 TO REMOTE START RELAY FROM REMOTE START RELAY /4.E2 FROM 4.00 mm² 004A
P119:1 P119:2 11 3A 12 1.00 mm² 107B
/5.C1
E
TO
1.00 mm² 100 4.00 mm² 010B 13 30A 14 2.00 mm² 102 TO
/14.C1
7
-P006 15 10A 16 1.00 mm² 108 TO
/10.F5
IGNITION RELAY 1 8
4 17 3A 18
4.00 mm² 200B 1 2 4.00 mm² 015B 9
19 3A 20 1.00 mm² 104 TO
/11.B1
-SP20 3 5 10
0.75 mm² 100J 0.75 mm² 601HB TO
/20.F4 TO GROUND
SPLICE SP3
-P006
IGNITION RELAY 2
9 -P002
FROM PRIMARY FUSE A /2.D6 4.00 mm² 202B 4.00 mm² 203B 6 7 4.00 mm² 010B FUSE BOX B
FROM
P045:A -SP35
8 10
/20.F4 TO GROUND
0.75 mm² 100B 0.75 mm² 601EK 4.00 mm² 013C 1 25A 2 2.00 mm² 116
TO TO
/14.D4
D SPLICE SP3 11
3 20A 4 2.00 mm² 133 TO
/13.D3
-P007 12
IGNITION RELAY 3 5 15A 6 1.50 mm² 110 TO
/13.B2
4 13
4.00 mm² 201C 1 2 4.00 mm² 013C 4.00 mm² 012CA 7 20A 8 2.00 mm² 997 TO
/14.C2
14
3 5
/20.F4 TO GROUND
0.75 mm² 100H 0.75 mm² 601HL 9 15A 10 1.50 mm² 119
TO TO
/15.B3
15
Page 33-19
FROM PRIMARY FUSE D /2.D4 FROM 4.00 mm² 200D 11 5A 12 2.00 mm² 3100A TO
/6.D1
ADDITIONAL FUSES P046:B 16
13 25A 14 2.00 mm² 308 TO
/12.D3
17

4.00 mm² 203C 1 20A 2 1.00 mm² 300RDM 15 7.5A 16 1.00 mm² 310
TO TO
/12.B1
-P132 P137:1 18
17 10A 18 1.50 mm² 300TR TO
/22.D5
-SP66 1.00 mm²
1 20A 2 1.00 mm² 100EX 100RDM TO 19
-P131 P137:8 19 25A 20 2.00 mm² 312

C /12.C3
TO
1.00 mm² 100WBL TO

/13.C6 TO WASHER BOTTLE LEVEL 20
-P007 4.00 mm² 012CB C001:1 / P135:1
IGNITION RELAY 4
9
FROM PRIMARY FUSE C /2.D4 4.00 mm² 200C 4.00 mm² 202C 6 7 4.00 mm² 012C
FROM
P046:A -SP26 -SP53

8 10
0.75 mm² 100G 0.75 mm² 601HK TO
/20.F4 TO GROUND -P003
SPLICE SP3 FUSE BOX C
4.00 mm² 202E 4.00 mm² 017E 1 10A 2 1.50 mm² 109RA TO
/10.C5
21
-P008 3 5A 4 1.00 mm² 121 TO
/15.A3
IGNITION RELAY 5 22
4 5 3A 6
FROM PRIMARY FUSE F /2.C4 4.00 mm² 200E 4.00 mm² 201E 1 2 4.00 mm² 017E 23
FROM
P047:B -SP15 7 10A 8 1.00 mm² 181 TO

/15.E2
3 5
0.75 mm² 100F 0.75 mm² 601JJ TO
/20.F4 TO GROUND 24
SPLICE SP3 9 10
B 5A
25
4.00 mm² 201G FROM PRIMARY FUSE E 4.00 mm² 200F 11 5A 12 1.00 mm² 299LL
/2.C4 FROM TO
/8.D2
P047:A 26
-P008 13 25A 14 2.00 mm² 309 TO
/12.C3
IGNITION RELAY 6 27
9 15 10A 16 2.00 mm² 307 TO
/10.C1
FROM PRIMARY FUSE G /2.C6 4.00 mm² 200G 4.00 mm² 202G 6 7 4.00 mm² 011G 28
FROM
P048:A -SP30 17 20A 18 2.00 mm² 306 TO

/10.C1
8 10
0.75 mm² 100A 0.75 mm² 601X TO
/20.F4 TO GROUND 29
SPLICE SP3 19 25A 20
30
1 2 3 4
33 - 18 9813/9050-1 33 - 18
Page Page
33-18 33-19
Figure 885. (Part

5 2 of 2) 6 7 8
-P004
FUSE BOX A FUSE BOX D
/23.E1 C045 / P039:C8

2 1.00 mm² 100 4.00 mm² 201G 1 20A 2 2.00 mm² 203 TO
1 31
-P039
4 4.00 mm² 842 TO
/4.F3 TO ENGINE SUPPLY 3 3A 4 2.00 mm² 3711 A8/84
2 P093:2 32
6 2.00 mm² 150 TO
/14.E4 TO HEATED GLASS 5 10A 6 1.50 mm² 300NX TO
/6.B1 TO NOx SENSOR RELAY
3 P054:1 33 P101:1
/25.D3 FRONT/REAR AUX SW /11.C3 TO HAZARD SWITCH
8 1.50 mm² 114 TO
7 3A 8 1.00 mm² 300 TO
4 P017:2 34 P020:5
/6.B1 HOSE HEATER RELAY /9.C3 TO INSTRUMENT V+
10 1.00 mm² 1100A TO
9 15A 10 1.00 mm² 301E TO
5 P101:3 35 SPLICE SP40 / P071

/5.C1 TO ENGINE POD CON /6.B1 TO SCR ECU /22.E5 TO 07/11 CONNECTOR 2
12 1.00 mm² 107B TO
1.00 mm² 1100 TO 4.00 mm² 011G 11 3A 12 1.00 mm² 100TR TO
6 C032:5 / P039:E7 C010E:22 / P199:9 36 P070:1

E
/14.C1 TO HEATER CON /8.D1 TO LIVE LINK RELAY
14 2.00 mm² 102 TO
13 5A 14 1.00 mm² 110LL TO
7 P033:3 37 P013:1
/10.F5 TO BRAKE LIGHT RELAY /29.E4 TO LLMI
16 1.00 mm² 108 TO
15 3A 16 1.00 mm² 101A TO
8 P011:1 38 P042-A
/27.D1 TO PARKBRAKE SW /9.E3 TO INSTRUMENT CLUSTER J1
18 1.00 mm² 107PB TO
17 3A 18 1.00 mm² 106 TO
9 RC012:3 / P049:10 39 P071:2 FROM

/29.C1
TO COLUMN SWITCH RH 1.00 mm² 107SP C032-3
/15.C2 SEAT PRESSURE SW /8.D4 TO IMMOBILISER RELAY
20 1.00 mm² 104 19 5A 20 1.00 mm² Y
TO
/11.B1 TO TO
10 P038:14 RC012:1 / P049:14 40 P101:6 1.00 mm² 155EC FROM

/23.D5
C017-15
-P039 -C001
1.50 mm² 155 F9/84 F9/84 1.50 mm² 155
-SC6
1.00 mm² 155B C081-1
TO
/16.D7
-P005
FUSE BOX B FUSE BOX E 1.00 mm² 155C C081-4
TO
/16.D7
TO ROOF AC FANS RELAY COLUMN SWITCH RH

/10.B4 TO DIPPED BEAM
2 2.00 mm² 116 2.00 mm² 833 1 15A 2 1.50 mm² 834
TO
/14.D4 /10.B3 FROM TO
11 P015:6 P038:9 41 SPLICE SP18

4 2.00 mm² 133 TO
/13.D3 TO WIPER PARK COLUMN SWITCH RH
/10.B3 FROM 2.00 mm² 836 3 20A 4 2.00 mm² 838 TO
/10.B4 TO MAIN BEAM
D
12 SPLICE SP16 P038:13 42 SPLICE SP19
TO WIPER HEADLIGHT SWITCH
/19.C3 TO SIDE LIGHTS
6 1.50 mm² 110 2.00 mm² 942D 5 7.5A 6 1.50 mm² 829E
TO
/13.B2 /10.C3 FROM TO
13 SPLICE SP33 SPLICE SP22 43 SPICE SP7

TO AC RELAY HEADLIGHT SWITCH
8 2.00 mm² 997 2.00 mm² 942E 7 5A 8 0.75 mm² 830
TO
/14.C2 /10.C3 FROM TO
14 P015:1 SPLICE SP22 44 P039:E2

TO MOBILE PHONE HEADLIGHT SWITCH
/10.F3 TO FOG LIGHT SWITCH
10 1.50 mm² 119 1.00 mm² 832B 9 3A 10 1.00 mm² 905
TO
/15.B3 /10.C3 FROM TO
15 P056:1 SPLICE SP21 45 P023:2

Page 33-18
12 2.00 mm² 3100A

/6.D1 TO TANK HARNESS 1.00 mm² 601LL 11 5A 12 1.00 mm² 601L
/8.C4 TO LIVE LINK TO HEATED SEAT
TO TO
16 C199:1 46 2.00 mm² 151 P068:9

/14.F3 RC002:1 / P049:7
TO
14 2.00 mm² 308 TO

/12.D3 TO FRONT WORKLIGHT RELAY 4.00 mm² 014 13 20A 14 2.00 mm² 151B
/14.E3 TO FACE FAN
TO
17 P012:1 47
P051:1
16 1.00 mm² 310 TO
/12.B1 TO BEACON SWITCH 4.00 mm² 202E 15 20A 16 1.50 mm² 275 TO
/11.E5 TO TRAILER DI RELAYS
18 P028:2 48 SPLICE SP25
18 1.50 mm² 300TR TO
/22.D5 TO 07/11 VBATT 17 20A 18 2.00 mm² 300HH TO
/6.D1 TO HOSE HEATER RELAY
19 SPLICE SP38 49 P009:1
BOOM WORK LIGHTS RELAY 301 -SP27 1.00 mm² 301J
/12.A1 TO INTERIOR LIGHT
20 2.00 mm² 312 19 10A 20 1.00 mm²
TO
/12.C3 TO
20 P011:6 50 RC010:1 / P049:9

C
1.00 mm² 301F TO
/15.E2 TO RADIO
LIVE LINK PERM GROUND P058:2
-P113 M10
1.00 mm² Y TO
/8.D5 TO IMMOBILISER
P066:7
1.00 mm² 301M TO
/17.D1 TO DIAG CONNECTOR
P073:B
FUSE BOX C
1.00 mm² 109E
/31.C2 TO
C062-2
/10.C5 TO REVERSE ALARM RELAY TO LIVE LINK RELAY
2 1.50 mm² 109RA 1.00 mm² 100LL
TO TO
/8.C1
21 P010:6 1.00 mm² 109TD P013:3
/7.B5 TO
C061-1
/15.A3 TO AUXILLIARY CONNECTOR
4 1.00 mm² 121 TO
P065:1 C002-15
22
/5.D7 FROM 1.00 mm² 109SS 0.75 mm² 100QA TO
/12.C1 TO ITALIAN HEADLIGHTS
6 P126:1
23 1.00 mm² 109CS TO
/7.B1 TO COLUMN SWITCH L/H
SP65 / P037
/15.E2 RADIO TO INFO BUTTON SWITCH
8 1.00 mm² 181 0.75 mm² 100K
TO TO
/9.E7
24 P058:1 -P039 -C001 P063:2
10 1.00 mm² 109 D2/84 D2/84 1.00 mm² 109 1.00 mm² 109
25
/30.F2 TO
1.00 mm² 109FB -SC2 1.00 mm² 100ISO TO
/6.F1 TO PURGE HOLD RELAY B
12 1.00 mm² 299LL TO LIVE LINK C027-2 P013:3
TO
/8.D2
26 P068:4 1.00 mm² 109LM
/29.F4 TO
C025-4
/12.C3 TO REAR WORKLIGHT RELAY /16.D2 TO REVERSE FAN SWITCH
14 2.00 mm² 309 TO 1.00 mm² 100P TO
27 P012:6 P061:2
16 2.00 mm² 307 TO
P024:2
28 1.00 mm² 100RH TO
/24.E3 TO PIN LOCK SWITCH 0.75 mm² 100D TO
P114:2 P024:8
/10.C1 TO ROADLIGHT RELAY
18 2.00 mm² 306 TO
P013:6
29 0.75 mm² 100M TO
P027:2
/10.B1 TO COLUMN SWITCH R/H /10.C1 TO ROADLIGHT RELAY
20 2.00 mm² 304A TO 0.75 mm² 100C TO
P038:4 P013:8
30 0.75 mm² 100J TO
/10.F5 TO BRAKE LIGHT RELAY
P011:3
2.00 mm² 304B TO
/7.C1 TO COLUMN SWITCH L/H
P037:11 0.50 mm² 106C TO CENTER CLUSTER
TO
/9.A5
P040:20
0.75 mm² 100H TO
/4.F1 TO NEUTRAL START RELAY
P010:3
5 6 7 8
33 - 19 9813/9050-1 33 - 19
33 - 20 9813/9050-1 33 - 20
Page 33-22 Figure 886. Engine Fuses and

Starter 160/B4268 Issue 2- Sheet 4 Page 33-23
1 2 3 4 5 6 7 8
F
F
FROM BATTERY /2.E4 FROM 95.00 mm² RED 25.00 mm² RED 25.00 mm² RED
-ST03 M10
-P010 #574
TO ENGINE ECU /5.D3 TO 1.00 mm² E105B
NEUTRAL START -B002
E004:39 V-Batt
4 M10
-P093 -E009 -E009 -C002
1 2 4.00 mm² 842A M5 U
FROM CRANK /3.F2 FROM 4.00 mm² 004 TO
/3.F4 TO FUSE 02A FROM FUSE 02A /3.F5 FROM 4.00 mm² 842 2/2 2/2 4.00 mm² 842 4/29 4.00 mm² 842 4.00 mm² 842A 2/29 842A 4.00 mm²
W
V
Start
SPLICE SP52 P001:3 P001:4 -SE04 -C073 Control
3 5 M
FROM IGNITION FUSE /3.A6
DF W B+
0.75 mm² 100H
M8 B+
D-
M5 W
W B+
L
FROM
REGULATOR
L
P001:2 / SP20
M5
GND
ALTERNATOR
TO 07/11 CONNECTOR 1 /22.E3 1.00 mm² 601NS
-ST04
-ST05
-ST06
TO
P069:2
25.00 mm² RED

E -P119 -P039 -C012 -ST01
REMOTE START
TO INSTRUMENT CLUSTER J2 /9.E5 TO 412 1.00 mm² 412 1.00 mm² A5/84 1.00 mm² 412 A/3 A/3 1.00 mm² 412
E
4 A5/84
P072:7 -C001 -ST01
1 2
FROM IGNITION FEED /3.E1 FROM 4.00 mm² 200AB 4.00 mm² 004A
/3.E2 TO CRANK
TO
TO INSTRUMENT CLUSTER J1 /9.D3 TO 407B 1.00 mm² 407 1.00 mm² B5/84 1.00 mm² 407 B/3 B/3 1.00 mm² 407
B5/84
SPLICE SP51 -P039 332/D2535 -P039 SPLICE SP52 P071:11 -SP14
A9/84 1.00 mm² 718RSH 3 5 1.00 mm² 781RSL C3/84
TO ENGINE RUNNING RELAY 1.00 mm² 407F

/12.F1 TO
P014:3
D
D
GRID HEATER
-CS2 -CS4
-C002
M6 1
1 2
FROM BATTERY /2.B4 FROM 20.00 mm² RED 150A 20.00 mm² RED 12V
-CS5
-E001 GRID HEATER FUSE
70 A
FUSE/RELAY BOX GRID HEATER
START SIGNAL
(MICRO RELAY)
K2 M6 M6 -C001 20.00 mm² RED

G B
-E020
0.75 mm² E115 1/2 2/2
E116 0.75 mm²
TO
/5.D5 TO ENGINE ECU
F3
N N/21 1.00 mm² E407 TO
/5.C3 TO ENGINE ECU E004:48
E004:28
F5 - 10A
K
C F6 - 10A
J
C
FUEL PUMP
(MICRO RELAY) -E003
K3 FUEL PUMP
F2 -
L 1 2
L/21 1.50 mm² E801 M 1.50 mm² E601F TO
/21.B5 TO GROUND
SPLICE SE02
F4 - 3A
M M/21 1.00 mm² E408 TO
/5.C3 TO ENGINE ECU
E004:40
F7 - 10A
H H/21 0.75 mm² E115
F8 - 10A
X X/21 1.00 mm² E106 TO
/5.D3 TO ENGINE ECU
E004:49
F9 - 10A
W W/211.00 mm² E107 TO
/5.C3 TO ENGINE ECU
E004:53
F17 - 10A
V V/21 1.50 mm² E108 TO
/5.C3 TO ENGINE ECU
E004:57
F16 - 10A
U
B POWER HOLD RELAY U/21 1.50 mm² E109 TO
/5.C3 TO ENGINE ECU
D K1
-P093 -C008 -C002 -E009 E004:60 B
E F15 - 10A
T
FROM PRIMARY FUSE H /2.C6 FROM 4.00 mm² 319 1/2 1/2 4.00 mm² 319 1/29 1/29 4.00 mm² E300 E/21 T/21 2.00 mm² E110 TO
/5.C5 TO ENGINE CONNECTOR
P048:B E005:A
F1 - 3A F14 - 10A
S S/21 2.00 mm² E111 TO
/5.B5 TO ENGINE CONNECTOR
E005:E
F13 - 5A
R R/21 1.00 mm² E119 TO
/5.E7 TO COOLANT & ENG OIL LEVEL
SPLICE SE11
F11 - 5A
A A/21 1.00 mm² E463 TO
/6.E3 TO PURGE HOLD INHIBIT RELAY
P013:1 / E026:11
F12 - 3A
F F/21 1.00 mm² E112 TO
/5.D5 TO AGGLOMERATOR
E002:A
F10 - 5A
C
P P/21 1.00 mm² E400 TO

/5.C3 TO ENGINE ECU
E004:2
A
A
1 2 3 4 5 6 7 8
33 - 21 9813/9050-1 33 - 21
Page Page
33-22 33-23

1 2 3 4
FROM BATTERY /2.E4 FROM
-P010 #574
TO ENGINE ECU /5.D3 TO 1.00 mm² E105B
NEUTRAL START E004:39
4
-P093 -E009
1 2 4.00 mm² 842A
FROM CRANK /3.F2 FROM 4.00 mm² 004 TO
/3.F4 TO FUSE 02A FROM FUSE 02A /3.F5 FROM 4.00 mm² 842 2/2 2/2 4.00 mm² 842 4/29 4.00 mm² 842 4.00 mm² 842A
SPLICE SP52 P001:3 P001:4 -SE04

3 5
FROM IGNITION FUSE /3.A6 FROM 0.75 mm² 100H
P001:2 / SP20
TO 07/11 CONNECTOR 1 /22.E3 TO 1.00 mm² 601NS
P069:2
E -P119
REMOTE START
TO INSTRUMENT CLUSTER J2 /9.E5
4
P072:7
1 2
FROM IGNITION FEED /3.E1 FROM 4.00 mm² 200AB 4.00 mm² 004A
/3.E2 TO CRANK
TO
TO INSTRUMENT CLUSTER J1 /9.D3
SPLICE SP51 -P039 332/D2535 -P039 SPLICE SP52 P071:11
A9/84 1.00 mm² 718RSH 3 5 1.00 mm² 781RSL C3/84
TO ENGINE RUNNING RELAY

/12.F1
P014:3
-CS2
FROM BATTERY /2.B4 FROM 20.00 mm² RED
-E001
FUSE/RELAY BOX
Page 33-23
START SIGNAL
(MICRO RELAY)
K2
G B
F3
N N/21 1.00 mm² E407 TO
/5.C3
F5 - 10A
K
C F6 - 10A
J
FUEL PUMP
(MICRO RELAY)
K3
F2 -
L L/21 1.50 mm² E801
F4 - 3A
M M/21 1.00 mm² E408 TO
/5.C3
F7 - 10A
H H/21 0.75 mm² E115
F8 - 10A
X X/21 1.00 mm² E106 TO
/5.D3
F9 - 10A
W W/211.00 mm² E107 TO
/5.C3
F17 - 10A
V V/21 1.50 mm² E108 TO
/5.C3
F16 - 10A
U U/21 1.50 mm² E109
B D
POWER HOLD RELAY
K1
TO
/5.C3
-P093 -C008 -C002 -E009
E F15 - 10A
T
FROM PRIMARY FUSE H /2.C6 FROM 4.00 mm² 319 1/2 1/2 4.00 mm² 319 1/29 1/29 4.00 mm² E300 E/21 T/21 2.00 mm² E110 TO
/5.C5
P048:B
F1 - 3A F14 - 10A
S S/21 2.00 mm² E111 TO
/5.B5
F13 - 5A
R R/21 1.00 mm² E119 TO
/5.E7
F11 - 5A
A A/21 1.00 mm² E463 TO
/6.E3
F12 - 3A
F F/21 1.00 mm² E112 TO
/5.D5
F10 - 5A
C
P P/21 1.00 mm² E400 TO

/5.C3
1 2 3 4
33 - 22 9813/9050-1 33 - 22
Page Page
33-22 33-23

5 6 7 8
F
FROM BATTERY /2.E4 FROM 95.00 mm² RED 25.00 mm² RED 25.00 mm² RED
-ST03 M10
1.00 mm² E105B

-B002
V-Batt
M10
-E009 -C002
M5 U
4.00 mm² 842 4.00 mm² 842A 2/29 842A 4.00 mm²
W
V
Start
-SE04 -C073 Control
M DF W B+
M8 B+
D-
M5 W
W B+
L
REGULATOR
L
M5
GND
ALTERNATOR
-ST04
-ST05
-ST06
25.00 mm² RED
-P039 -C012 -ST01

TO INSTRUMENT CLUSTER J2 /9.E5 TO 412 1.00 mm² 412 1.00 mm² A5/84 1.00 mm² 412 A/3 A/3 1.00 mm² 412
E
A5/84
P072:7 -C001 -ST01
TO INSTRUMENT CLUSTER J1 /9.D3 TO 407B 1.00 mm² 407 1.00 mm² B5/84 1.00 mm² 407 B/3 B/3 1.00 mm² 407
B5/84
P071:11 -SP14
TO ENGINE RUNNING RELAY 1.00 mm² 407F

/12.F1 TO
P014:3
D
GRID HEATER
-CS2 -CS4
-C002
M6 1
20.00 mm² RED 1 150A 2 20.00 mm² RED 12V
-CS5
GRID HEATER FUSE
70 A
GRID HEATER
Page 33-22
M6 M6 -C001 20.00 mm² RED
-E020
0.75 mm² E115 1/2 2/2
E116 0.75 mm²
TO
/5.D5 TO ENGINE ECU
1.00 mm² E407 TO
/5.C3 TO ENGINE ECU E004:48
E004:28
C
-E003
FUEL PUMP
1 2
1.50 mm² E801 M 1.50 mm² E601F TO
/21.B5 TO GROUND
SPLICE SE02
1.00 mm² E408 TO
/5.C3 TO ENGINE ECU
E004:40
0.75 mm² E115
1.00 mm² E106 TO

/5.D3 TO ENGINE ECU
E004:49
1.00 mm² E107 TO
/5.C3 TO ENGINE ECU
E004:53
1.50 mm² E108 TO
/5.C3 TO ENGINE ECU
E004:57
1.50 mm² E109 TO
/5.C3 TO ENGINE ECU
E004:60 B
2.00 mm² E110 TO
/5.C5 TO ENGINE CONNECTOR
E005:A
2.00 mm² E111 TO
/5.B5 TO ENGINE CONNECTOR
E005:E
1.00 mm² E119 TO
/5.E7 TO COOLANT & ENG OIL LEVEL
SPLICE SE11
1.00 mm² E463 TO
/6.E3 TO PURGE HOLD INHIBIT RELAY
P013:1 / E026:11
1.00 mm² E112 TO
/5.D5 TO AGGLOMERATOR
E002:A
1.00 mm² E400 TO

/5.C3 TO ENGINE ECU
E004:2
5 6 7 8
33 - 23 9813/9050-1 33 - 23
33 - 24 9813/9050-1 33 - 24
Page 33-26 Figure 887. Engine- ECU and

Sensors 160/B4268 Issue 2- Sheet 5 Page 33-27
1 2 3 4 5 6 7 8
F
-E008
-E004 F
ENGINE ECU
TMAF
BLANK A x/6
BATTERY VOLTAGE B 2/6 0.50 mm² E424 18/62 18/62
GROUND
C 3/6 0.50 mm² E422 52/62 52/62 FROM ADDITIONAL FUSE /3.C3 FROM 1.00 mm² 100RDM
OUTPUT SIGNAL D 4/6 0.50 mm² E421 38/62 38/62 P131:2 / SP66
IAT E 5/6 0.50 mm² E423 22/62 22/62 TO GROUND /20.E4 TO 1.00 mm² 600RDM
BLANK
F x/6 SPLICE SP3
FROM ADDITIONAL FUSE /3.C3 FROM 1.00 mm² 300RDM 0.50 mm² CAN 10 L FROM
/17.F4 FROM CAN L
P132:2
0.50 mm² CAN 10 H FROM
/17.F4 FROM CAN H
-P137 -E030
DAILY CHECKS ENG OIL LEVEL
11/20 1/20 1.00 mm² 300RDM -P135 -C123 -C167 -E026 1.00 mm² E119A 1/2
-C004 -C002 -E009
1.00 mm² 562 6/29 6/29 1.00 mm² E430 21/62 21/62 12/20 2/20 1.00 mm² 600RDM 3/6 3/6 1.00 mm² 419E 9/12 9/12 1.00 mm² E419 2/2
E ACCELERATOR 13/20 3/20 0.50 mm² CAN 10 L
1/6 1 2 2/6 1.00 mm² 561 7/29 7/29 1.00 mm² E429 17/62 17/62 14/20 4/20 0.50 mm² CAN 10 H
E
+5V TR1 SIG
3 15/20 5/20 1.00 mm² 419E 0.75 mm² E119B 1/2
TR1 GND 3/6 -P135 -C123 -C167 -E026
1.00 mm² 560 8/29 8/29 1.00 mm² E428 14/62 14/62 16/20 6/20 1.00 mm² 420CL 4/6 4/6 1.00 mm² 420CL 10/12 10/12 -SE11 0.75 mm² E420 2/2
5 5/6 17/20 7/20 1.00 mm² 421WBL
TR2 SIG
4/6 4 6 6/6 1.00 mm² 564 10/29 10/29 1.00 mm² E426 29/62 29/62 18/20 8/20 1.00 mm² 100RDM -E021
+5V TR2 GND
19/20 9/20 FROM FUSE / RELAY BOX /4.B5 FROM 1.00 mm² E119 COOLANT LEVEL
1.00 mm² 565 11/29 11/29 1.00 mm² E425 19/62 19/62 20/20 10/20 F13 / E001:R
1.00 mm² 563 9/29 9/29 1.00 mm² E427 15/62 15/62
1.00 mm² 421WBL FROM
/13.C6 FROM WASHER BOTTLE LEVEL
C001:2 / P039:G4
FROM CAN L0 0.50 mm² CAN L 23/62 23/62 -C002
/17.B8 FROM
ENGINE POD CONNECTOR

FROM CAN HI 0.50 mm² CAN H 27/62 27/62
/17.B8 FROM
3/29
D FROM ENG CAN HI 0.50 mm² CAN H 45/62 45/62

/18.D2
D
FROM
48/62 48/62 FROM GRID HEATER 1.00 mm² 109SS 15/29 15/29
SC2-3 /3.B6
0.75 mm² E116 FROM
/4.C7 TO
FROM ENG CAN LO 0.50 mm² CAN L 50/62 50/62 E020:2

/18.D2 FROM
1.00 mm² 602SS 16/29 16/29

SC9-8 /21.E2 FROM
17/29
-E002
FROM CRANK SIGNAL #574
/4.F4 FROM 1.00 mm² E105B 39/62 39/62
AGGLOMERATOR -P039 -C001
SPLICE SE04 /9.E5 FROM 1.00 mm² 593 F5/84 F5/84 1.00 mm² 593 18/29 18/29
A/3 1.00 mm² E112 FROM FUSE / RELAY BOX
FROM
/4.A5
FROM FUSE / RELAY BOX 1.00 mm² E106 49/62 49/62 55/62 55/62 1.00 mm² E401 B/3 F12 / E001:F 29/29
/4.B5 FROM
F8 / E001:X C/3 1.00 mm² E601B TO CHASSIS GROUND

TO
/21.C5
FROM FUSE / RELAY BOX 1.00 mm² E407 28/62 28/62 SPLICE SE02
/4.C5 FROM
K2 / E001:N (START)
FROM FUSE / RELAY BOX /4.A5 FROM 1.00 mm² E400 2/62 2/62
K1 / E001:P (POWER HOLD)
FROM FUSE / RELAY BOX /4.C5 FROM 1.00 mm² E408 40/62 40/62
K3 / E001:M (FUEL PUMP) 6/62 6/62 1.00 mm² E411
FROM FUSE / RELAY BOX 1.00 mm² E107 53/62 53/62

C /4.B5 FROM
F9 / E001:W
FROM FUSE / RELAY BOX /4.B5
C
FROM FUSE / RELAY BOX /4.B5 FROM 1.50 mm² E108 57/62 57/62 FROM
F17 / E001:V F15 / E001:T

FROM FUSE / RELAY BOX /4.B5 FROM 1.50 mm² E109 60/62 60/62 TO CHASSIS GROUND /21.C5 TO
F16 / E001:U SPLICE SE02

FROM ENG CAN LO /18.C4 -E005
-P039 -C001 -C002 -E009 FROM
ENGINE CONNECTOR
FROM FUSE 06A 1.00 mm² 107B E7/84 E7/84 1.00 mm² 107Y 5/29 18/29 1.00 mm² E103 44/62 44/62
/3.E5 FROM
P001:12 FROM ENG CAN HI /18.C4 FROM 2.00 mm² E110 A/14 A/14
1.00 mm² E601E B/14 B/14
FROM FUSE / RELAY BOX /4.B5 FROM 0.50 mm² CAN L C/14 C/14
F14 / E001:S 0.50 mm² CAN H D/14 D/14
TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600A 58/62 58/62 TO CHASSIS GROUND /21.C5 2.00 mm² E111 E/14 E/14
/21.D5 TO TO
SPLICE SE01 SPLICE SE02 1.00 mm² E601D F/14 F/14

TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600B 59/62 59/62 1.00 mm² E411 G/14 G/14
/21.D5 TO
SPLICE SE01
TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600C 61/62 61/62
/21.D5 TO
SPLICE SE01
GROUND CHASSIS 1.50 mm² E600D -E006
B TO CHASSIS GROUND /21.D5 62/62 62/62
TO
VACUUM SWITCH
SPLICE SE01 B
-P039 -C001 -C002 -E009
1 2
TO INSTRUMENT CLUSTER J2 /9.E5 TO 1.00 mm² 402 B7/84 B7/84 402 1.00 mm² 27/29 27/29 0.50 mm² E441 1/2 2/2 0.50 mm² E601K TO
/21.B5 TO CHASSIS GROUND
P072:1 SPLICE SE02
A
A
1 2 3 4 5 6 7 8
33 - 25 9813/9050-1 33 - 25
Page Page
33-26 33-27

1 2 3 4
F
-E004
-E008
ENGINE ECU
TMAF
BLANK A x/6
BATTERY VOLTAGE B 2/6 0.50 mm² E424 18/62 18/62
GROUND
C 3/6 0.50 mm² E422 52/62 52/62 FROM ADDITIONAL FUSE /3.C3 FROM 1.00 mm²
OUTPUT SIGNAL D 4/6 0.50 mm² E421 38/62 38/62 P131:2 / SP66
IAT E 5/6 0.50 mm² E423 22/62 22/62 TO GROUND /20.E4 TO 1.00 mm²
BLANK
F x/6 SPLICE SP3
FROM ADDITIONAL FUSE /3.C3 FROM 1.00 mm²
P132:2
-P137
DAILY CHECKS
11/20 1/20 1.00 mm²

-C004 -C002 -E009
1.00 mm² 562 6/29 6/29 1.00 mm² E430 21/62 21/62 12/20 2/20 1.00 mm²
E ACCELERATOR 13/20 3/20 0.50 mm²
1/6 1 2 2/6 1.00 mm² 561 7/29 7/29 1.00 mm² E429 17/62 17/62 14/20 4/20 0.50 mm²
+5V TR1 SIG
3 3/6 15/20 5/20 1.00 mm²
TR1 GND
1.00 mm² 560 8/29 8/29 1.00 mm² E428 14/62 14/62 16/20 6/20 1.00 mm²
5 5/6 17/20 7/20 1.00 mm²
TR2 SIG
4/6 4 6 6/6 1.00 mm² 564 10/29 10/29 1.00 mm² E426 29/62 29/62 18/20 8/20 1.00 mm²
+5V TR2 GND
19/20 9/20
1.00 mm² 565 11/29 11/29 1.00 mm² E425 19/62 19/62 20/20 10/20
1.00 mm² 563 9/29 9/29 1.00 mm² E427 15/62 15/62
FROM CAN L0 0.50 mm² CAN L 23/62 23/62

/17.B8 FROM
FROM CAN HI 0.50 mm² CAN H 27/62 27/62

/17.B8 FROM
D FROM ENG CAN HI 0.50 mm² CAN H 45/62 45/62

/18.D2 FROM
48/62 48/62 0.75 mm² E116 FROM GRID HEATER

FROM
/4.C7
FROM ENG CAN LO 0.50 mm² CAN L 50/62 50/62 E020:2
/18.D2 FROM
-E002
FROM CRANK SIGNAL #574 1.00 mm² E105B 39/62 39/62
/4.F4 FROM
AGGLOMERATOR
SPLICE SE04
A/3
Page 33-27
FROM FUSE / RELAY BOX /4.B5 FROM 1.00 mm² E106 49/62 49/62 55/62 55/62 1.00 mm² E401 B/3
F8 / E001:X C/3
K2 / E001:N (START)
FROM FUSE / RELAY BOX /4.A5 FROM 1.00 mm² E400 2/62 2/62
K1 / E001:P (POWER HOLD)
K3 / E001:M (FUEL PUMP) 6/62 6/62 1.00 mm² E411
FROM FUSE / RELAY BOX 1.00 mm² E107 53/62 53/62

C /4.B5 FROM
F9 / E001:W
FROM FUSE / RELAY BOX /4.B5 FROM 1.50 mm² E108 57/62 57/62 FROM FUSE / RELAY BOX
F17 / E001:V F15 / E001:T
FROM FUSE / RELAY BOX /4.B5 FROM 1.50 mm² E109 60/62 60/62 TO CHASSIS GROUND /21.C5
F16 / E001:U SPLICE SE02
FROM ENG CAN LO /18.C4
-P039 -C001 -C002 -E009
FROM FUSE 06A 1.00 mm² 107B E7/84 E7/84 1.00 mm² 107Y 5/29 18/29 1.00 mm² E103 44/62 44/62
/3.E5 FROM
P001:12 FROM ENG CAN HI /18.C4
FROM FUSE / RELAY BOX

F14 / E001:S
TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600A 58/62 58/62 TO CHASSIS GROUND /21.C5
/21.D5 TO
SPLICE SE01 SPLICE SE02

TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600B 59/62 59/62
/21.D5 TO
SPLICE SE01
TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600C 61/62 61/62
/21.D5 TO
SPLICE SE01
TO CHASSIS GROUND GROUND CHASSIS 1.50 mm² E600D
B /21.D5 TO 62/62 62/62
SPLICE SE01
TO INSTRUMENT CLUSTER J2 /9.E5 TO 1.00 mm² 402
P072:1
1 2 3 4
33 - 26 9813/9050-1 33 - 26
Page Page
33-26 33-27

5 6 7 8
FROM ADDITIONAL FUSE /3.C3 FROM 1.00 mm² 100RDM
P131:2 / SP66
TO GROUND /20.E4 TO 1.00 mm² 600RDM
SPLICE SP3
FROM ADDITIONAL FUSE /3.C3 FROM 1.00 mm² 300RDM 0.50 mm² CAN 10 L FROM
/17.F4 FROM CAN L
P132:2
0.50 mm² CAN 10 H FROM
/17.F4 FROM CAN H
-P137 -E030
DAILY CHECKS ENG OIL LEVEL
11/20 1/20 1.00 mm² 300RDM -P135 -C123 -C167 -E026 1.00 mm² E119A 1/2
12/20 2/20 1.00 mm² 600RDM 3/6 3/6 1.00 mm² 419E 9/12 9/12 1.00 mm² E419 2/2
13/20 3/20 0.50 mm² CAN 10 L
14/20 4/20 0.50 mm² CAN 10 H
E
15/20 5/20 1.00 mm² 419E -P135 -C123 -C167 -E026 0.75 mm² E119B 1/2
16/20 6/20 1.00 mm² 420CL 4/6 4/6 1.00 mm² 420CL 10/12 10/12 -SE11 0.75 mm² E420 2/2
17/20 7/20 1.00 mm² 421WBL
18/20 8/20 1.00 mm² 100RDM -E021
19/20 9/20 FROM FUSE / RELAY BOX /4.B5 FROM 1.00 mm² E119 COOLANT LEVEL
20/20 10/20 F13 / E001:R
1.00 mm² 421WBL FROM

/13.C6 FROM WASHER BOTTLE LEVEL
C001:2 / P039:G4
-C002
3/29
FROM GRID HEATER 1.00 mm² 109SS 15/29 15/29 D

/4.C7 SC2-3 /3.B6
TO
FROM
E020:2
1.00 mm² 602SS 16/29 16/29
SC9-8 /21.E2 FROM
17/29
-E002
AGGLOMERATOR -P039 -C001
1.00 mm² 593 F5/84 F5/84 1.00 mm² 593 18/29 18/29
/9.E5 FROM
A/3 1.00 mm² E112 FROM FUSE / RELAY BOX

/4.A5
Page 33-26
FROM
B/3 F12 / E001:F 29/29

C/3 1.00 mm² E601B TO CHASSIS GROUND
TO
/21.C5
SPLICE SE02
FROM FUSE / RELAY BOX /4.B5 FROM

C
F15 / E001:T
TO CHASSIS GROUND /21.C5 TO
SPLICE SE02
FROM ENG CAN LO /18.C4 -E005
ENGINE CONNECTOR
FROM
FROM ENG CAN HI /18.C4 FROM 2.00 mm² E110 A/14 A/14
1.00 mm² E601E B/14 B/14
FROM FUSE / RELAY BOX /4.B5 FROM 0.50 mm² CAN L C/14 C/14
F14 / E001:S 0.50 mm² CAN H D/14 D/14
TO CHASSIS GROUND /21.C5 TO 2.00 mm² E111 E/14 E/14
SPLICE SE02 1.00 mm² E601D F/14 F/14
1.00 mm² E411 G/14 G/14
-E006
VACUUM SWITCH
B
-P039 -C001 -C002 -E009
1 2
TO 1.00 mm² 402 B7/84 B7/84 402 1.00 mm² 27/29 27/29 0.50 mm² E441 1/2 2/2 0.50 mm² E601K TO
SPLICE SE02
5 6 7 8
33 - 27 9813/9050-1 33 - 27
33 - 28 9813/9050-1 33 - 28
Page 33-30 Figure 888. Engine- After Treatment

