Bobcat Loader Bachkhoe B730 B750 Service Manual - 7310058

Service Manual
B730 & B750 Backhoe Loader
(B730) S/N B4B611001 & Above

(B750) S/N B4BM11001 & Above
Dealer Copy -- Not for Resale
7310058enUS (02-19) (A) Printed in Belgium ©2019 Bobcat Company. All rights reserved.
LAAP T2
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-16768 B-16738

Never service the Bobcat Backhoe Always use an approved lift arm Cleaning and maintenance are
Loader without instructions. support device when servicing the required daily.
backhoe loader with the lift arms NEVER modify equipment or add
raised. Replace the lift arm support attachments not approved by
device if damaged or missing. Bobcat.
Disconnecting or loosening any
hydraulic tubeline, hose, fitting
component, or part failure can

cause lift arms or backhoe boom
to drop.
WRONG WRONG WRONG
B-16730 B-16746 B-16719

Have good ventilation when Vent exhaust to outside when Never work on backhoe loader
welding or grinding painted engine must be run for service. with lift arms raised unless
parts. Exhaust system must be tightly supported by an approved lift
Wear dust mask when grinding sealed. Exhaust Fumes can kill arm support device.
painted parts. Toxic dust and gas without warning. Always lower the backhoe bucket
can be produced. to the ground before doing any
maintenance.
WRONG WRONG WRONG
B-16571 B-16731 B-6589
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust machine exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep engine cover closed except attention.
running, while smoking or when for service. Close and latch
near open flame. engine cover before operating
the backhoe loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts. MSW46-0116
1-1 B730 & B750 Service Manual

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1-2 B730 & B750 Service Manual

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CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
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GENERAL INFORMATION
MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

B730 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
B750 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-3
TECHNICAL PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

B730 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Axle / Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Cab / Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
B750 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Axle / Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Cab / Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-6
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-6
MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POSITION OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loader Attachment Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Backhoe Attachment Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SAFETY INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2
Crushing And Burning Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-3
Fire And Explosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-3
Hydraulic Lines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-4
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Preparing The Machine For Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Preparing The Machine For Work After A Long Period Of Storage . . . . . . . . . . . . . 10-60-1


MACHINE INFORMATION
B730 Specification
These are backhoe loaders that are designed with operating weight up to 8.2 tons, rigid frame, bucket capacity of 0,2 m³
and shovel capacity of 1,1 m³. This machine is designed to dig and load in closed and open terrain.

WARNING: Because of exhaust gas, use the machine only in well ventilated areas.

S47161
S47162A
A Overall Machine Length In Travel Position 7585 mm (298.62 in) G Machine Width 2280 mm (89.76 in)
B Wheelbase 2175 mm (85.63 in) H Rear Wheel Track 1770 mm (69.68 in)
C Backhoe Swing Centre Distance 3060 mm (120.47 in) J Stabilisers Up 2200 mm (86.61 in)
D Minimum Machine Height 290 mm (11.41 in) K Stabilisers Down 3685 mm (145.00 in)
E Cab Height 2900 mm (114.17 in) L Front Wheel Track 1895 mm (74.61 in)
F Machine Height In Travel Position 3900 mm (153.54 in) M Overall Width With Bucket 2280 mm (89.76 in)
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MACHINE INFORMATION (CONT’D)
B730 Specification (Cont’d)

S47163
Retracted Extended
A Maximum Dig Depth 4600 mm (181.10 in) 5800 mm (228.35 in) I Distance Between Hinge Pin And 1220mm (48.03 in)
Front Axle Centre
B Max Reach From Rear Axle Centre 7000mm (275.59 in) 8100 mm (318.90 in) J Max Rollback Angle, Fully Raised 59.2°
C Max Reach From Swing Centre 5700 mm (224.41 in) 6800 mm (267.72 in) K Dump Height 2810 mm (110.63 in)
D Maximum Digging Height 5600 mm (220.47 in) 6450 mm (253.94 in) L Load-over Height 3280 mm (129.13 in)
E Maximum Dumping Height 3850 mm (151.57 in) 4700 mm (185.04 in) M Height To Hinge Pin 3520 mm (138.58 in)
F Loading Reach 1800 mm (70.87 in) 2650 mm (104.33 in) N Max Reach At Full Height 1070 mm (42.13 in)
G Bucket Rotation Angle 200.4° 200.4° O Dumping Reach 620 mm (24.41 in)
H Max Bucket Hinge Pin Height 4750 mm (187.01 in) 5550 mm (218.50 in) P Digging Depth 115 mm (4.53 in)
R Dump Angle 45°

B750 Specification
These are backhoe loaders that are designed with operating weight up to 8.2 tons, rigid frame, bucket capacity of 0,2 m³
and shovel capacity of 1,1 m³. This machine is designed to dig and load in closed and open terrain.