160/B4268 Issue 2- Sheet 6 Page 33-31
1 2 3 4 5 6 7 8
-C010E
SCR ECU
-C001
F ISOLATION FUSE 1/94 1/94
TO BATT ISOLATOR
2.50 mm² 6300A
F
-P018 /2.C2 FROM 10.00 mm² BLACK 80A 10.00 mm² BLACK -C002 2.50 mm² 6300E 2/94 2/94 GROUND
PURGE HOLD INHIBIT BATTERY SIDE GROUND 1.50 mm² 6300C 7/94 7/94
7216/0001 -P135 -C123
4 1.00 mm² 463A 6/6 6/6
M10
4.00 mm² 6300B -SJ8 1.50 mm² 6300F 29/94 29/94
1.00 mm² 463 1 2
-C003 -C003_NB
PURGE HOLD 7207/1303
7207/1303
FROM IGNITION FUSE 1.00 mm² 100ISO 3 5 1.00 mm² 600ISO TO BATT ISOLATOR 10.00 mm² BLACK
M6 1/1 1/1 M6
/3.B7 FROM
/2.C2 FROM
P001:2 / SP20 CHASSIS SIDE

-C086 -C001 -C003 -C003
TO GROUND /20.C6 1.00 mm² 463A 1/20 1/20 1.00 mm² 463 1/2 1/2 2/2 2/2 1.00 mm² 663
TO
ISOLATION RELAY
SPLICE SP62
-C410LH
-P135 -C123 -C167 -E026 SUPPLY MODULE
1.00 mm² 463 5/6 5/6 1.00 mm² 463 11/12 11/12 1.00 mm² E463 FROM FUSE / RELAY BOX
FROM
/4.A5
F11 / E001:A -E097 1/12
-E035 DOSING MODULE 2/12 0.75 mm² 8207 76/94 76/94
NOx DOWNSTREAM/TAIL PIPE
1/2 3/12 0.75 mm² 8206 55/94 55/94
1/5 8223A 0.50 mm² 2/2 4/12 0.75 mm² 8208 54/94 54/94
E 2/5 6302C 0.50 mm²
/21.D5 TO CHASSIS GROUND 5/12 0.75 mm² 8209 77/94 77/94
E
TO
3/5 CAN L 0.50 mm² SPLICE SE01 6/12 0.75 mm² 8210 78/94 78/94
4/5 CAN H 0.50 mm² FROM
/18.D4 FROM ENG CAN LO -E109 7/12
5/5 EXHAUST INLET TEMP 8/12 0.75 mm² 8213 40/94 40/94
1 2 9/12 0.75 mm² 8212 39/94 -BC2 39/94
FROM
/18.D4 FROM ENG CAN HI + SIG
10/12 0.75 mm² 8211 17/94 17/94
-E036 11/12 1.50 mm² 8204 4/94 4/94
NOx UPSTREAM ENG OUT
12/12 1.50 mm² 8205 3/94 3/94
1/5 8223C 0.50 mm² -SE09
2/5 6302A 0.50 mm² TO CHASSIS GROUND
TO
/21.D5 -E026 -C167 -C086 -C001
3/5 CAN L 0.50 mm² SPLICE SE01 1/12 1/12 1.00 mm² 4205 2/20 2/20 0.75 mm² 4205 0.75 mm² 4205 83/94 83/94
4/5 CAN H 0.50 mm² 2/12 2/12 1.00 mm² 4206 3/20 3/20 0.75 mm² 4206 0.75 mm² 4206 61/94 -BC13 61/94
FROM
/18.D5 FROM ENG CAN LO
5/5 6302B 0.50 mm² FROM ENG CAN HI 3/12 3/12 1.00 mm² 8202 4/20 4/20 0.75 mm² 8202 0.75 mm² 8202 80/94 80/94
/18.D3 FROM
4/12 4/12 1.00 mm² 8203 5/20 5/20 0.75 mm² 8203 0.75 mm² 8203 58/94 58/94
FROM
/18.D5 FROM ENG CAN HI
FROM ENG CAN LO 0.50 mm² CAN H 5/12 5/12 0.50 mm² CAN HI -SDMC10 0.50 mm² CAN HI 12/20 12/20 0.50 mm² CAN H -SDMC13 0.50 mm² CAN H 82/94 82/94
/18.D3 FROM
TO CHASSIS GROUND 0.50 mm² CAN L 6/12 6/12 0.50 mm² CAN LO -SDMC11 0.50 mm² CAN LO 13/20 13/20 0.50 mm² CAN L -SDMC14 0.50 mm² CAN L 60/94 60/94
TO
/21.D5
SPLICE SE01 FROM ENG CAN SHLD 0.50 mm² SCR 7/12 7/12 0.50 mm² CAN SCR -SDMC12 0.50 mm² CAN SCR 14/20 14/20 0.50 mm² SCREEN -SDMC15 0.50 mm² SCREEN
/18.D3 FROM
D 8/12 8/12 1.00 mm² 8223A -SC28 1.00 mm² 8223 7/20 7/20 1.00 mm² 8223X -SCREEN 7
D
FROM CAN H 0.50 mm² CAN H 66/94 66/94
/17.A7 FROM
-C440E
FROM FUSE 16B 2.00 mm² 3100A FROM CAN L 0.50 mm² CAN L 65/94 65/94
/3.D5 FROM
CAN BASED QUALITY SENSOR /17.A7 FROM
P002:12 -P009
HEATED HOSE POWER RELAY 1/4 1/4 0.50 mm² CAN HI
0.50 mm² SCREEN

4 2/4 2/4 0.50 mm² CAN LO
0.50 mm² CAN H

0.50 mm² CAN L
FROM FUSE 49E 2.00 mm² 300HH 2.00 mm² 300HH 1 2 2.00 mm² 8214A 3/4 3/4 1.00 mm² 8223B
/3.C7 FROM
P005:18 4/4 4/4 1.00 mm² 6300F SC4-10

TO
/21.D3
1.00 mm² 8215A 3 5 1.00 mm² 8216 0.50 mm² CAN SCR
-SCREEN 6
A/3
C/3
B/3
-P009 -C440E
HOSE HEATER 1 (RED) C B A
3/4 1.00 mm² 8223Z -SJ45
9
1.50 mm² 8225 6 7 1.50 mm² 6301A DIESEL MAX TERMINATOR RES
C -C006
1.00 mm² 8215B 8 10 1.00 mm² 8217
C
2.50 mm² 3100C 5/94 5/94 V+ BATT

1.00 mm² 8215 2.50 mm² 3100E 6/94 6/94
-SP39
-P199 -C007 1.50 mm² 3100F 51/94 51/94
-P101 2.00 mm² 3100A 1/12 1/12 2.00 mm² 3100A 1.50 mm² 3100G 73/94 73/94
NOx SENSOR 1.50 mm² 8223 2/12 2/12 1.50 mm² 8223 -SAB1
4 1.00 mm² 8215 3/12 3/12 0.75 mm² 8215 0.75 mm² 8215 53/94 53/94
FROM FUSE 33D 1.50 mm² 300NX 1.50 mm² 300NX 1 2 1.50 mm² 8223 1.00 mm² 8217 4/12 4/12 0.75 mm² 8217 0.75 mm² 8217 94/94 94/94
/3.F7 FROM
P004:6 1.00 mm² 8219 5/12 5/12 0.75 mm² 8219 0.75 mm² 8219 50/94 50/94
FROM FUSE 05A /3.E5 1.00 mm² 1100A 1.00 mm² 1100A 3 5 1.00 mm² 6302X 1.00 mm² 8222 6/12 6/12 0.75 mm² 8222 0.75 mm² 8222 28/94 28/94
FROM
P001:10 1.00 mm² 8216 7/12 7/12 0.75 mm² 8216 0.75 mm² 8216 93/94 93/94
2.00 mm² 8214A 8/12 8/12 2.00 mm² 8214A -SJ64 0.75 mm² 8214 71/94 -BC3 71/94
FROM FUSE 05A 1.00 mm² 1100 1.00 mm² 1100 9/12 9/12 0.75 mm² 1100 0.75 mm² 1100 22/94 22/94
/3.E5 FROM
P001:10 1.50 mm² 8225 10/12 10/12 1.50 mm² 8225 -SJ65 0.75 mm² 8218 72/94 72/94
1.50 mm² 8226 11/12 11/12 1.50 mm² 8226 -SJ66 0.75 mm² 8220 49/94 49/94
-P102 12/12 12/12 -SJ67 27/94 27/94
B HOSE HEATER 2 (WHITE)
1.50 mm² 8227 1.50 mm² 8227A 0.75 mm² 8221
B
4
-C240E
1.50 mm² 8226 1 2 1.50 mm² 6301B
1/2 1/2 1.50 mm² 8214C
1.00 mm² 8215C 3 5 1.00 mm² 8219 2/2 2/2 1.50 mm² 8225A
-C260E
-C200E
TANK HEATER VALVE
-P102 1/2 1/2 1.50 mm² 8214E
HOSE HEATER 3 (YELLOW) -P025 2/2 2/2 1.50 mm² 8226A 1/2 1/2 0.75 mm² 8200 75/94 75/94
9 AFTER TREATMENT GND 2/2 2/2 0.75 mm² 8201 92/94 92/94
6 7 M10
1.50 mm² 8227 1.50 mm² 6031C 4.00 mm² 6001
-C280E
-SP46
1.00 mm² 8215D 8 10 1.00 mm² 8222 1/2 1/2 1.50 mm² 8214F
2/2 2/2 1.50 mm² 8227
A
A
1 2 3 4 5 6 7 8
33 - 29 9813/9050-1 33 - 29
Page Page
33-30 33-31

1 2 3 4
-C001
F ISOLATION FUSE
-P018 TO BATT ISOLATOR 10.00 mm² BLACK 80A 10.00 mm² BLACK
/2.C2 FROM
PURGE HOLD INHIBIT BATTERY SIDE

7216/0001 -P135 -C123
4 1.00 mm² 463A 6/6 6/6
1.00 mm² 463 1 2
-C003 -C003_NB
PURGE HOLD 7207/1303
7207/1303
FROM IGNITION FUSE 1.00 mm² 100ISO 3 5 1.00 mm² 600ISO TO BATT ISOLATOR 10.00 mm² BLACK
M6 1/1 1/1 M6
/3.B7 FROM
/2.C2 FROM
P001:2 / SP20 CHASSIS SIDE

-C086 -C001 -C003 -C003
TO GROUND /20.C6 1.00 mm² 463A 1/20 1/20 1.00 mm² 463 1/2 1/2 2/2 2/2
TO
ISOLATION RELAY
SPLICE SP62
-P135 -C123 -C167 -E026
1.00 mm² 463 5/6 5/6 1.00 mm² 463 11/12 11/12 1.00 mm² E463 FROM FUSE / RELAY BOX
FROM
/4.A5
F11 / E001:A -E097
-E035 DOSING MODULE
NOx DOWNSTREAM/TAIL PIPE
1/2
1/5 8223A 0.50 mm² 2/2
E 2/5 6302C 0.50 mm² TO
/21.D5 TO CHASSIS GROUND
3/5 CAN L 0.50 mm² SPLICE SE01
4/5 CAN H 0.50 mm² FROM
/18.D4 FROM ENG CAN LO -E109
5/5 EXHAUST INLET TEMP
1 2
FROM
/18.D4 FROM ENG CAN HI + SIG
-E036
NOx UPSTREAM ENG OUT
1/5 8223C 0.50 mm² -SE09

2/5 6302A 0.50 mm² TO CHASSIS GROUND
TO
/21.D5 -E026 -C167 -C086
3/5 CAN L 0.50 mm² SPLICE SE01 1/12 1/12 1.00 mm² 4205
4/5 CAN H 0.50 mm² 2/12 2/12 1.00 mm² 4206
FROM
/18.D5 FROM ENG CAN LO
5/5 6302B 0.50 mm² FROM ENG CAN HI 3/12 3/12 1.00 mm² 8202
/18.D3 FROM
4/12 4/12 1.00 mm² 8203

FROM
/18.D5 FROM ENG CAN HI
FROM ENG CAN LO 0.50 mm² CAN H 5/12 5/12 0.50 mm² CAN HI -SDMC10 0.50 mm² CAN HI
/18.D3 FROM
TO CHASSIS GROUND 0.50 mm² CAN L 6/12 6/12 0.50 mm² CAN LO -SDMC11 0.50 mm² CAN LO
TO
/21.D5
SPLICE SE01 FROM ENG CAN SHLD 0.50 mm² SCR 7/12 7/12 0.50 mm² CAN SCR -SDMC12 0.50 mm² CAN SCR
/18.D3 FROM
D 8/12 8/12 1.00 mm² 8223A -SC28 1.00 mm² 8223
-C440E
FROM FUSE 16B 2.00 mm² 3100A
/3.D5 FROM
CAN BASED QUALITY SENSOR

P002:12 -P009
HEATED HOSE POWER RELAY 1/4 1/4 0.50 mm² CAN HI
4 2/4 2/4 0.50 mm² CAN LO
FROM FUSE 49E 1 2
Page 33-31
2.00 mm² 300HH 2.00 mm² 300HH 2.00 mm² 8214A 3/4 3/4 1.00 mm² 8223B
/3.C7 FROM
P005:18 4/4 4/4 1.00 mm² 6300F SC4-10

TO
/21.D3
1.00 mm² 8215A 3 5 1.00 mm² 8216 0.50 mm² CAN SCR
-SCREEN 6
-P009 -C440E
HOSE HEATER 1 (RED) 3/4
9
1.50 mm² 8225 6 7 1.50 mm² 6301A

C
1.00 mm² 8215B 8 10 1.00 mm² 8217
1.00 mm² 8215

-SP39
-P199 -C007
-P101 2.00 mm² 3100A 1/12 1/12 2.00 mm² 3100A
NOx SENSOR 1.50 mm² 8223 2/12 2/12 1.50 mm² 8223
4 1.00 mm² 8215 3/12 3/12 0.75 mm² 8215
FROM FUSE 33D 1.50 mm² 300NX 1.50 mm² 300NX 1 2 1.50 mm² 8223 1.00 mm² 8217 4/12 4/12 0.75 mm² 8217
/3.F7 FROM
P004:6 1.00 mm² 8219 5/12 5/12 0.75 mm² 8219

FROM FUSE 05A /3.E5 1.00 mm² 1100A 1.00 mm² 1100A 3 5 1.00 mm² 6302X 1.00 mm² 8222 6/12 6/12 0.75 mm² 8222
FROM
P001:10 1.00 mm² 8216 7/12 7/12 0.75 mm² 8216

2.00 mm² 8214A 8/12 8/12 2.00 mm² 8214A
FROM FUSE 05A 1.00 mm² 1100 1.00 mm² 1100 9/12 9/12 0.75 mm² 1100
/3.E5 FROM
P001:10 1.50 mm² 8225 10/12 10/12 1.50 mm² 8225

1.50 mm² 8226 11/12 11/12 1.50 mm² 8226
-P102 12/12 12/12
B HOSE HEATER 2 (WHITE)
1.50 mm² 8227 1.50 mm² 8227A
4
-C240E
1.50 mm² 8226 1 2 1.50 mm² 6301B
1/2 1/2 1.50 mm² 8214C
1.00 mm² 8215C 3 5 1.00 mm² 8219 2/2 2/2 1.50 mm² 8225A
-C260E
-P102 1/2 1/2 1.50 mm² 8214E

HOSE HEATER 3 (YELLOW) -P025 2/2 2/2 1.50 mm² 8226A
9 AFTER TREATMENT GND
6 7 M10
1.50 mm² 8227 1.50 mm² 6031C 4.00 mm² 6001
-C280E
-SP46
1.00 mm² 8215D 8 10 1.00 mm² 8222 1/2 1/2 1.50 mm² 8214F
2/2 2/2 1.50 mm² 8227
1 2 3 4
33 - 30 9813/9050-1 33 - 30
Page Page
33-30 33-31

5 6 7 8
-C010E
SCR ECU
1/94 1/94
2.50 mm² 6300A
F
BLACK -C002 2.50 mm² 6300E 2/94 2/94 GROUND
GROUND 1.50 mm² 6300C 7/94 7/94
M10
4.00 mm² 6300B -SJ8 1.50 mm² 6300F 29/94 29/94
-C003_NB
7207/1303
-C003
2/2 2/2 1.00 mm² 663
ISOLATION RELAY
-C410LH
SUPPLY MODULE
1/12
2/12 0.75 mm² 8207 76/94 76/94
3/12 0.75 mm² 8206 55/94 55/94
4/12 0.75 mm² 8208 54/94 54/94
5/12 0.75 mm² 8209 77/94 77/94
6/12 0.75 mm² 8210 78/94 78/94 E
7/12
EXHAUST INLET TEMP 8/12 0.75 mm² 8213 40/94 40/94
9/12 0.75 mm² 8212 39/94 -BC2 39/94
10/12 0.75 mm² 8211 17/94 17/94
11/12 1.50 mm² 8204 4/94 4/94
12/12 1.50 mm² 8205 3/94 3/94
-C086 -C001
2/20 2/20 0.75 mm² 4205 0.75 mm² 4205 83/94 83/94
3/20 3/20 0.75 mm² 4206 0.75 mm² 4206 61/94 -BC13 61/94
4/20 4/20 0.75 mm² 8202 0.75 mm² 8202 80/94 80/94
5/20 5/20 0.75 mm² 8203 0.75 mm² 8203 58/94 58/94
0.50 mm² CAN HI 12/20 12/20 0.50 mm² CAN H -SDMC13 0.50 mm² CAN H 82/94 82/94
0.50 mm² CAN LO 13/20 13/20 0.50 mm² CAN L -SDMC14 0.50 mm² CAN L 60/94 60/94
-SDMC12 0.50 mm² CAN SCR 14/20 14/20 0.50 mm² SCREEN -SDMC15 0.50 mm² SCREEN
-SC28 1.00 mm² 8223 7/20 7/20 1.00 mm² 8223X -SCREEN 7
D
FROM CAN H 0.50 mm² CAN H 66/94 66/94
/17.A7 FROM
FROM CAN L 0.50 mm² CAN L 65/94 65/94

/17.A7 FROM
0.50 mm² SCREEN
0.50 mm² CAN H

0.50 mm² CAN L
Page 33-30
SC4-10
TO
/21.D3
A/3
C/3
B/3
-C440E C B A
3/4 1.00 mm² 8223Z -SJ45
DIESEL MAX TERMINATOR RES

-C006
C
2.50 mm² 3100C 5/94 5/94 V+ BATT

2.50 mm² 3100E 6/94 6/94
-C007 1.50 mm² 3100F 51/94 51/94

2.00 mm² 3100A 1.50 mm² 3100G 73/94 73/94
1.50 mm² 8223 -SAB1
0.75 mm² 8215 0.75 mm² 8215 53/94 53/94
0.75 mm² 8217 0.75 mm² 8217 94/94 94/94
0.75 mm² 8219 0.75 mm² 8219 50/94 50/94
0.75 mm² 8222 0.75 mm² 8222 28/94 28/94
0.75 mm² 8216 0.75 mm² 8216 93/94 93/94
2.00 mm² 8214A -SJ64 0.75 mm² 8214 71/94 -BC3 71/94
0.75 mm² 1100 0.75 mm² 1100 22/94 22/94
1.50 mm² 8225 -SJ65 0.75 mm² 8218 72/94 72/94
1.50 mm² 8226 -SJ66 0.75 mm² 8220 49/94 49/94
1.50 mm² 8227A -SJ67 0.75 mm² 8221 27/94 27/94
1.50 mm² 8214C

1.50 mm² 8225A
-C200E
TANK HEATER VALVE
1.50 mm² 8214E
1.50 mm² 8226A 1/2 1/2 0.75 mm² 8200 75/94 75/94
2/2 2/2 0.75 mm² 8201 92/94 92/94
1.50 mm² 8214F

1.50 mm² 8227
5 6 7 8
33 - 31 9813/9050-1 33 - 31
33 - 32 9813/9050-1 33 - 32
Page 33-34 Figure 889. PS750 Transmission

1 2 3 4 5 6 7 8
F
F
-T001 -T003
TRANS OIL PRESSURE
-C006
H/23 1.00 mm² 405 1/2 2/2 1.00 mm² 600TP
TRANSMISSION CONNECTOR
-P039 -C001 -P039

-C001
FROM 07/11 CONNECTOR J1 /22.E3 FROM 1.00 mm² 859 B12/84 B12/84 1.50 mm² 859 A/23 1/23 13/23 N/23 1.50 mm² 630 G4/84 G4/84 1.50 mm² 630 FROM
/22.E3 FROM 07/11 CONNECTOR J1
P069:5 P069:1
-T004
FROM 07/11 CONNECTOR J1 /22.E3 1.00 mm² 812 C6/84 C6/84 1.50 mm² 812 B/23 2/23 14/23
FROM
REVERSE LOW SOLENOID

P069:6
FROM 07/11 CONNECTOR J1 /22.C3 FROM 1.00 mm² 811 C4/84 C4/84 1.50 mm² 811 C/23 3/23 15/23 D/23 1.00 mm² 860 1/2 2/2 1.00 mm² 632
P069:18
FROM 07/11 CONNECTOR J1 /22.C3 FROM 1.00 mm² 860 C5/84 C5/84 1.50 mm² 860 D/23 4/23 16/23
P069:17
FROM 07/11 CONNECTOR J1 /22.D3 1.00 mm² 620 G3/84 G3/84 1.50 mm² 620 E/23 5/23 17/23
E -T005
TO
P069:13
FROM 07/11 CONNECTOR J1 /22.C3 FROM 1.50 mm² 858 B1/84 B1/84 2.00 mm² 858 F/23 6/23 18/23
REVERSE HIGH SOLENOID E
P069:16 C/23 1.00 mm² 811 1/2 2/2 1.00 mm² 631
FROM 07/11 CONNECTOR J1 /22.D3 FROM 1.00 mm² 857 B2/84 B2/84 2.00 mm² 857 G/23 7/23 19/23
P069:15
TO CENTER CLUSTER /9.B5 FROM 0.50 mm² 405 B10/84 B10/84 1.00 mm² 405 H/23 8/23 20/23
P040:17
-T008
9/23 21/23
FORWARD LOW SOLENOID
C017-13 1.50 mm² 818A K/23 10/23 22/23 B/23 1.00 mm² 812 1/2 2/2 1.00 mm² 622
/23.D5 FROM
SC9-6 1.00 mm² 602G L/23 11/23 23/23

/21.F2 TO
C015-18 1.00 mm² 650 M/23 12/23

/23.E7 FROM
-T009
FORWARD HIGH SOLENOID
A/23 1.00 mm² 859 1/2 2/2 1.00 mm² 621
D
D
N/23 1.50 mm² 630
-ST2
-T006
MAINSHAFT SOLENOID
F/23 1.00 mm² 858 1/2 2/2 1.00 mm² 642
E/23 1.50 mm² 620

-ST1
-T007
LAYSHAFT SOLENOID
G/23 1.00 mm² 857 1/2 2/2 1.00 mm² 641
C
-T010 C
COLUMN SWITCH L/H 4 WHEEL DRIVE SOLENOID
K/23 1.00 mm² 818 1/2 2/2

FROM FUSE 30C 11/14 TO HORN
/3.A5 FROM
2.00 mm² 304B
HORN 8/14 1.00 mm² 814 TO
/10.E2 P039:E9
P003:20
-P106 M/23 1.00 mm² 650

13/14 1.00 mm² 874 1 2 1.00 mm² 415B
4TH
-P105
5/14 1.00 mm² 873 1 2 1.00 mm² 415A 1.00 mm² 415 TO 07/11 CONNECTOR 1
3RD /22.D3
-SP65
TO
FROM FUSE 25C 1.00 mm² 109CS 1.00 mm² 109CS2 14/14 -SP34 P069:11
/3.B5 FROM
-P104
P003:10 9/14 1.00 mm² 872 1 2 1.00 mm² 414B
2ND
-C035
-P103
1 2 FUEL LEVEL SENDER
1ST 12/14 1.00 mm² 871 1.00 mm² 414A 1.00 mm² 414 TO
/22.E3 TO 07/11 CONNECTOR 1 -C001 -P039
-SP24 P069:3 SC7-6
/21.E5 FROM 1.00 mm² 603E A/2 1/2 2/2 B/2 1.00 mm² 408 B6/84 B6/84 1.00 mm² 408 TO
/9.D5 TO INSTRUMENT DISP J2
-P039 -C001 -C039 P072:11
4/14 0.75 mm² 416F C10/84 C10/84 1 2 0.75 mm² 416FF
F 330R FROM
/23.E2 C013/18
B 1
-C040
2 -C061
1.00 mm² 109CS1 7/14 N 6/14 1.00 mm² 416N E12/84 E12/84 0.75 mm² 416N 330R 0.75 mm² 416NN FROM
/23.E2 C013/17 TRANSMISSION DUMP
B
-C041 -C001 -P039
1 2 SC2-5 TO 07/11 J2
R 10/14 1.00 mm² 416R D9/84 D9/84 1.00 mm² 416R 0.75 mm² 416RR 1.00 mm² 109TD A/2 1/2 2/2 B/2 1.00 mm² 864TD B8/84 B8/84 1.00 mm² 864TD
330R FROM
/23.E4 C014-6 /3.B6 FROM FROM
/22.D5
P070:14
-P107
1&2 GEAR PULL DOWN 332R -E011
TO 07/11 SENSOR GROUND 2 1 TRANS OIL TEMP
/22.D6 TO 1.00 mm² 688A 1.00 mm² 414C TO 07/11 -P039 -C002 -E009
SPLICE SP41 CONNECTOR 1 /22.E3 1.00 mm² 100TT F12/84 1.00 mm² 100TT 28/29 28/29 1.00 mm² 100TT 1 2
TO
F12/84 +VE -VE

-P108 P069:4
-C001
3&4 GEAR PULL DOWN 332R 332/D2535 -P039 -E009
TO 07/11 SENSOR GROUND 1.00 mm² 688E 2 1 1.00 mm² 415C 0.75 mm² 688C E1/84 1.00 mm² 600TT 29/29 29/29 1.00 mm² 600TT
/22.D6 TO
/22.D6 TO
E1/84
SPLICE SP41
-C001
A
A
1 2 3 4 5 6 7 8
33 - 33 9813/9050-1 33 - 33
Page Page
33-34 33-35
Figure 889. (Part

1
1 of 2) 2 3 4
-C006
TRANSMISSION CONNECTOR
-P039 -C001 -P039

-C001
FROM 07/11 CONNECTOR J1 /22.E3 FROM 1.00 mm² 859 B12/84 B12/84 1.50 mm² 859 A/23 1/23 13/23 N/23 1.50 mm² 630 G4/84 G4/84 1.50 mm² 630 FROM
/22.E3
P069:5
FROM 07/11 CONNECTOR J1 /22.E3 FROM 1.00 mm² 812 C6/84 C6/84 1.50 mm² 812 B/23 2/23 14/23
P069:6
FROM 07/11 CONNECTOR J1 /22.C3 FROM 1.00 mm² 811 C4/84 C4/84 1.50 mm² 811 C/23 3/23 15/23
P069:18
FROM 07/11 CONNECTOR J1 /22.C3 FROM 1.00 mm² 860 C5/84 C5/84 1.50 mm² 860 D/23 4/23 16/23
P069:17
FROM 07/11 CONNECTOR J1 /22.D3 1.00 mm² 620 G3/84 G3/84 1.50 mm² 620 E/23 5/23 17/23
E
TO
P069:13
FROM 07/11 CONNECTOR J1 /22.C3 FROM 1.50 mm² 858 B1/84 B1/84 2.00 mm² 858 F/23 6/23 18/23
P069:16
FROM 07/11 CONNECTOR J1 /22.D3 FROM 1.00 mm² 857 B2/84 B2/84 2.00 mm² 857 G/23 7/23 19/23
P069:15
TO CENTER CLUSTER /9.B5 FROM 0.50 mm² 405 B10/84 B10/84 1.00 mm² 405 H/23 8/23 20/23
P040:17
9/23 21/23
C017-13 1.50 mm² 818A K/23 10/23 22/23

/23.D5 FROM
SC9-6 1.00 mm² 602G L/23 11/23 23/23

/21.F2 TO
C015-18 1.00 mm² 650 M/23 12/23

/23.E7 FROM
Page 33-35
C
COLUMN SWITCH L/H
FROM FUSE 30C 11/14 TO HORN

/3.A5 FROM
2.00 mm² 304B
HORN 8/14 1.00 mm² 814 TO
/10.E2 P039:E9
P003:20
-P106
13/14 1.00 mm² 874 1 2 1.00 mm² 415B
4TH
-P105
5/14 1.00 mm² 873 1 2 1.00 mm² 415A 1.00 mm² 415 TO 07/11 CONNECTOR 1
3RD /22.D3
-SP65
TO
FROM FUSE 25C 1.00 mm² 109CS 1.00 mm² 109CS2 14/14 -SP34 P069:11
/3.B5 FROM
-P104
P003:10 9/14 1.00 mm² 872 1 2 1.00 mm² 414B
2ND
-P103
1 2
1ST 12/14 1.00 mm² 871 1.00 mm² 414A 1.00 mm² 414 TO
/22.E3 TO 07/11 CONNECTOR 1
-SP24 P069:3
-P039 -C001 -C039
4/14 0.75 mm² 416F C10/84 C10/84 1 2 0.75 mm² 416FF
F 330R FROM
/23.E2 C013/18
B 1
-C040
2
1.00 mm² 109CS1 7/14 N 6/14 1.00 mm² 416N E12/84 E12/84 0.75 mm² 416N 0.75 mm² 416NN
330R FROM
/23.E2 C013/17
-C041
10/14 1.00 mm² 416R D9/84 D9/84 1.00 mm² 416R 1 2 0.75 mm² 416RR
R 330R FROM
/23.E4 C014-6
-P107
1&2 GEAR PULL DOWN 332R
TO 07/11 SENSOR GROUND 1.00 mm² 688A 2 1 1.00 mm² 414C TO 07/11
/22.D6 TO
-P039
SPLICE SP41 CONNECTOR 1 /22.E3 TO 1.00 mm² 100TT F12/84
-P108 P069:4
3&4 GEAR PULL DOWN 332R 332/D2535 -P039
TO 07/11 SENSOR GROUND 1.00 mm² 688E 2 1 1.00 mm² 415C 0.75 mm² 688C E1/84
/22.D6 TO
/22.D6 TO
SPLICE SP41
1 2 3 4
33 - 34 9813/9050-1 33 - 34
Page Page
33-34 33-35
Figure 889. (Part

5
2 of 2) 6 7 8
-T001 -T003
TRANS OIL PRESSURE
H/23 1.00 mm² 405 1/2 2/2 1.00 mm² 600TP
1.50 mm² 630 FROM

/22.E3 FROM 07/11 CONNECTOR J1
P069:1
-T004
REVERSE LOW SOLENOID
D/23 1.00 mm² 860 1/2 2/2 1.00 mm² 632
-T005
REVERSE HIGH SOLENOID E
C/23 1.00 mm² 811 1/2 2/2 1.00 mm² 631
-T008
FORWARD LOW SOLENOID
B/23 1.00 mm² 812 1/2 2/2 1.00 mm² 622
-T009
FORWARD HIGH SOLENOID
A/23 1.00 mm² 859 1/2 2/2 1.00 mm² 621
D
N/23 1.50 mm² 630
-ST2
-T006
MAINSHAFT SOLENOID
F/23 1.00 mm² 858 1/2 2/2 1.00 mm² 642

Page 33-34
E/23 1.50 mm² 620

-ST1
-T007
LAYSHAFT SOLENOID
G/23 1.00 mm² 857 1/2 2/2 1.00 mm² 641
-T010 C
4 WHEEL DRIVE SOLENOID
K/23 1.00 mm² 818 1/2 2/2
M/23 1.00 mm² 650
TO 07/11 CONNECTOR 1
/22.D3
P069:11
-C035
FUEL LEVEL SENDER
/22.E3 TO 07/11 CONNECTOR 1 -C001 -P039
P069:3 SC7-6
/21.E5 FROM 1.00 mm² 603E A/2 1/2 2/2 B/2 1.00 mm² 408 B6/84 B6/84 1.00 mm² 408 TO
/9.D5 TO INSTRUMENT DISP J2
P072:11
/23.E2 C013/18
-C061
/23.E2 C013/17 TRANSMISSION DUMP
B
-C001 -P039
SC2-5 TO 07/11 J2
1.00 mm² 109TD A/2 1/2 2/2 B/2 1.00 mm² 864TD B8/84 B8/84 1.00 mm² 864TD
/23.E4 C014-6 /3.B6 FROM FROM
/22.D5
P070:14
-E011
TRANS OIL TEMP
-P039 -C002 -E009
1.00 mm² 100TT F12/84 1.00 mm² 100TT 28/29 28/29 1.00 mm² 100TT 1 2
TO
F12/84 +VE -VE

-C001
332/D2535 -P039 -E009
TO 0.75 mm² 688C E1/84 1.00 mm² 600TT 29/29 29/29 1.00 mm² 600TT
E1/84
-C001
5 6 7 8
33 - 35 9813/9050-1 33 - 35
33 - 36 9813/9050-1 33 - 36
Page 33-38 Figure 890. Livelink and Immobiliser

1 2 3 4 5 6 7 8
F
F
E
E
-P068 -P066
LIVE LINK IMMOBILISER
/17.F3 FROM
-P101
FROM CAN SHIELD
IMMOBILISER IGN RELAY
C4 B7 G1
/17.F3 FROM 0.50 mm² CAN 5 SCR V_BATT FROM FUSE 19B /3.C7 1.00 mm² Y +12/24VDC Key 7
FROM CAN L
FROM
0.50 mm² CAN 5 L 9 P002:18 / SP27 BATT Feed G2

Key 6
0.50 mm² CAN 5 H C7 1.00 mm² Y 6 7 B8 G3
/17.F3 FROM
ENG_RUN FROM FUSE 40D /3.E7 1.00 mm² Y +12/24VDC Key 5
FROM CAN H
FROM
C8 G4
V_IGN P004:20 IGN Feed Key 4
D FROM FUSE 26C /3.B5 FROM 1.00 mm² 299LL 1.00 mm² Y 8 10
Key 3
G5
P003:12 D8
CH_1_1 V_PWR
C3
Key 2
G6 D
D4 G7
CH_2_1 Key 1
1.00 mm² 110LLA D10 C6 G8
CH_3_1 RLY_0 TO GROUND /20.E4 TO 1.00 mm² 601TS Key 0
D5
CH_4_1 SPLICE SP3
-P013 C12 G9
RLY_1 Status LED LS Out
LIVE LINK RELAY D1 G10
RS232_TX Status LED 5V Feed
4 D2 G11
RS232_DTR Antenna Coil
1 2 G12
FROM FUSE 37D /3.E7 FROM 1.00 mm² 110LL D3
Antenna Coil
RS232_DCD
P004:14 D6
3 5 RS232_CTS C5
FROM IGNITION FUSE /3.B7 1.00 mm² 100LL D7 Relay 1
FROM
RS232_RTS GND
P001:2 / SP20 D12
RS232_RX C9
GND-BATT 1.00 mm² 601L FROM
/3.D7 FROM FUSE 46E NO
D11 B12 MAX 7A B5
SATCOM_RING P005:12
C10 B6
TO GROUND /20.E4 1.00 mm² 601LL
CAN_SHD
TO
GND_PWR COM
SPLICE SP3
CAN_H
CAN_L
NC
D9 Relay 2
GND
C11
C
C2
C1
B3 MAX 7A B4 C
COM NO
Relay 3
B1 MAX 7A B2
COM NO
FROM CAN H /17.B3 FROM 0.50 mm² CAN H
B11
FROM CAN L /17.B3 /20.C4 TO GROUND
B10
0.50 mm² CAN L GND 1.00 mm² Y
B9
FROM TO
CAN_H CAN_L SPLICE SP6
B
B
A
A
1 2 3 4 5 6 7 8
33 - 37 9813/9050-1 33 - 37
Page Page
33-38 33-39

1 2 3 4
-P068
LIVE LINK
/17.F3 FROM
-P101
FROM CAN SHIELD
0.50 mm² CAN 5 SCR C4
/17.F3 FROM
V_BATT
FROM CAN L 0.50 mm² CAN 5 L
0.50 mm² CAN 5 H C7 1.00 mm² Y 6
/17.F3 FROM
ENG_RUN FROM FUSE 40D /3.E7
FROM CAN H
FROM
C8
V_IGN P004:20
D FROM FUSE 26C /3.B5 FROM 1.00 mm² 299LL 1.00 mm² Y 8
D8 C3
P003:12 CH_1_1 V_PWR
D4
CH_2_1
1.00 mm² 110LLA D10 C6
CH_3_1 RLY_0 TO GROUND /20.E4 TO 1.00 mm² 601TS
D5
CH_4_1 SPLICE SP3
-P013 C12
RLY_1
LIVE LINK RELAY D1
4 RS232_TX
D2
1 2 RS232_DTR
FROM FUSE 37D /3.E7 FROM 1.00 mm² 110LL D3
RS232_DCD
P004:14 D6
Page 33-39
3 5 RS232_CTS C5
FROM IGNITION FUSE /3.B7 FROM 1.00 mm² 100LL D7 GND
RS232_RTS
P001:2 / SP20 D12
RS232_RX C9
GND-BATT 1.00 mm² 601L FROM
/3.D7 FROM FUSE 46E
D11
SATCOM_RING P005:12
C10
TO GROUND /20.E4 1.00 mm² 601LL
CAN_SHD
TO
GND_PWR
SPLICE SP3
CAN_H
CAN_L
D9
GND
C11
C
C2
C1
1 2 3 4
33 - 38 9813/9050-1 33 - 38
Page Page
33-38 33-39

5 6 7 8
-P066
IMMOBILISER
-P101
FROM FUSE 19B /3.C7 1.00 mm² Y B7 G1
FROM
+12/24VDC Key 7
9 P002:18 / SP27 BATT Feed G2
Key 6
1.00 mm² Y 6 7 1.00 mm² Y B8 G3
+12/24VDC Key 5
IGN Feed G4
Key 4
1.00 mm² Y 8 10 G5
Key 3
Key 2
G6 D
G7
Key 1
1.00 mm² 601TS G8
Key 0
G9
Status LED LS Out
G10
Status LED 5V Feed
G11
Antenna Coil
G12
Antenna Coil
Page 33-38
Relay 1
NO
B12 MAX 7A B5
COM B6
NC
Relay 2
B3 MAX 7A B4 C
COM NO
Relay 3
B1 MAX 7A B2
COM NO
FROM CAN H /17.B3 FROM 0.50 mm² CAN H
B11
FROM CAN L /17.B3 /20.C4 TO GROUND
B10
0.50 mm² CAN L GND 1.00 mm² Y

B9
FROM TO
CAN_H CAN_L SPLICE SP6
5 6 7 8
33 - 39 9813/9050-1 33 - 39
33 - 40 9813/9050-1 33 - 40
Page 33-42 Figure 891. Instruments

1 2 3 4 5 6 7 8
F
F
TO
/20.E6 TO GROUND
SPLICE SP11
-P071 -P072
INSTRUMENT CLUSTER INSTRUMENT CLUSTER -P063
INFO BUTTON
J1 J2
7 8
1.00 mm² 601HP 1.00 mm² 829AH FROM
/19.D4 FROM ILLUMINATION
FROM ILLUMINATION /19.D5 FROM 1.00 mm² 829AB 1/20 1/20 1.00 mm² 402 FROM
/5.B4 FROM VACUUM SWITCH SPLICE SP7
SPLICE SP7 E006:1 / P039:B7
FROM FUSE 39D /3.E7 FROM
1.00 mm² 106 2/20 2/20
2
P004:18 0.75 mm² 100K FROM
/3.B7 FROM IGNITION FUSE
3
TO AC RELAY /14.C2 1.00 mm² 884AC 3/20 3/20 0.75 mm² 2910 0.75 mm² 2910 P001:2 / SP20
E
TO
P015:3
1.00 mm² 877 4/20 4/20 0.75 mm² 800R
E
FROM
/11.B3 FROM COLUMN SWITCH
RH P038:10
5/20 5/20 1.00 mm² 887A FROM
/14.A4 FROM HEATER CONTROL
P034:3
6/20 6/20 1.00 mm² 1840C FROM
/16.D3 FROM REVERSE FAN SWITCH
P061:6
FROM CAN L /17.F4 FROM 0.50 mm² CAN 7 L 7/20 7/20 1.00 mm² 412 FROM
/4.E5 FROM STARTER MOTOR
C005:B / P039:C1
FROM CAN H /17.F3 FROM 0.50 mm² CAN 7 H 8/20 8/20 1.00 mm² 593 TO
/5.D6
FROM CAN SHIELD /17.F4 FROM 0.50 mm² CAN 7 SCR 9/20 9/20 1.00 mm² 801A FROM
/14.B1 FROM HEATER
SPLICE SP50
1.00 mm² 301EA 10/20 10/20 2.00 mm² 805F TO
/11.B5 TO INDICATOR DIODE
SPLICE SP8
FROM ENGINE RUNNING /4.E5 FROM 1.00 mm² 407B 11/20 11/20 1.00 mm² 408 FROM
/7.B7 FROM FUEL LEVEL SENSOR
SPLICE SP14 C010:B / P039:B6
D TO REV FAN SOLENOID /16.E4 TO 1.00 mm² 1840 12/20 12/20
E012:2 / P039:A10 D
FROM HAZARD SWITCH /11.C3 FROM 0.75 mm² 509 13/20 13/20
P020:6
TO FOOTBRAKE DUMP SW /30.E4 TO 1.00 mm² 601EC FROM TRAILER R/H DI RELAY /11.E7 FROM 0.75 mm² 806RC 14/20 14/20
P019:7 P016:7 / SP36

FROM HEATER CONTROL /14.B4 FROM 1.00 mm² 610HV 15/20 15/20 1.00 mm² 481A FROM
/25.D5 FROM FRONT/REAR AUX SWITCH
-P099 P034:5 P017:3 / SP69
ECO SWITCH
FROM TRAILER L/H DI RELAY /11.E7 FROM 0.75 mm² 805LC 16/20 16/20 1.00 mm² 410 TO
/31.C2 TO RH STAB TRANS
8 7
P016:2 / SP37 P039:G1
FROM FOOTBRAKE DUMP SW /30.E2 FROM 1.00 mm² 829EC
P019:8 FROM COLUMN SWITCH /11.B3 FROM 0.75 mm² 800L 17/20 17/20 1.00 mm² 601DE TO
/20.E6 TO GROUND
RH P038:11 SPLICE SP11
FROM REVERSE FAN SWITCH /16.D3 FROM 1.00 mm² 1840D 18/20 18/20 1.00 mm² 997 FROM
2
0.75 mm² 601EO P061:3 SPLICE SP5
3 P039:F6
1.00 mm² 601EC 1.00 mm² 601EC 19/20 19/20 1.00 mm² 592 TO
/16.E4 TO PROP FAN
FROM FUSE 35D/3.E7 FROM 1.00 mm² 301E 1.00 mm² 301EB 20/20 20/20 2.00 mm² 806A TO
P004:10 -SP40 /9.C4 /9.C4 SPLICE SP9
C
C
-P040
CENTER CLUSTER
FROM ILLUMINATION /19.C4 FROM 0.50 mm² 829WL 1/20 11/20 0.50 mm² 941A FROM
/10.F4 FROM FOG LIGHT SWITCH
SPLICE SP7 P023:3
FROM MAIN BEAM /10.B4 FROM 0.50 mm² 838A 2/20 12/20
-P014 SPLICE SP19
TRAILER SENSE
FROM INDICATORS /11.C3 FROM 0.50 mm² 804B 3/20 13/20
9
SPLICE SP49
6 7
FROM ENGINE RUNNING RELAY /12.E1 FROM
0.75 mm² 601TS 0.50 mm² 601TSW 0.50 mm² 601TSW 4/20 14/20
P014:5
1.00 mm² 877 8 10 0.75 mm² 601TSA 5/20 15/20
B
FROM WORKLIGHTS SWITCH /12.F5 FROM 0.50 mm² 609BC 6/20 16/20 B
P026:6
FROM WORKLIGHTS SWITCH /12.F5 FROM 0.50 mm² 609AB 7/20 17/20 0.50 mm² 405 TO
/7.E2 TO TRANS OIL PRESSURE
P026:3 T003:1 / P039:B10
FROM BOOM WORKLIGHTS SWITCH /12.F5 FROM 0.50 mm² 610AB 8/20 18/20
P029:3
9/20 19/20
TO GROUND /20.C4 TO 0.50 mm² 601P 10/20 IGN 20/20 0.50 mm² 106C FROM
/3.A7 FROM IGNITION FUSE
SPLICE SP6 P001:2 / SP20
A
A
1 2 3 4 5 6 7 8
33 - 41 9813/9050-1 33 - 41
Page Page
33-42 33-43

1 2 3 4
-P071 -P072
INSTRUMENT CLUSTER INSTRUMENT CLUSTER
J1 J2
FROM ILLUMINATION /19.D5 FROM 1.00 mm² 829AB 1/20 1/20

SPLICE SP7
FROM FUSE 39D /3.E7 FROM
1.00 mm² 106 2/20 2/20
P004:18
1.00 mm² 884AC 3/20 3/20
TO AC RELAY /14.C2
E
TO
P015:3
1.00 mm² 877 4/20 4/20
5/20 5/20
6/20 6/20
FROM CAN L /17.F4 FROM 0.50 mm² CAN 7 L 7/20 7/20
FROM CAN H /17.F3 FROM 0.50 mm² CAN 7 H 8/20 8/20
FROM CAN SHIELD /17.F4 FROM 0.50 mm² CAN 7 SCR 9/20 9/20
1.00 mm² 301EA 10/20 10/20
FROM ENGINE RUNNING /4.E5 FROM 1.00 mm² 407B 11/20 11/20
SPLICE SP14
D TO REV FAN SOLENOID /16.E4 TO 1.00 mm² 1840 12/20 12/20
E012:2 / P039:A10
FROM HAZARD SWITCH /11.C3 FROM 0.75 mm² 509 13/20 13/20
P020:6
TO FOOTBRAKE DUMP SW /30.E4 TO 1.00 mm² 601EC FROM TRAILER R/H DI RELAY /11.E7 FROM 0.75 mm² 806RC 14/20 14/20
P019:7 P016:7 / SP36

FROM HEATER CONTROL /14.B4 FROM 1.00 mm² 610HV 15/20 15/20
-P099 P034:5
ECO SWITCH
FROM TRAILER L/H DI RELAY /11.E7 FROM 0.75 mm² 805LC 16/20 16/20
Page 33-43
8 7
FROM FOOTBRAKE DUMP SW /30.E2 FROM 1.00 mm² 829EC P016:2 / SP37
P019:8 FROM COLUMN SWITCH /11.B3 FROM 0.75 mm² 800L 17/20 17/20
RH P038:11
FROM REVERSE FAN SWITCH /16.D3 FROM 1.00 mm² 1840D 18/20 18/20
2
0.75 mm² 601EO P061:3
3 1.00 mm² 601EC 1.00 mm² 601EC 19/20 19/20
FROM FUSE 35D/3.E7 FROM 1.00 mm² 301E 1.00 mm² 301EB 20/20 20/20
P004:10 -SP40 /9.C4 /9.C4
C
-P040
CENTER CLUSTER
FROM ILLUMINATION /19.C4 FROM 0.50 mm² 829WL 1/20 11/20 0.50 mm² 941A
SPLICE SP7
FROM MAIN BEAM /10.B4 FROM 0.50 mm² 838A 2/20 12/20
-P014 SPLICE SP19
TRAILER SENSE
FROM INDICATORS /11.C3 FROM 0.50 mm² 804B 3/20 13/20
9
SPLICE SP49
6 7
FROM ENGINE RUNNING RELAY /12.E1 FROM
0.75 mm² 601TS 0.50 mm² 601TSW 0.50 mm² 601TSW 4/20 14/20
P014:5
1.00 mm² 877 8 10 0.75 mm² 601TSA 5/20 15/20
B
FROM WORKLIGHTS SWITCH /12.F5 FROM 0.50 mm² 609BC 6/20 16/20
P026:6
FROM WORKLIGHTS SWITCH /12.F5 FROM 0.50 mm² 609AB 7/20 17/20 0.50 mm² 405
P026:3
FROM BOOM WORKLIGHTS SWITCH /12.F5 FROM 0.50 mm² 610AB 8/20 18/20
P029:3
9/20 19/20
TO GROUND /20.C4 TO 0.50 mm² 601P 10/20 IGN 20/20 0.50 mm² 106C
SPLICE SP6
1 2 3 4
33 - 42 9813/9050-1 33 - 42
Page Page
33-42 33-43

5 6 7 8
TO
/20.E6 TO GROUND
SPLICE SP11
-P072
INSTRUMENT CLUSTER -P063
INFO BUTTON
J2
7 8
1.00 mm² 601HP 1.00 mm² 829AH FROM
/19.D4 FROM ILLUMINATION
1/20 1.00 mm² 402 FROM
/5.B4 FROM VACUUM SWITCH SPLICE SP7
E006:1 / P039:B7
2/20
2 0.75 mm² 100K FROM
/3.B7 FROM IGNITION FUSE
3
3/20 0.75 mm² 2910 0.75 mm² 2910 P001:2 / SP20
4/20 0.75 mm² 800R

E
FROM
/11.B3 FROM COLUMN SWITCH
RH P038:10
5/20 1.00 mm² 887A FROM
P034:3
6/20 1.00 mm² 1840C FROM
/16.D3 FROM REVERSE FAN SWITCH
P061:6
7/20 1.00 mm² 412 FROM
/4.E5 FROM STARTER MOTOR
C005:B / P039:C1
8/20 1.00 mm² 593 TO
/5.D6
9/20 1.00 mm² 801A FROM

/14.B1 FROM HEATER
SPLICE SP50
10/20 2.00 mm² 805F TO
SPLICE SP8
11/20 1.00 mm² 408 FROM
/7.B7 FROM FUEL LEVEL SENSOR
C010:B / P039:B6
12/20
D
13/20
14/20
15/20 1.00 mm² 481A FROM

/25.D5 FROM FRONT/REAR AUX SWITCH
P017:3 / SP69
16/20 1.00 mm² 410 TO
/31.C2 TO RH STAB TRANS
Page 33-42
P039:G1
17/20 1.00 mm² 601DE TO
/20.E6 TO GROUND
SPLICE SP11
18/20 1.00 mm² 997 FROM
SPLICE SP5
P039:F6
19/20 1.00 mm² 592 TO
/16.E4 TO PROP FAN
20/20 2.00 mm² 806A TO

/9.C4 SPLICE SP9
CENTER CLUSTER
11/20 0.50 mm² 941A FROM

/10.F4 FROM FOG LIGHT SWITCH
P023:3
12/20
13/20
14/20
15/20
16/20 B
17/20 0.50 mm² 405 TO
/7.E2 TO TRANS OIL PRESSURE
T003:1 / P039:B10
18/20
19/20
20/20 0.50 mm² 106C FROM

/3.A7 FROM IGNITION FUSE
P001:2 / SP20
5 6 7 8
33 - 43 9813/9050-1 33 - 43
33 - 44 9813/9050-1 33 - 44
Page 33-46 Figure 892. Roadlights 160/

B4268 Issue 2- Sheet 10 Page 33-47
1 2 3 4 5 6 7 8
TO GROUND /20.C4 TO
-P011
F SPLICE SP6
-P023 BRAKE LIGHTS
FOG LIGHT SWITCH 4
-C443
REVERSE ALARM
F
1.00 mm² 816
8 7 1 2
FROM ILLUMINATION /19.D5 FROM 1.00 mm² 829AE 1.00 mm² 601DC FROM FUSE 08A /3.E5 FROM 1.00 mm² 108
SPLICE SP7 P001:16

3 5
FROM IGNITION FUSE /3.A6 FROM 0.75 mm² 100J 0.75 mm² 616B TO
/22.E3 1.00 mm² 807C
1/2
P001:2 / SP20 P069:7
2
FROM FUSE 45E /3.D7 FROM 1.00 mm² 905
/21.E1 1.00 mm² 601CD
2/2
TO
P005:10 3 1.00 mm² 941 SC10-3

0.50 mm² 941A TO
/9.C5 TO CENTER CLUSTER
P040:11
-C019
LH REAR LAMP
-P039 -C001
-SC26
-C444 1.00 mm² 816 A7/84 A7/84 1.50 mm² 816 1.50 mm² 816B 1/6
HORN 1.00 mm² 829A D11/84 D11/84 1.00 mm² 829E 2/6
TO L/H TURN SIGNAL DIODE /11.D6 2.00 mm² 805D D4/84 D4/84 2.00 mm² 805 3/6
E
FROM
-C001 -P039 P031:1 / SP8 1.00 mm² 941 E5/84 C7/84 1.00 mm² 807 1.00 mm² 941B 4/6
2.00 mm² 814 E9/84 E9/84 1.00 mm² 814 TO LH COLUMN SWITCH 1.00 mm² 807B 5/6
E
FROM
/7.C2P037:8
-SC24 2.00 mm² 603BR 6/6
/21.E5 TO
2.00 mm² 600F TO GROUND SC7-8

TO
/21.E4 SC11-4
-C018
RH REAR LAMP
-P039 -C001
E2/84 E2/84 1.00 mm² 830 TO SIDE LIGHTS
TO
/10.B5 SC5
TO R/H TURN SIGNAL DIODE /11.C6 FROM 2.00 mm² 806C D3/84 D3/84 2.00 mm² 806C TO
/10.A5 TO RH INDICATOR 1.50 mm² 816A 1/6
P032:1 / SP9 SC1 1.00 mm² 830G 2/6
2.00 mm² 806F 3/6
C7/84 E5/84 1.00 mm² 941 1.00 mm² 941A 4/6
-SC25 1.00 mm² 807A 5/6
2.00 mm² 601EC 6/6
/21.E1 TO
SC10-6
D -C020
D
No. PLATE LAMP
-P064B
1.00 mm² 830D 1.00 mm² 601CE SC10-4
DIODE TO
/21.E1
2 1 2.00 mm² 947B
2.00 mm² 942C FROM
/12.E6 FROM BOOM WORKLIGHTS
SPLICE SP31
TO GROUND 0.75 mm² 601BF -P010
/20.C4 TO
-P064A
SPLICE SP6 REVERSE ALARM
DIODE -C009
2.00 mm² 942A 2.00 mm² 831J 9
-P024
FROM
/12.E6 FROM WORKLIGHTS
2 1 7 6 1.50 mm² 109RA FROM FUSE 21C No. PLATE LAMP
FROM IGNITION FUSE /3.B7 FROM 0.75 mm² 100D SPLICE SP23 1.50 mm² 807A FROM
/3.B5 P003:2
P001:2 / SP20 HEADLIGHTS
8 7 10 8 0.50 mm² 807 FROM 07/11 CONNECTOR 1 SC10-5
0.75 mm² 601BF 2.00 mm² 942D TO
/3.D6 TO FUSE 0.75 mm² 601RA FROM
/22.D3 P069:14 1.00 mm² 830E 1.00 mm² 601CF TO
/21.E1
FROM FUSE 28C /3.B5 FROM 2.00 mm² 307 P005:5 FROM ILLUMINATION /19.C4 FROM 1.00 mm² 829A
P003:16 SPLICE SP7
1 FROM ROADLIGHT RELAY
FROM FUSE 44E /3.D7 0.75 mm²FROM 830 FROM
/10.C1 P013:10
-P013 2
P005:8
2.00 mm² 942E TO
/3.D6 TO FUSE
ROADLIGHTS 3 2.00 mm² 942B -SP22 P005:7
C 9 4 FROM TOWING LINK
1.00 mm² 891 TO
/12.D3 TO FRONT WORKLIGHTS RELAY 1.00 mm² 830F FROM
/11.E6 C060:B C
6 7 5
FROM FUSE 29C /3.A5 FROM 2.00 mm² 306 2.00 mm² 828 P012:3
P003:18 6 -SP21
2.00 mm² 832 1.00 mm² 832B TO
/3.D6 TO FUSE
8 10
P005:9 -P041
IGNITION FUSE /3.A7 FROM 0.75 mm² 100C
P001:2 / SP20 LH HEADLIGHT
Dipped
2
TO REVERSE ALARM /10.C5 TO
1.00 mm² 601RA 1.50 mm² 834A
RELAY P010:10 Main

3 TO GROUND
1.00 mm² 601V 2.00 mm² 838C
TO GROUND/20.D4 TO
SPLICE SP61
6 2.00 mm² 601BZ
SPLICE SP29 Side TO
/20.B2
FROM ILLUMINATION /19.E4 1.00 mm² 829 4
FROM
-P038 SPLICE SP7 DI

COLUMN SWITCH R/H 5
TO L/H TURN SIGNAL DIODE /11.D6 FROM 2.00 mm² 805C
3/14 P031:1 / SP8 1
TWO SPEED
ONLY
2/14
-C005
RH HEADLIGHT
B FROM FUSE 30C /3.A5 FROM
2.00 mm² 304A 4/14
P003:20 9/14 2.00 mm² 833 TO
/3.D6 TO FUSE -P039 -C001 Dipped B
HEADLIGHT P005:1 FROM FUSE 41E 2
2.00 mm² 832A 8/14 1.50 mm² 834 1.50 mm² 834B D10/84 D10/84 1.50 mm² 834
P005:2 /3.D7
FROM
FLASHER
13/14 2.00 mm² 836 TO
/3.D6 TO FUSE FROM FUSE 42E
-SP18 Main
P005:3 2.00 mm² 838 2.00 mm² 838B A11/84 A11/84 2.00 mm² 838D 3
P005:4 /3.D7
FROM
-SP19 6 2.00 mm² 602E SC9-4

Side TO
/21.F2
L 10/14 FROM FUSE 44E /10.E5 1.00 mm² 830 1.00 mm² 830B 4
FROM
14/14 INDICATORS TO CENTER CLUSTER 0.50 mm² 838A C001:E2 -SC5

/9.B4 TO
DI
R 11/14 P040:2 TO R/H TURN SIGNAL DIODE /10.E5 FROM 2.00 mm² 806C 2.00 mm² 806D 5
C001:D3 -SC1 1
7/14
1/14 WIPER 12/14
WASHER 6/14
A
A
1 2 3 4 5 6 7 8
33 - 45 9813/9050-1 33 - 45
Page Page
33-46 33-47
Figure 892. (Part

1 1 of 2) 2 3 4
TO GROUND /20.C4 TO
F SPLICE SP6
-P023
FOG LIGHT SWITCH
8 7
FROM ILLUMINATION /19.D5 FROM 1.00 mm² 829AE 1.00 mm² 601DC FROM FUSE 08A /3.E5 FROM 1.00 mm²
SPLICE SP7 P001:16

FROM IGNITION FUSE /3.A6 FROM 0.75 mm²
P001:2 / SP20
2
FROM FUSE 45E /3.D7 FROM 1.00 mm² 905
3
P005:10 1.00 mm² 941
0.50 mm² 941A TO
P040:11
-P039 -C001
-C444 1.00 mm² 816 A7/84 A7/84
HORN 1.00 mm² 829A D11/84 D11/84
TO L/H TURN SIGNAL DIODE /11.D6 2.00 mm² 805D D4/84 D4/84
E
FROM
-C001 -P039 P031:1 / SP8 1.00 mm² 941 E5/84 C7/84

2.00 mm² 814 E9/84 E9/84 1.00 mm² 814 TO LH COLUMN SWITCH
FROM
/7.C2P037:8
2.00 mm² 600F TO GROUND

TO
/21.E4 SC11-4
-P039 -C001
E2/84 E2/84 1.00 mm² 830
TO R/H TURN SIGNAL DIODE /11.C6 FROM 2.00 mm² 806C D3/84 D3/84 2.00 mm² 806C
P032:1 / SP9
C7/84 E5/84
-P064B
DIODE
2 1 2.00 mm² 947B
2.00 mm² 942C FROM
/12.E6 FROM BOOM WORKLIGHTS
SPLICE SP31
TO GROUND 0.75 mm² 601BF -P010
/20.C4 TO
-P064A
SPLICE SP6 REVERSE ALARM
DIODE
2.00 mm² 942A 2.00 mm² 831J 9
/12.E6 FROM WORKLIGHTS
Page 33-47
-P024
FROM
2 1 7 6 1.50 mm² 109RA

FROM IGNITION FUSE /3.B7 FROM 0.75 mm² 100D SPLICE SP23 1.50 mm² 807A FROM
/3.B5
P001:2 / SP20 HEADLIGHTS
8 7 10 8 0.50 mm² 807
0.75 mm² 601BF 2.00 mm² 942D TO
/3.D6 TO FUSE 0.75 mm² 601RA FROM
/22.D3
FROM FUSE 28C /3.B5 FROM 2.00 mm² 307 P005:5 FROM ILLUMINATION /19.C4 1.00 mm² FROM 829A
P003:16 SPLICE SP7
1
FROM FUSE 44E /3.D7 0.75 mm² 830
FROM FROM
/10.C1
-P013 2
P005:8
2.00 mm² 942E TO
/3.D6 TO FUSE
ROADLIGHTS 3 2.00 mm² 942B -SP22 P005:7
C 9 4 1.00 mm² 891 TO
/12.D3 TO FRONT WORKLIGHTS RELAY
6 7 5
FROM FUSE 29C /3.A5 FROM 2.00 mm² 306 2.00 mm² 828 P012:3
P003:18 6 -SP21
2.00 mm² 832 1.00 mm² 832B TO
/3.D6 TO FUSE
8 10
IGNITION FUSE /3.A7 FROM 0.75 mm² 100C P005:9
P001:2 / SP20
TO REVERSE ALARM /10.C5 TO

1.00 mm² 601RA
RELAY P010:10
1.00 mm² 601V
TO GROUND/20.D4 TO
SPLICE SP29
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY
2/14
B FROM FUSE 30C /3.A5 FROM

2.00 mm² 304A 4/14
P003:20 9/14 2.00 mm² 833 TO
2.00 mm² 832A 8/14 HEADLIGHT P005:1 1.50 mm² 834
P005:2 /3.D7
FROM
FLASHER
13/14 2.00 mm² 836 TO
-SP18
P005:3 2.00 mm² 838
P005:4 /3.D7
FROM
-SP19
L 10/14
14/14 INDICATORS TO CENTER CLUSTER 0.50 mm² 838A
/9.B4 TO
R 11/14 P040:2 TO R/H TURN SIGNAL DIODE
7/14
1/14 WIPER 12/14
WASHER 6/14
1 2 3 4
33 - 46 9813/9050-1 33 - 46
Page Page
33-46 33-47
Figure 892. (Part

5 2 of 2) 6 7 8
-P011
BRAKE LIGHTS
4
-C443
REVERSE ALARM
F
1.00 mm² 816
1 2
FROM FUSE 08A /3.E5 FROM 1.00 mm² 108
P001:16
3 5
FROM IGNITION FUSE /3.A6 FROM 0.75 mm² 100J 0.75 mm² 616B TO
/22.E3 1.00 mm² 807C
1/2
P001:2 / SP20 P069:7
1.00 mm² 601CD
/21.E1 TO
2/2
SC10-3
TO CENTER CLUSTER
P040:11
-C019
LH REAR LAMP
-P039 -C001
A7/84 A7/84 1.50 mm² 816 -SC26 1.50 mm² 816B 1/6
D11/84 D11/84 1.00 mm² 829E 2/6
D4/84 D4/84 2.00 mm² 805 3/6
E5/84 C7/84 1.00 mm² 807 1.00 mm² 941B 4/6
1.00 mm² 807B 5/6
E
-SC24 2.00 mm² 603BR 6/6
/21.E5 TO
SC7-8
-C018
RH REAR LAMP
-C001
E2/84 1.00 mm² 830 TO SIDE LIGHTS
TO
/10.B5 SC5
D3/84 2.00 mm² 806C TO
/10.A5 TO RH INDICATOR 1.50 mm² 816A 1/6
SC1 1.00 mm² 830G 2/6
2.00 mm² 806F 3/6
E5/84 1.00 mm² 941 1.00 mm² 941A 4/6
-SC25 1.00 mm² 807A 5/6
2.00 mm² 601EC 6/6
/21.E1 TO
SC10-6
-C020
D
No. PLATE LAMP
1.00 mm² 830D 1.00 mm² 601CE SC10-4

TO
/21.E1
-P010
REVERSE ALARM
-C009
9
Page 33-46
7 6 1.50 mm² 109RA FROM FUSE 21C No. PLATE LAMP

FROM
/3.B5 P003:2
10 8 0.50 mm² 807 FROM 07/11 CONNECTOR 1 1.00 mm² 830E 1.00 mm² 601CF SC10-5
FROM
/22.D3 P069:14 TO
/21.E1
FROM ROADLIGHT RELAY

FROM
/10.C1 P013:10
1.00 mm² 830F

FROM TOWING LINK
/11.E6 C060:B C
FROM
-P041
LH HEADLIGHT
Dipped
1.50 mm² 834A 2
Main
3 TO GROUND
2.00 mm² 838C
6 SPLICE SP61
2.00 mm² 601BZ
Side TO
/20.B2
FROM ILLUMINATION /19.E4 1.00 mm² 829 4
FROM
SPLICE SP7 DI
TO L/H TURN SIGNAL DIODE /11.D6 2.00 mm² 805C 5
FROM
P031:1 / SP8 1
-C005
RH HEADLIGHT
-P039 -C001 Dipped B

1.50 mm² 834 1.50 mm² 834B D10/84 D10/84 1.50 mm² 834 2
-SP18 Main
2.00 mm² 838 2.00 mm² 838B A11/84 A11/84 2.00 mm² 838D 3
-SP19 6 2.00 mm² 602E SC9-4
Side TO
/21.F2
FROM FUSE 44E /10.E5 1.00 mm² 830 1.00 mm² 830B 4
FROM
0.50 mm² 838A C001:E2 -SC5 DI

TO R/H TURN SIGNAL DIODE /10.E5 2.00 mm² 806C 2.00 mm² 806D 5
FROM
C001:D3 -SC1 1
5 6 7 8
33 - 47 9813/9050-1 33 - 47
33 - 48 9813/9050-1 33 - 48
Page 33-50 Figure 893. Directional Indicators

1 2 3 4 5 6 7 8
F
F
-P016
TRAILER L/H DIRECTIONAL
4
-SP25 1 2 -SP37
FROM FUSE 48E /3.C7 FROM 1.50 mm² 275 1.00 mm² 275LH 1.00 mm² 805LB 0.75 mm² 805LC TO
/9.D3 TO INSTRUMENT CLUSTER J1
P005:16 P071:16
3 5 -C060
0.75 mm² 805E 0.75 mm² 601SY TO
/20.E4 TO GROUND TOWING LINK
SPLICE SP3 -P039 -C001
1.50 mm² 805LA E10/84 E11/84 1.00 mm² 806R A/3
TO FUSE 44E 1.00 mm² 830F B/3
E SC5-5 /10.C7
TO
1.50 mm² 806RA E11/84 E10/84 1.00 mm² 805L C/3

-P016
E
TRAILER R/H DIRECTIONAL
9
6 7
1.00 mm² 275RH 1.00 mm² 806RB 0.75 mm² 806RC TO
-SP36 P071:14
8 10
0.50 mm² 806D 0.75 mm² 601JB TO
/20.E4 TO GROUND
SPLICE SP3
TO GROUND 0.75 mm² 601AD

SPLICE SP11 /20.E6
TO
-SP49
D
1.00 mm² 804D D
-P020
HARZARD SWITCH
8 7 2.00 mm² 805C TO
/10.B6 TO L/H HEADLIGHTS
P041:5
-P031
L/H TURN SIGNAL DIODE
1 -SP8
2.00 mm² 804 2.00 mm² 805B 2.00 mm² 805D TO
/10.E4 FROM L/H TURN LIGHTS
2.00 mm² 804A 2 2 1 RL002:3 / P039:D4
3
4
-P032
FROM FUSE 34D /3.E7 5
FROM 1.00 mm² 300 R/H TURN SIGNAL DIODE
P004:8 6 -SP9
2.00 mm² 804C 2.00 mm² 806B 2.00 mm² 806C TO
2 1 RL003:3 / P039:D3
TO INSTRUMENT CLUSTER J1 0.75 mm² 509

C P071:13 /9.D3 TO
-P038 TO CENTER CLUSTER 0.50 mm² 804B

C
P040:3 /9.B4 TO
COLUMN SWITCH R/H

3/14
TWO SPEED
ONLY
2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14 FROM INSTRUMENT CLUSTER J2 /9.D5 FROM 2.00 mm² 805F
P072:10
FROM INSTRUMENT CLUSTER J2 /9.C5 FROM 2.00 mm² 806A
P072:20
L 10/14 0.75 mm² 800R
/9.E5 TO INSTRUMENT CLUSTER J2
FROM FUSE 10A
TO
1.00 mm² 104 14/14 INDICATORS P072:4

P001:20 /3.E5 FROM
R 11/14 0.75 mm² 800L TO

/9.C3 TO INSTRUMENT CLUSTER J1
P071:17
B
7/14 B
1/14 WIPER 12/14
WASHER 6/14
A
A
1 2 3 4 5 6 7 8
33 - 49 9813/9050-1 33 - 49
Page Page
33-50 33-51
Figure 893. (Part

1 1 of 2) 2 3 4
FROM FUSE 48E /3.C7 FROM 1.50 mm²

P005:16
TO GROUND 0.75 mm² 601AD

SPLICE SP11 /20.E6
TO
-SP49
D
1.00 mm² 804D
-P020
HARZARD SWITCH
8 7
-P031
1 2.00 mm² 804
2 2 1
Page 33-51
2.00 mm² 804A
3
4
-P032
FROM FUSE 34D /3.E7 5
FROM 1.00 mm² 300 R/H TURN SIGNAL DIODE
P004:8 6 2.00 mm² 804C
2 1
TO INSTRUMENT CLUSTER J1 0.75 mm² 509

C P071:13 /9.D3 TO
-P038 TO CENTER CLUSTER 0.50 mm² 804B

P040:3 /9.B4 TO
COLUMN SWITCH R/H

3/14
TWO SPEED
ONLY
2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14 FROM INSTRUMENT CLUSTER J2 /9.D5 FROM
P072:10
FROM INSTRUMENT CLUSTER J2 /9.C5 FROM
P072:20
L 10/14 0.75 mm² 800R
FROM FUSE 10A
TO
1.00 mm² 104 14/14 INDICATORS P072:4

P001:20 /3.E5 FROM
R 11/14 0.75 mm² 800L TO

P071:17
B
7/14
1/14 WIPER 12/14
WASHER 6/14
1 2 3 4
33 - 50 9813/9050-1 33 - 50
Page Page
33-50 33-51
Figure 893. (Part

5 2 of 2) 6 7 8
-P016
TRAILER L/H DIRECTIONAL
4
-SP25 1 2 -SP37
FROM FUSE 48E /3.C7 FROM 1.50 mm² 275 1.00 mm² 275LH 1.00 mm² 805LB 0.75 mm² 805LC TO
P005:16 P071:16
3 5 -C060
0.75 mm² 805E 0.75 mm² 601SY TO
/20.E4 TO GROUND TOWING LINK
SPLICE SP3 -P039 -C001
1.50 mm² 805LA E10/84 E11/84 1.00 mm² 806R A/3
TO FUSE 44E 1.00 mm² 830F B/3
SC5-5 /10.C7
TO
1.50 mm² 806RA E11/84 E10/84 1.00 mm² 805L C/3

-P016
E
TRAILER R/H DIRECTIONAL
9
6 7
1.00 mm² 275RH 1.00 mm² 806RB 0.75 mm² 806RC TO
-SP36 P071:14
8 10
0.50 mm² 806D 0.75 mm² 601JB TO
/20.E4 TO GROUND
SPLICE SP3
2.00 mm² 805C TO

P041:5
-P031
-SP8
2.00 mm² 805B 2.00 mm² 805D TO
2 1 RL002:3 / P039:D4
Page 33-50
-P032
R/H TURN SIGNAL DIODE
-SP9
2.00 mm² 806B 2.00 mm² 806C TO
2 1 RL003:3 / P039:D3
FROM INSTRUMENT CLUSTER J2 /9.D5 FROM 2.00 mm² 805F

P072:10
FROM INSTRUMENT CLUSTER J2 /9.C5 FROM 2.00 mm² 806A
P072:20
5 6 7 8
33 - 51 9813/9050-1 33 - 51
33 - 52 9813/9050-1 33 - 52
Page 33-54 Figure 894. Worklights 160/

1 2 3 4 5 6 7 8
-P026
WORKLIGHTS
FROM ILLUMINATION /19.C5 8 7
F
FROM 1.00 mm² 829J 1.00 mm² 601AC TO
/20.C4 TO GROUND
-P014 SPLICE SP7 SPLICE SP6
ENGINE RUNNING
F
4 1
TO GROUND 0.75 mm² 601LH 1 2 0.75 mm² 609LH 0.75 mm² 609LH 2
SPLICE SP3 /20.E4
TO
3 0.50 mm² 609AB 0.50 mm² 609AB TO CENTER CLUSTER

FROM ENGINE RUNNING
TO
/9.B4
1.00 mm² 407F 3 5 4 0.75 mm² 609AA P040:7
SPLICE SP14 /4.E5
FROM
0.75 mm² 609RH 5

6 0.50 mm² 609BC 0.50 mm² 609BC TO CENTER CLUSTER
TO
/9.B4
0.75 mm² 609BB P040:6
TO GROUND /20.E4 TO
0.75 mm² 601SH
SPLICE SP3 0.50 mm² 610AB

/9.B4 TO CENTER CLUSTER
-P029
TO
TO TRAILER SENSE RELAY /9.B1 TO

0.75 mm² 601TS P040:8
P014:6 BOOM WORKLIGHTS
FROM ILLUMINATION/19.B5 8 7
FROM 1.00 mm² 829AJ 1.00 mm² 601KA TO
/20.B4 TO GROUND
E 0.75 mm² 610 2

3 0.50 mm² 610AB
E
0.75 mm² 610A
FRONT WORK LIGHTS DIODE
REAR WORK LIGHTS DIODE

2.00 mm² 947B
/10.D3 TO BOOM WORKLIGHT DIODE
BOOM WORKLIGHT DIODE

TO
P064B:1
2
2.00 mm² 831J TO
/10.D3 TO WORKLIGHT DIODE
P064A:1
-P128
-P129
-P130
-P012 -WLF003
FRONT WORKLIGHTS LH FRONT WORKLIGHT
1
4
-P059A -WLF001 -WLF001
1 2 -SP23 1 2
FROM FUSE 17B /3.C5 FROM 2.00 mm² 308 2.00 mm² 831 2.00 mm² 831 2.00 mm² 831B 1/2 2/4 2.00 mm² RED 2.00 mm² BLACK 4/4 2/2 2.00 mm² 601BU TO
/20.B2 TO GROUND
P002:14 SPLICE SP61
FROM HEADLIGHT SWICH /10.C3 1.00 mm² 891 3 5 0.75 mm² 609A
FROM
P024:4 1.00 mm² 891A
D -WLF002
RH FRONT WORKLIGHT D
-P059B -WLF001 -WLF001
1 2
2.00 mm² 831K 1/2 1/4 2.00 mm² RED 2.00 mm² BLACK 3/4 2/2 2.00 mm² 601AL TO
/20.B1 TO GROUND
SPLICE SP61
-P012 -WLR003
REAR WORKLIGHTS LH REAR WORKLIGHT
9
-P049 -RC01 -RC05 -WLR001 -WLR001 -RC05
FROM FUSE 27C /3.B5 6 7 -SRC2 1 2
FROM 2.00 mm² 309 2.00 mm² 945 6/20 6/20 2.00 mm² 945 2.00 mm² 945A 1/2 1/2 1/2 2/2 2/2 2.00 mm² 601DG TO
/20.E1 TO GROUND
P003:14 SPLICE SCR6
1.00 mm² 891A 8 10 0.75 mm² 609B
1.00 mm² 891B
2.00 mm² 947B
-P011 -WLR004
BOOM WORK LIGHTS RH REAR WORKLIGHT
9
C -RC08 -WLR002 -WLR002 -RC08
FROM FUSE 20B /3.C5 6 7 1 2
FROM 2.00 mm² 312 2.00 mm² 947 2.00 mm² 945B 1/2 1/2 2/2 2/2 2.00 mm² 601KG TO
/20.E1 TO GROUND C
-P126 -P127 -P127 -P126 P002:20 -SP31 SPLICE SCR6
FROM IGNITION FUSE /3.B7 0.75 mm² 100QA 1/2 1/2 0.75 mm² LINK 2/2 2/2 1.00 mm² 100QB 8 10 1.00 mm² 610B
FROM
P001:2 / SP20 ITALIAN HEAD LIGHTS (DEL)

1.00 mm² 891B
-P039
2.00 mm² 946 A3/84
-P028
BEACON SWITCH
BEACON & INTERIOR LIGHT
FROM ILLUMINATION /19.C4 1.00 mm² 829U 8 7 1.00 mm² 601AY TO GROUND
FROM TO
/20.B4
SPLICE SP7 SPLICE SP6 BOOM WORKLIGHT
7219/0059 7219/0068 7212/0052
-P039 -C001 -C032 -B001 -B008
-RC07 1 2
B 2 BEACON SOCKET
2.00 mm² 947A A1/84 A1/84 2.00 mm² 947A 1/12 1/12 2.00 mm² 947A 1/2 2/2
FROM FUSE 18B /3.C5 FROM 1.00 mm² 310 -P049 -RC01 B
3 2 1
P002:16 1.00 mm² 844A 8/20 8/20 1.00 mm² 844A 2/2 1/2 1.00 mm² 601AX TO
/20.F1 TO GROUND 7219/0059 7219/0068
GND SPLICE SRC5 -C032 -B001
TO SPLICE SC7-9 /21.E5 TO
2.00 mm² 603GB 2/12 2/12 2.00 mm² 601GB
INTERIOR LIGHT
-P049 -RC01 -RC10 -RC11
2 1
FROM FUSE 19B /3.C7 FROM 1.00 mm² 301J 9/20 9/20 1.00 mm² 301J 1/1 1/1 1.00 mm² 601AV TO
/20.F1 TO GROUND
P002:18 / SP27 GND SPLICE SRC5
A
A
1 2 3 4 5 6 7 8
33 - 53 9813/9050-1 33 - 53
Page Page
33-54 33-55
Figure 894. (Part