S47161
S47162A
A Overall Machine Length In Travel Position 7735 mm (304.5 in) G Machine Width 2280 mm (89.76 in)
B Wheelbase 2175 mm (85.63 in) H Rear Wheel Track 1770 mm (69.68 in)
C Backhoe Swing Centre Distance 3060mm (120.47 in) J Stabilisers Up Width 2200 mm (86.61 in)
D Minimum Machine Height 310 mm (12.20 in) K Stabilisers Down Width 3685 mm (145.08 in)
E Cab Height 2900 mm (11.17 in) L Front Wheel Track 1895 mm (74.61 in)
F Machine Height In Travel Position 3900 mm (153.54 in) M Overall Width With Bucket 2280 mm (89.76 in)

B750 Specification (Cont’d)

S47163
Retracted Extended
A Maximum Dig Depth 4600 mm (181.10 in) 5800 mm (228.35 in) I Distance Between Hinge 1460mm (57.48 in)
Pin And Front Axle Centre
B Max Reach From Rear Axle Centre 7000mm (275.59 in) 8100 mm (318.90 in) J Max Rollback Angle, Fully 59.2°
Raised
C Max Reach From Swing Centre 5700 mm (224.41 in) 6800 mm (267.72 in) K Dump Height 2950 mm (116.14 in)
D Maximum Digging Height 5600 mm (220.47 in) 6450 mm (253.94 in) L Loadover Height 3370 mm (132.68 in)
E Maximum Dumping Height 3850 mm (151.57 in) 4700 mm (185.04 in) M Height To Hinge Pin 3670 mm (144.49 in)
F Loading Reach 1800 mm (70.87 in) 2650 mm (104.33 in) N Max Reach At Full Height 1125 mm (44.29 in)
G Bucket Rotation Angle 200.4° 200.4° O Dumping Reach 685 mm (24.41 in)
H Max Bucket Hinge Pin Height 4750 mm (187.01 in) 5550 mm (218.50 in) P Digging Depth 113 mm (4.45 in)
R Dump Angle 45°

TECHNICAL PROPERTIES
B730 Specifications
Engine
Make & Model PERKINS 1104C-44T

Emission Type Tier II
Engine Type 4 Stroke diesel, Turbocharged
Engine Power 74,5 kW / 100 hp
Rated Speed 2200 rpm
Displacement 4,4 L (268.5 ci)
Bore And Stroke 105 x 127 mm (4.13 x 5.00 in)
Number Of Cylinder 4
Maximum Torque 408 N•m (300.92 ft-lb)
Cooling Water cooled
Electrical System
Battery 12 volt / 120 Ah

Starter 3,2 kW (4.3 hp)

Alternator 75A
Hydraulic System
Type Open center

Hydraulic Pump Tandem Gear
Maximum Flow 90 + 64 Lpm (23.78 + 16.91 gpm)
Maximum Pressure 22000 kPa (220 bar) (3191 psi)
Hydraulic Oil Filter Full flow filter in return line with integrated fine filter area
Hydraulic Oil Cooler Hydraulic and transmission oil cooler
Hydraulic Controls
Backhoe Control Mechanical control lever
Loader Control Mechanical control lever
Transmission
Make ZF
Drive 4 Wheel Drive
Type Powershift
2WD / 4WD Selection By switch on dash panel
Transmission Disconnect Push button and brake system
Travel Speeds Forward Reverse
1st 6,5 km/h (4.0 mph) 7,0 km/h (4.4 mph)
2nd 11 km/h (6.8 mph) 12 km/h (7.5 mph)
3rd 26 km/h (16.2 mph) 30 km/h (18.6 mph)
4th 40 km/h (24.9 mph)

TECHNICAL PROPERTIES (CONT’D)
B730 Specifications (Cont’d)
Axle / Brakes
Type (Front and Rear) ZF

Front Axle Oscillation 20 degrees
Steering angle 52 degrees
Rear Axle Electro-hydraulic operated differential lock, outboard planetary design,
self-adjusting high torque internal wet service brake
Service Brake Type Hydraulic wet multi-disc
Parking Brake Type Mechanical control on rear axle
Tires
Front 2WD / 4WD - standard 12.5 - 18