1 1 of 2) 2 3 4
-P026
WORKLIGHTS
FROM ILLUMINATION /19.C5 8 7
F
FROM 1.00 mm² 829J 1.00 mm² 601AC TO
/20.C4 TO GROUND
-P014 SPLICE SP7 SPLICE SP6
ENGINE RUNNING
4 1
TO GROUND 0.75 mm² 601LH 1 2 0.75 mm² 609LH 0.75 mm² 609LH 2
SPLICE SP3 /20.E4
TO
3 0.50 mm² 609AB 0.50 mm² 609AB

FROM ENGINE RUNNING 3 5 4
1.00 mm² 407F 0.75 mm² 609AA
SPLICE SP14 /4.E5
FROM
0.75 mm² 609RH 5

6 0.50 mm² 609BC 0.50 mm² 609BC
0.75 mm² 609BB
TO GROUND /20.E4 TO
0.75 mm² 601SH
SPLICE SP3 0.50 mm² 610AB

-P029
TO TRAILER SENSE RELAY /9.B1 TO
0.75 mm² 601TS
P014:6 BOOM WORKLIGHTS
FROM ILLUMINATION/19.B5 8 7
FROM 1.00 mm² 829AJ 1.00 mm² 601KA TO
/20.B4 TO GROUND
E 0.75 mm² 610 2

3 0.50 mm² 610AB
0.75 mm² 610A
FRONT WORK LIGHTS DIODE
REAR WORK LIGHTS DIODE

2
2
-P128
-P129
-P130
-P012
FRONT WORKLIGHTS
1
4
FROM FUSE 17B /3.C5 2.00 mm² 308 1 2 2.00 mm² 831
FROM
P002:14
FROM HEADLIGHT SWICH /10.C3 1.00 mm² 891 3 5 0.75 mm² 609A
FROM
P024:4 1.00 mm² 891A
-P012
REAR WORKLIGHTS
Page 33-55
9
-P049 -RC01
FROM FUSE 27C /3.B5 FROM 2.00 mm² 309 6 7 2.00 mm² 945 6/20 6/20 2.00 mm² 945 -SRC2
P003:14
1.00 mm² 891A 8 10 0.75 mm² 609B
1.00 mm² 891B
2.00 mm² 947B

-P011
BOOM WORK LIGHTS
9
C FROM FUSE 20B /3.C5 FROM 2.00 mm² 312 6 7 2.00 mm² 947
-P126 -P127 -P127 -P126 P002:20 -SP31

FROM IGNITION FUSE /3.B7 0.75 mm² 100QA 1/2 1/2 0.75 mm² LINK 2/2 2/2 1.00 mm² 100QB 8 10 1.00 mm² 610B
FROM
P001:2 / SP20 ITALIAN HEAD LIGHTS (DEL)

1.00 mm² 891B
-P028
BEACON SWITCH
BEACON & INTERIOR LIGHT
FROM ILLUMINATION /19.C4 1.00 mm² 829U 8 7 1.00 mm² 601AY TO GROUND
FROM TO
/20.B4
-RC07
B 2 BEACON SOCKET
FROM FUSE 18B /3.C5 FROM 1.00 mm² 310 -P049 -RC01
3 2 1
P002:16 1.00 mm² 844A 8/20 8/20 1.00 mm² 844A 2/2 1/2 1.00 mm² 601AX TO
/20.F1 TO GROUND
GND SPLICE SRC5
INTERIOR LIGHT
-P049 -RC01 -RC10 -RC11
2 1
FROM FUSE 19B /3.C7 FROM 1.00 mm² 301J 9/20 9/20 1.00 mm² 301J 1/1 1/1 1.00 mm² 601AV TO
/20.F1 TO GROUND
P002:18 / SP27 GND SPLICE SRC5
1 2 3 4
33 - 54 9813/9050-1 33 - 54
Page Page
33-54 33-55
Figure 894. (Part

5 2 of 2) 6 7 8
0.50 mm² 609AB TO

P040:7
0.50 mm² 609BC TO

P040:6
0.50 mm² 610AB TO

P040:8
2.00 mm² 947B

/10.D3 TO BOOM WORKLIGHT DIODE
TO
P064B:1
2
2.00 mm² 831J TO

/10.D3 TO WORKLIGHT DIODE
P064A:1
-WLF003
LH FRONT WORKLIGHT
1
-P059A -WLF001 -WLF001

-SP23 1 2
2.00 mm² 831 2.00 mm² 831B 1/2 2/4 2.00 mm² RED 2.00 mm² BLACK 4/4 2/2 2.00 mm² 601BU TO
/20.B2 TO GROUND
SPLICE SP61
-WLF002
RH FRONT WORKLIGHT D
-P059B -WLF001 -WLF001
1 2
2.00 mm² 831K 1/2 1/4 2.00 mm² RED 2.00 mm² BLACK 3/4 2/2 2.00 mm² 601AL TO
/20.B1 TO GROUND
SPLICE SP61
-WLR003
LH REAR WORKLIGHT
Page 33-54
-P049 -RC01 -RC05 -WLR001 -WLR001 -RC05

-SRC2 1 2
6/20 6/20 2.00 mm² 945 2.00 mm² 945A 1/2 1/2 1/2 2/2 2/2 2.00 mm² 601DG TO
/20.E1 TO GROUND
SPLICE SCR6
-WLR004
RH REAR WORKLIGHT
-RC08 -WLR002 -WLR002 -RC08

1 2
2.00 mm² 945B 1/2 1/2 2/2 2/2 2.00 mm² 601KG TO
/20.E1 TO GROUND C
SPLICE SCR6
-P039
2.00 mm² 946 A3/84
BOOM WORKLIGHT
7219/0059 7219/0068 7212/0052
-P039 -C001 -C032 -B001 -B008
2.00 mm² 947A A1/84 A1/84 2.00 mm² 947A 1/12 1/12 2.00 mm² 947A 1/2 1 2 2/2
B
7219/0059 7219/0068
-C032 -B001
TO SPLICE SC7-9 /21.E5 TO
2.00 mm² 603GB 2/12 2/12 2.00 mm² 601GB
5 6 7 8
33 - 55 9813/9050-1 33 - 55
33 - 56 9813/9050-1 33 - 56
Page 33-58 Figure 895. Wiper Motors

1 2 3 4 5 6 7 8
F TO GROUND
SPLICE SP28 /20.B6
TO
F
-P021
ROOF WIPER
FROM ILLUMINATION 8 7
1.00 mm² 829M 1.00 mm² 601BH
SPLICE SP7 /19.C5
FROM
TO
/20.F1 TO SPLICE SRC5
GROUND
1 2.00 mm² 854
2 -RC09
2.00 mm² 849
3 2.00 mm² 133E ROOF WIPER
4 2.00 mm² 601AR 1
5
6 2.00 mm² 901 2.00 mm² 133F 3
-
w
-P049 -RC01
+
2.00 mm² 854 2/20 2/20 2.00 mm² 854 2.00 mm² 854 2
2.00 mm² 849 3/20 3/20 2.00 mm² 849 2.00 mm² 849 4
E 2.00 mm² 925 5/20 5/20 2.00 mm² 925
TO GROUND E
SPLICE SP28 /20.B6
TO
TO
/20.E1 TO SPLICE SRC5
-P022 GROUND
REAR WASH WIPE
FROM ILLUMINATION 8 7 -RC04
1.00 mm² 829AF 1.00 mm² 601DX
SPICE SP7 /19.C4
FROM
REAR WIPER
2.00 mm² 601AW 1
1 2.00 mm² 926 2.00 mm² 926 4/20 4/20 2.00 mm² 926
2.00 mm² 925 2 2.00 mm² 133B 1/20 1/20 2.00 mm² 133B 2.00 mm² 133D 3
-
3 -SP16 -SRC3
w
2.00 mm² 133C
4
+
5 2.00 mm² 926 2
6 2.00 mm² 901B 2.00 mm² 925 4
-SP17
TO FUSE 12B
D P002:4 /3.D5 2.00 mm² 133
D
FROM
-P053
WASHER PUMPS
2.00 mm² 901A 1/3

3/3 2.00 mm² 601JG TO
/20.C6 TO SPLICE SP62
1.50 mm² 839A 2/3 GROUND
-C169
WATER BOTTLE LVL
-C123 -P135
2/2 2/2 1.00 mm² 421WBL 1/6 2/6 1.00 mm² 421WBL TO
/5.D6 TO DAILY CHECKS
P137:7
-C123 -P135
C 1/2 1/2 1.00 mm² 100WBL 2/6 1/6 1.00 mm² 100WBL
/3.C3 FROM ADDITIONAL FUSE
C
FROM
P131:2 / SP66
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY 2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
-P055
B FRONT WIPER MOTOR
B
L 10/14 1.50 mm² 983 4/8 1/8 2.00 mm² 600P
/20.B1 TO SPLICE SP61
1.50 mm² 110D
TO
14/14 INDICATORS GROUND

R 11/14 1.50 mm² 982 3/8
7/14 1.50 mm² 840 2/8 6/8 1.50 mm² 110D

FROM FUSE 13B /3.D5 FROM 1.50 mm² 110 1.50 mm² 110E 1/14 WIPER 12/14 1.50 mm² 841 5/8
P002:6 -SP33
WASHER 6/14 1.50 mm² 839 1.50 mm² 839B 7/8
-SP32
A
A
1 2 3 4 5 6 7 8
33 - 57 9813/9050-1 33 - 57
Page Page
33-58 33-59
Figure 895. (Part

1 1 of 2) 2 3 4
F TO GROUND
SPLICE SP28 /20.B6
TO
-P021
ROOF WIPER
1.00 mm² 829M 1.00 mm² 601BH
SPLICE SP7 /19.C5
FROM
1 2.00 mm² 854

2.00 mm² 849 2
3 2.00 mm² 133E
4
5
6 2.00 mm² 901
-P049 -RC01
2.00 mm² 854 2/20 2/20 2.00 mm²
2.00 mm² 849 3/20 3/20 2.00 mm²
E 2.00 mm² 925 5/20 5/20 2.00 mm²
TO GROUND
SPLICE SP28 /20.B6
TO
-P022
REAR WASH WIPE
1.00 mm² 829AF 1.00 mm² 601DX
SPICE SP7 /19.C4
FROM
1 2.00 mm² 926 2.00 mm² 926 4/20 4/20 2.00 mm²
2.00 mm² 925 2 2.00 mm² 133B 1/20 1/20 2.00 mm²
3 2.00 mm² 133C -SP16
4
5
6 2.00 mm² 901B
-SP17
TO FUSE 12B
D P002:4 /3.D5 FROM 2.00 mm² 133
2.00 mm² 901A
1.50 mm² 839A
Page 33-59
C
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY 2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
B
L 10/14 1.50 mm² 983
1.50 mm² 110D
14/14 INDICATORS
R 11/14 1.50 mm² 982
7/14 1.50 mm² 840

FROM FUSE 13B /3.D5 FROM 1.50 mm² 110 1.50 mm² 110E 1/14 WIPER 12/14 1.50 mm² 841
P002:6 -SP33
WASHER 6/14 1.50 mm² 839 1.50 mm² 839B
-SP32
1 2 3 4
33 - 58 9813/9050-1 33 - 58
Page Page
33-58 33-59
Figure 895. (Part

5 2 of 2) 6 7 8
TO
/20.F1 TO SPLICE SRC5
GROUND
-RC09
ROOF WIPER
2.00 mm² 601AR 1
-
2.00 mm² 133F
w
-P049 -RC01 +
854 2/20 2/20 2.00 mm² 854 2.00 mm² 854 2
849 3/20 3/20 2.00 mm² 849 2.00 mm² 849 4
925 5/20 5/20 2.00 mm² 925

E
TO
/20.E1 TO SPLICE SRC5
GROUND
-RC04
REAR WIPER
2.00 mm² 601AW 1
926 4/20 4/20 2.00 mm² 926

1/20 1/20 3
-
133B 2.00 mm² 133B 2.00 mm² 133D

-SRC3
w
+
2.00 mm² 926 2
2.00 mm² 925 4
-P053 D
WASHER PUMPS
2.00 mm² 901A 1/3

3/3 2.00 mm² 601JG TO
/20.C6 TO SPLICE SP62
1.50 mm² 839A 2/3 GROUND
Page 33-58
-C169
WATER BOTTLE LVL
-C123 -P135
2/2 2/2 1.00 mm² 421WBL 1/6 2/6 1.00 mm² 421WBL TO
/5.D6 TO DAILY CHECKS
P137:7
-C123 -P135
1/2 1/2 1.00 mm² 100WBL 2/6 1/6 1.00 mm² 100WBL
/3.C3 FROM ADDITIONAL FUSE
C
FROM
P131:2 / SP66
-P055
FRONT WIPER MOTOR
B
4/8 1/8 2.00 mm² 600P TO
/20.B1 TO SPLICE SP61
GROUND
3/8
2/8 6/8 1.50 mm² 110D

5/8
1.50 mm² 839B 7/8

-SP32
5 6 7 8
33 - 59 9813/9050-1 33 - 59
33 - 60 9813/9050-1 33 - 60
Page 33-62 Figure 896. HVAC 160/B4268 Issue 2- Sheet 14 Page 33-63
1 2 3 4 5 6 7 8
F
-RC02 F
HEATED SEAT
-P049 -RC01
-SRC1
FROM FUSE 47E /3.C7 FROM
2.00 mm² 151 7/20 7/20 2.00 mm² 151 2.00 mm² 151B 1/2 2/2 2.00 mm² 601EF TO
/20.E1 TO GROUND
P005:14 SPLICE SRC5
-RC03
AIR SEAT
2.00 mm² 151A 1/2 2/2 2.00 mm² 601FK TO

/20.E1 TO GROUND
SPLICE SRC5
-P051 -P052
FACE FAN
M5 M6
2.00 mm² 151B 2.00 mm² 151B 1/1 1/1 1.00 mm² 601DD TO
/20.C6 TO GROUND
P005:14 SPLICE SP62
E
-P054 E
HEATED GLASS
FROM FUSE 03A /3.F5 FROM 2.00 mm² 150 1/2 1/2
P001:6
FROM ILLUMINATION /19.D4 FROM 1.00 mm² 829AN 2/2 2/2
SPLICE SP7
-P015
ROOF AC FANS
9
-P049
FROM FUSE 11B 2.00 mm² 116 6 7 2.00 mm² 2855 12/20
/3.D5 FROM
D P002:2
2.00 mm² 886B 8 10 1.00 mm² 601KP TO
/20.D4 TO GROUND
D
SPLICE SP29
-P015
AIR CON
-P049
4 2.00 mm² 2856 15/20
FROM FUSE 14B 1 2
2.00 mm² 997 2.00 mm² 883
P002:8 /3.D5 FROM
FROM INSTRUMENT CLUSTER J1 3 5

P071:3 /9.E3 FROM 1.00 mm² 884AC 1.00 mm² 601AC TO
/20.D4 TO GROUND
SPLICE SP29 -P039 -C001 -C002 -E009
C11/84 C11/84 2.00 mm² 886B 25/29 25/29 2.00 mm² E115A
-E025
-P018
C -P033
FREEZE VALVE BINARY SWITCH AC COMPRESSOR
HEATER CONNECTOR 2.00 mm² 883 9 C
FROM FUSE 07A -P039 -C001 -C002 -E009 -E024-1 -E024-2
6 7 1 2
P001:14 /3.E5 FROM 2.00 mm² 102 3/6 4/6 2.00 mm² 883A 2.00 mm² 883A 2.00 mm² 884A A12/84 A12/84 2.00 mm² 884 26/29 26/29 2.00 mm² E116 1/1 1/1 2.00 mm² E115B 2.00 mm² E115 1/2 2/2 1.50 mm² E601J TO
-SE03 SPLICE SE02
TO GROUND 8 10
SPLICE SP62 /20.C6
TO
2.00 mm² 600T 1/6 5/6 2.00 mm² 884 1.00 mm² 601FV TO
/20.D4 TO GROUND
SPLICE SP29
1.00 mm² 801 2/6 6/6
-P112
HEATER 100R
TO INSTRUMENT CLUSTER J2 1 2
P072:9 /9.D5 TO
1.00 mm² 801A 1.00 mm² 801B 1.00 mm² 601HT TO
/20.E6 TO GROUND
-SP50 SPLICE SP11
B
B
-P034
HEATER CONTROL
FROM ILLUMINATION /19.D4 FROM 1.00 mm² 829HC 2/6 5/6 1.00 mm² 610HV TO
SPLICE SP7 P071:15
3/6 1.00 mm² 887A TO
P072:5
4/6 1.00 mm² 997A
1/6 6/6 1.00 mm² 997B 1.00 mm² 997 TO
-SP5 P072:18
A
A
1 2 3 4 5 6 7 8
33 - 61 9813/9050-1 33 - 61
Page Page
33-62 33-63
Figure 896. (Part

1 1 of 2) 2 3 4
F
-RC02
HEATED SEAT
-P049 -RC01
-SRC1
2.00 mm² 151 7/20 7/20 2.00 mm² 151 2.00 mm² 151B 1/2
P005:14
-RC03
AIR SEAT
2.00 mm² 151A 1/2
-P051
FACE FAN
M5
2.00 mm² 151B 2.00 mm² 151B 1/1
P005:14
E
-P054
HEATED GLASS
FROM FUSE 03A /3.F5 FROM 2.00 mm² 150 1/2 1/2
P001:6
FROM ILLUMINATION /19.D4 FROM 1.00 mm² 829AN 2/2 2/2
SPLICE SP7
-P015
ROOF AC FANS
9
FROM FUSE 11B 2.00 mm² 116 6 7 2.00 mm² 2855

/3.D5 FROM
D P002:2
2.00 mm² 886B 8 10 1.00 mm² 601KP
-P015
AIR CON
-P049
4
Page 33-63
2.00 mm² 2856 15/20
FROM FUSE 14B 1 2
2.00 mm² 997 2.00 mm² 883
P002:8 /3.D5 FROM
FROM INSTRUMENT CLUSTER J1 3 5

P071:3 /9.E3 FROM 1.00 mm² 884AC 1.00 mm² 601AC TO
/20.D4 TO GROUND
SPLICE SP29 -P039 -C001 -C002 -E009
C11/84 C11/84 2.00 mm² 886B 25/29 25/29
-P018
C -P033
FREEZE VALVE
HEATER CONNECTOR 2.00 mm² 883 9
FROM FUSE 07A -P039 -C001 -C002 -E009
2.00 mm² 102 3/6 4/6 2.00 mm² 883A 2.00 mm² 883A 6 7 2.00 mm² 884A A12/84 A12/84 2.00 mm² 884 26/29 26/29
P001:14 /3.E5 FROM
TO GROUND 8 10
SPLICE SP62 /20.C6
TO
2.00 mm² 600T 1/6 5/6 2.00 mm² 884 1.00 mm² 601FV TO
/20.D4 TO GROUND
SPLICE SP29
1.00 mm² 801 2/6 6/6
-P112
HEATER 100R
TO INSTRUMENT CLUSTER J2 1 2
P072:9 /9.D5 TO
1.00 mm² 801A 1.00 mm² 801B 1.00 mm² 601HT TO
/20.E6 TO GROUND
-SP50 SPLICE SP11
-P034
HEATER CONTROL
FROM ILLUMINATION /19.D4 FROM 1.00 mm² 829HC 2/6 5/6 1.00 mm² 610HV TO
SPLICE SP7 P071:15
3/6 1.00 mm² 887A TO
P072:5
4/6 1.00 mm² 997A
1/6 6/6 1.00 mm² 997B 1.00 mm² 997 TO
-SP5 P072:18
1 2 3 4
33 - 62 9813/9050-1 33 - 62
Page Page
33-62 33-63
Figure 896. (Part

5 2 of 2) 6 7 8
-RC02 F
HEATED SEAT
1/2 2/2 2.00 mm² 601EF TO

/20.E1 TO GROUND
SPLICE SRC5
-RC03
AIR SEAT
1/2 2/2 2.00 mm² 601FK TO

/20.E1 TO GROUND
SPLICE SRC5
-P051 -P052
FACE FAN
M5 M6
/20.C6 TO GROUND
1/1 1/1 1.00 mm² 601DD TO
SPLICE SP62
-P054 E
HEATED GLASS
1/2 1/2
2/2 2/2
-P015
ROOF AC FANS
9
-P049
6 7 2.00 mm² 2855 12/20
8 10 1.00 mm² 601KP TO

/20.D4 TO GROUND
D
SPLICE SP29
Page 33-62
-C002 -E009
886B 25/29 25/29 2.00 mm² E115A
-E025
BINARY SWITCH AC COMPRESSOR
C
-C002 -E009 -E024-1 -E024-2
1 2
26/29 26/29 2.00 mm² E116 1/1 1/1 2.00 mm² E115B 2.00 mm² E115 1/2 2/2 1.50 mm² E601J TO
-SE03 SPLICE SE02
TO GROUND
SPLICE SP29
TO GROUND
SPLICE SP11
TO INSTRUMENT CLUSTER J1
P071:15
P072:5
P072:18
5 6 7 8
33 - 63 9813/9050-1 33 - 63
33 - 64 9813/9050-1 33 - 64
Page 33-66 Figure 897. In Cab Entertainment

1 2 3 4 5 6 7 8
F
F
-P058 -RH01 L/H SPEAKER

FROM FUSE 24C /3.B5 FROM 1.00 mm² 181 1/4 1/4 1.00 mm² 181 -RH04
P003:8 1.00 mm² 445 1/1 +
RADIO
FROM FUSE 19B /3.C7 1.00 mm² 301F 2/4 2/4 1.00 mm² 301F -RH05
E
FROM
P002:18 / SP27 -RH02 1.00 mm² 446 1/1 -

A2 MUTE A1
E
SPEED
SIGNAL
FROM ILLUMINATION /19.C5 FROM 1.00 mm² 829AM 3/4 3/4 1.00 mm² 829AM 1.00 mm² 301F A4 BATT + N/C A3
SPLICE SP7 1.00 mm² 829AM A6 ILLUM
AUTO
ANTENNA A5
TO GROUND /20.E4 TO
1.00 mm² 601RD 4/4 4/4 1.00 mm² 601AG 1.00 mm² 601AG A8 GND IGN A7 1.00 mm² 181
SPLICE SP3
-RH03 B2 RR(-) RR(+)
B1
1.00 mm² 448 B4 RF(-) RF(+)
B3 1.00 mm² 447
1.00 mm² 446 B6 LF(-) LF(+)
B 1.00 mm² 445
B8 LR(-) LR(+) B7 R/H SPEAKER

-RH06
1.00 mm² 447 1/1 +
-RH07
1.00 mm² 448 1/1 -
D
D
-RC17
SEAT PRESSURE SWITCH
4 4/6 1.00 mm² 847SS
C -P049 -RC01 Channel 1 (NC)
-SRC4 1 Supply 5
FROM FUSE 09A 1.00 mm² 107SP 14/20 14/20 1.00 mm² 107SS 1.00 mm² 107SA 1/6 5/6 1.00 mm² 846SS
/3.E5 C
FROM Channel 2 (NO)
(12Vdc)
P001:18 1.00 mm² 107SB 2/6 6 TO GROUND
6/6 1.00 mm² 601SP
1.00 mm² 107SC 3/6
GND TO
/20.F1 SPLICE SRC5
332/C8190 -P049 -RC01 332/C8203

TO 07/11 CONNECTOR 1 /22.D3 TO 1.00 mm² 846SS 20/20 20/20 1.00 mm² 846SS
P069:12 332/C8190 -P049 -RC01 332/C8203
P069:10
-P056
MOBILE PHONE
2 1
FROM FUSE 15B /3.D5 FROM 1.50 mm² 119 2/2 1.50 mm² 601AS TO
/20.B2 TO GROUND
1/2
P002:10 SPLICE SP61
B GND
B
FROM ILLUMINATION /19.D5 FROM 1.00 mm² 829AK
1/1
SPLICE SP7 -P057
-P065
AUXILLIARY CONNECTOR
FROM FUSE 03A /3.B5 FROM 1.00 mm² 121 1/2 2/2 1.00 mm² 601KC TO
/20.B6 TO GROUND
P001:6 SPLICE SP28
A
A
1 2 3 4 5 6 7 8
33 - 65 9813/9050-1 33 - 65
Page Page
33-66 33-67
Figure 897. (Part

1 1 of 2) 2 3 4
-P058 -RH01
FROM FUSE 24C /3.B5 FROM 1.00 mm² 181 1/4 1/4 1.00 mm² 181
P003:8 RADIO
FROM FUSE 19B /3.C7 1.00 mm² 301F 2/4 2/4 1.00 mm² 301F
E
FROM
P002:18 / SP27 -RH02 A2 MUTE SPEED

A1
SIGNAL
FROM ILLUMINATION /19.C5 FROM 1.00 mm² 829AM 3/4 3/4 1.00 mm² 829AM 1.00 mm² 301F A4 BATT + N/C A3
SPLICE SP7 1.00 mm² 829AM A6 ILLUM
AUTO
ANTENNA A5
TO GROUND /20.E4 TO
1.00 mm² 601RD 4/4 4/4 1.00 mm² 601AG 1.00 mm² 601AG A8 GND IGN A7 1.00 mm² 181
SPLICE SP3
-RH03 B2 RR(-) RR(+)
B1
1.00 mm² 448 B4 RF(-) RF(+)
B3 1.00 mm² 447
1.00 mm² 446 B6 LF(-) LF(+)
B 1.00 mm² 445
B8 LR(-) LR(+) B7
Page 33-67
-RC17
SEAT PRESSURE SWITCH
4 4/6 1.00 mm² 847SS
C -P049 -RC01 Channel 1 (NC)
-SRC4 1 Supply 5
FROM FUSE 09A /3.E5 FROM
1.00 mm² 107SP 14/20 14/20 1.00 mm² 107SS 1.00 mm² 107SA 1/6 Channel 2 (NO) 5/6 1.00 mm² 846SS
(12Vdc)
P001:18 1.00 mm² 107SB 2/6 6
GND 6/6 1.00 mm² 601SP
1.00 mm² 107SC 3/6
332/C8190 -P049 -RC01 332/C8203

P069:12 332/C8190 -P049 -RC01 332/C8203
P069:10
-P056
MOBILE PHONE
2 1
FROM FUSE 15B /3.D5 FROM 1.50 mm² 119 2/2 1.50 mm² 601AS
1/2
P002:10
B GND
FROM ILLUMINATION /19.D5 FROM 1.00 mm² 829AK

1/1
SPLICE SP7 -P057
-P065
FROM FUSE 03A /3.B5 FROM 1.00 mm² 121 1/2 2/2 1.00 mm² 601KC
P001:6
1 2 3 4
33 - 66 9813/9050-1 33 - 66
Page Page
33-66 33-67
Figure 897. (Part

5 2 of 2) 6 7 8
L/H SPEAKER
-RH04
1.00 mm² 445 1/1 +
-RH05
1.00 mm² 446 1/1 -
A1
E
A3
A5
A7 1.00 mm² 181
B1
B3 1.00 mm² 447
B 1.00 mm² 445
B7 R/H SPEAKER
-RH06
1.00 mm² 447 1/1 +
-RH07
1.00 mm² 448 1/1 -
D
Page 33-66
AT PRESSURE SWITCH
4/6 1.00 mm² 847SS

5/6 1.00 mm² 846SS
TO GROUND
C
6/6 1.00 mm² 601SP TO
/20.F1 SPLICE SRC5
1/2
1.50 mm² 601AS TO
/20.B2 TO GROUND
SPLICE SP61
B
1.00 mm² 601KC TO

/20.B6 TO GROUND
SPLICE SP28
5 6 7 8
33 - 67 9813/9050-1 33 - 67
33 - 68 9813/9050-1 33 - 68
Page 33-70 Figure 898. Reverse Fan 160/

1 2 3 4 5 6 7 8
F
F
-E012
REV FAN
-P039 -C001 -C002 -E009
TO INSTRUMENT CLUSTER J1/9.D3 FROM 1.00 mm² 1840 A10/84 A10/84 1.00 mm² 1840 19/29 19/29 1.00 mm² 1840 1/2 1/2
P071:12
TO CHASSIS GND /21.E1 TO 1.00 mm² 601AN 20/29 20/29 1.00 mm² 603T 2/2 2/2
SC10-2
E
E
TO GROUND /20.D6 TO
SPLICE SP11 -E013

PROPORTIONAL FAN
-P061 -P039 -C001 -C002 -E009
REVERSE FAN 1.00 mm² 592 F6/84 F6/84 1.00 mm² 592 21/29 21/29 1.00 mm² 592 1/2 1/2
/9.C5 FROM
FRON ILLUMINATION /19.D4 1.00 mm² 829AL 8 7 1.00 mm² 601AL

FROM
SPLICE SP7 TO CHASSIS GND 1.00 mm² 602C 22/29 22/29 1.00 mm² 615 2/2 2/2
SC9-3 /21.F2
FROM
FROM IGNITION FUSE 1.00 mm² 100P 2

/3.B7 FROM
P001:2 / SP20 3 1.00 mm² 1840D TO

4 P071:18
1.00 mm² 100 PA 5
6 1.00 mm² 1840C TO
/9.E5 TO INSTRUMENT CLUSTER J2 -C081
P072:6
TO SENSOR GND 3626 SPEED SENSOR
D 1.00 mm² 699M
SC16-4 /21.D1 D
TO
1 1/6 1.00 mm² 155B

FROM FUSE 40D
B+ (RED) FROM
/3.D8 SC6-3
2/6 2
GND (BLK)
TO 3626 J2 1.00 mm² 480A 3/6 3
C014-5 /23.F4
TO
OUT A (WHITE)
4 4/6 1.00 mm² 155C

FROM FUSE 40D
B+ (ORANGE) FROM
/3.D8 SC6-4
TO SENSOR GND 3626 1.00 mm² 699P 5/6 5
SC16-5 /21.D1
TO
GND (BROWN)
6/6 6
OUT B (YELLOW)
TO 3626 J1 /23.F2 FROM 1.00 mm² 480

C013-11
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 69 9813/9050-1 33 - 69
Page Page
33-70 33-71
Figure 898. (Part

1 1 of 2) 2 3 4
-P039
TO INSTRUMENT CLUSTER J1/9.D3 FROM 1.00 mm² 1840 A10/84
P071:12
TO CHASSIS GND /21.E1
SC10-2
E
TO GROUND /20.D6 TO
SPLICE SP11
-P061 -P039
REVERSE FAN 1.00 mm² 592 F6/84
/9.C5 FROM
FRON ILLUMINATION /19.D4 1.00 mm² 829AL 8 7 1.00 mm² 601AL

FROM
SPLICE SP7 TO CHASSIS GND

SC9-3 /21.F2
1
FROM IGNITION FUSE 1.00 mm² 100P 2

/3.B7 FROM
P001:2 / SP20 3 1.00 mm² 1840D TO

4 P071:18
1.00 mm² 100 PA 5
6 1.00 mm² 1840C TO
P072:6
TO SENSOR GND 3626
D
SC16-4 /21.D1
TO
TO 3626 J2
C014-5 /23.F4
TO
TO SENSOR GND 3626

SC16-5 /21.D1
TO
Page 33-71
TO 3626 J1 /23.F2 FROM
C013-11
1 2 3 4
33 - 70 9813/9050-1 33 - 70
Page Page
33-70 33-71
Figure 898. (Part

5 2 of 2) 6 7 8
-E012
REV FAN
-P039 -C001 -C002 -E009
1.00 mm² 1840 A10/84 A10/84 1.00 mm² 1840 19/29 19/29 1.00 mm² 1840 1/2 1/2
TO CHASSIS GND /21.E1 TO 1.00 mm² 601AN 20/29 20/29 1.00 mm² 603T 2/2 2/2
SC10-2
-E013
PROPORTIONAL FAN
-P039 -C001 -C002 -E009
1.00 mm² 592 F6/84 F6/84 1.00 mm² 592 21/29 21/29 1.00 mm² 592 1/2 1/2
TO CHASSIS GND 1.00 mm² 602C 22/29 22/29 1.00 mm² 615 2/2 2/2
SC9-3 /21.F2
FROM
-C081
1.00 mm² 699M SPEED SENSOR

/21.D1
D
TO
1 1/6 1.00 mm² 155B

FROM FUSE 40D
B+ (RED) FROM
/3.D8 SC6-3
2/6 2
GND (BLK)
1.00 mm² 480A 3/6 3
/23.F4 TO
OUT A (WHITE)
4 4/6 1.00 mm² 155C

FROM FUSE 40D
B+ (ORANGE) FROM
/3.D8 SC6-4
1.00 mm² 699P 5/6 5
/21.D1 TO
GND (BROWN)
6/6 6
OUT B (YELLOW)
Page 33-70
1.00 mm² 480

/23.F2 FROM
5 6 7 8
33 - 71 9813/9050-1 33 - 71
33 - 72 9813/9050-1 33 - 72
Page 33-74 Figure 899. CAN BUS Architecture

1 2 3 4 5 6 7 8
F
F
TO DAILY CHECKS
TO DAILY CHECKS
TO LIVE LINK
TO LIVE LINK
TO LIVE LINK
/29.E4 TO LLMI CAN
/29.E4 TO LLMI CAN
/29.D4 TO LLMI CAN

P042-B:C
P042-B:B
P042-B:A
P068:11
P068:1
P068:2
P071:8
P071:7
P071:9
P137:4
P137:3
/8.D2
/8.D2
/8.D2
/9.D3
/9.E3
/9.E3
/5.E6
/5.F6
VEHICLE BUS (250KB/S)
TO
TO
TO
TO
TO
TO
TO
TO
TO
TO
TO
0.50 mm² CAN 5 SCR
0.50 mm² CAN 7 SCR

0.50 mm² CAN 5 H
0.50 mm² CAN 7 H

0.50 mm² CAN 5 L
0.50 mm² CAN 7 L

-SCREEN 7
0.50 mm² CAN 10 SCR
0.50 mm² CAN 9 SCR

0.50 mm² CAN 10 H
0.50 mm² CAN 10 L
0.50 mm² CAN 9 H
0.50 mm² CAN 9 L

-C051
CAN TERMINATOR RES
CAN TERMINATOR
-P074 -P039 -C001
0.50 mm² CAN 12 H -SVMC01 0.50 mm² CAN 3 H 0.50 mm² CAN 4 H 0.50 mm² CAN 6 H 0.50 mm² CAN 8 H 0.50 mm² CAN 11 H G12/84 G12/84 0.50 mm² CAN HI -SVMC19 0.50 mm² CAN HI A/3 A/3
E A/3 -SVMC04 -SVMC07 -SVMC10 -SVMC13
C B A
B/3 0.50 mm² CAN 12 L -SVMC02 0.50 mm² CAN 3 L 0.50 mm² CAN 4 L 0.50 mm² CAN 6 L 0.50 mm² CAN 8 L 0.50 mm² CAN 11 L G11/84 G11/84 0.50 mm² CAN LO -SVMC20 0.50 mm² CAN LO B/3 B/3
E
C/3 -SVMC05 -SVMC08 -SVMC11 -SVMC14
0.50 mm² CAN 12 SCR -SVMC03 0.50 mm² CAN 3 SCR 0.50 mm² CAN 4 SCR 0.50 mm² CAN 6 SCR 0.50 mm² CAN 8 SCR 0.50 mm² CAN 11 SCR G10/84 G10/84 0.50 mm² CAN SCR -SVMC21 0.50 mm² CAN SCR C/3 C/3
-SVMC06 -SVMC09 -SVMC12 -SVMC15
TO 07/11 CONNECTOR 2 /22.D5 TO 0.50 mm² CAN 14 H

P070:10
FROM FUSE 19B /3.C7 FROM TO 07/11 CONNECTOR 2 /22.E5 TO 0.50 mm² CAN 14 L
P002:18 / SP27 P070:4
TO GROUND /20.D6 TO
-PC01-V 0.50 mm² CAN 14 SCR
SPLICE SP11 -SCREEN 8
1/2 0.50 mm² CAN 13 H 0.50 mm² CAN HI CAN HI C016-18
TO
/23.C2
-P073
CAN LO C016-12
DIAGNOSTIC CONNECTOR 2/2 0.50 mm² CAN 13 L 0.50 mm² CAN LO TO
/23.D2
D
A/9 1.00 mm² 601C 0.50 mm² CAN 13 SCR 0.50 mm² CAN SCR TO
C016-6
/23.D1
D
-SCREEN 1
B/9 1.00 mm² 301M
-P0D1
E/9 C/9 0.50 mm² CAN H 1/2 0.50 mm² CAN HI C016-17
TO
/23.C2
F/9 MATE TO PC01-V OR PC02-P
G/9 D/9 0.50 mm² CAN L 2/2 FOR CAN COMMUNICATION 0.50 mm² CAN LO C016-11
TO
/23.D2
H/9
J/9 0.50 mm² CAN SCR 0.50 mm² CAN SCR C016:5
TO
/23.D1
-SCREEN 4 -SCREEN 2
-PC02-P
1/2
2/2
C
-SCREEN 5
POWERTRAIN BUS (250KB/S) C
CHASSIS
0.50 mm² CAN SCR
2.00 mm² SCR

/20.B2 TO GROUND
0.50 mm² CAN H
0.50 mm² CAN L

TO
SPLICE SP61
CONNECTOR
-C002 -E009
-P039 -C001
-SPMC13 -SPMC04 -SPMC01 E004:27
G9/84 G9/84 13/29 13/29
TERMINATOR
-P125 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN HI 0.50 mm² CAN HI 0.50 mm² CAN HI 0.50 mm² CAN H 0.50 mm² CAN H TO
/5.D3
A/3 0.50 mm² CAN H -SPMC16 -SPMC01
C B A
-SPMC14 -SPMC05 -SPMC02 E004:23

B/3 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L G8/84 G8/84 0.50 mm² CAN LO 0.50 mm² CAN LO 0.50 mm² CAN LO 14/29 14/29 0.50 mm² CAN L 0.50 mm² CAN L TO
/5.D3
C/3 0.50 mm² SCR -SPMC17 -SPMC02
-SPMC15 -SPMC06 -SPMC03
0.50 mm² SCR 0.50 mm² SCR G7/84 G7/84 0.50 mm² CAN SCR 0.50 mm² CAN SCR 0.50 mm² CAN SCR 12/29 12/29 0.50 mm² SCR 0.50 mm² SCR
-SPMC18 -SPMC03 -SCREEN 1
0.50 mm² CAN H

0.50 mm² CAN L
0.50 mm² SCR
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
B -E010
A B C
B
-SCREEN 3 TERMINATOR RESISTOR

AFTER TREATMENT
TO
TO
-E010A
/8.B5
/8.B5
-C086 -C001
P066:10
P066:9
TO IMMOBILISER
TO IMMOBILISER
0.50 mm² CAN HI 9/20 9/20 0.50 mm² CAN H TO

/6.D6
P086:9
0.50 mm² CAN LO 10/20 10/20 0.50 mm² CAN L TO
/6.D6
P086:10
0.50 mm² CAN SCR 20/20 20/20 0.50 mm² SCREEN
-SCREEN 8
A
A
1 2 3 4 5 6 7 8
33 - 73 9813/9050-1 33 - 73
Page Page
33-74 33-75
Figure 899. (Part

1 1 of 2) 2 3 4
F
TO DAILY CHECKS
TO DAILY CHECKS
TO LIVE LINK
TO LIVE LINK
TO LIVE LINK
/29.E4 TO LLMI CAN

P042-B:A
P068:11
P068:1
P068:2
P071:8
P071:7
P071:9
P137:4
P137:3
/8.D2
/8.D2
/8.D2
/9.D3
/9.E3
/9.E3
/5.E6
/5.F6
TO
TO
TO
TO
TO
TO
TO
TO
TO
0.50 mm² CAN 5 SCR
0.50 mm² CAN 7 SCR

0.50 mm² CAN 5 H
0.50 mm² CAN 7 H

0.50 mm² CAN 5 L
0.50 mm² CAN 7 L

-SCREEN 7

0.50 mm² CAN 10 H
0.50 mm² CAN 10 L
0.50 mm² CAN 9 H

CAN TERMINATOR RES
-P074
0.50 mm² CAN 12 H -SVMC01 0.50 mm² CAN 3 H 0.50 mm² CAN 4 H 0.50 mm² CAN 6 H 0.50 mm² CAN 8 H
E A/3 -SVMC04 -SVMC07 -SVMC10 -SVMC13
C B A
B/3 0.50 mm² CAN 12 L -SVMC02 0.50 mm² CAN 3 L 0.50 mm² CAN 4 L 0.50 mm² CAN 6 L 0.50 mm² CAN 8 L
C/3 -SVMC05 -SVMC08 -SVMC11
0.50 mm² CAN 12 SCR -SVMC03 0.50 mm² CAN 3 SCR 0.50 mm² CAN 4 SCR 0.50 mm² CAN 6 SCR 0.50 mm² CAN 8 SCR
-SVMC06 -SVMC09 -SVMC12
TO 07/11 CONNECTOR 2 /22.D5 TO 0.50 mm² CAN 14 H

P070:10
FROM FUSE 19B /3.C7 FROM TO 07/11 CONNECTOR 2 /22.E5 TO 0.50 mm² CAN 14 L
P002:18 / SP27 P070:4
TO GROUND /20.D6 TO
-PC01-V 0.50 mm² CAN 14 SCR
SPLICE SP11 -SCREEN 8
1/2 0.50 mm² CAN 13 H
-P073
DIAGNOSTIC CONNECTOR 2/2 0.50 mm² CAN 13 L
D
A/9 1.00 mm² 601C 0.50 mm² CAN 13 SCR
-SCREEN 1
B/9 1.00 mm² 301M
-P0D1
E/9 C/9 0.50 mm² CAN H 1/2

F/9 MATE TO PC01-V OR PC02-P
G/9 D/9 0.50 mm² CAN L 2/2 FOR CAN COMMUNICATION
H/9
Page 33-75
J/9 0.50 mm² CAN SCR
-SCREEN 4 -SCREEN 2
-PC02-P
1/2
2/2
C
-SCREEN 5
CHASSIS
0.50 mm² CAN SCR
2.00 mm² SCR

/20.B2 TO GROUND
0.50 mm² CAN H
0.50 mm² CAN L
TO
SPLICE SP61
CONNECTOR
-P039 -C001
-SPMC13
G9/84 G9/84
TERMINATOR
-P125 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN HI
A/3 0.50 mm² CAN H -SPMC16
C B A
-SPMC14 -SPMC05
B/3 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L G8/84 G8/84 0.50 mm² CAN LO
C/3 0.50 mm² SCR -SPMC17
0.50 mm² SCR -SPMC15 0.50 mm² SCR G7/84 G7/84 0.50 mm² CAN SCR -SPMC06
-SPMC18
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
-SCREEN 3
TO
TO
/8.B5
/8.B5
P066:10
P066:9
TO IMMOBILISER
TO IMMOBILISER
1 2 3 4
33 - 74 9813/9050-1 33 - 74
Page Page
33-74 33-75
Figure 899. (Part5 2 of 2) 6 7 8
F
/29.E4 TO LLMI CAN
/29.E4 TO LLMI CAN
/29.D4 TO LLMI CAN

P042-B:C
P042-B:B
P042-B:A
P137:3
VEHICLE BUS (250KB/S)

TO
TO
TO
-SCREEN 7
0.50 mm² CAN 9 SCR

0.50 mm² CAN 9 H
0.50 mm² CAN 9 L
-C051
CAN TERMINATOR
-P039 -C001
0.50 mm² CAN 8 H 0.50 mm² CAN 11 H G12/84 G12/84 0.50 mm² CAN HI -SVMC19 0.50 mm² CAN HI A/3 A/3
-SVMC13
0.50 mm² CAN 8 L 0.50 mm² CAN 11 L G11/84 G11/84 0.50 mm² CAN LO -SVMC20 0.50 mm² CAN LO B/3 B/3
E
-SVMC11 -SVMC14
0.50 mm² CAN 8 SCR 0.50 mm² CAN 11 SCR G10/84 G10/84 0.50 mm² CAN SCR -SVMC21 0.50 mm² CAN SCR C/3 C/3
-SVMC12 -SVMC15
0.50 mm² CAN HI CAN HI C016-18

TO
/23.C2
0.50 mm² CAN LO CAN LO C016-12

TO
/23.D2
0.50 mm² CAN SCR TO

C016-6
/23.D1
D
0.50 mm² CAN HI C016-17

TO
/23.C2
0.50 mm² CAN LO C016-11

TO
/23.D2
Page 33-74
0.50 mm² CAN SCR C016:5

TO
/23.D1
POWERTRAIN BUS (250KB/S) C

-C002 -E009
0.50 mm² CAN HI -SPMC04 0.50 mm² CAN HI 0.50 mm² CAN HI 13/29 13/29 0.50 mm² CAN H -SPMC01 0.50 mm² CAN H E004:27
TO
/5.D3
-SPMC01
0.50 mm² CAN LO -SPMC05 0.50 mm² CAN LO 0.50 mm² CAN LO 14/29 14/29 0.50 mm² CAN L -SPMC02 0.50 mm² CAN L E004:23
TO
/5.D3
-SPMC02
-SPMC06 -SPMC03
0.50 mm² CAN SCR 0.50 mm² CAN SCR 0.50 mm² CAN SCR 12/29 12/29 0.50 mm² SCR 0.50 mm² SCR
-SPMC03 -SCREEN 1
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
-E010
A B C
B
TERMINATOR RESISTOR
AFTER TREATMENT -E010A
-C086 -C001
0.50 mm² CAN HI 9/20 9/20 0.50 mm² CAN H TO

/6.D6
P086:9
0.50 mm² CAN LO 10/20 10/20 0.50 mm² CAN L TO
/6.D6
P086:10
0.50 mm² CAN SCR 20/20 20/20 0.50 mm² SCREEN
-SCREEN 8
5 6 7 8
33 - 75 9813/9050-1 33 - 75
33 - 76 9813/9050-1 33 - 76
Page 33-78 Figure 900. CAN BUS Engine

1 2 3 4 5 6 7 8
F
F
TO NOx DOWNSTREAM/TAIL PIPE

E
E
E035:4
E035:3
E026:7
E026:6
E026:5
/6.D3
/6.D3
/6.D3
/6.E2
/6.E2
TO
TO
TO
TO
TO
-SCREEN 4
0.50 mm² CAN H
0.50 mm² CAN H

0.50 mm² CAN L
0.50 mm² CAN L

0.50 mm² SCR
0.50 mm² SCR
D TO ENGINE ECU /5.D3 TO 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H TO
/6.D2 TO NOx UPSTREAM ENG OUT
E004:45 -SDMC07 -SDMC01 E036:4 D
TO ENGINE ECU /5.D3 TO 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L TO
E004:50 -SDMC08 -SDMC02 E036:3
0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR
-SCREEN 2 -SDMC09 -SDMC03 -SCREEN 5
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
-SCREEN 3
TO
TO
TO ENGINE CONNECTOR /5.C5

E005:D
E005:C
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 77 9813/9050-1 33 - 77
Page Page
33-78 33-79
Figure 900. (Part

1 1 of 2) 2 3 4

E
E035:4
E035:3
E026:7
E026:6
E026:5
/6.D3
/6.D3
/6.D3
/6.E2
/6.E2
TO
TO
TO
TO
TO
-SCREEN 4
0.50 mm² CAN H
0.50 mm² CAN H

0.50 mm² CAN L
0.50 mm² CAN L

0.50 mm² SCR
0.50 mm² SCR

D TO ENGINE ECU /5.D3 TO 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H
E004:45 -SDMC07 -SDMC01

TO ENGINE ECU /5.D3 TO 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L
E004:50 -SDMC08 -SDMC02

0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR
-SCREEN 2 -SDMC09 -SDMC03 -SCREEN 5
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
Page 33-79
-SCREEN 3
TO
TO

E005:D
E005:C
1 2 3 4
33 - 78 9813/9050-1 33 - 78
Page Page
33-78 33-79
Figure 900. (Part

5 2 of 2) 6 7 8
0.50 mm² CAN H TO

E036:4 D
0.50 mm² CAN L TO
E036:3
0.50 mm² SCR
-SCREEN 5
Page 33-78
5 6 7 8
33 - 79 9813/9050-1 33 - 79
33 - 80 9813/9050-1 33 - 80
Page 33-82 Figure 901. Switch Illumination

1 2 3 4 5 6 7 8
F
F
E
E
1.00 mm² 829SW TO

/32.D2 TO SWAY SWITCH
P141:8
0.75 mm² 829Y
/32.F2
TO
TO JOYSTICK ISOLATION SW
P140:8
1.00 mm² 829 TO
??? / P041:4
1.00 mm² 829RH
/24.E3
TO
TO PIN LOCK SWITCH
P114:8
1.00 mm² 829AN TO
/14.E4 TO HEATED GLASS
P054:2
1.00 mm² 829X
/25.D3 TO FRONT/REAR AUX SWITCH
TO
P017:8
1.00 mm² 829AL TO
/16.E2 TO REVERSE FAN SWITCH
P061:8
D 1.00 mm² 829AB
D
TO
P071:1
1.00 mm² 829AH TO
/9.E7 TO INFO BUTTON
P063:8
1.00 mm² 829AK TO
/15.B3 TO MOBILE PHONE
P057:1
1.00 mm² 829HC TO
/14.B2 TO HEATER CONTROL
P034:2
1.00 mm² 829AE TO
P023:8
1.00 mm² 829AF TO
/13.E3 TO REAR WASH WIPE SW
P022:8
FROM FUSE 43E -SP7
1.50 mm² 829E 1.00 mm² 829M
/3.D7 FROM TO
/13.F3 TO ROOF WIPER SW
P005:6
P021:8
1.00 mm² 829A TO
P039:D11
1.00 mm² 829J TO
/12.F2 TO WORKLIGHTS SWITCH
C P026:8
1.00 mm² 829U TO
/12.B1 TO BEACON SWITCH C
P028:8
1.00 mm² 829AM TO
/15.E2 TO RADIO
P058:3
0.50 mm² 829WL TO
P040:1
1.00 mm² 829FD TO
/30.D2 TO FOOTBRAKE DUMP SW
P019:8
1.00 mm² 829V TO
P027:8
1.00 mm² 829AJ TO
/12.E2 TO BOOM WORKLIGHTS SWITCH
P029:8
1.00 mm² 829AR TO
/28.E3 TO SRS SWITCH
P062:8
1.00 mm² 829AX TO
/31.E5 TO STAB ISO SWITCH
P036:8
B
B
A
A
1 2 3 4 5 6 7 8
33 - 81 9813/9050-1 33 - 81
Page Page
33-82 33-83
Figure 901. (Part

1 1 of 2) 2 3 4
1.00 mm² 829SW TO

/32.D2
0.75 mm² 829Y
1.00 mm² 829 TO

/10.B6
1.00 mm² 829RH
1.00 mm² 829AN TO

P054:2
1.00 mm² 829X
1.00 mm² 829AL TO

P061:8
D 1.00 mm² 829AB
1.00 mm² 829AH TO

P063:8
1.00 mm² 829AK
1.00 mm² 829HC TO

P034:2
1.00 mm² 829AE
Page 33-83
1.00 mm² 829AF TO
P022:8
FROM FUSE 43E -SP7
1.50 mm² 829E 1.00 mm² 829M
/3.D7 FROM
P005:6
1.00 mm² 829A TO
P039:D11
1.00 mm² 829J
C 1.00 mm² 829U TO

/12.B1 TO BEACON SWITCH
P028:8
1.00 mm² 829AM
0.50 mm² 829WL TO

P040:1
1.00 mm² 829FD
1.00 mm² 829V TO

/22.B3 TO FOUR WHEEL DRIVE SWITC
P027:8
1.00 mm² 829AJ
1.00 mm² 829AR TO

P062:8
1.00 mm² 829AX
1 2 3 4
33 - 82 9813/9050-1 33 - 82
Page Page
33-82 33-83
Figure 901. (Part

5 2 of 2) 6 7 8
TO
/32.D2 TO SWAY SWITCH
P141:8
/32.F2
TO
TO JOYSTICK ISOLATION SW
P140:8
TO
??? / P041:4
/24.E3
TO
TO PIN LOCK SWITCH
P114:8
TO
P054:2
/25.D3 TO FRONT/REAR AUX SWITCH
TO
P017:8
TO
P061:8
D
TO
P071:1
TO
P063:8
TO
/15.B3 TO MOBILE PHONE
P057:1
TO
P034:2
Page 33-82
TO
P023:8
TO
P022:8
TO
/13.F3 TO ROOF WIPER SW
P021:8
TO
P039:D11
TO
/12.F2 TO WORKLIGHTS SWITCH
P026:8
TO
/12.B1 TO BEACON SWITCH C
P028:8
TO
/15.E2 TO RADIO
P058:3
TO
P040:1
TO
/30.D2 TO FOOTBRAKE DUMP SW
P019:8
TO
P027:8
TO
/12.E2 TO BOOM WORKLIGHTS SWITCH
P029:8
TO
P062:8
TO
/31.E5 TO STAB ISO SWITCH
P036:8
5 6 7 8
33 - 83 9813/9050-1 33 - 83
33 - 84 9813/9050-1 33 - 84
Page 33-86 Figure 902. Ground Panel

1 2 3 4 5 6 7 8
FROM IGNITION RELAY 1 /3.E2 0.75 mm² 601HB

F
FROM
P006:5
F
FROM IGNITION RELAY 2 /3.D2 FROM 0.75 mm² 601EK
FROM SEAT PRESSURE /15.C5 FROM 1.00 mm² 601SP P006:10

RC012:6 FROM IGNITION RELAY 4 /3.C2 FROM 0.75 mm² 601HK
FROM INTERIOR LIGHT /12.A4 FROM 1.00 mm² 601AV P007:10

RC011:1 FROM IGNITION RELAY 3 /3.D2 FROM 0.75 mm² 601HL
FROM BEACON /12.B4 FROM 1.00 mm² 601AX P007:5

RC007:2 FROM IGNITION RELAY 6 /3.A2 FROM 0.75 mm² 601X
FROM ROOF WIPER /13.F6 FROM 2.00 mm² 601AR 6.00 mm² 601RC1 P008:10
RC009:1 -SRC5 FROM IGNITION RELAY 5 /3.B2 FROM 0.75 mm² 601JJ
P008:5
-SP3
FROM IMMOBILISER RELAY /8.D4 FROM 1.00 mm² 601TS 3.00 mm² 601JC
P101:10
FROM ENGINE RUNNING RELAY /12.F1 FROM 0.75 mm² 601LH
FROM REAR WIPER /13.E6 FROM 2.00 mm² 601AW P014:1

RC004:1 FROM ENGINE RUNNING RELAY /12.F1 FROM 0.75 mm² 601SH
FROM AIR SEAT /14.F5 2.00 mm² 601FK P014:5

E
FROM
RC003:2 FROM RADIO /15.E2 1.00 mm² 601RD FROM STAB ISO SWITCH /31.E7 1.00 mm² 601DZ
E
FROM
FROM
FROM HEATED SEAT /14.F5 FROM 2.00 mm² 601EF P058:4 P036:7
RC002:2 FROM DAILY CHECKS /5.F5 FROM 1.00 mm² 600RDM FROM INSTRUMENT CLUSTER J2 /9.C5 FROM 1.00 mm² 601DE
FROM LH REAR WORKLIGHT /12.C7 FROM 2.00 mm² 601DG P137:2 P072:17
RC005:2 -RC06 FROM LIVE LINK RELAY /8.C1 FROM 1.00 mm² 601LL FROM HEATER RESISTOR /14.B4 FROM 1.00 mm² 601HT
FROM RH REAR WORKLIGHT /12.C7 FROM 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC P013:5 P112:2
RC008:2 -SRC6 -SRC7 M10 FROM TRAILER L/H DI RELAY /11.E6 FROM 0.75 mm² 601SY FROM HAZARD SWITCH /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
P016:5 P020:7 -SP11
FROM TRAILER R/H DI RELAY /11.E6 FROM 0.75 mm² 601JB FROM INFO BUTTON /9.F7 FROM 1.00 mm² 601HP
P016:10 P063:7
FROM JOYSTICK ISOLATION /32.F6 FROM 0.75 mm² 699CE FROM REVERSE FAN /16.E2 FROM 1.00 mm² 601AL
SPLICE SP43 P061:7
FROM STABILISER SWITCH /31.E7 FROM 1.00 mm² 699SK FROM DIAGNOSTIC CONNECTOR /17.D1 FROM 1.00 mm² 601C
SPLICE SP44 P073:A
FROM STEER MODE SWITCH /26.E2 FROM 1.00 mm² 699CH
P095:3
FROM STEER MODE SWITCH /26.D2 FROM 1.00 mm² 699SJ
D P095:6
FROM FOOTBRAKE RESISTOR /30.B4 FROM 0.75 mm² 699CB D
P091:2
FROM FOOTBRAKE RESISTOR /30.B4 -SP42 1.50 mm²
/21.C4 FROM 3626 SENSOR GROUND FROM FREEZE VALVE RELAY /14.C4
0.75 mm² 699CC 699CA FROM 1.00 mm² 601FV
-P030
FROM FROM
P092:2 SPLICE SC9 / P039:F7 P067:10

-SP29 -SP62 M10
FROM 2/4 WD 1K 8R /22.B7 FROM 0.75 mm² 699CD FROM RAC AC FANS RELAY /14.D5 FROM 1.00 mm² 601KP 3.00 mm² 601JH 10.00 mm² 600
P087:2 P015:10
FROM SRS /28.E5 FROM 1.00 mm² 699CG FROM ROAD LIGHT RELAY /10.C1 FROM 1.00 mm² 601V
SPLICE SP2 P013:10

FROM PARK BRAKE RES /27.D6 FROM 0.75 mm² 699CF FROM AC RELAY /14.C3 FROM 1.00 mm² 601AC
P111:2 P015:5 FROM 07/11 CONNECTOR 2 /22.C5 FROM

2.00 mm² 601TR
FROM PIN LOCK RESISTOR /24.E6 FROM 1.00 mm² 699PL P070:16
P114A:2 FROM WASHER PUMPS /13.D6 FROM 2.00 mm² 601JG
FROM SWAY SWITCH RESISTOR 1.00 mm² 699SL P053:3

/32.D5 FROM
P141A:2 FROM HEATER CONNECTOR /14.C1 FROM 2.00 mm² 600T
FROM SWAY SWITCH RESISTOR /32.D5 FROM 1.00 mm² 699SM P033:1
P141B:2 FROM SRS SWITCH /28.E5 FROM 1.00 mm² 601KK FROM FACE FAN /14.E5 FROM 1.00 mm² 601DD
FROM SWAY SWITCH RESISTOR 1.00 mm² 699SO P062:7 P052:1

C /32.D5 FROM
P141C:2 FROM CENTER CLUSTER /9.A4 0.50 mm² 601P FROM PURGE HOLD INHIBIT RELAY /6.F1 1.00 mm² 600ISO
C
FROM FROM
P40:10 P013:5
FROM IMMOBILISER /8.B7 FROM 1.00 mm² Y
P066:11
FROM HEADLIGHT SWITCH /10.D1 FROM 0.75 mm² 601BF
P024:7
-SP6
FROM FOG LIGHT SWITCH /10.F3 FROM 1.00 mm² 601DC 2.00 mm² 601JD
P023:7
FROM WORKLIGHT SWITCH /12.F3 FROM 1.00 mm² 601AC FROM PIN LOCK SWITCH /24.E4 FROM 1.00 mm² 601RH
P026:7 P114:7
TO L/H HEADLIGHT /10.B8 FROM
2.00 mm² 601BZ FROM BEACON SWITCH /12.B2 FROM 1.00 mm² 601AY FROM FRONT/REAR AUX SWITCH /25.D4 FROM 1.00 mm² 601BB
??? / P041:6 P028:7 P017:7
FROM 07/11 CONNECTOR 2 /22.D5 FROM
1.50 mm² 606TR FROM FOOTBRAKE DUMP SW /30.D4 FROM 0.75 mm² 601FD TO ROOF WIPER SW /13.F3 FROM 1.00 mm² 601BH
P070:15 P019:7 P021:7
FROM MOBILE PHONE /15.B5 FROM 1.50 mm² 601AS FROM BOOM WORKLIGHTS SWITCH /12.E3 FROM 1.00 mm² 601KA TO REAR WASH WIPE SW /13.E3 FROM 1.00 mm² 601DX 2.00 mm² 601JF
P056:2 -P035 P029:7 P022:7 -SP28

FROM FRONT WIPER MOTOR /13.B6 -SP61 FROM SWAY SWITCH /32.E2 1.00 mm² 601SW
FROM 2.00 mm² 600P 10.00 mm² 600 FROM
FROM AUXILLIARY CONNECTOR /15.A5 FROM 1.00 mm² 601KC
P055:1 M10 P141:7
B P065:2
FROM LH FROM WORKLIGHT /12.D7 FROM 2.00 mm² 601BU FROM FOUR WHEEL DRIVE SWITCH /22.C3 FROM 1.00 mm² 601N B
P130:3 P027:7
FROM RH FRONT WORKLIGHT /12.D7 FROM 2.00 mm² 601AL FROM LLMI /29.E4 FROM 0.75 mm² 601AK
P130:4 P042-A
FROM PWR CAN SCR /17.C3 FROM
2.00 mm² SCR FROM JOYSTICK ISOLATION SW /32.F2 FROM 1.00 mm² 601EN
SPMC12 P140:7
A
A
1 2 3 4 5 6 7 8
33 - 85 9813/9050-1 33 - 85
Page Page
33-86 33-87
Figure 902. (Part

1 1 of 2) 2 3 4
FROM IGNITION RELAY 1 /3.E2 0.75 mm² 601HB

F
FROM
P006:5
FROM IGNITION RELAY 2 /3.D2 FROM 0.75 mm² 601EK
FROM SEAT PRESSURE /15.C5 FROM 1.00 mm² 601SP P006:10

RC012:6 FROM IGNITION RELAY 4 /3.C2 FROM 0.75 mm² 601HK
FROM INTERIOR LIGHT /12.A4 FROM 1.00 mm² 601AV P007:10

RC011:1 FROM IGNITION RELAY 3 /3.D2 FROM 0.75 mm² 601HL
FROM BEACON /12.B4 FROM 1.00 mm² 601AX P007:5

RC007:2 FROM IGNITION RELAY 6 /3.A2 FROM 0.75 mm² 601X
FROM ROOF WIPER /13.F6 FROM 2.00 mm² 601AR 6.00 mm² 601RC1 P008:10
RC009:1 -SRC5 FROM IGNITION RELAY 5 /3.B2 FROM 0.75 mm² 601JJ
P008:5
FROM IMMOBILISER RELAY /8.D4 FROM 1.00 mm² 601TS
P101:10
FROM ENGINE RUNNING RELAY /12.F1 FROM 0.75 mm² 601LH
FROM REAR WIPER /13.E6 FROM 2.00 mm² 601AW P014:1

RC004:1 FROM ENGINE RUNNING RELAY /12.F1 FROM 0.75 mm² 601SH
FROM AIR SEAT /14.F5 2.00 mm² 601FK P014:5

E
FROM
RC003:2 FROM RADIO /15.E2 FROM 1.00 mm² 601RD
FROM HEATED SEAT /14.F5 FROM 2.00 mm² 601EF P058:4

RC002:2 FROM DAILY CHECKS /5.F5 FROM 1.00 mm² 600RDM
FROM LH REAR WORKLIGHT /12.C7 FROM 2.00 mm² 601DG P137:2

RC005:2 -RC06 FROM LIVE LINK RELAY /8.C1 FROM 1.00 mm² 601LL
FROM RH REAR WORKLIGHT /12.C7 FROM 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC P013:5
RC008:2 -SRC6 -SRC7 M10 FROM TRAILER L/H DI RELAY /11.E6 FROM 0.75 mm² 601SY
P016:5
FROM TRAILER R/H DI RELAY /11.E6 FROM 0.75 mm² 601JB
P016:10
FROM JOYSTICK ISOLATION /32.F6 FROM 0.75 mm² 699CE
SPLICE SP43
FROM STABILISER SWITCH /31.E7 FROM 1.00 mm² 699SK
SPLICE SP44
FROM STEER MODE SWITCH /26.E2 FROM 1.00 mm² 699CH
P095:3
FROM STEER MODE SWITCH /26.D2 FROM 1.00 mm² 699SJ
D P095:6
FROM FOOTBRAKE RESISTOR /30.B4 FROM 0.75 mm² 699CB
P091:2
FROM FOOTBRAKE RESISTOR /30.B4 -SP42 1.50 mm²
/21.C4 FROM 3626 SENSOR GROUND FROM FREEZE VALVE RELAY /14.C4
FROM 0.75 mm² 699CC 699CA FROM
FROM 1.00 mm² 601FV
P092:2 SPLICE SC9 / P039:F7 P067:10

FROM 2/4 WD 1K 8R /22.B7 FROM 0.75 mm² 699CD FROM RAC AC FANS RELAY /14.D5 FROM 1.00 mm² 601KP
P087:2 P015:10
FROM SRS /28.E5 FROM 1.00 mm² 699CG FROM ROAD LIGHT RELAY /10.C1 FROM 1.00 mm² 601V
SPLICE SP2 P013:10
Page 33-87
FROM PARK BRAKE RES /27.D6 FROM 0.75 mm² 699CF FROM AC RELAY /14.C3 FROM 1.00 mm² 601AC
P111:2 P015:5
FROM PIN LOCK RESISTOR /24.E6 FROM 1.00 mm² 699PL
P114A:2
FROM SWAY SWITCH RESISTOR /32.D5 FROM 1.00 mm² 699SL
P141A:2
FROM SWAY SWITCH RESISTOR /32.D5 FROM 1.00 mm² 699SM
P141B:2 FROM SRS SWITCH /28.E5 FROM 1.00 mm² 601KK
FROM SWAY SWITCH RESISTOR 1.00 mm² 699SO P062:7

C /32.D5 FROM
P141C:2 FROM CENTER CLUSTER /9.A4 FROM 0.50 mm² 601P
P40:10
FROM IMMOBILISER /8.B7 FROM 1.00 mm² Y
P066:11
FROM HEADLIGHT SWITCH /10.D1 FROM 0.75 mm² 601BF
P024:7
FROM FOG LIGHT SWITCH /10.F3 FROM 1.00 mm² 601DC
P023:7
FROM WORKLIGHT SWITCH /12.F3 FROM 1.00 mm² 601AC
P026:7
TO L/H HEADLIGHT /10.B8 FROM
2.00 mm² 601BZ FROM BEACON SWITCH /12.B2 FROM 1.00 mm² 601AY
??? / P041:6 P028:7

FROM 07/11 CONNECTOR 2 /22.D5 FROM
1.50 mm² 606TR FROM FOOTBRAKE DUMP SW /30.D4 FROM 0.75 mm² 601FD
P070:15 P019:7
FROM MOBILE PHONE /15.B5 FROM 1.50 mm² 601AS FROM BOOM WORKLIGHTS SWITCH /12.E3 FROM 1.00 mm² 601KA
P056:2 -P035 P029:7

FROM FRONT WIPER MOTOR /13.B6 FROM 2.00 mm² 600P -SP61 10.00 mm² 600 FROM SWAY SWITCH /32.E2 FROM 1.00 mm² 601SW
P055:1 M10 P141:7

B
FROM LH FROM WORKLIGHT /12.D7 FROM 2.00 mm² 601BU
P130:3
FROM RH FRONT WORKLIGHT /12.D7 FROM 2.00 mm² 601AL
P130:4
FROM PWR CAN SCR /17.C3 FROM
2.00 mm² SCR
SPMC12
1 2 3 4
33 - 86 9813/9050-1 33 - 86
Page Page
33-86 33-87
Figure 902. (Part

5 2 of 2) 6 7 8
0.75 mm² 601HB
F
0.75 mm² 601EK
0.75 mm² 601HK
0.75 mm² 601HL
0.75 mm² 601X
0.75 mm² 601JJ
1.00 mm² 601TS -SP3 3.00 mm² 601JC
0.75 mm² 601LH
0.75 mm² 601SH
1.00 mm² 601RD FROM STAB ISO SWITCH /31.E7 1.00 mm² 601DZ
E
FROM
P036:7
1.00 mm² 600RDM FROM INSTRUMENT CLUSTER J2 /9.C5 FROM 1.00 mm² 601DE
P072:17
1.00 mm² 601LL FROM HEATER RESISTOR /14.B4 FROM 1.00 mm² 601HT
P112:2
0.75 mm² 601SY FROM HAZARD SWITCH /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
P020:7 -SP11
0.75 mm² 601JB FROM INFO BUTTON /9.F7 FROM 1.00 mm² 601HP
P063:7
FROM REVERSE FAN /16.E2 FROM 1.00 mm² 601AL
P061:7
FROM DIAGNOSTIC CONNECTOR /17.D1 FROM 1.00 mm² 601C
P073:A
D
1.00 mm² 601FV
-P030
1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600
M10
1.00 mm² 601V

Page 33-86
1.00 mm² 601AC
FROM 07/11 CONNECTOR 2 /22.C5 FROM

2.00 mm² 601TR
P070:16
FROM WASHER PUMPS /13.D6 FROM 2.00 mm² 601JG
P053:3
FROM HEATER CONNECTOR /14.C1 FROM 2.00 mm² 600T
P033:1
1.00 mm² 601KK FROM FACE FAN /14.E5 FROM 1.00 mm² 601DD
P052:1
0.50 mm² 601P FROM PURGE HOLD INHIBIT RELAY /6.F1 1.00 mm² 600ISO
C
FROM
P013:5
1.00 mm² Y
0.75 mm² 601BF
1.00 mm² 601DC -SP6 2.00 mm² 601JD
1.00 mm² 601AC FROM PIN LOCK SWITCH /24.E4 FROM 1.00 mm² 601RH
P114:7
1.00 mm² 601AY FROM FRONT/REAR AUX SWITCH /25.D4 FROM 1.00 mm² 601BB
P017:7
0.75 mm² 601FD TO ROOF WIPER SW /13.F3 FROM 1.00 mm² 601BH
P021:7
1.00 mm² 601KA 2.00 mm² 601JF
TO REAR WASH WIPE SW /13.E3 FROM 1.00 mm² 601DX
P022:7 -SP28
1.00 mm² 601SW FROM AUXILLIARY CONNECTOR /15.A5 FROM 1.00 mm² 601KC
P065:2
FROM FOUR WHEEL DRIVE SWITCH /22.C3 FROM 1.00 mm² 601N B
P027:7
FROM LLMI /29.E4 FROM 0.75 mm² 601AK
P042-A
FROM JOYSTICK ISOLATION SW /32.F2 FROM 1.00 mm² 601EN
P140:7
5 6 7 8
33 - 87 9813/9050-1 33 - 87
33 - 88 9813/9050-1 33 - 88
Page 33-90 Figure 903. Ground Chassis

1 2 3 4 5 6 7 8
F
F
C006-L 1.00 mm² 602G

/7.D2 FROM
C005-6 2.00 mm² 602E

/10.B8 FROM
1.00 mm² 602H

/26.B6 TO
C026-2 1.00 mm² 603BK FROM

/32.B2
1.00 mm² 602C C063-4
/16.E5 TO
C002-22 1.00 mm² 603LM FROM

/29.E4
1.00 mm² 602B C025-6
/26.B6 TO
C026-5 M10
10.00 mm² 600 1.00 mm² 603RS
-C010 FROM
/26.C6
1.00 mm² 602SS C024-5
/5.D7 TO
C002-16 -SC9 8.00 mm² 602 1.00 mm² 603A

-SC11 FROM
/26.C6
C024-2
6.00 mm² 601 -SC7
4.00 mm² 603 2.00 mm² 603BR
/10.E6
E
FROM
C020-2 C019-6
/10.D8 FROM 1.00 mm² 601CE
-SC10
4.00 mm² 601
1.00 mm² 603E
E
TO
/7.B5
C009-2 1.00 mm² 601CF C035-A
/10.C8 FROM
1.00 mm² 603LMI

2.00 mm² 600F FROM
/10.E2 TO
/29.F3
C002-20 1.00 mm² 601AN C058-2 C025-1
/16.E5 FROM
1.00 mm² 600FB 2.00 mm² 603GB

TO
/30.F2 FROM
/12.B6
C021-2 C002-3 4.00 mm² 601G C027-1 C064-2
/10.F6 FROM 1.00 mm² 601CD /21.D7 FROM
1.00 mm² 603P FROM

/31.F6
C018-6 C017-12 1.00 mm² 601H C065-2
/10.D6 FROM 2.00 mm² 601EC /23.D5 FROM
C013-12 1.00 mm² 601A -SC4

/23.F2 FROM
C014-11 1.00 mm² 601B

/23.F5 FROM
E004:58 1.50 mm² E600A

/5.B3 FROM
C014-12 1.00 mm² 601C

/23.F5 FROM
E004:59 1.50 mm² E600B

/5.B3 FROM
C015-11 1.00 mm² 601D

/23.F7 FROM
E004:61
D /5.B3 FROM 1.50 mm² E600C
C015-12
/23.F7 1.00 mm² 601G -E009 -C002 D
E004:62 -SE01
FROM
1.50 mm² E600D 4.00 mm² E600 3/29 3/29 601G 4.00 mm²
/5.B3 FROM TO
/21.E3
C002-17 2.00 mm² 601F SC4-8
/21.C7 FROM
E036:2
C045-2 0.50 mm² 6302A
FROM BOOM HARNESS /29.C7 FROM 1.00 mm² 699BB /6.E2 FROM
C440E-4 1.00 mm² 6300F

/6.D5 FROM
E035:2
C081-5 0.50 mm² 6302C
/16.D4 FROM 1.00 mm² 699P /6.E2 FROM
C081-2 E036:5 0.50 mm² 6302B

/16.D4 FROM 1.00 mm² 699M /6.D2 FROM
C062-4 1.00 mm² 604C

/31.C2 FROM
-C001 -P039
C017-7 1.50 mm² 699 -SC16 1.50 mm² 699SG F7/84 F7/84 1.50 mm² 699CA
/23.C4 FROM TO
/20.D3
C023-3 0.75 mm² 699V
/29.B2 FROM
C023-6 0.75 mm² 699W

/29.A2 FROM
C C052-3 0.75 mm² 699S

/29.B5 C
FROM
C052-6 0.75 mm² 699T

/29.A5 FROM
E005:B 1.00 mm² E601E

/5.C5 FROM
E005:F 1.00 mm² E601D

/5.B5 FROM
-E009 -C002
C072-5 E002:C -SE02 SC4-7
1.00 mm² E601B 2.00 mm² E601 17/29 17/29 601F 2.00 mm²
/31.D3 FROM 0.75 mm² 609M /5.C5 FROM TO
/21.D3
C072-2 E003:2 1.50 mm² E601F

/31.D2 FROM 0.75 mm² 609L /4.C7 FROM
C071-5 E025:2 1.50 mm² E601J

/31.E3 FROM 0.75 mm² 609K /14.C7 FROM
C071-2 E006:2 0.50 mm² E601K

/31.E2 FROM 0.75 mm² 609J /5.B7 FROM
C070-5 0.75 mm² 609H

/31.F3 FROM
B -SC21 0.75 mm² 609SP
B
C067-2 0.75 mm² 609A
/31.B6 FROM
C067-5 0.75 mm² 609B

/31.B6 FROM
C068-2 0.75 mm² 609C

/31.B4 FROM
C068-5 0.75 mm² 609D

/31.B4 FROM
C069-2 0.75 mm² 609E

/31.B2 FROM
C069-5 0.75 mm² 609F

/31.B2 FROM
C070-2 0.75 mm² 609G

/31.F2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 89 9813/9050-1 33 - 89
Page Page
33-90 33-91
Figure 903. (Part

1 1 of 2) 2 3 4
C006-L 1.00 mm² 602G

/7.D2 FROM
C005-6 2.00 mm² 602E

/10.B8 FROM
1.00 mm² 602H

/26.B6 TO
C026-2
1.00 mm² 602C
/16.E5 TO
C002-22
1.00 mm² 602B
/26.B6 TO
C026-5 M10
10.00 mm² 600
-C010
1.00 mm² 602SS
/5.D7 TO
C002-16 -SC9 8.00 mm² 602

-SC11
6.00 mm² 601 -SC7
4.00 mm² 603
E C020-2 1.00 mm² 601CE 4.00 mm² 601
/10.D8 FROM
-SC10
C009-2 1.00 mm² 601CF
/10.C8 FROM
2.00 mm² 600F FROM

/10.E2
C002-20 1.00 mm² 601AN C058-2
/16.E5 FROM
1.00 mm² 600FB TO

/30.F2
C021-2 C002-3 4.00 mm² 601G C027-1
/10.F6 FROM 1.00 mm² 601CD /21.D7 FROM
C018-6 C017-12 1.00 mm² 601H

/10.D6 FROM 2.00 mm² 601EC /23.D5 FROM
C013-12 1.00 mm² 601A -SC4

/23.F2 FROM
C014-11 1.00 mm² 601B

/23.F5 FROM
E004:58
/5.B3
C014-12 1.00 mm² 601C
/23.F5 FROM
E004:59
/5.B3
C015-11 1.00 mm² 601D
/23.F7 FROM
E004:61
D /5.B3
C015-12 1.00 mm² 601G
/23.F7 FROM
E004:62
/5.B3
C002-17 2.00 mm² 601F
/21.C7 FROM
E036:2
C045-2
FROM BOOM HARNESS /29.C7 FROM 1.00 mm² 699BB /6.E2
C440E-4 1.00 mm² 6300F
/6.D5 FROM
E035:2
C081-5
/16.D4 FROM 1.00 mm² 699P /6.E2
C081-2 E036:5
/16.D4 1.00 mm² 699M /6.D2
Page 33-91
FROM
C062-4 1.00 mm² 604C

/31.C2 FROM
-C001 -P039
C017-7 1.50 mm² 699 -SC16 1.50 mm² 699SG F7/84 F7/84 1.50 mm² 699CA
/23.C4 FROM TO
/20.D3
C023-3 0.75 mm² 699V
/29.B2 FROM
C023-6 0.75 mm² 699W

/29.A2 FROM
C C052-3 0.75 mm² 699S

/29.B5 FROM
C052-6 0.75 mm² 699T

/29.A5 FROM
E005:B
/5.C5 FROM
E005:F
/5.B5 FROM
C072-5 E002:C
/31.D3 FROM 0.75 mm² 609M /5.C5 FROM
C072-2 E003:2
/31.D2 FROM 0.75 mm² 609L /4.C7 FROM
C071-5 E025:2
/31.E3 FROM 0.75 mm² 609K /14.C7 FROM
C071-2 E006:2
/31.E2 FROM 0.75 mm² 609J /5.B7 FROM
C070-5 0.75 mm² 609H

/31.F3 FROM
B -SC21 0.75 mm² 609SP
C067-2 0.75 mm² 609A

/31.B6 FROM
C067-5 0.75 mm² 609B

/31.B6 FROM
C068-2 0.75 mm² 609C

/31.B4 FROM
C068-5 0.75 mm² 609D

/31.B4 FROM
C069-2 0.75 mm² 609E

/31.B2 FROM
C069-5 0.75 mm² 609F

/31.B2 FROM
C070-2 0.75 mm² 609G

/31.F2 FROM
1 2 3 4
33 - 90 9813/9050-1 33 - 90
Page Page
33-90 33-91
Figure 903. (Part

5 2 of 2) 6 7 8
1.00 mm² 603BK FROM

/32.B2
C063-4
1.00 mm² 603LM FROM
/29.E4
C025-6
1.00 mm² 603RS FROM
/26.C6
C024-5
1.00 mm² 603A FROM
/26.C6
C024-2
-SC7
4.00 mm² 603 2.00 mm² 603BR FROM
/10.E6
C019-6
1.00 mm² 603E
E
TO
/7.B5
C035-A
1.00 mm² 603LMI
FROM
/10.E2 TO
/29.F3
C058-2 C025-1
600FB 2.00 mm² 603GB
TO
/30.F2 FROM
/12.B6
C027-1 C064-2
1.00 mm² 603P FROM
/31.F6
C065-2
E004:58 1.50 mm² E600A

/5.B3 FROM
E004:59 1.50 mm² E600B

/5.B3 FROM
E004:61 1.50 mm² E600C

/5.B3 FROM
-E009 -C002 D
E004:62 1.50 mm² E600D -SE01 4.00 mm² E600 3/29 3/29 601G 4.00 mm²
/5.B3 FROM TO
/21.E3
SC4-8
E036:2 0.50 mm² 6302A
/6.E2 FROM
E035:2 0.50 mm² 6302C

/6.E2 FROM
E036:5 0.50 mm² 6302B

/6.D2 FROM
Page 33-90
C
E005:B 1.00 mm² E601E
/5.C5 FROM
E005:F 1.00 mm² E601D

/5.B5 FROM
-E009 -C002
E002:C -SE02 SC4-7
1.00 mm² E601B 2.00 mm² E601 17/29 17/29 601F 2.00 mm²
/5.C5 FROM TO
/21.D3
E003:2 1.50 mm² E601F
/4.C7 FROM
E025:2 1.50 mm² E601J

/14.C7 FROM
E006:2 0.50 mm² E601K

/5.B7 FROM
5 6 7 8
33 - 91 9813/9050-1 33 - 91
33 - 92 9813/9050-1 33 - 92
Page 33-94 Figure 904. Transmission ECU

1 2 3 4 5 6 7 8
F
F
-P069 -P070
07/11 CONNECTOR 07/11 CONNECTOR
TO TRANS SOLENOID GROUND /7.F5 TO 1.50 mm² 630 1/18 1/18 1.00 mm² 100TR FROM
/3.E7 FROM FUSE 36D
ST2 / P039:G4 P004:12
FROM NEUTRAL START RELAY /4.E1 FROM 1.00 mm² 601NS 2/18 2/18
E P010:5
FROM COLUMN SWITCH L/H /7.B4 FROM 1.00 mm² 414 3/18 3/18 E
SPLICE SP24
TO TRANS OIL TEMP /7.A4 FROM 1.00 mm² 100TT 4/18 4/18 0.50 mm² CAN 14 L FROM
/17.D4 FROM CAN L
E011:1 / P039:72 SVMC11
TO FORWARD HIGH SOLENOID /7.F2 TO 1.00 mm² 859 5/18 5/18
T009:1 / T002:1
TO FORWARD LOW SOLENOID /7.F2 TO 1.00 mm² 812 6/18 6/18
T008:1 / T007:1
FROM BRAKE LIGHT RELAY /10.F6 FROM 0.75 mm² 616B 7/18 7/18
P011:5
TO FOOTBRAKE DUMP SW /30.D2 TO 0.75 mm² 699G 8/18 8/18 1.00 mm² 688A FROM
/7.A2 FROM 1ST&2ND GEAR PULL DOWN
P019:2 P107:2
FROM FOOTBRAKE TRANSDUCER /30.F5 FROM 0.75 mm² 468 9/18 9/18 1.00 mm² 688E FROM
/7.A2 FROM 3RD&4TH GEAR PULL DOWN
C027:4 / P039:F3 P108:2
FROM SEAT PRESSURE SWITCH /15.C2 FROM 1.00 mm² 847SS 10/18 10/18 0.50 mm² CAN 14 H FROM
/17.E4 FROM CAN H 0.75 mm² 688C FROM
/7.A4 FROM TEMPERATURE SENDER
RC012:4 / P049:19 SVMC10 P039:E1
D FROM COLUMN SWITCH L/H /7.B4 FROM 1.00 mm² 415 11/18 11/18 1.00 mm² 688 0.75 mm² 688D FROM
/30.D4 FROM FOOTBRAKE DUMP SW
SPLICE SP34 -SP41 P019:1 D
FROM SEAT PRESSURE SWITCH /15.C2 -SP38
FROM 1.00 mm² 846SS 12/18 12/18 1.00 mm² 300TRA 300TR 1.50 mm² FROM
/3.C5 FROM FUSE 32D
RC012:5 / P049:20 P004:4
FROM SHAFT RETURN /7.E2 FROM 1.00 mm² 620 13/18 13/18
SPLICE ST1 / P039:G3
TO REVERSE ALARM RELAY /10.C5 TO
0.50 mm² 807 14/18 14/18 1.00 mm² 864TD TO
/7.B7 P039:B8
P010:8
TO LAYSHAFT SOLENOID /7.E2 TO 1.00 mm² 857 15/18 15/18 1.50 mm² 606TR TO
/20.B1 TO GROUND
T007:1 / T009:1 SPLICE SP61
TO MAINSHAFT SOLENOID /7.E2 TO 1.50 mm² 858 16/18 16/18 2.00 mm² 601TR TO
/20.C6 TO GROUND
T006:1 / T010:1 SPLICE SP62
TO REVERSE LOW SOLENOID /7.E2 TO 1.00 mm² 860 17/18 17/18 1.00 mm² 300TRB
T004:1 / T008:1
TO REVERSE HIGH SOLENOID /7.E2 TO 1.00 mm² 811 18/18 18/18 1.00 mm² 300TRC
T005:1 / T003 /22.C4 /22.C3
C
C
TO GROUND /20.B6 TO
SPLICE SP28
-P027
FOUR WHEEL DRIVE
8 7
FROM ILLUMINATION /19.C4 FROM 1.00 mm² 829V 1.00 mm² 601N
SPLICE SP7
-P088
2/4 WD 5K 6R
1 0.75 mm² 818B 1 2 0.75 mm² 818D
2
FROM IGNITION FUSE /3.A6 FROM 0.75 mm² 100M
3
B P001:2 / SP20
4
-P089 -P087
B
0.75 mm² 100MA 5
2/4 WD 33K 2/4 WD 1K 8R
6 1 2 -SP12 0.75 mm² 1 2
0.75 mm² 818C 0.75 mm² 818E 818G 0.75 mm² 699CD TO
/20.D2 TO 3626 SENSOR GROUND
SPLICE SP42
-C001 -P039
1.00 mm² 818 F2/84 F2/84 0.75 mm² 818
/23.F5 TO
A
A
1 2 3 4 5 6 7 8
33 - 93 9813/9050-1 33 - 93
Page Page
33-94 33-95
Figure 904. (Part

1 1 of 2) 2 3 4
-P069 -P070
07/11 CONNECTOR 07/11 CONNECTOR
TO TRANS SOLENOID GROUND /7.F5 TO 1.50 mm² 630 1/18 1/18 1.00 mm² 100TR
ST2 / P039:G4
FROM NEUTRAL START RELAY /4.E1 FROM 1.00 mm² 601NS 2/18 2/18
E P010:5
FROM COLUMN SWITCH L/H /7.B4 FROM 1.00 mm² 414 3/18 3/18
SPLICE SP24
TO TRANS OIL TEMP /7.A4 FROM 1.00 mm² 100TT 4/18 4/18 0.50 mm² CAN 14 L
E011:1 / P039:72
TO FORWARD HIGH SOLENOID /7.F2 TO 1.00 mm² 859 5/18 5/18
T009:1 / T002:1
TO FORWARD LOW SOLENOID /7.F2 TO 1.00 mm² 812 6/18 6/18
T008:1 / T007:1
FROM BRAKE LIGHT RELAY /10.F6 FROM 0.75 mm² 616B 7/18 7/18
P011:5
TO FOOTBRAKE DUMP SW /30.D2 TO 0.75 mm² 699G 8/18 8/18
P019:2
FROM FOOTBRAKE TRANSDUCER /30.F5 FROM 0.75 mm² 468 9/18 9/18
C027:4 / P039:F3
FROM SEAT PRESSURE SWITCH /15.C2 FROM 1.00 mm² 847SS 10/18 10/18 0.50 mm² CAN 14 H
RC012:4 / P049:19
D FROM COLUMN SWITCH L/H /7.B4 FROM 1.00 mm² 415 11/18 11/18 1.00 mm²
SPLICE SP34
FROM SEAT PRESSURE SWITCH /15.C2 FROM 1.00 mm² 846SS 12/18 12/18 1.00 mm²
RC012:5 / P049:20
FROM SHAFT RETURN /7.E2 FROM 1.00 mm² 620 13/18 13/18
SPLICE ST1 / P039:G3
0.50 mm² 807 14/18 14/18 1.00 mm²
TO REVERSE ALARM RELAY /10.C5 TO
P010:8
TO LAYSHAFT SOLENOID /7.E2 TO 1.00 mm² 857 15/18 15/18 1.50 mm² 606TR
Page 33-95
T007:1 / T009:1
TO MAINSHAFT SOLENOID /7.E2 TO 1.50 mm² 858 16/18 16/18 2.00 mm² 601TR
T006:1 / T010:1
TO REVERSE LOW SOLENOID /7.E2 TO 1.00 mm² 860 17/18 17/18 1.00 mm²
T004:1 / T008:1
TO REVERSE HIGH SOLENOID /7.E2 TO 1.00 mm² 811 18/18 18/18 1.00 mm²
T005:1 / T003 /22.C4 /22.C3
TO GROUND /20.B6 TO
SPLICE SP28
-P027
FOUR WHEEL DRIVE
8 7
FROM ILLUMINATION /19.C4 FROM 1.00 mm² 829V
SPLICE SP7
1
2
FROM IGNITION FUSE /3.A6 FROM 0.75 mm² 100M
3
B P001:2 / SP20
4
0.75 mm² 100MA 5

6
1.00 mm² 818

/23.F5 TO
1 2 3 4
33 - 94 9813/9050-1 33 - 94
Page Page
33-94 33-95
Figure 904. (Part

5 2 of 2) 6 7 8
-P070
07/11 CONNECTOR
1/18 1.00 mm² 100TR FROM

/3.E7 FROM FUSE 36D
P004:12
2/18
3/18 E
4/18 0.50 mm² CAN 14 L FROM

/17.D4 FROM CAN L
SVMC11
5/18
6/18
7/18
8/18 1.00 mm² 688A FROM

/7.A2 FROM 1ST&2ND GEAR PULL DOWN
P107:2
9/18 1.00 mm² 688E FROM
/7.A2 FROM 3RD&4TH GEAR PULL DOWN
P108:2
10/18 0.50 mm² CAN 14 H FROM
/17.E4 FROM CAN H 0.75 mm² 688C FROM
/7.A4 FROM TEMPERATURE SENDER
SVMC10 P039:E1
11/18 1.00 mm² 688 0.75 mm² 688D FROM
/30.D4 FROM FOOTBRAKE DUMP SW
-SP41 P019:1 D
-SP38
12/18 1.00 mm² 300TRA 300TR 1.50 mm² FROM
/3.C5 FROM FUSE 32D
P004:4
13/18
14/18 1.00 mm² 864TD TO

/7.B7 P039:B8
15/18 1.50 mm² 606TR TO

/20.B1 TO GROUND
Page 33-94
SPLICE SP61
16/18 2.00 mm² 601TR TO
/20.C6 TO GROUND
SPLICE SP62
17/18 1.00 mm² 300TRB
18/18 1.00 mm² 300TRC

/22.C3
-P027
FOUR WHEEL DRIVE
829V 8 7 1.00 mm² 601N
-P088
2/4 WD 5K 6R
1 0.75 mm² 818B 1 2 0.75 mm² 818D
100M 2
3
4
-P089 -P087
B
0.75 mm² 100MA 5
2/4 WD 33K 2/4 WD 1K 8R
6 1 2 -SP12 0.75 mm² 1 2
0.75 mm² 818C 0.75 mm² 818E 818G 0.75 mm² 699CD TO
SPLICE SP42
-C001 -P039
1.00 mm² 818 F2/84 F2/84 0.75 mm² 818
/23.F5 TO
5 6 7 8
33 - 95 9813/9050-1 33 - 95
33 - 96 9813/9050-1 33 - 96
Page 33-98 Figure 905. Hydraulic ECU

1 2 3 4 5 6 7 8
-C014 -C015
-C013 3626 J2 3626 J3
F
3626 J1 F
1.00 mm² 824A 1/18 10/18 1.00 mm² 818 C001:F2 1.00 mm² 850E 1/18 10/18 1.00 mm² 481 C062-3
/26.D1 TO FROM
/22.A4 /32.B2 TO TO
/31.C2
1.00 mm² 203A 1/18 10/18 1.00 mm² 410 C062-1 C031-1 C063-3
TO
/31.C2
1.00 mm² 848 2/18 11/18 1.00 mm² 601B SC4-2 11/18 1.00 mm² 601D SC4-4
/26.C1 TO TO
/21.D3 TO
/21.D3
1.00 mm² 203B 2/18 11/18 1.00 mm² 480 C081-5 C029-1
TO
/16.D4
C052-2 0.75 mm² 475 3/18 12/18 1.00 mm² 601C SC4-3 0.75 mm² 489 3/18 12/18 1.00 mm² 601G SC4-5
/29.B5 FROM TO
/21.D3 /31.F3 TO TO
/21.D3
1.00 mm² 203C 3/18 12/18 1.00 mm² 601A SC4-1 C070-6
TO
/21.D3
C052-5 0.75 mm² 476 4/18 13/18 1.00 mm² 826A C030-1 0.75 mm² 484 4/18 13/18 1.00 mm² 145TS C001:F1
/29.B5 FROM TO
/26.C1 /31.B4 TO TO
/33.D2
0.75 mm² 449 4/18 13/18 1.00 mm² 932D C063-2 C068-3
/29.B2 TO TO
/32.B2
C023/5 C081-3 1.00 mm² 480A 5/18 0.75 mm² 485 5/18 14/18
-C001 /16.D4 FROM
/31.B4 TO
14/18 1.00 mm² 438 A2/84 C068-6

-C001 -P039
0.75 mm² 416RR 6/18 15/18 1.00 mm² 492 C072-3 15/18 1.00 mm² 551SW C1/84 C1/84 1.00 mm² 551SW P141:2
-C001 -P039 /7.B4 TO TO
/31.D2 TO
/32.D2
1.00 mm² 481 6/18 15/18 1.00 mm² 876 C2/84 C2/84 0.75 mm² 876 SP1 C041-2
FROM
/30.B3 -C001 -P039
1.00 mm² 825 7/18 16/18 0.75 mm² 490 C071-3 1.00 mm² 819B 7/18 16/18 1.00 mm² 485D F11/84 F11/84 0.75 mm² 485D P036:2
/26.C1 TO TO
/31.E2 /26.B6 TO TO
/31.E4
1.00 mm² 203D 7/18 16/18 1.00 mm² 439 C025-5 C028-1 C026-6
FROM
/29.F4
0.75 mm² 493 8/18 17/18 0.75 mm² 491 C071-6 1.00 mm² 820B 8/18 17/18 1.00 mm² 603A SC29-3
-C076 /31.D3 /31.E3 /26.C6 /26.C3
E
TO TO TO TO
PROPORTIONAL SOL 1.00 mm² 203E 8/18 17/18 0.75 mm² 416NN C040-2 C072-6 C024-6
/7.B4 E
TO
0.75 mm² 448 9/18 18/18 18/18 1.00 mm² 650 C006-M
/29.B2 TO TO
/7.D2
1.00 mm² 203G 9/18 18/18 0.75 mm² 416FF C039-2 C023-2
TO
/7.B4
2/2
-C066
STABILISER ISO VALVE
1/2
-P039 -C001 1.00 mm² 600BJ 2/2 1/2 1.00 mm² 910
P004:2
/3.F7 FROM 2.00 mm² 203 C8/84 C8/84 1.00 mm² 203 -SC14
-C016 -C017
3626 J4 3626 J5
-C001 -P039
1.00 mm² 480 1/18 10/18 1.00 mm² 888C G6/84 G6/84 1.00 mm² 888C P095:5
FROM
/26.D4
D
2/18 11/18 0.50 mm² CAN LO FROM
/17.D7 11/18 0.75 mm² 482 TO
C067-3
/31.B6
D
SPMC02
C067-6 SC4-6
12/18 0.50 mm² CAN LO 0.75 mm² 483 3/18 12/18 1.00 mm² 601H
FROM
/17.D7 /31.B6 TO TO
/21.E3
SVMC20
-P039 -C001
13/18 1.00 mm² 931D C063-1 SP45 0.75 mm² 875 C12/84 C12/84 1.00 mm² 875 4/18 13/18 1.50 mm² 818A C006-K
TO
/32.C2 /27.D5 FROM TO
/7.E2
SPMC03 0.50 mm² CAN SCR 5/18 1.00 mm² 452EC 5/18 14/18
/17.D7 FROM
TO BOOM HARNESS /29.D7 TO
SVMC21 0.50 mm² CAN SCR 6/18 0.75 mm² 486 6/18 15/18 1.00 mm² 155EC SC6-2
/17.D7 FROM
/31.B2 TO TO
/3.E8
C069-3
0.75 mm² 487 7/18 1.50 mm² 699 7/18 16/18 1.00 mm² 1823
/31.B2 TO
/21.C1 TO TO
/29.C1
C069-6 SC16-1
0.75 mm² 488 8/18 17/18 0.50 mm² CAN HI 1.00 mm² 820A 8/18 17/18 1.00 mm² 819A C026-3
/31.F2 TO FROM
/17.D7 /26.C6 TO TO
/26.B6
C070-3 SPMC01 C024-3
18/18 0.50 mm² CAN HI -P039 -C001 1.00 mm² 888A 9/18 18/18 1.00 mm² 203H
FROM
/17.D7
SVMC19 P095:2 1.00 mm² 888A G5/84 G5/84
/26.E4 FROM
C
C
C053:1 FROM
C067-1 0.75 mm² 456A

/31.B6 FROM
C026-1 1.00 mm² 456FA C067-4 0.75 mm² 456B

/26.B6 FROM
/31.B6 FROM
C026-4 1.00 mm² 456FB C068-1 0.75 mm² 456C

/26.B6 FROM
/31.B4 FROM
C024-1 1.00 mm² 456RA C068-4 0.75 mm² 456D

/26.C6 FROM
/31.B4 FROM
C024-4 1.00 mm² 456RB C069-1 0.75 mm² 456E

/26.C6 FROM
/31.B2 FROM
C069-4
B /31.B2 FROM 0.75 mm² 456F
-P039 -C001 B
P095:1 1.50 mm² 456PC D1/84 D1/84 1.50 mm² 456PC -SC31 1.50 mm² 456 C070-1 0.75 mm² 456G
/26.E2 FROM
/31.F2 FROM
0.75 mm² 456SP -SC20
C023-1 0.75 mm² 456V C070-4 0.75 mm² 456H

/29.B2 FROM
/31.E2 FROM
C023-4 0.75 mm² 456W C071-1 0.75 mm² 456J

/29.B2 FROM
/31.E2 FROM
C052-1 0.75 mm² 456S C071-4 0.75 mm² 456K

/29.B5 FROM
/31.E2 FROM
C052-4 0.75 mm² 456T C072-1 0.75 mm² 456L

/29.B5 FROM
/31.D2 FROM
C072-4 0.75 mm² 456M

/31.D2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 97 9813/9050-1 33 - 97
Page Page
33-98 33-99
Figure 905. (Part

1 1 of 2) 2 3 4
-C014
-C013 3626 J2
F
3626 J1
1.00 mm² 824A 1/18 10/18 1.00 mm² 818

/26.D1 TO
1.00 mm² 203A 1/18 10/18 1.00 mm² 410 C062-1 C031-1
TO
/31.C2
1.00 mm² 848 2/18 11/18 1.00 mm² 601B
/26.C1 TO
1.00 mm² 203B 2/18 11/18 1.00 mm² 480 C081-5 C029-1
TO
/16.D4
C052-2 0.75 mm² 475 3/18 12/18 1.00 mm² 601C
/29.B5 FROM
1.00 mm² 203C 3/18 12/18 1.00 mm² 601A SC4-1

TO
/21.D3
C052-5 0.75 mm² 476 4/18 13/18 1.00 mm² 826A
/29.B5 FROM
0.75 mm² 449 4/18 13/18 1.00 mm² 932D C063-2

/29.B2 TO TO
/32.B2
C023/5 C081-3 1.00 mm² 480A 5/18
-C001 /16.D4 FROM
14/18 1.00 mm² 438 A2/84
-C001 -P039 0.75 mm² 416RR 6/18 15/18 1.00 mm² 492
/7.B4 TO
1.00 mm² 481 6/18 15/18 1.00 mm² 876 C2/84 C2/84 0.75 mm² 876 SP1 C041-2
FROM
/30.B3
1.00 mm² 825 7/18 16/18 0.75 mm² 490
/26.C1 TO
1.00 mm² 203D 7/18 16/18 1.00 mm² 439 C025-5 C028-1
FROM
/29.F4
-C076 0.75 mm² 493 8/18 17/18 0.75 mm² 491
/31.D3
E
TO
PROPORTIONAL SOL 1.00 mm² 203E 8/18 17/18 0.75 mm² 416NN C040-2 C072-6
TO
/7.B4
0.75 mm² 448 9/18 18/18
/29.B2 TO
1.00 mm² 203G 9/18 18/18 0.75 mm² 416FF C039-2 C023-2
TO
/7.B4
2/2
1/2
-P039 -C001
P004:2
/3.F7 FROM 2.00 mm² 203 C8/84 C8/84 1.00 mm² 203 -SC14
-C016 -C017
3626 J4 3626 J5
-C001
1.00 mm² 480 1/18 10/18 1.00 mm² 888C
D
2/18 11/18 0.50 mm² CAN LO 11/18 0.75 mm² 482
FROM
/17.D7
SPMC02
C067-6
12/18 0.50 mm² CAN LO 0.75 mm² 483 3/18 12/18 1.00 mm² 601H
FROM
/17.D7 /31.B6 TO
SVMC20
-P039 -C001
13/18 1.00 mm² 931D C063-1 SP45 0.75 mm² 875 C12/84 C12/84 1.00 mm² 875 4/18 13/18 1.50 mm² 818A
TO
/32.C2 /27.D5 FROM
SPMC03 0.50 mm² CAN SCR 5/18 1.00 mm² 452EC 5/18 14/18
/17.D7 FROM
TO BOOM HARNESS /29.D7 TO
Page 33-99
SVMC21 0.50 mm² CAN SCR 6/18 0.75 mm² 486 6/18 15/18 1.00 mm² 155EC
/17.D7 FROM
/31.B2 TO
C069-3
0.75 mm² 487 7/18 1.50 mm² 699 7/18 16/18 1.00 mm² 1823
/31.B2 TO
/21.C1 TO
C069-6 SC16-1
0.75 mm² 488 8/18 17/18 0.50 mm² CAN HI 1.00 mm² 820A 8/18 17/18 1.00 mm² 819A
/31.F2 TO FROM
/17.D7 /26.C6 TO
C070-3 SPMC01 C024-3

18/18 0.50 mm² CAN HI -P039 -C001 1.00 mm² 888A 9/18 18/18 1.00 mm²
FROM
/17.D7
SVMC19 P095:2 1.00 mm² 888A G5/84 G5/84
/26.E4 FROM
C026-1 1.00 mm² 456FA

/26.B6 FROM
C026-4 1.00 mm² 456FB

/26.B6 FROM
C024-1 1.00 mm² 456RA

/26.C6 FROM
C024-4 1.00 mm² 456RB

/26.C6 FROM
B
-P039 -C001
P095:1 1.50 mm² 456PC D1/84 D1/84 1.50 mm² 456PC -SC31 1.50 mm² 456
/26.E2 FROM
0.75 mm² 456SP
C023-1 0.75 mm² 456V

/29.B2 FROM
C023-4 0.75 mm² 456W

/29.B2 FROM
C052-1 0.75 mm² 456S

/29.B5 FROM
C052-4 0.75 mm² 456T

/29.B5 FROM
1 2 3 4
33 - 98 9813/9050-1 33 - 98
Page Page
33-98 33-99
Figure 905. (Part

5 2 of 2) 6 7 8
-C015
3626 J3
F
1.00 mm² 818 C001:F2 1.00 mm² 850E 1/18 10/18 1.00 mm² 481 C062-3
FROM
/22.A4 /32.B2 TO TO
/31.C2
C063-3
1.00 mm² 601B SC4-2 11/18 1.00 mm² 601D SC4-4
TO
/21.D3 TO
/21.D3
1.00 mm² 601C SC4-3 0.75 mm² 489 3/18 12/18 1.00 mm² 601G SC4-5
TO
/21.D3 /31.F3 TO TO
/21.D3
C070-6
1.00 mm² 826A C030-1 0.75 mm² 484 4/18 13/18 1.00 mm² 145TS C001:F1
TO
/26.C1 /31.B4 TO TO
/33.D2
C068-3
0.75 mm² 485 5/18 14/18
/31.B4 TO
C068-6
-C001 -P039
1.00 mm² 492 C072-3 15/18 1.00 mm² 551SW C1/84 C1/84 1.00 mm² 551SW P141:2
TO
/31.D2 TO
/32.D2
-C001 -P039
0.75 mm² 490 C071-3 1.00 mm² 819B 7/18 16/18 1.00 mm² 485D F11/84 F11/84 0.75 mm² 485D P036:2
TO
/31.E2 /26.B6 TO TO
/31.E4
C026-6
0.75 mm² 491 C071-6 1.00 mm² 820B 8/18 17/18 1.00 mm² 603A SC29-3
TO
/31.E3 /26.C6 TO TO
/26.C3
C024-6
18/18 1.00 mm² 650 C006-M E
TO
/7.D2
-C066
STABILISER ISO VALVE
1.00 mm² 600BJ 2/2 1/2 1.00 mm² 910
-C001 -P039
1.00 mm² 888C G6/84 G6/84 1.00 mm² 888C P095:5
FROM
/26.D4
0.75 mm² 482 TO

C067-3
/31.B6
D
1.00 mm² 601H SC4-6

TO
/21.E3
1.50 mm² 818A C006-K

TO
/7.E2
Page 33-98
1.00 mm² 155EC SC6-2

TO
/3.E8
1.00 mm² 1823 TO

/29.C1
1.00 mm² 819A C026-3

TO
/26.B6
1.00 mm² 203H
C053:1 FROM
C067-1 0.75 mm² 456A

/31.B6 FROM
C067-4 0.75 mm² 456B

/31.B6 FROM
C068-1 0.75 mm² 456C

/31.B4 FROM
C068-4 0.75 mm² 456D

/31.B4 FROM
C069-1 0.75 mm² 456E

/31.B2 FROM
C069-4 0.75 mm² 456F

/31.B2 FROM
B
C070-1 0.75 mm² 456G
/31.F2 FROM
-SC20
C070-4 0.75 mm² 456H

/31.E2 FROM
C071-1 0.75 mm² 456J

/31.E2 FROM
C071-4 0.75 mm² 456K

/31.E2 FROM
C072-1 0.75 mm² 456L

/31.D2 FROM
C072-4 0.75 mm² 456M

/31.D2 FROM
5 6 7 8
33 - 99 9813/9050-1 33 - 99
33 - 100 9813/9050-1 33 - 100

Page 33-102 Figure 906. Pin Lock 160/

1 2 3 4 5 6 7 8
F
F
-P039
1.00 mm² 867PL A4/84
-P114
PIN LOCK SWITCH
E FROM ILLUMINATION /19.E5 1.00 mm² 829RH 8 7 1.00 mm² 601RH
/20.C6 TO GROUND E
FROM TO
SPLICE SP7 SPLICE SP28 -P114A

-P114B
PINK LOCK 5K6 PIN LOCK 1K8
1 1 2 1 2
1.00 mm² 867 1.00 mm² 867C 1.00 mm² 867B 1.00 mm² 699PL TO
/20.C1 TO 3626 SENSOR GROUND
FROM IGNITION FUSE 1.00 mm² 100RH 2 -SP48 SPLICE SP42
/3.B6 FROM
P001:2 / SP20 3
4
5 -P114C
1.00 mm² 100RHA
PIN LOCK 33K
6 1.00 mm² 867A 1 2 1.00 mm² 867D
D
D
REEL
332/D2537 7214/0025 7214/0024 7214/0034 7214/0024 7214/0025 332/D2537
-C001 -C032A -B002 -B009 -B002 -C032A -C001
D5/84 2.00 mm² 435PL 1/4 1/4 2.00 mm² 435PL 1/4 1/4 3/4 3/4 2.00 mm² 601PAU 3/4 3/4 2.00 mm² 601PAU E4/84
-C001 -C032A -B002

D6/84 2.00 mm² 8213AU 2/4 2/4 2.00 mm² 8213AU 2/4 2/4 4/4
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 101 9813/9050-1 33 - 101

Page Page
33-102 33-103
Figure 906. (Part

1 1 of 2) 2 3 4
-P114
PIN LOCK SWITCH
E FROM ILLUMINATION /19.E5 FROM 1.00 mm² 829RH 8 7 1.00 mm² 601RH TO
/20.C6 TO GROUND
-P114B
PINK LOCK 5K6
1 1.00 mm² 867 1 2 1.00 mm² 867C
FROM IGNITION FUSE 1.00 mm² 100RH 2
/3.B6 FROM
P001:2 / SP20 3
4
5 -P114C
1.00 mm² 100RHA
PIN LOCK 33K
6 1.00 mm² 867A 1 2 1.00 mm² 867D
Page 33-103
REEL
332/D2537 7214/0025 7214/0024 7214/0034
-C001 -C032A -B002 -B009
D5/84 2.00 mm² 435PL 1/4 1/4 2.00 mm² 435PL 1/4 1/4 3/4 3/4
-C001 -C032A -B002

D6/84 2.00 mm² 8213AU 2/4 2/4 2.00 mm² 8213AU 2/4 2/4 4/4
1 2 3 4
33 - 102 9813/9050-1 33 - 102

Page Page
33-102 33-103
Figure 906. (Part

5 2 of 2) 6 7 8
-P039
1.00 mm² 867PL A4/84
TO
/20.C6 TO GROUND E
SPLICE SP28 -P114A
-P114B
PINK LOCK 5K6 PIN LOCK 1K8
2 1 2
1.00 mm² 867C 1.00 mm² 867B 1.00 mm² 699PL TO
-SP48 SPLICE SP42
-P114C
PIN LOCK 33K
2 1.00 mm² 867D
D
Page 33-102
REEL
7214/0024 7214/0025 332/D2537
-B002 -C032A -C001
3/4 3/4 2.00 mm² 601PAU 3/4 3/4 2.00 mm² 601PAU E4/84
4/4
5 6 7 8
33 - 103 9813/9050-1 33 - 103

33 - 104 9813/9050-1 33 - 104

Page 33-106 Figure 907. Hitch Harness

1 2 3 4 5 6 7 8
F
F
E
E
-P017
FRONT / REAR AUX
FRON ILLUMINATION /19.D5 8 7
FROM 1.00 mm² 829X 1.00 mm² 601BB TO
/20.B6 TO GROUND
D FROM FUSE 04A /3.E5 1.50 mm² 114 2

-P039 -C001
D
FROM
P001:8 3 1.50 mm² 850 A6/84 A6/84 1.00 mm² 850 TO

/31.F5 TO TRAILER TIP VALVE
C065:1
-SP4
1.00 mm² 481B 1.00 mm² 481A TO
P072:15
1.00 mm² 481 TO

/31.C2 TO LH STAB TRANS
P039:G2
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 105 9813/9050-1 33 - 105

Page Page
33-106 33-107
Figure 907. (Part

1 1 of 2) 2 3 4
-P017
FRONT / REAR AUX
FRON ILLUMINATION /19.D5 8 7
FROM 1.00 mm² 829X 1.00 mm² 601BB TO
/20.B6 TO GROUND
D FROM FUSE 04A /3.E5 FROM 1.50 mm² 114 2

-P039 -C001
P001:8 3 1.50 mm² 850 A6/84
1.00 mm² 481B

-SP4
1.00 mm²
Page 33-107
1.00 mm²
1 2 3 4
33 - 106 9813/9050-1 33 - 106

Page Page
33-106 33-107
Figure 907. (Part

5 2 of 2) 6 7 8
TO
/20.B6 TO GROUND
SPLICE SP28
-P039 -C001
A6/84 A6/84 1.00 mm² 850 TO
/31.F5 TO TRAILER TIP VALVE
D
C065:1
-SP4
1.00 mm² 481B 1.00 mm² 481A TO
P072:15
Page 33-106
1.00 mm² 481 TO

/31.C2 TO LH STAB TRANS
P039:G2
5 6 7 8
33 - 107 9813/9050-1 33 - 107

33 - 108 9813/9050-1 33 - 108

Page 33-110 Figure 908. Steer Mode 160/

1 2 3 4 5 6 7 8
F
F
TO FOOTBRAKE RESISTOR /30.B4 TO 0.75 mm² 456FB

P090:1
E
TO E-STOP SWITCH /33.D2
E
TO 1.00 mm² 456ES -P095
P049:18 STEER MODE SWITCH
P039:D1 1.50 mm² 456PC -SP10 1.00 mm² 456SA 1/6

/23.B2 TO
2/6 1.00 mm² 888A P039:G5

TO
/23.C3
TO 3626 SENSOR GROUND /20.D2 TO 1.00 mm² 699CH 3/6

SPLICE SP42
1.00 mm² 456SB 4/6
5/6 1.00 mm² 888C P039:G6

TO
/23.D5
TO 3626 SENSOR GROUND /20.D1 TO 1.00 mm² 699SJ 6/6

SPLICE SP42
D
D
-C031
CRAB STEER D -C024
REAR STEER SENSOR
C014-1 1.00 mm² 824A 1/2 2/2 1.00 mm² 603D
/23.F4 FROM
1/6 1.00 mm² 456RA SC31-10

TO
/23.B2
-C030
2/6 1.00 mm² 603A SC7-2
4 WHEEL STEER B TO
/21.E5
C014-13 1.00 mm² 826A 1/2 2/2 1.00 mm² 603C 3/6 1.00 mm² 820A C017-8
/23.F5 FROM FROM
/23.C4
4/6 1.00 mm² 456RB SC31-11

TO
/23.B2
C015-17
-C029 /23.E7 1.00 mm² 603A -SC29
C
FROM
5/6 1.00 mm² 603RS SC7-3

ALL WHEEL STEER C /21.E5
C
TO
C014-2 1.00 mm² 848 1/2 2/2 1.00 mm² 603B 6/6 1.00 mm² 820B C015-8
/23.F4 FROM FROM
/23.E6
-C028
2 WHEEL STEER A
C014-7 1.00 mm² 825 1/2 2/2 1.00 mm² 603A
/23.E4 FROM
-C026
FRONT STEER SENSOR
1/6 1.00 mm² 456FA SC31-8

TO
/23.B2
2/6 1.00 mm² 602H SC9-2

FROM
/21.F2
3/6 C017-17
B 1.00 mm² 819A FROM
/23.C5
B
4/6 1.00 mm² 456FB SC31-9
TO
/23.B2
5/6 1.00 mm² 602B SC9-5

FROM
/21.E2
6/6 1.00 mm² 819B C015-7

FROM
/23.E6
A
A
1 2 3 4 5 6 7 8
33 - 109 9813/9050-1 33 - 109

Page Page
33-110 33-111
Figure 908. (Part

1 1 of 2) 2 3 4
TO FOOTBRAKE RESISTOR /30.B4 TO 0.75 mm² 456FB

P090:1
E
TO E-STOP SWITCH /33.D2 TO 1.00 mm² 456ES -P095
P049:18 STEER MODE SWITCH
P039:D1 1.50 mm² 456PC -SP10 1.00 mm² 456SA 1/6

/23.B2 TO
2/6 1.00 mm² 888A P039:G5

TO
/23.C3
TO 3626 SENSOR GROUND /20.D2 TO 1.00 mm² 699CH 3/6

SPLICE SP42
1.00 mm² 456SB 4/6
5/6 1.00 mm² 888C P039:G6

TO
/23.D5
TO 3626 SENSOR GROUND /20.D1 TO 1.00 mm² 699SJ 6/6

SPLICE SP42
D
-C031
CRAB STEER D
C014-1 1.00 mm² 824A 1/2 2/2 1.00 mm² 603D

/23.F4
Page 33-111
FROM
-C030
4 WHEEL STEER B
C014-13 1.00 mm² 826A 1/2 2/2 1.00 mm² 603C

/23.F5 FROM
C015-17
-C029 /23.E7 1.00 mm² 603A -SC29
C
FROM
ALL WHEEL STEER C
C014-2 1.00 mm² 848 1/2 2/2 1.00 mm² 603B

/23.F4 FROM
-C028
2 WHEEL STEER A
C014-7 1.00 mm² 825 1/2 2/2 1.00 mm² 603A
/23.E4 FROM
1 2 3 4
33 - 110 9813/9050-1 33 - 110

Page Page
33-110 33-111
Figure 908. (Part

5 2 of 2) 6 7 8
P039:G5
TO
/23.C3
P039:G6
TO
/23.D5
-C024
REAR STEER SENSOR
Page 33-110
1/6 1.00 mm² 456RA SC31-10

TO
/23.B2
2/6 1.00 mm² 603A SC7-2

TO
/21.E5
3/6 1.00 mm² 820A C017-8

FROM
/23.C4
4/6 1.00 mm² 456RB SC31-11

TO
/23.B2
5/6 1.00 mm² 603RS SC7-3

/21.E5
C
TO
6/6 1.00 mm² 820B C015-8

FROM
/23.E6
-C026
FRONT STEER SENSOR
1/6 1.00 mm² 456FA SC31-8

TO
/23.B2
2/6 1.00 mm² 602H SC9-2

FROM
/21.F2
3/6 1.00 mm² 819A C017-17

FROM
/23.C5
B
4/6 1.00 mm² 456FB SC31-9
TO
/23.B2
5/6 1.00 mm² 602B SC9-5

FROM
/21.E2
6/6 1.00 mm² 819B C015-7

FROM
/23.E6
5 6 7 8
33 - 111 9813/9050-1 33 - 111

33 - 112 9813/9050-1 33 - 112

Page 33-114 Figure 909. Park Brake and Auto/

Man 160/B4268 Issue 2- Sheet 27 Page 33-115
1 2 3 4 5 6 7 8
F
F
E
E
0.75 mm² 875 TO

/23.D3 TO 3626 J5
P039:C12
D
D
-P109 -P111
-RC12 -RC01 -P049 PARKBRAKE 33K PARKBRAKE 1K8
1 2 -SP45 1 2
PARK BRAKE 0.75 mm² 815B 13/20 13/20 0.75 mm² 815B 0.75 mm² 875B 0.75 mm² 875CC 0.75 mm² 699CF TO
SPLICE SP42
-P049 -RC01 2/3
FROM FUSE 09A /3.E5 FROM 1.00 mm² 107PB 10/20 10/20 1.00 mm² 107PB 3/3
P001:18 1/3 -P110
-RC01 -P049 PARKBRAKE 5K6
0.75 mm² 815A 11/20 11/20 0.75 mm² 815A 1 2 0.75 mm² 875AA
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 113 9813/9050-1 33 - 113

Page Page
33-114 33-115
Figure 909. (Part

1 1 of 2) 2 3 4
-P109
-RC12 -RC01 -P049 PARKBRAKE 33K
1 2
PARK BRAKE 0.75 mm² 815B 13/20 13/20 0.75 mm² 815B 0.75 mm² 875B
-P049 -RC01 2/3
Page 33-115
FROM FUSE 09A /3.E5 FROM 1.00 mm² 107PB 10/20 10/20 1.00 mm² 107PB 3/3
P001:18 1/3 -P110
-RC01 -P049 PARKBRAKE 5K6
0.75 mm² 815A 11/20 11/20 0.75 mm² 815A 1 2 0.75 mm² 875AA
1 2 3 4
33 - 114 9813/9050-1 33 - 114

Page Page
33-114 33-115
Figure 909. (Part

5 2 of 2) 6 7 8
0.75 mm² 875 TO

/23.D3 TO 3626 J5
P039:C12
-P111
PARKBRAKE 33K PARKBRAKE 1K8
-SP45 1 2
0.75 mm² 875B 0.75 mm² 875CC 0.75 mm² 699CF TO
SPLICE SP42
Page 33-114
PARKBRAKE 5K6
0.75 mm² 875AA
5 6 7 8
33 - 115 9813/9050-1 33 - 115

33 - 116 9813/9050-1 33 - 116

Page 33-118 Figure 910. SRS 160/B4268 Issue 2- Sheet 28 Page 33-119
1 2 3 4 5 6 7 8
F
F
-P062
SRS SWITCH
8 7
FROM ILLUMINATION /19.B4 FROM 1.00 mm² 829AR 1.00 mm² 601KK TO
/20.C4 TO GROUND
1 -SP2
-P039 0.75 mm² 699DD 1.00 mm² 699CG
E
TO
F10/84 1.00 mm² 499A 2 -P075 SPLICE SP42

3 1.00 mm² 499AA
SRS 1K 300R
1 2 0.75 mm² 699AA
E
1.00 mm² 499L 4
5 -P076
SRS 5K 360R
6 0.75 mm² 499BB 1 2 0.75 mm² 699BB
-P077
SRS 10K
1.00 mm² 499M 1 2 1.00 mm² 699CC
D
D
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 117 9813/9050-1 33 - 117

Page Page
33-118 33-119
Figure 910. (Part

1 1 of 2) 2 3 4
-P062
SRS SWITCH
8 7
FROM ILLUMINATION /19.B4 FROM 1.00 mm² 829AR 1.00 mm² 601KK
SPLICE SP7
1 0.75 mm² 699DD -SP2 1.00 mm²

-P039
E F10/84 1.00 mm² 499A 2 -P075
SRS 1K 300R
3 1.00 mm² 499AA 1 2 0.75 mm² 699AA
1.00 mm² 499L 4
5 -P076
SRS 5K 360R
6 0.75 mm² 499BB 1 2 0.75 mm² 699BB
-P077
SRS 10K
1.00 mm² 499M 1 2 1.00 mm² 699CC
Page 33-119
C
1 2 3 4
33 - 118 9813/9050-1 33 - 118

Page Page
33-118 33-119
Figure 910. (Part

5 2 of 2) 6 7 8
TO
/20.C4 TO GROUND
SPLICE SP6
-SP2 1.00 mm² 699CG TO

SPLICE SP42
SRS 1K 300R
2 0.75 mm² 699AA
E
SRS 5K 360R
2 0.75 mm² 699BB
2 1.00 mm² 699CC
D
Page 33-118
5 6 7 8
33 - 119 9813/9050-1 33 - 119

33 - 120 9813/9050-1 33 - 120

Page 33-122 Figure 911. LLMI 160/B4268 Issue 2- Sheet 29 Page 33-123
1 2 3 4 5 6 7 8
F
F
-C025
LLMI TRANSDUCER
SC7-10 SC2-4
1.00 mm² 603LMI 1/6 4/6 1.00 mm² 109LM
/21.E5 FROM FROM
/3.B6
-P039 -C001
B3/84 B3/84 1.00 mm² 413 2/6 5/6 1.00 mm² 439 C013-16
TO
/23.E2
-P039 -C001
B4/84 B4/84 1.00 mm² 414 3/6 6/6 1.00 mm² 603LM SC7-5
TO
/21.F5
-P042-A
LLMI
P004:16 1.00 mm² 101A 1/4 1/4

/3.E7 FROM
0.75 mm² 413 2/4 2/4

E 0.75 mm² 414 3/4 3/4
SP28 0.75 mm² 601AK 4/4 4/4
E
/20.B6 TO
-P042-B
LLMI CAN
SVMC13 0.50 mm² CAN 9 H

/17.F5 FROM
A/3 A/3
SVMC14 0.50 mm² CAN 9 L B/3 B/3
/17.F5 FROM
C/3 C/3
SVMC15 0.50 mm² CAN 9 SCR
/17.F5 FROM
-B005
RETRACT PROXIMITY SWITCH
334/G1248
7214/0025 BOOM BACK RESISTOR 5K6
-B007 2/4 2/4 1.00 mm² 450 1 2 1.00 mm² 452B
D 1.00 mm² 155B1 1/4 1/4

-B004 D
334/G1261
1.00 mm² 155B2 3/4 3/4 BOOM BACK RESISTOR 33K
4/4 4/4 1.00 mm² 451 1 2 1.00 mm² 452A
7219/0068 7219/0059
-B001 -C032
1.00 mm² 452C 1.00 mm² 452EC 7/12 7/12 1.00 mm² 452EC FROM
/23.D4 FROM HYD ECU J5-5
-SB5
-B006
334/G1168 7219/0068 7219/0059
BOOM BACK RESISTOR 1K8 -B001 -C032
1 2 1.00 mm² 699BB 8/12 8/12 1.00 mm² 699BB
BOOM EXT SWITCH TO
/21.D1 TO SPLICE SC16
7219/0059 7214/0025
12V +
-C032 -B001 7219/0068 -SB4 -B003
1.00 mm² 155EB 5/12 5/12 1.00 mm² 155EB 1.00 mm² 155B3 3/4 3/4
/3.E8 TO
C -C032A -B002 7214/0024

FROM HYD ECU J5-16 /23.C5 1.00 mm² 1823 4/4 4/4 1.00 mm² 1823 4/4 4/4
C
FROM
7214/0025 -BC35
BLOCK_7214/0025
-C023 -C052
BOOM ANGLE SENSOR CHASSIS ANGLE SENSOR
0.75 mm² 456V 1/6 0.75 mm² 456S 1/6

/23.B2 TO
/23.A2 TO
SC31-3 SC31-5
B
/23.E4 FROM 0.75 mm² 448 2/6
/23.F4 TO
0.75 mm² 475 2/6 B
C014-9 C014-3
0.75 mm² 699V 3/6 0.75 mm² 699S 3/6
/21.C1 TO
/21.C1 TO
SC16-6 SC16-8
0.75 mm² 456W 4/6 0.75 mm² 456T 4/6
/23.A2 TO
/23.A2 TO
SC31-4 SC31-6
0.75 mm² 449 5/6 0.75 mm² 476 5/6
/23.F1 FROM
/23.F4 TO
C013/4 C014-4
0.75 mm² 699W 6/6 0.75 mm² 699T 6/6
/21.C1 TO
/21.C1 TO
SC16-7 SC16-9
A
A
1 2 3 4 5 6 7 8
33 - 121 9813/9050-1 33 - 121

Page Page
33-122 33-123
Figure 911. (Part

1 1 of 2) 2 3 4
-C025
LLMI TRANSDUCER
SC7-10 SC2-4
1.00 mm² 603LMI 1/6 4/6 1.00 mm² 109LM
/21.E5 FROM FROM
/3.B6
-P039 -C001
B3/84 B3/84 1.00 mm² 413 2/6 5/6 1.00 mm² 439 C013-16
TO
/23.E2
-P039 -C001
B4/84 B4/84 1.00 mm² 414 3/6 6/6 1.00 mm² 603LM SC7-5
TO
/21.F5
P004:16 1.00 mm² 101A 1/4

/3.E7 FROM
0.75 mm² 413 2/4

E 0.75 mm² 414 3/4
SP28 0.75 mm² 601AK 4/4
/20.B6 TO
SVMC13 0.50 mm² CAN 9 H

/17.F5 FROM
A/3
SVMC14 0.50 mm² CAN 9 L B/3
/17.F5 FROM
C/3
SVMC15 0.50 mm² CAN 9 SCR
/17.F5 FROM
-B005
RETRACT PROXIMITY SWITCH
334/G1248
7214/0025 BOOM BACK RESISTOR 5K6
-B007 2/4 2/4 1.00 mm² 450 1 2
D 1.00 mm² 155B1 1/4 1/4

-B004
334/G1261
1.00 mm² 155B2 3/4 3/4 BOOM BACK RESISTOR 33K
4/4 4/4 1.00 mm² 451 1 2
Page 33-123
-B006
334/G1168
BOOM BACK RESISTOR 1K8
1 2
BOOM EXT SWITCH
7219/0059 7214/0025
12V +
-C032 -B001 7219/0068 -SB4 -B003
1.00 mm² 155EB 5/12 5/12 1.00 mm² 155EB 1.00 mm² 155B3 3/4 3/4
/3.E8 TO
C -C032A -B002 7214/0024

FROM HYD ECU J5-16 /23.C5 FROM 1.00 mm² 1823 4/4 4/4 1.00 mm² 1823 4/4 4/4
7214/0025 -BC35
BLOCK_7214/0025
-C023
BOOM ANGLE SENSOR
0.75 mm² 456V 1/6

/23.B2 TO
/23.A2 TO
SC31-3 SC31-5
B
0.75 mm² 448 2/6
/23.E4 FROM
/23.F4 TO
C014-9 C014-3
0.75 mm² 699V 3/6
/21.C1 TO
/21.C1 TO
SC16-6 SC16-8
0.75 mm² 456W 4/6
/23.A2 TO
/23.A2 TO
SC31-4 SC31-6
0.75 mm² 449 5/6
/23.F1 FROM
/23.F4 TO
C013/4 C014-4
0.75 mm² 699W 6/6
/21.C1 TO
/21.C1 TO
SC16-7 SC16-9
1 2 3 4
33 - 122 9813/9050-1 33 - 122

Page Page
33-122 33-123
Figure 911. (Part

5 2 of 2) 6 7 8
SC2-4
FROM
/3.B6
C013-16
TO
/23.E2
SC7-5
TO
/21.F5
-P042-A
LLMI
1/4 1/4
2/4 2/4
3/4 3/4
4/4 4/4
E
-P042-B
LLMI CAN
CAN 9 H
A/3 A/3
CAN 9 L B/3 B/3
C/3 C/3
CAN 9 SCR
-B005
334/G1248
BOOM BACK RESISTOR 5K6
2 1.00 mm² 452B
-B004 D
334/G1261
BOOM BACK RESISTOR 33K
2 1.00 mm² 452A
7219/0068 7219/0059
Page 33-122
-B001 -C032
1.00 mm² 452C 1.00 mm² 452EC 7/12 7/12 1.00 mm² 452EC FROM
/23.D4 FROM HYD ECU J5-5
-SB5
-B006
334/G1168 7219/0068 7219/0059
BOOM BACK RESISTOR 1K8 -B001 -C032
2 1.00 mm² 699BB 8/12 8/12 1.00 mm² 699BB TO
/21.D1 TO SPLICE SC16
-C052
CHASSIS ANGLE SENSOR
0.75 mm² 456S 1/6

/23.A2 TO
SC31-5
/23.F4 TO
0.75 mm² 475 2/6 B
C014-3
0.75 mm² 699S 3/6
/21.C1 TO
SC16-8
0.75 mm² 456T 4/6
/23.A2 TO
SC31-6
0.75 mm² 476 5/6
/23.F4 TO
C014-4
0.75 mm² 699T 6/6
/21.C1 TO
SC16-9
5 6 7 8
33 - 123 9813/9050-1 33 - 123

33 - 124 9813/9050-1 33 - 124

Page 33-126 Figure 912. Footbrake Dump

1 2 3 4 5 6 7 8
F
F
-C027
FOOTBRAKE TRANSDUCER
SC11-5 1.00 mm² 600FB 1/4 1/4 3/4

/21.E4 FROM
-C001 -P039
SC2-2 1.00 mm² 109FB 2/4 2/4 4/4 1.00 mm² 468 F3/84 F3/84 0.75 mm² 468 P069:9
/3.B6 FROM TO
/22.D3
E
E
-P019
TO ECO SWITCH /9.D1 TO 1.00 mm² 829EC FOOTBRAKE DUMP 1.00 mm² 601EC FROM
/9.D1 FROM ECO SWITCH
P099:8 P099:7
8 7
FROM ILLUMINATION /19.C5 FROM 1.00 mm² 829FD 0.75 mm² 601FD TO
/20.B4 TO GROUND
1 -SP47
0.75 mm² 598D 0.75 mm² 688D TO
/22.D6 TO 07/11 SENSOR GROUND
2 -P078 SPLICE SP41
FROM 07/11 CONNECTOR 1 /22.D3 FROM 0.75 mm² 699G FOOTBRAKE DUMP 1K 300R
3 1 2
P069:8 0.75 mm² 598AA 0.75 mm² 598A
D 0.75 mm² 699H 4

-P079
5
FOOTBRAKE DUMP 5K 360R
D
6 0.75 mm² 598BB 1 2 0.75 mm² 598B
-P080
FOOTBRAKE DUMP 10K
0.75 mm² 699J 1 2 0.75 mm² 598C
C
C
-P050
FOOT BRAKE SWITCH
-P092
FOOTBRAKE 5K 360R
1 2
1/3 0.75 mm² 887 0.75 mm² 699CC TO
0.75 mm² 876B 3/3 SPLICE SP42
1 2
2/3 0.75 mm² 886 0.75 mm² 699CB TO
SPLICE SP42
-P091
FOOTBRAKE 1K 300R
B
-P090 B
FOOTBRAKE 10K
2 1
-SP1 0.75 mm² 876A 0.75 mm² 456FB FROM
/26.E2 FROM 5V REF 3626
SPLICE SP10
0.75 mm² 876 TO

/23.E3 TO 3626 J1
C013:15
A
A
1 2 3 4 5 6 7 8
33 - 125 9813/9050-1 33 - 125

Page Page
33-126 33-127
Figure 912. (Part

1 1 of 2) 2 3 4
-C027
FOOTBRAKE TRANSDUCER
SC11-5 1.00 mm² 600FB 1/4 1/4 3/4

/21.E4 FROM
-C001 -P039
SC2-2 1.00 mm² 109FB 2/4 2/4 4/4 1.00 mm² 468 F3/84 F3/84 0.75 mm² 468
/3.B6 FROM
-P019
TO ECO SWITCH /9.D1 TO 1.00 mm² 829EC FOOTBRAKE DUMP 1.00 mm² 601EC FROM
P099:8 P099:7
8 7
FROM ILLUMINATION /19.C5 FROM 1.00 mm² 829FD 0.75 mm² 601FD TO
/20.B4 TO GROUND
1 -SP47
0.75 mm² 598D 0.75 mm² 688D TO
2 -P078 SPLICE SP41
FROM 07/11 CONNECTOR 1 /22.D3 FROM 0.75 mm² 699G FOOTBRAKE DUMP 1K 300R
3 1 2
P069:8 0.75 mm² 598AA 0.75 mm² 598A
D 0.75 mm² 699H 4

-P079
5
FOOTBRAKE DUMP 5K 360R
6 0.75 mm² 598BB 1 2 0.75 mm² 598B
-P080
FOOTBRAKE DUMP 10K
0.75 mm² 699J 1 2 0.75 mm² 598C
Page 33-127
C
-P050
FOOT BRAKE SWITCH
-P092
FOOTBRAKE 5K 360R
1 2
1/3 0.75 mm² 887 0.75 mm² 699CC TO
0.75 mm² 876B 3/3 SPLICE SP42
1 2
2/3 0.75 mm² 886 0.75 mm² 699CB TO
SPLICE SP42
-P091
FOOTBRAKE 1K 300R
B
-P090
FOOTBRAKE 10K
2 1
-SP1 0.75 mm² 876A 0.75 mm² 456FB FROM
/26.E2 FROM 5V REF 3626
SPLICE SP10
0.75 mm² 876 TO

/23.E3 TO 3626 J1
C013:15
1 2 3 4
33 - 126 9813/9050-1 33 - 126

Page Page
33-126 33-127
Figure 912. (Part

5 2 of 2) 6 7 8
0.75 mm² 468 P069:9

TO
/22.D3
FROM
P099:7
TO
/20.B4 TO GROUND
SPLICE SP6
TO
SPLICE SP41
D
Page 33-126
TO 3626 SENSOR GROUND

SPLICE SP42
SPLICE SP42
B
FROM 5V REF 3626
SPLICE SP10
5 6 7 8
33 - 127 9813/9050-1 33 - 127

33 - 128 9813/9050-1 33 - 128

Page 33-130 Figure 913. Valve Block 160/

1 2 3 4 5 6 7 8
-C065
TRAILER TIP VALVE
F
F
C001:A6 /25.D5 1.00 mm² 850 1/2 1/2 2/2 2/2 1.00 mm² 603P
FROM TO
/21.E5 SC7-7
-C070
AUX STAB SPOOL
SC20-8 /23.B7 0.75 mm² 456G 1/8 5/8 0.75 mm² 609H
TO TO
/21.B1 SC21-9
SC21-8 /21.A1 0.75 mm² 609G 2/8 6/8 0.75 mm² 489
TO FROM
/23.F6 C015-3
C016-8 /23.C1 FROM 0.75 mm² 488 3/8 7/8
SC20-9 /23.B7 0.75 mm² 456H 4/8 8/8

-P036
TO
STABILISER ISOLATION
8 7
FROM ILLUMINATION /19.B5 FROM 1.00 mm² 829AX 1.00 mm² 601DZ
SPLICE SP7
-P205
STAB ISO. 1K 300R /20.E6 TO GROUND
E
TO
-C071 1 0.75 mm² 485AA 1 2 1.00 mm² 699SA SPLICE SP11

LH STAB SPOOL TO 3626 J3 /23.E8 FROM 0.75 mm² 485D 2 E
P039:F11 3
0.75 mm² 456J 1/8 5/8 0.75 mm² 609K 4
SC20-10 /23.A7 TO TO
/21.B1 SC21-11 0.75 mm² 485E
-P206
5
STAB ISO. 5K 360R
0.75 mm² 609J 2/8 6/8 0.75 mm² 491 6 1 2
SC21-10 /21.B1 TO FROM
/23.E5 C014-17 0.75 mm² 485BB 1.00 mm² 699SC
C014-16 /23.E5 0.75 mm² 490 3/8 7/8

-P207
FROM
STAB ISO. 10K

1 2
0.75 mm² 456K 4/8 8/8
SC20-11 /23.A7 TO 0.75 mm² 485F 1.00 mm² 699SB 1.00 mm² 699SK TO
-SP44 SPLICE SP42
-C072
RH STAB SPOOL
D SC20-12 /23.A7 TO
0.75 mm² 456L 1/8 5/8 0.75 mm² 609M TO
/21.C1 SC21-13 -SH003 -SH002
RH STAB TRANSDUCER LH STAB TRANSDUCER D
SC21-12 /21.B1 0.75 mm² 609L 2/8 6/8 0.75 mm² 493
TO FROM
/23.E4 C014-8
4/4
2/4
4/4
2/4
3/4
3/4
1/4
1/4
C014-15 /23.E5 FROM 1.00 mm² 492 3/8 7/8
0.75 mm² 456M 4/8 8/8

SC20-13 /23.A7 TO
3/4
3/4
4/4
2/4
1/4
4/4
2/4
1/4
-C062 -SH001
C013-10 /23.F2 FROM 1.00 mm² 410 1/6 1/6 1.00 mm² 410
SC2-6 /3.C6 FROM 1.00 mm² 109E 2/6 2/6 1.00 mm² 121F 1.00 mm² 121G
-SS2
C015-10 /23.F7 FROM 1.00 mm² 481 3/6 3/6 1.00 mm² 481
C 1.00 mm² 604C 4/6 4/6 1.00 mm² 604B 1.00 mm² 604C
SC16-3 /21.C1 TO
C
-P039 -C001 -SS1
SP4 /25.D5 FROM 1.00 mm² 481 G2/84 G2/84 1.00 mm² 495 5/6 5/6 1.00 mm² 495
-P039 -C001
1.00 mm² 410 G1/84 G1/84 1.00 mm² 496 6/6 6/6 1.00 mm² 496
P072:16 /9.D5 FROM
-C069 -C068 -C067

CROWD/DUMP SPOOL EXTEND/RETRACT SPOOL LIFT/LOWER SPOOL
SC20-6 /23.B7 TO
0.75 mm² 456E 1/8 SC20-4 /23.B7 TO
0.75 mm² 456C 1/8 SC20-2 /23.C7 TO
0.75 mm² 456A 1/8
SC31-6 /21.A1 TO
0.75 mm² 609E 2/8 SC21-4 /21.B1 TO
0.75 mm² 609C 2/8 SC21-2 /21.B1 TO
0.75 mm² 609A 2/8
B C017-6 /23.D4 FROM 0.75 mm² 486 3/8 C015-4 /23.F6 FROM 0.75 mm² 484 3/8 C017-11 /23.D5 FROM 0.75 mm² 482 3/8
B
SC20-7 /23.B7 TO
0.75 mm² 456F 4/8 SC20-5 /23.B7 TO
0.75 mm² 456D 4/8 SC20-3 /23.B7 TO
0.75 mm² 456B 4/8
SC31-7 /21.A1 0.75 mm² 609F 5/8 0.75 mm² 609D 5/8 SC21-3 /21.B1 0.75 mm² 609B 5/8
TO
SC31-5 /21.A1 TO TO
C016-7 /23.C1 FROM 0.75 mm² 487 6/8 C015-5 /23.F6 FROM 0.75 mm² 485 6/8 C017-3 /23.D4 FROM 0.75 mm² 483 6/8
7/8 7/8 7/8
8/8 8/8 8/8
A
A
1 2 3 4 5 6 7 8
33 - 129 9813/9050-1 33 - 129

Page Page
33-130 33-131
Figure 913. (Part

1 1 of 2) 2 3 4
F
C001:A6 /25.D5 FROM
-C070
AUX STAB SPOOL
SC20-8 /23.B7 0.75 mm² 456G 1/8 5/8 0.75 mm² 609H
TO TO
/21.B1 SC21-9
SC21-8 /21.A1 0.75 mm² 609G 2/8 6/8 0.75 mm² 489
TO FROM
/23.F6 C015-3
C016-8 /23.C1 FROM 0.75 mm² 488 3/8 7/8
SC20-9 /23.B7 TO
0.75 mm² 456H 4/8 8/8
FROM ILLUMINATION /19.B5 FROM
SPLICE SP7
E -C071
LH STAB SPOOL TO 3626 J3 /23.E8 FROM 0.75 mm² 485D
P039:F11
0.75 mm² 456J 1/8 5/8 0.75 mm² 609K
SC20-10 /23.A7 TO TO
/21.B1 SC21-11
0.75 mm² 609J 2/8 6/8 0.75 mm² 491

SC21-10 /21.B1 TO FROM
/23.E5 C014-17
C014-16 /23.E5 FROM 0.75 mm² 490 3/8 7/8
0.75 mm² 456K 4/8 8/8

SC20-11 /23.A7 TO
-C072
RH STAB SPOOL
D SC20-12 /23.A7 TO
0.75 mm² 456L 1/8 5/8 0.75 mm² 609M TO
/21.C1 SC21-13
SC21-12 /21.B1 0.75 mm² 609L 2/8 6/8 0.75 mm² 493
TO FROM
/23.E4 C014-8
C014-15 /23.E5 FROM 1.00 mm² 492 3/8 7/8
0.75 mm² 456M 4/8 8/8

SC20-13 /23.A7 TO
Page 33-131
-C062 -SH001
C013-10 /23.F2 FROM 1.00 mm² 410 1/6 1/6
SC2-6 /3.C6 FROM 1.00 mm² 109E 2/6 2/6
C015-10 /23.F7 FROM 1.00 mm² 481 3/6 3/6
C 1.00 mm² 604C 4/6 4/6

SC16-3 /21.C1 TO
-P039 -C001
SP4 /25.D5 FROM 1.00 mm² 481 G2/84 G2/84 1.00 mm² 495 5/6 5/6
-P039 -C001
1.00 mm² 410 G1/84 G1/84 1.00 mm² 496 6/6 6/6
P072:16 /9.D5 FROM
-C069 -C068
CROWD/DUMP SPOOL EXTEND/RETRACT SPOOL
SC20-6 /23.B7 TO
0.75 mm² 456E 1/8 SC20-4 /23.B7 TO
0.75 mm² 456C 1/8
SC31-6 /21.A1 TO
0.75 mm² 609E 2/8 SC21-4 /21.B1 TO
0.75 mm² 609C 2/8
B C017-6 /23.D4 FROM 0.75 mm² 486 3/8 C015-4 /23.F6 FROM 0.75 mm² 484 3/8
SC20-7 /23.B7 TO
0.75 mm² 456F 4/8 SC20-5 /23.B7 TO
0.75 mm² 456D 4/8
SC31-7 /21.A1 0.75 mm² 609F 5/8 0.75 mm² 609D 5/8
TO
SC31-5 /21.A1 TO
C016-7 /23.C1 FROM 0.75 mm² 487 6/8 C015-5 /23.F6 FROM 0.75 mm² 485 6/8
7/8 7/8
8/8 8/8
1 2 3 4
33 - 130 9813/9050-1 33 - 130

Page Page
33-130 33-131
Figure 913. (Part

5 2 of 2) 6 7 8
-C065
TRAILER TIP VALVE
F
C001:A6 /25.D5 1.00 mm² 850 1/2 1/2 2/2 2/2 1.00 mm² 603P
FROM TO
/21.E5 SC7-7
-P036
STABILISER ISOLATION
8 7
FROM ILLUMINATION /19.B5 FROM 1.00 mm² 829AX 1.00 mm² 601DZ
SPLICE SP7
-P205
STAB ISO. 1K 300R TO
/20.E6 TO GROUND
1 0.75 mm² 485AA 1 2 1.00 mm² 699SA SPLICE SP11
0.75 mm² 485D 2 E
3
0.75 mm² 485E 4

5 -P206
STAB ISO. 5K 360R
6 0.75 mm² 485BB 1 2 1.00 mm² 699SC
-P207
STAB ISO. 10K
1 2
0.75 mm² 485F 1.00 mm² 699SB 1.00 mm² 699SK TO
-SP44 SPLICE SP42
-SH003 -SH002
RH STAB TRANSDUCER LH STAB TRANSDUCER D
4/4
2/4
4/4
2/4
3/4
3/4
1/4
1/4
3/4
3/4
4/4
2/4
1/4
4/4
2/4
1/4
Page 33-130
1.00 mm² 410
1.00 mm² 121F 1.00 mm² 121G

-SS2
1.00 mm² 481
1.00 mm² 604B 1.00 mm² 604C

-SS1
C
1.00 mm² 495
1.00 mm² 496
-C068 -C067
EXTEND/RETRACT SPOOL LIFT/LOWER SPOOL
1/8 SC20-2 /23.C7 TO

0.75 mm² 456A 1/8
2/8 SC21-2 /21.B1 TO

0.75 mm² 609A 2/8
3/8 C017-11 /23.D5 FROM 0.75 mm² 482 3/8

B
4/8 SC20-3 /23.B7 TO
0.75 mm² 456B 4/8
5/8 SC21-3 /21.B1 TO

0.75 mm² 609B 5/8
6/8 C017-3 /23.D4 FROM 0.75 mm² 483 6/8
7/8 7/8
8/8 8/8
5 6 7 8
33 - 131 9813/9050-1 33 - 131

33 - 132 9813/9050-1 33 - 132

Page 33-134 Figure 914. Joystick and Sway

Isolation 160/B4268 Issue 2- Sheet 32 Page 33-135
1 2 3 4 5 6 7 8
F
F
TO GROUND /20.B6 TO 1.00 mm² 601EN
SPLICE SP28 -P140

JOYSTICK ISOLATION
8 7
FROM ILLUMINATION /19.E5 FROM 0.75 mm² 829Y
SPLICE SP7
-P084
JOYSTICK ISO. 1K 300R
1 1 2 -SP43
-P039 0.75 mm² 433AA 0.75 mm² 699JJ 0.75 mm² 699CE TO
2
F4/84 0.75 mm² 433A SPLICE SP42
3
0.75 mm² 433B 4

5 -P085
0.75 mm² 433C JOYSTICK ISO. 5K 360R
6 0.75 mm² 433BB 1 2 0.75 mm² 699KK
-P086
JOYSTICK ISO. 10K
E 0.75 mm² 433C 1 2 0.75 mm² 699LL
E
TO GROUND /20.B4 TO 1.00 mm² 601SW
SPLICE SP6
-P141
SWAY SWITCH
8 7
FROM ILLUMINATION /19.E4 FROM 1.00 mm² 829SW
SPLICE SP7
-P141A
SWAY 1K 300R
1 1 2
1.00 mm² 552 1.00 mm² 699SL TO
2
D TO 3626 J3 /23.E8 FROM 1.00 mm² 551SW SPLICE SP42
P039:C1 3 D
4
5 -P141B
SWAY 5K 360R
6 1 2
1.00 mm² 553 1.00 mm² 699SM TO
SPLICE SP42
-P141C
SWAY 10K
1 2
1.00 mm² 551RE 1.00 mm² 699SO TO
SPLICE SP42
-AD
SWAY LEFT SOLENOID
C -C063 -AA
C
C016-13 1.00 mm² 931D 1/4 1/4 1.00 mm² 931D 1/2 1/2
/23.D2 FROM
1.00 mm² 600CT 2/2 2/2
-AB
SWAY RIGHT SOLENOID
C013-13 1.00 mm² 932D 2/4 2/4 1.00 mm² 932D 1/2 1/2
/23.F2 FROM
1.00 mm² 600CW 2/2 2/2
B
-AC B
SWAY ISO SOLENOID
C015-1 1.00 mm² 850E 3/4 3/4 1.00 mm² 850E 1/2 1/2
/23.F6 FROM
1.00 mm² 603BK 4/4 4/4 1.00 mm² 600CS 1.00 mm² 600CU 2/2 2/2
/21.F5 TO
SC7-4 -S1
A
A
1 2 3 4 5 6 7 8
33 - 133 9813/9050-1 33 - 133

Page Page
33-134 33-135
Figure 914. (Part

1 1 of 2) 2 3 4
F
TO GROUND /20.B6 TO 1.00 mm² 601EN
SPLICE SP28 -P140

JOYSTICK ISOLATION
8 7
FROM ILLUMINATION /19.E5 FROM 0.75 mm² 829Y
SPLICE SP7
-P084
1 0.75 mm² 433AA 1 2
-P039
F4/84 0.75 mm² 433A 2
3
0.75 mm² 433B 4

5 -P085
0.75 mm² 433C JOYSTICK ISO. 5K 360R
6 0.75 mm² 433BB 1 2
-P086
JOYSTICK ISO. 10K
E 0.75 mm² 433C 1 2
TO GROUND /20.B4 TO 1.00 mm² 601SW
SPLICE SP6
-P141
SWAY SWITCH
8 7
FROM ILLUMINATION /19.E4 FROM 1.00 mm² 829SW
SPLICE SP7
-P141A
SWAY 1K 300R
1 1.00 mm² 552 1 2
2
D TO 3626 J3 /23.E8 FROM 1.00 mm² 551SW
3
P039:C1
4
5 -P141B
SWAY 5K 360R
6 1.00 mm² 553 1 2
-P141C
SWAY 10K
1 2
Page 33-135
1.00 mm² 551RE
SWAY LEFT SOLENOID

C -C063 -AA
C016-13 1.00 mm² 931D 1/4 1/4 1.00 mm² 931D 1/2 1/2
/23.D2 FROM
1.00 mm² 600CT 2/2 2/2
SWAY RIGHT SOLENOID
C013-13 1.00 mm² 932D 2/4 2/4 1.00 mm² 932D 1/2 1/2
/23.F2 FROM
1.00 mm² 600CW 2/2 2/2
B
SWAY ISO SOLENOID
C015-1 1.00 mm² 850E 3/4 3/4 1.00 mm² 850E 1/2 1/2
/23.F6 FROM
1.00 mm² 603BK 4/4 4/4 1.00 mm² 600CS 1.00 mm² 600CU 2/2 2/2
/21.F5 TO
SC7-4 -S1
1 2 3 4
33 - 134 9813/9050-1 33 - 134

Page Page
33-134 33-135
Figure 914. (Part

5 2 of 2) 6 7 8
-P084
1 2 -SP43
0.75 mm² 699JJ 0.75 mm² 699CE TO
SPLICE SP42
-P085
1 2 0.75 mm² 699KK
-P086
JOYSTICK ISO. 10K
1 2 0.75 mm² 699LL
E
-P141A
SWAY 1K 300R
1 2 1.00 mm² 699SL TO
SPLICE SP42
D
-P141B
SWAY 5K 360R
1 2 1.00 mm² 699SM TO
SPLICE SP42
-P141C
SWAY 10K
1 2
Page 33-134
1.00 mm² 699SO TO

/20.C2
SPLICE SP42
-AD
SWAY LEFT SOLENOID
C
931D 1/2 1/2
600CT 2/2 2/2
-AB
SWAY RIGHT SOLENOID
932D 1/2 1/2
600CW 2/2 2/2
-AC B
SWAY ISO SOLENOID
850E 1/2 1/2
600CU 2/2 2/2
5 6 7 8
33 - 135 9813/9050-1 33 - 135

33 - 136 9813/9050-1 33 - 136

Page 33-138 Figure 915. E-Stop 160/B4268 Issue 2- Sheet 33 Page 33-139
1 2 3 4 5 6 7 8
F
F
E
E
-RC18
701/80644
E-STOP SWITCH
PUSH
-C001 -P039 -P049 -RC01

D TO 3626 J3 /23.F7 1.00 mm² 145TS F1/84 F1/84 1.00 mm² 810ES 17/20 17/20 1.00 mm² 810ES 1/4 1 3 3/4 1.00 mm² LINK
D
FROM
C015:13
TO 5V REF /26.E2 1.00 mm² 456ES 18/20 18/20 1.00 mm² 456ES 2/4 2 4 4/4
FROM
SP10
C
C
B
B
A
A
1 2 3 4 5 6 7 8
33 - 137 9813/9050-1 33 - 137

Page Page
33-138 33-139
Figure 915.1(Part 1 of 2) 2 3 4
-RC18
701/80644
E-STOP SWITCH
PUSH
-C001 -P039 -P049 -RC01

D TO 3626 J3 /23.F7 FROM 1.00 mm² 145TS F1/84 F1/84 1.00 mm² 810ES 17/20 17/20 1.00 mm² 810ES 1/4 1 3 3/4 1.00 mm² LINK
C015:13
TO 5V REF /26.E2 1.00 mm² 456ES 18/20 18/20 1.00 mm² 456ES 2/4 2 4 4/4
FROM
SP10
Page 33-139
C
1 2 3 4
33 - 138 9813/9050-1 33 - 138

Page Page
33-138 33-139
Figure 915. (Part

5 2 of 2) 6 7 8
1.00 mm² LINK

D
Page 33-138
5 6 7 8
33 - 139 9813/9050-1 33 - 139

Table 469.
Sheet Content
2 Battery And Primary Fuses
3 Ignition And Secondary Fuses
4 Engine- Fuse And Starter Motor
5 Engine- ECU (Electronic Control Unit) And Sensors
6 Engine- After Treatment
7 Transmission
8 Livelink and Immobiliser
9 Instruments
10 Roadlights
11 Directional Indicators
12 Worklights And Beacon
13 Wiper Motors
14 HVAC (Heating Ventilation Air Conditioning)
15 In Cab Entertainment
16 Reverse Fan
17 CAN (Controller Area Network) Bus
18 CAN Bus Engine
19 Switch Illumination Splice
20 Ground Panel Splices
21 Ground Chassis Splices
22 Transmission ECU
23 Hydraulic ECU
24 Pin Lock
25 Hitch Harness
26 Steer Mode
27 Park Brake & Auto Manual
28 SRS (Smooth Ride System)
29 LLMI (Longitudinal Load Moment Indicator)
30 Footbrake Dump
31 Valve Block
32 Joystick And Sway Isolation
33 E-Stop
33 - 140 9813/9050-1 33 - 140

(For: 531-70 [5AA], 535-95 [5AB], 541-70 [5AD])

Figure 916. Primary Fuses, Secondary Fuses, Ignition Relays 160/16000 Issue 1 (sheet 1 of
20)......................................................................................................................................... Page 33-143
Figure 917. Engine Senders, Starting and Charging 160/16000 Issue 1 (sheet 2 of 20)......Page 33-147
Figure 918. Instruments, Warning Lamps 160/16000 Issue 1 (sheet 3 of 20)......................Page 33-151
Figure 919. Road light, Reverse Alarm, Trailer Electrics 160/16000 Issue 1 (sheet 4 of
20)......................................................................................................................................... Page 33-155
Figure 920. Work lights, Rotating Beacon, Heated Seat, Interior light 160/16000 Issue 1 (sheet 5 of
20)......................................................................................................................................... Page 33-159
Figure 921. Horn, Wipers, Heater, Air Conditioning, Low Beam, Main Beam and Indicator Switching
160/16000 Issue 1 (sheet 6 of 20)....................................................................................... Page 33-163
Figure 922. 6 Speed Transmission Control Machine Interface 160/16000 Issue 1 (sheet 7 of
20)......................................................................................................................................... Page 33-167
Figure 923. 6 Speed Transmission Control Gearbox Interface, Tow Mode Control 160/16000 Issue 1
(sheet 8 of 20)...................................................................................................................... Page 33-171
Figure 924. Steer Mode Control 160/16000 Issue 1 (sheet 9 of 20).................................... Page 33-175
Figure 925. LSP Hydraulic Control 160/16000 Issue 1 (sheet 10 of 20).............................. Page 33-179
Figure 926. Smooth Ride System 160/16000 Issue 1 (sheet 11 of 20)................................Page 33-183
Figure 927. Inloader Control, Reverse Fan, Hitch Control, LLMI, Sway Control 160/16000 Issue 1
(sheet 12 of 20).................................................................................................................... Page 33-187
Figure 928. Twin Auxiliary- Non LSP Hydraulics 160/16000 Issue 1 (sheet 13 of 20)..........Page 33-191
Figure 929. Single Auxiliary- Non LSP Hydraulics 160/16000 Issue 1 (sheet 14 of 20)....... Page 33-195
Figure 930. In Cab Entertainment 160/16000 Issue 1 (sheet 15 of 20)............................... Page 33-199
Figure 931. Engine Splices, Chassis Splices 160/16000 Issue 1 (sheet 16 of 20)...............Page 33-203
Figure 932. Cab Splices 160/16000 Issue 1 (sheet 17 of 20)..............................................Page 33-207
Figure 935. Cab Splices, Rear Cab Ground 160/16000 Issue 1 (sheet 20 of 20)................ Page 33-219
33 - 141 9813/9050-1 33 - 141

Notes:
33 - 142 9813/9050-1 33 - 142

Figure 916. Primary Fuses,
Page 33-144 Secondary Fuses, Ignition Relays

160/16000 Issue 1 (sheet 1 of 20) Page 33-145
33 - 143 9813/9050-1 33 - 143

Page Page
33-144 33-145
Page 33-145
33 - 144 9813/9050-1 33 - 144

Page Page
33-144 33-145

Page 33-144
33 - 145 9813/9050-1 33 - 145

33 - 146 9813/9050-1 33 - 146

Page 33-148 Figure 917. Engine Senders, Starting and

Charging 160/16000 Issue 1 (sheet 2 of 20) Page 33-149
33 - 147 9813/9050-1 33 - 147

Page Page
33-148 33-149
Page 33-149
33 - 148 9813/9050-1 33 - 148

Page Page
33-148 33-149

Page 33-148
33 - 149 9813/9050-1 33 - 149

33 - 150 9813/9050-1 33 - 150

Page 33-152 Figure 918. Instruments, Warning

Lamps 160/16000 Issue 1 (sheet 3 of 20) Page 33-153
33 - 151 9813/9050-1 33 - 151

Page Page
33-152 33-153
Page 33-153
33 - 152 9813/9050-1 33 - 152

Page Page
33-152 33-153

Page 33-152
33 - 153 9813/9050-1 33 - 153

33 - 154 9813/9050-1 33 - 154

Page 33-156 Figure 919. Road light, Reverse Alarm, Trailer

Electrics 160/16000 Issue 1 (sheet 4 of 20) Page 33-157
33 - 155 9813/9050-1 33 - 155

Page Page
33-156 33-157
Page 33-157
33 - 156 9813/9050-1 33 - 156

Page Page
33-156 33-157

Page 33-156
33 - 157 9813/9050-1 33 - 157

33 - 158 9813/9050-1 33 - 158

Figure 920. Work lights, Rotating
Page 33-160 Beacon, Heated Seat, Interior light

33 - 159 9813/9050-1 33 - 159

Page Page
33-160 33-161
Page 33-161
33 - 160 9813/9050-1 33 - 160

Page Page
33-160 33-161

Page 33-160
33 - 161 9813/9050-1 33 - 161

33 - 162 9813/9050-1 33 - 162

Figure 921. Horn, Wipers, Heater,

Air Conditioning, Low Beam, Main
Page 33-164 Beam and Indicator Switching

33 - 163 9813/9050-1 33 - 163

Page Page
33-164 33-165
Page 33-165
33 - 164 9813/9050-1 33 - 164

Page Page
33-164 33-165

Page 33-164
33 - 165 9813/9050-1 33 - 165

33 - 166 9813/9050-1 33 - 166

Figure 922. 6 Speed Transmission
Page 33-168 Control Machine Interface

33 - 167 9813/9050-1 33 - 167

Page Page
33-168 33-169
Page 33-169
33 - 168 9813/9050-1 33 - 168

Page Page
33-168 33-169

Page 33-168
33 - 169 9813/9050-1 33 - 169

33 - 170 9813/9050-1 33 - 170

Figure 923. 6 Speed Transmission
Page 33-172 Control Gearbox Interface, Tow Mode

Control 160/16000 Issue 1 (sheet 8 of 20) Page 33-173
33 - 171 9813/9050-1 33 - 171

Page Page
33-172 33-173
Page 33-173
33 - 172 9813/9050-1 33 - 172

Page Page
33-172 33-173

Page 33-172
33 - 173 9813/9050-1 33 - 173

33 - 174 9813/9050-1 33 - 174

Page 33-176 Figure 924. Steer Mode Control

33 - 175 9813/9050-1 33 - 175

Page Page
33-176 33-177
Page 33-177
33 - 176 9813/9050-1 33 - 176

Page Page
33-176 33-177

Page 33-176
33 - 177 9813/9050-1 33 - 177

33 - 178 9813/9050-1 33 - 178

Page 33-180 Figure 925. LSP Hydraulic Control

33 - 179 9813/9050-1 33 - 179

Page Page
33-180 33-181
Page 33-181
33 - 180 9813/9050-1 33 - 180

Page Page
33-180 33-181

Page 33-180
33 - 181 9813/9050-1 33 - 181

33 - 182 9813/9050-1 33 - 182

Page 33-184 Figure 926. Smooth Ride System

33 - 183 9813/9050-1 33 - 183

Page Page
33-184 33-185
Page 33-185
33 - 184 9813/9050-1 33 - 184

Page Page
33-184 33-185

Page 33-184
33 - 185 9813/9050-1 33 - 185

33 - 186 9813/9050-1 33 - 186

Figure 927. Inloader Control, Reverse
Page 33-188 Fan, Hitch Control, LLMI, Sway Control

33 - 187 9813/9050-1 33 - 187

Page Page
33-188 33-189
Page 33-189
33 - 188 9813/9050-1 33 - 188

Page Page
33-188 33-189

Page 33-188
33 - 189 9813/9050-1 33 - 189

33 - 190 9813/9050-1 33 - 190

Page 33-192 Figure 928. Twin Auxiliary- Non LSP

Hydraulics 160/16000 Issue 1 (sheet 13 of 20) Page 33-193
33 - 191 9813/9050-1 33 - 191

Page Page
33-192 33-193
Page 33-193
33 - 192 9813/9050-1 33 - 192

Page Page
33-192 33-193

Page 33-192
33 - 193 9813/9050-1 33 - 193

33 - 194 9813/9050-1 33 - 194

Page 33-196 Figure 929. Single Auxiliary- Non LSP

Hydraulics 160/16000 Issue 1 (sheet 14 of 20) Page 33-197
33 - 195 9813/9050-1 33 - 195

Page Page
33-196 33-197
Page 33-197
33 - 196 9813/9050-1 33 - 196

Page Page
33-196 33-197

Page 33-196
33 - 197 9813/9050-1 33 - 197

33 - 198 9813/9050-1 33 - 198

Page 33-200 Figure 930. In Cab Entertainment

33 - 199 9813/9050-1 33 - 199

Page Page
33-200 33-201
Page 33-201
33 - 200 9813/9050-1 33 - 200

Page Page
33-200 33-201

Page 33-200
33 - 201 9813/9050-1 33 - 201

33 - 202 9813/9050-1 33 - 202

Page 33-204 Figure 931. Engine Splices, Chassis

Splices 160/16000 Issue 1 (sheet 16 of 20) Page 33-205
33 - 203 9813/9050-1 33 - 203

Page Page
33-204 33-205
Page 33-205
33 - 204 9813/9050-1 33 - 204

Page Page
33-204 33-205

Page 33-204
33 - 205 9813/9050-1 33 - 205

33 - 206 9813/9050-1 33 - 206

Page 33-208 Figure 932. Cab Splices

33 - 207 9813/9050-1 33 - 207

Page Page
33-208 33-209
Page 33-209
33 - 208 9813/9050-1 33 - 208

Page Page
33-208 33-209

Page 33-208
33 - 209 9813/9050-1 33 - 209

33 - 210 9813/9050-1 33 - 210


33 - 211 9813/9050-1 33 - 211

Page Page
33-212 33-213
Page 33-213
33 - 212 9813/9050-1 33 - 212

Page Page
33-212 33-213

Page 33-212
33 - 213 9813/9050-1 33 - 213

33 - 214 9813/9050-1 33 - 214


33 - 215 9813/9050-1 33 - 215

Page Page
33-216 33-217
Page 33-217
33 - 216 9813/9050-1 33 - 216

Page Page
33-216 33-217

Page 33-216
33 - 217 9813/9050-1 33 - 217

33 - 218 9813/9050-1 33 - 218

Page 33-220 Figure 935. Cab Splices, Rear Cab

Ground 160/16000 Issue 1 (sheet 20 of 20) Page 33-221
33 - 219 9813/9050-1 33 - 219

Page Page
33-220 33-221
Page 33-221
33 - 220 9813/9050-1 33 - 220

Page Page
33-220 33-221

Page 33-220
33 - 221 9813/9050-1 33 - 221

(For: 531-70 [5AA], 535-95 [5AB], 541-70 [5AD], JCB Tier 4F Elec 430 Engine 4 Cyl)
Figure 936. Engine Pod Schematic- JCB 430 (160/H3446-1) Page 1................................. Page 33-223
33 - 222 9813/9050-1 33 - 222

Page 33-224 Figure 936. Engine Pod Schematic-

JCB 430 (160/H3446-1) Page 1 Page 33-225
1 2 3 4 5 6
D
D
FUSE/RELAY BOX
START SIGNAL
(MICRO RELAY)
K2
B G
-BC8 STARTER RELAY 1 N F3

1.50 mm² E407 N/21 C
-WIF SENSOR /2.B2 TO
C
-E002 7212/0179
1/2 1/2 0.75 mm² E401 WATER IN FUEL SIG K F5 - 10A
FROM
/2.B2
2/2 2/2 0.50 mm² E601B GND TO
/2.B2
J F6 - 10A
FUEL PUMP
(MICRO RELAY)
-E003 FUEL PUMP
K3
-E003
1/2 1/2 1.50 mm² E801 1.50 mm² E801 L/21 L F2 - 10A
2/2 1.50 mm² E601F GND TO

/5.D2
2/2 Fuel Lift Pump Relay
0.75 mm² E408 M/21 M F4 - 3A
/2.C2 TO
GLOW PLUG TRELAY SIGNAL

1.50 mm² E117 H/21 H F7 - 10A
/5.B6 FROM
Starter relay contact monitor

0.75 mm² E106 X/2 X F8 - 10A
/2.B2 TO
W F9 - 10A
BATTERY 1.50 mm² E108 V F17 - 10A B

V/21
B /2.C2 TO
BATTERY 1.50 mm² E109 U/21 U F16 - 10A
/2.C2 TO POWER HOLD RELAY
K1 D
T F15 - 10A
E E/21 4.00 mm² E300 BATT +VE
-E005 7218/0050 TO
/3.C1
1/8 0.50 mm² 5512
2/8 0.50 mm² 5021 S F14 - 10A F1 - 3A
3/8 0.50 mm² CAN 2 H

-SDMC01 0.50 mm² CAN 2 HI CAN 2 HI
FROM
/2.B3
4/8 0.50 mm² CAN 2 L -SDMC02 0.50 mm² CAN 2 L CAN 2 LO R F13 - 5A
FROM
/2.C3
1/1 -SDMC03 CUT END 0.50 mm² 5512 A/21 A F11 - 5A
-C1 CUTEND CUTEND

1/1-C2
CUT END 5/8 2.00 mm² 200GP1 GP4
FROM
/5.C4 160/H3446-1
6/8 2.00 mm² 200GP2 GP4 0.50 mm² 5021 F/21 F F12 - 3A
FROM
/5.C4
7/8 2.00 mm² 200GP3 GP4
FROM
/5.C4
8/8 2.00 mm² 200GP4 GP4 C F10 - 5A
FROM
/5.C4
-C3 1/1 CUTEND
CUT END
727/00002
MAIN POWER RELAY 1.50 mm² E400 P/21 P

-E007 7213/0015 /2.B2 TO
-CAN1
B/3 0.50 mm² CAN 2 LO

SCREEN
A
A B
A A/3 0.50 mm² CAN 2 HI
-MC1:TW1 -MC1:SH1
1 2 3 4 5 6
33 - 223 9813/9050-1 33 - 223

Page Page
33-224 33-225
Figure 936. (Part

1
1 of 2) 2 3
-BC8 STARTER RELAY 1 N

1.50 mm² E407 N/21
-WIF SENSOR /2.B2 TO
C
-E002 7212/0179
1/2 1/2 0.75 mm² E401 WATER IN FUEL SIG K
FROM
/2.B2
2/2 2/2 0.50 mm² E601B GND TO
/2.B2
J
-E003 FUEL PUMP

-E003
1/2 1/2 1.50 mm² E801 1.50 mm² E801 L/21 L
Page 33-225
2/2 1.50 mm² E601F GND TO
/5.D2
2/2 Fuel Lift Pump Relay
0.75 mm² E408 M/21 M
/2.C2 TO
GLOW PLUG TRELAY SIGNAL

1.50 mm² E117 H/21 H
/5.B6 FROM
Starter relay contact monitor

0.75 mm² E106 X/2 X
/2.B2 TO
BATTERY 1.50 mm² E108 V/21 V

B /2.C2 TO
BATTERY 1.50 mm² E109 U/21 U

/2.C2 TO
T
-E005 7218/0050
1/8 0.50 mm² 5512
2/8 0.50 mm² 5021 S
3/8 0.50 mm² CAN 2 H

-SDMC01 0.50 mm² CAN 2 HI CAN 2 HI
FROM
/2.B3
4/8 0.50 mm² CAN 2 L -SDMC02 0.50 mm² CAN 2 L CAN 2 LO R
FROM
/2.C3
1/1 -SDMC03 CUT END 0.50 mm² 5512 A/21 A
-C1 CUTEND CUTEND
1/1-C2
CUT END 5/8 2.00 mm² 200GP1 GP4
FROM
/5.C4
6/8 2.00 mm² 200GP2 GP4 0.50 mm² 5021 F/21 F
FROM
/5.C4
7/8 2.00 mm² 200GP3 GP4
FROM
/5.C4
8/8 2.00 mm² 200GP4 GP4 C
FROM
/5.C4
-C3 1/1 CUTEND
CUT END
727/00002
MAIN POWER RELAY 1.50 mm² E400 P/21 P

-E007 7213/0015 /2.B2 TO
-CAN1
B/3 0.50 mm² CAN 2 LO

SCREEN
A B
A A/3 0.50 mm² CAN 2 HI
-MC1:TW1 -MC1:SH1
1 2 3
33 - 224 9813/9050-1 33 - 224

Page Page
33-224 33-225
Figure 936. (Part 42 of 2) 5 6
FUSE/RELAY BOX
START SIGNAL
(MICRO RELAY)
K2
B G
N/21 N F3
C
K F5 - 10A
J F6 - 10A
FUEL PUMP
(MICRO RELAY)
K3
L/21 L F2 - 10A
Page 33-224
M/21 M F4 - 3A
H/21 H F7 - 10A
X/2 X F8 - 10A
W F9 - 10A
V F17 - 10A B
V/21
U/21 U F16 - 10A

POWER HOLD RELAY
K1 D
T F15 - 10A
E E/21 4.00 mm² E300 BATT +VE
TO
/3.C1
S F14 - 10A F1 - 3A
R F13 - 5A
A/21 A F11 - 5A
160/H3446-1
F/21 F F12 - 3A
C F10 - 5A
P/21 P
4 5 6
33 - 225 9813/9050-1 33 - 225

33 - 226 9813/9050-1 33 - 226


JCB 430 (160/H3446-1) Page 2 Page 33-229
1 2 3 4 5 6
D
D
BLOCK_7219/0268
-ENGINE ECU
-E004
4/64 D1/64 0.75 mm² E408 Fuel Lift Pump Relay
/1.B3
FROM
9/64 J1/64 0.75 mm² E616 GRID HEATER RELAY

/5.B4
FROM
15/64 P1/64 1.50 mm² E600B GROUND TO

/5.B2
16/64 Q1/64 1.50 mm² E108 BATTERY
/1.B3
FROM
17/64 A2/64 0.75 mm² CAN H -SPMC04 0.50 mm² CAN H CAN 1 HI C
FROM
/4.C2
C 18/64 B2/64 0.75 mm² CAN L -SDMC04 0.50 mm² CAN 2 L CAN 2 LO TO
/1.A2
20/64 D2/64 0.75 mm² E425 Acc Pedal 2 GND
TO
/3.B1
21/64 E2/64 0.75 mm² E426 Acc Pedal 2 SIG
TO
/3.B1
22/64 F2/64 0.75 mm² E427 Acc Pedal 2 SUPPLY
TO
/3.C1
26/64
27/64
31/64 P2/64 1.50 mm² E600A GROUND TO

/5.B2
32/64 Q2/64 1.50 mm² E109 BATTERY
/1.B3
FROM
33/64 A3/64 0.75 mm² CAN L -SPMC05 0.50 mm² CAN L CAN 1 LO
FROM
/4.C2
34/64 B3/64 0.75 mm² CAN H -SDMC05 0.50 mm² CAN 2 HI CAN 2 HI TO
/1.B2
40/64 H3/64 0.75 mm² E401 WATER IN FUEL SIG
TO
/1.C2
46/64 O3/64 0.75 mm² E842B STARTER MOTOR RELAY
TO
/3.C3
47/64 P3/64 1.50 mm² E600C GROUND TO
/5.B2
48/64 Q3/64 1.50 mm² E407 STARTER RELAY 1
/1.C3
FROM
52/64 D4/64 0.75 mm² E106 Starter relay contact monitor

/1.B3
FROM
58/64 K4/64 0.50 mm² E428 Accelerator Pedal 1 GND

TO
/3.C1
59/64 L4/64 0.50 mm² E429 Acc Pedal 1 SIG
TO
/3.C1 B
60/64 M4/64 0.50 mm² E430 Acc Pedal 1 SUPPLY
B
TO
/3.C1 160/H3446-1
61/64 N4/64 0.50 mm² E601B GND
/1.C2
FROM
63/64 P4/64 1.50 mm² E103 IGN

/3.C1
FROM
64/64 Q4/64 1.50 mm² E400 MAIN POWER RELAY

/1.A3
FROM
A
A
1 2 3 4 5 6
33 - 227 9813/9050-1 33 - 227

Page Page
33-228 33-229
Figure 937. (Part

1
1 of 2) 2 3
BLOCK_7219/0268
-ENGINE ECU
-E004
4/64 D1/64 0.75 mm² E408 Fuel Lift Pump Relay
/1.B3
FROM
9/64 J1/64 0.75 mm² E616 GRID HEATER RELAY

/5.B4
FROM
15/64 P1/64 1.50 mm² E600B GROUND TO

/5.B2
16/64 Q1/64 1.50 mm² E108 BATTERY
/1.B3
FROM
17/64 A2/64 0.75 mm² CAN H -SPMC04 0.50 mm² CAN H CAN 1 HI
FROM
/4.C2
C 18/64 B2/64 0.75 mm² CAN L -SDMC04 0.50 mm² CAN 2 L CAN 2 LO TO
/1.A2
20/64 D2/64 0.75 mm² E425 Acc Pedal 2 GND
TO
/3.B1
21/64 E2/64 0.75 mm² E426 Acc Pedal 2 SIG
TO
/3.B1
22/64 F2/64 0.75 mm² E427 Acc Pedal 2 SUPPLY
TO
/3.C1
26/64
27/64
31/64 P2/64 1.50 mm² E600A GROUND

/5.B2
Page 33-229
TO
32/64 Q2/64 1.50 mm² E109 BATTERY

/1.B3
FROM
33/64 A3/64 0.75 mm² CAN L -SPMC05 0.50 mm² CAN L CAN 1 LO
FROM
/4.C2
34/64 B3/64 0.75 mm² CAN H -SDMC05 0.50 mm² CAN 2 HI CAN 2 HI TO
/1.B2
40/64 H3/64 0.75 mm² E401 WATER IN FUEL SIG
TO
/1.C2
46/64 O3/64 0.75 mm² E842B STARTER MOTOR RELAY
TO
/3.C3
47/64 P3/64 1.50 mm² E600C GROUND TO
/5.B2
48/64 Q3/64 1.50 mm² E407 STARTER RELAY 1
/1.C3
FROM
52/64 D4/64 0.75 mm² E106 Starter relay contact monitor

/1.B3
FROM
58/64 K4/64 0.50 mm² E428 Accelerator Pedal 1 GND

TO
/3.C1
59/64 L4/64 0.50 mm² E429 Acc Pedal 1 SIG
TO
/3.C1
60/64 M4/64 0.50 mm² E430 Acc Pedal 1 SUPPLY
B
TO
/3.C1 160/H3446-1
61/64 N4/64 0.50 mm² E601B GND
/1.C2
FROM
63/64 P4/64 1.50 mm² E103 IGN

/3.C1
FROM
64/64 Q4/64 1.50 mm² E400 MAIN POWER RELAY

/1.A3
FROM
1 2 3
33 - 228 9813/9050-1 33 - 228

Page Page
33-228 33-229
C
Page 33-228
4 5 6
33 - 229 9813/9050-1 33 - 229

33 - 230 9813/9050-1 33 - 230


JCB 430 (160/H3446-1) Page 3 Page 33-233
1 2 3 4 5 6
D
D
C
C 1/29 4.00 mm² E300 BATT +VE
FROM
/1.B5
2/29 2.00 mm² E842A
3/29 4.00 mm² E600 GROUND TO
/5.C2
4/29 2.00 mm² E842 0.75 mm² E842B STARTER MOTOR RELAY FROM
/2.B2
5/29 1.50 mm² E103 IGN -S4
TO
/2.B2
6/29 0.50 mm² E430 Acc Pedal 1 SUPPLY
/2.B2
FROM
7/29 0.50 mm² E429 Acc Pedal 1 SIG

/2.B2
FROM
8/29 0.50 mm² E428 Accelerator Pedal 1 GND

/2.B2
FROM

/2.C2
FROM

/2.C2
FROM
11/29 0.75 mm² E425 Acc Pedal 2 GND

/2.C2
FROM
-SCREEN 3
12/29 1.00 mm² SCR 0.50 mm² SCREEN SCREEN
FROM
/4.D2
13/29 0.50 mm² CAN H CAN 1 HI
FROM
/4.C3
14/29 0.50 mm² CAN L CAN 1 LO
FROM
/4.C3 -SPEED SENSOR
15/29 1.00 mm² 106SS
16/29 1.00 mm² 601SS 1.00 mm² 601SS -E014
17/29 2.00 mm² E601 GND 1 1/6 1.00 mm² 106SS
TO
/5.D2 B+ (RED) B
18/29 1.00 mm² 593 1.00 mm² 593 2/6 2
B GND (BLK)
19/29 1.00 mm² 1840 -REV FAN 3/6 3
-E012 OUT A (WHITE)
20/29 1.00 mm² 603T 1.00 mm² 1840 1/2 1/2
21/29 1.00 mm² 592 1.00 mm² 603T 2/2 2/2 4
B+ (ORANGE)
22/29 1.00 mm² 615 -PROP FAN 5
GND (BROWN)
2.00 mm² E115B 1/1 1.00 mm² 592 1/2 1/2 6
-E024/2 -E025 OUT B (YELLOW)
1.00 mm² 615 2/2 2/2 -E006
1/2 1/2 2/2 2/2 GND
25/29 2.00 mm² E115A 2.00 mm² E115 2.00 mm² E601J
/5.C2 -VACUUM SWITCH1
-AC COMP
TO
26/29 2.00 mm² E116 1/1 -S3 1/2 1 2 2/2 0.50 mm² E601K GND
-E024-1 TO
/5.C2
27/29 0.50 mm² E441 -E011 -E011
28/29 1.00 mm² 100TT 1/2 1 2 2/2 1.00 mm² 600TT
+ SIG
29/29 1.00 mm² 600TT
160/H3446-1
-TRANS OIL TEMP
A
A
1 2 3 4 5 6
33 - 231 9813/9050-1 33 - 231

Page Page
33-232 33-233
Figure 938. (Part

1
1 of 2) 2 3
C 1/29 4.00 mm² E300 BATT +VE

FROM
/1.B5
2/29 2.00 mm² E842A
3/29 4.00 mm² E600 GROUND TO
/5.C2
4/29 2.00 mm² E842 0.75 mm² E842B STARTER MOTOR RELAY FROM
/2.B2
5/29 1.50 mm² E103 IGN -S4
TO
/2.B2
/2.B2
FROM

/2.B2
FROM
8/29 0.50 mm² E428 Accelerator Pedal 1 GND

/2.B2
Page 33-233
FROM

/2.C2
FROM

/2.C2
FROM
11/29 0.75 mm² E425 Acc Pedal 2 GND

/2.C2
FROM
-SCREEN 3
12/29 1.00 mm² SCR 0.50 mm² SCREEN SCREEN
FROM
/4.D2
13/29 0.50 mm² CAN H CAN 1 HI
FROM
/4.C3
14/29 0.50 mm² CAN L CAN 1 LO
FROM
/4.C3
15/29 1.00 mm² 106SS
16/29 1.00 mm² 601SS 1.00 mm² 601SS
17/29 2.00 mm² E601 GND TO
/5.D2
18/29 1.00 mm² 593 1.00 mm² 593 2/6
B -REV FAN
19/29 1.00 mm² 1840 3/6
-E012
20/29 1.00 mm² 603T 1.00 mm² 1840 1/2 1/2
21/29 1.00 mm² 592 1.00 mm² 603T 2/2 2/2
22/29 1.00 mm² 615 -PROP FAN
2.00 mm² E115B 1/1 1.00 mm² 592 1/2 1/2
-E024/2 -E025
1.00 mm² 615 2/2 2/2
1/2 1/2 2/2 2/2 GND
25/29 2.00 mm² E115A 2.00 mm² E115 2.00 mm² E601J
-AC COMP
TO
/5.C2
26/29 2.00 mm² E116 1/1 -S3
-E024-1
27/29 0.50 mm² E441 -E011 -E011
28/29 1.00 mm² 100TT 1/2 1 2 2/2 1.00 mm² 600TT
+ SIG
29/29 1.00 mm² 600TT
-TRANS OIL TEMP
1 2 3
33 - 232 9813/9050-1 33 - 232

Page Page
33-232 33-233
C
Page 33-232
-SPEED SENSOR
-E014
1 1/6 1.00 mm² 106SS
B+ (RED) B
2/6 2
GND (BLK)
3/6 3
OUT A (WHITE)
4
B+ (ORANGE)
-PROP FAN 5
GND (BROWN)
1/2 6
OUT B (YELLOW)
2/2 -E006
-VACUUM SWITCH1
1/2 1 2 2/2 0.50 mm² E601K GND TO
/5.C2
160/H3446-1
4 5 6
33 - 233 9813/9050-1 33 - 233

33 - 234 9813/9050-1 33 - 234


JCB 430 (160/H3446-1) Page 4 Page 33-237
1 2 3 4 5 6
D
D
-SCREEN 1
0.50 mm² SCREEN
-POWERTRAIN CAN BUS
0.50 mm² SCREEN SCREEN

-SPMC03 TO
/3.B1
-E010
-SCREEN 2
RESISTOR
C/3 0.75 mm² SCR 0.50 mm² SCREEN

CAN 1 LO TO
/2.B3
-SPMC02
C
B/3 0.50 mm² CAN L 0.50 mm² CAN L CAN 1 LO TO

/3.B1
-SPMC01
A B
A/3 0.50 mm² CAN H 0.50 mm² CAN H CAN 1 HI TO

/3.B1
CAN 1 HI
-PMC01:SH1 -PMC01:TW1 TO
/2.C3
160/H3446-1
C
C
B
B
A
A
1 2 3 4 5 6
33 - 235 9813/9050-1 33 - 235

Page Page
33-236 33-237
Figure 939. (Part

1
1 of 2) 2 3
D
-SCREEN 1
0.50 mm² SCREEN

-POWERTRAIN CAN BUS
0.50 mm² SCREEN SCREEN

-SPMC03 TO
/3.B1
-E010
-SCREEN 2
CAN 1 LO
RESISTOR
C/3 0.75 mm² SCR 0.50 mm² SCREEN TO

/2.B3
-SPMC02
C
B/3 0.50 mm² CAN L 0.50 mm² CAN L CAN 1 LO TO

/3.B1
-SPMC01
A B
A/3 0.50 mm² CAN H 0.50 mm² CAN H CAN 1 HI TO

/3.B1
CAN 1 HI
-PMC01:SH1 -PMC01:TW1 TO
/2.C3
160/H3446-1
Page 33-237
B
1 2 3
33 - 236 9813/9050-1 33 - 236

Page Page
33-236 33-237
C
Page 33-236
4 5 6
33 - 237 9813/9050-1 33 - 237

33 - 238 9813/9050-1 33 - 238


JCB 430 (160/H3446-1) Page 5 Page 33-241
1 2 3 4 5 6
D
D
GND 2.00 mm² E601

/3.B1 FROM
GND 1.50 mm² E601F

/1.C2 FROM
-S2
GND 2.00 mm² E601J
/3.B3 FROM
GND 0.50 mm² E601K

/3.A5 FROM
GP4 2.00 mm² 200GP1

/1.A2 TO
GP4 2.00 mm² 200GP2

/1.A2 TO
GP4 2.00 mm² 200GP3

/1.A2 TO
GP4 2.00 mm² 200GP4

/1.A2 TO
-S5
GLOWPLUG SPLICE
C
C
GROUND 4.00 mm² E600

/3.C1 FROM
GROUND
/2.C2 FROM 1.50 mm² E600A -R1
GROUND 1.50 mm² E600B 716/30252
/2.C2 FROM
GROUND 1.50 mm² E600C GLOWPLUG RELAY

/2.B2 FROM
-S1 -T6 7207/1316

20.00 mm² RED 7208/1126 -T5 M6 3 4 M6 10.00 mm² 200GP
GRID HEATER RELAY 2/2 1 2

0.75 mm² E616 1/2 1.50 mm² GLOW
E117 PLUG TRELAY SIGNAL
/2.C2 TO TO
/1.B3
GLOWPLUG FUSE -E020
7208/1126 7207/1405 7207/1405
-FU1 7212/0044
-T2 B
M6 20.00 mm² RED -T3 M8 1 80A 2 M8 -T4
B
-FB2 160/H3446-1
716/30224
MEGA FUSE HOLDER
7208/1007
-T1
-VE +VE
LUG LUG
-BAT1
332/F0839
A
A
1 2 3 4 5 6
33 - 239 9813/9050-1 33 - 239

Page Page
33-240 33-241
Figure 940. (Part

1
1 of 2) 2 3
GND 2.00 mm² E601

/3.B1 FROM
GND 1.50 mm² E601F

/1.C2 FROM
-S2
GND 2.00 mm² E601J
/3.B3 FROM
GND 0.50 mm² E601K

/3.A5 FROM
/1.A2
/1.A2
/1.A2
/1.A2
Page 33-241
GROUND 4.00 mm² E600
/3.C1 FROM
GROUND 1.50 mm² E600A

/2.C2 FROM
GROUND 1.50 mm² E600B

/2.C2 FROM
GROUND 1.50 mm² E600C

/2.B2 FROM
-S1
7208/1126 7207/1405 GLOWPLUG FUSE 7207/1405

-T2 -FU1
M6 20.00 mm² RED -T3 M8 1 80A 2 M8 -T4
B
-FB2
716/30224
MEGA FUSE HOLDER
7208/1007
-T1
-VE +VE
LUG LUG
-BAT1
332/F0839
1 2 3
33 - 240 9813/9050-1 33 - 240

Page Page
33-240 33-241
GP4 2.00 mm² 200GP1

/1.A2 TO
GP4 2.00 mm² 200GP2

/1.A2 TO
GP4 2.00 mm² 200GP3

/1.A2 TO
GP4 2.00 mm² 200GP4

/1.A2 TO
-S5
GLOWPLUG SPLICE
C
Page 33-240
-R1
716/30252
GLOWPLUG RELAY
-T6 7207/1316
20.00 mm² RED 7208/1126 -T5 M6 3 4 M6 10.00 mm² 200GP
GRID HEATER RELAY 2/2 1 2

0.75 mm² E616 1/2 1.50 mm² GLOW
E117 PLUG TRELAY SIGNAL
/2.C2 TO TO
/1.B3
-E020
7207/1405 7212/0044
-T4 B
160/H3446-1
4 5 6
33 - 241 9813/9050-1 33 - 241

90 - Earth Point
90 - Earth Point Introduction

Introduction .................................................. 33-242 The ground or earth refers to the reference point in an
Component Identification ............................. 33-243 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 - 242 9813/9050-1 33 - 242

90 - Earth Point
Figure 941.
D C
Table 470. 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 - 243 9813/9050-1 33 - 243

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 471. 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 - 244 9813/9050-1 33 - 244

03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ......................................................................................................................... 33-247

33-03-03 Isolator Switch .............................................................................................................. 33-258
33 - 245 9813/9050-1 33 - 245

Notes:
33 - 246 9813/9050-1 33 - 246

03 - Battery
00 - General
Introduction .................................................. 33-247 Batteries used in normal temperate climate
Health and Safety ........................................ 33-248 applications should not need topping up. However,
Technical Data ............................................. 33-249 in certain conditions (such as prolonged operation
Fault-Finding ................................................ 33-250 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Disconnect and Connect ............................. 33-251 frequently and topped up as necessary.
Clean ........................................................... 33-254
Check (Condition) ........................................ 33-254 The electrolyte level should be checked in
Charge ......................................................... 33-255 accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
Remove and Install ..................................... 33-256 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 942.
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 - 247 9813/9050-1 33 - 247

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 - 248 9813/9050-1 33 - 248

03 - Battery
00 - General
suitable closed receptacle and must be disposed Technical Data

of in accordance with local environmental waste
regulations.
Table 472.
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 - 249 9813/9050-1 33 - 249

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 - 250 9813/9050-1 33 - 250

03 - Battery
00 - General
Disconnect and Connect
Notice: Before you install a pair of batteries to Figure 943. 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 944. 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 - 251 9813/9050-1 33 - 251

03 - Battery
00 - General
Figure 945. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 252 9813/9050-1 33 - 252

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 946.
Figure 946.
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 - 253 9813/9050-1 33 - 253

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 947. Figure 948.
Figure 947.
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 - 254 9813/9050-1 33 - 254

03 - Battery
00 - General
Table 473. 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 an 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 474. 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 - 255 9813/9050-1 33 - 255

03 - Battery
00 - General
Remove and Install
CAUTION This component is heavy. It must only 4. Disconnect the batteries. Refer to (PIL 33-03).
method and device. 5. Make sure that all battery connection wires are
clear of the top of the batteries.
Your machine will differ from that shown below. The 6. Remove the wing nuts and disconnect the battery
illustration is for information only. clamps.
Remove 7. Lift the clamp clear of the batteries. Make sure

you do not touch the battery terminals with the
1. Make the machine safe. Refer to (PIL 01-03). clamps.
2. Follow the hydraulic care and safety procedures. 8. Remove the batteries from the compartment and
Refer to (PIL 33-00). make sure that you do not use the access cover
to support the weight of the battery.
3. Get access to the battery (or batteries). Refer to
(PIL 06-06-03).
Figure 949.
B
A
A Wing nuts B Clamp

C Battery
33 - 256 9813/9050-1 33 - 256

03 - Battery
00 - General
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 - 257 9813/9050-1 33 - 257

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 - 258 9813/9050-1 33 - 258

06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ......................................................................................................................... 33-261

33-06-12 Earth Strap ................................................................................................................... 33-263
33 - 259 9813/9050-1 33 - 259

Notes:
33 - 260 9813/9050-1 33 - 260

06 - Battery Cable
00 - General
Introduction .................................................. 33-261 The cables connect the battery positive and negative
Check (Condition) ........................................ 33-262 terminals to the machine electrical system.
33 - 261 9813/9050-1 33 - 261

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 - 262 9813/9050-1 33 - 262

06 - Battery Cable
12 - Earth Strap
12 - Earth Strap
Figure 950. Earth Points
CT
DE
AE
Table 475. 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 - 263 9813/9050-1 33 - 263

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 - 264 9813/9050-1 33 - 264

09 - Power Distribution
Contents Page No.
33-09-00 General ......................................................................................................................... 33-267

33-09-03 Fuse ............................................................................................................................. 33-269
33-09-06 Relay ............................................................................................................................ 33-270
33 - 265 9813/9050-1 33 - 265

Notes:
33 - 266 9813/9050-1 33 - 266

00 - General
Introduction .................................................. 33-267 The electrical circuits are protected by fuses. If a
Health and Safety ........................................ 33-268 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 - 267 9813/9050-1 33 - 267

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 - 268 9813/9050-1 33 - 268

03 - Fuse
03 - Fuse
Figure 951. 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 - 269 9813/9050-1 33 - 269

06 - Relay
06 - Relay
The relay mounting bases are connected to the Each relay base can hold 2 relays. Pins 1-5 being
Panel Harness. used for relay position B and pins 6-10 being used
for relay position A. Therefore each relay could have
Specific location and connector number will change. alternative pin numbers due to its position in relay
base.
Figure 952. 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 - 270 9813/9050-1 33 - 270

12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ......................................................................................................................... 33-273

33-12-04 Chassis ......................................................................................................................... 33-286
33-12-06 Lift Arm ......................................................................................................................... 33-310
33-12-09 Engine .......................................................................................................................... 33-341
33-12-12 Operator Station ........................................................................................................... 33-359
33-12-14 Sway ............................................................................................................................. 33-381
33-12-15 Front Console ............................................................................................................... 33-387
33-12-22 Armrest ......................................................................................................................... 33-412
33-12-30 Gearbox ........................................................................................................................ 33-424
33-12-34 Trailer ........................................................................................................................... 33-435
33-12-36 Work Lights .................................................................................................................. 33-438
33-12-39 Road Lights .................................................................................................................. 33-450
33-12-46 Immobiliser ................................................................................................................... 33-455
33-12-58 Heater ........................................................................................................................... 33-461
33 - 271 9813/9050-1 33 - 271

Notes:
33 - 272 9813/9050-1 33 - 272

12 - Harness
00 - General
Introduction .................................................. 33-273
Health and Safety ........................................ 33-274
Harness Drawings
Component Identification ............................. 33-275 Drawings are reproduced from production electrical
Repair .......................................................... 33-280 harness drawings. Each harness drawing includes
Check (Condition) ........................................ 33-282 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 - 273 9813/9050-1 33 - 273

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 - 274 9813/9050-1 33 - 274

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 953.
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 476. 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 478. Wires 200-399 (These

numbers are reserved for battery feeds)
Table 477. 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 - 275 9813/9050-1 33 - 275

12 - Harness
00 - General
Table 479. Wires 400-599 Figure 955.

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 480. 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 954.
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 481. 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 482. 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 - 276 9813/9050-1 33 - 276

12 - Harness
00 - General
Table 483. 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 - 277 9813/9050-1 33 - 277

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 484. 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 - 278 9813/9050-1 33 - 278

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 - 279 9813/9050-1 33 - 279

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 957.
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 958.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 956.
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 - 280 9813/9050-1 33 - 280

12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 961.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 959.
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 960. 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 962.
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 - 281 9813/9050-1 33 - 281

12 - Harness
00 - General
Figure 963. 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 964.
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 - 282 9813/9050-1 33 - 282


Service Manual: Foreword

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Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADALL (ROUGH TERRAIN

Copyright 2017 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

531-70, 535-95, 541-70 531-70, 535-95, 541-70

SERVICE MANUAL SERVICE MANUAL

531-70, 535-95, 541-70 531-70, 535-95, 541-70

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual there are safety notices. Each notice

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system symbol (shown) also helps

Figure 1. The safety alert system symbol

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

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 and Filler

A Hydraulic oil level indicator B Label - hydraulic oil filling point

Figure 7. Machines with External Sight Gauge

A Hydraulic oil level indicator

A Secondary hydraulic tank filler cap - If applicable