Rear - standard 16.9 - 28
Loader

Bucket capacity 1,1 m³ (1.4 y³)
Breakout force - lift 81,5 kN (118322 lbf)
Breakout force shovel maximum 60,5 kN (13601 lbf)
Bucket width 2280 mm (69.76 in)
Lift height to hinge pin 3520 mm (138.58 in)
ROC (ISO 14397-1) Bucket 3413 kg (7524 lb)
Application
Backhoe
Maximum bucket break - out force 59,1 kN (13277 lbf)

Arm tear - out
Retracted 31,8 kN (7140 lbf)
Extended (With Optional extendable arm) 22,4 kN (5033 lbf)
Cab / Canopy
Cab ROPS (ISO 3741) and FOPS (ISO 3449 Level II) type tinted safety glass giving total visibility,
full opening rear-side windows, front and rear windshield wipers, fully adjustable front / rear and up
/ down seat, Fresh air heater / blower, full heat control
Canopy ROPS (ISO 3741) and FOPS (ISO 3449 Level II), fully adjustable front / rear and up / down seat.

Steering
Steering type 2 wheel hydraulic

Power steering Hydrostatic
Turning circle - outer front tire clearance 9500 mm (31.2 ft)
Turning circle - outer bucket clearance 12,320 mm (40.4 ft)
Capacities
MAXIMUM CAPACITY SERVICE CAPACITY

Engine oil (with filters) 8,4 L (8.9 qt) 8,0 L (8.5 qt)
Cooling system 25,0 L (6.6 U.S. gal) 25,0 L (6.6 U.S. gal)
Fuel tank 140,0 L (37 U.S. gal) 140,0 L (37 U.S. gal)
Hydraulic tank 75,0 L (19.8 U.S. gal) 90,0 L (23.8 U.S. gal)
Hydraulic system 130,0 L (34.3 U.S. gal) 130,0 L (34.3 U.S. gal)
Transmission 19,0 L (5.0 U.S. gal) 14,0 - 16 L (3.7 - 4.2 U.S. gal)

Axle oil
Front 8,0 L (8.5 qt) 5,5 L (5.8 qt)
Rear 16,0 L (4.2 U.S. gal) 9,0 L (2.4 U.S. gal)
Brake oil  0,4 L (0.42 qt) 0,4 L (0.42 qt)

(B730 S/N B45111001-B45111554
Weights
Operating Weight 7800 kg (17196 lb)

B750 Specifications
Engine
Make & Model PERKINS 1104C-44T

Emission Type Tier II
Engine Type 4 Stroke diesel, Turbocharged
Engine Power 74,5 kW/ 100 hp
Rated Speed 2200 rpm
Displacement 4,4 L (268.5 ci)
Bore And Stroke 105 x 127 mm (4.13 x 5.00 in)
Number Of Cylinder 4
Maximum Torque 408 N•m (300.92 ft-lb)
Cooling Water cooled
Electrical System
Battery 12 volt / 120 Ah

Starter 3,2 kW (4.3 hp)

Alternator 75A
Hydraulic System
Type Open Center

Hydraulic Pump Tandem Gear
Maximum Flow 90 + 64 Lpm (23.78 + 16.91 gpm)
Maximum Pressure 22000 kPa (220 bar) (3191 psi)
Hydraulic Oil Filter Full flow filter in return line with integrated fine filter area
Hydraulic Oil Cooler Hydraulic and transmission oil cooler
Hydraulic Controls
Backhoe Control Pilot controls
Loader Control Pilot controls
Transmission
Make ZF
Drive 4 Wheel Drive
2WD / 4WD Selection By switch on dash panel
Type Powershift
Transmission disconnect Push button and brake system
Travel Speeds Forward Reverse
1st 6,5 km/h (4.0 mph) 7,0 km/h (4.4 mph)
2nd 11 km/h (6.8 mph) 12 km/h (7.5 mph)
3rd 26 km/h (16.2 mph) 30 km/h (18.6 mph)
4th 40 km/h (24.9 mph)

Axle / Brakes
Type ZF
Front Oscillation 20 degrees
Steering angle 52 degrees
Rear Axle Electro-hydraulic operated differential lock, outboard planetary design,
self-adjusting high torque internal wet service brake
Service Brake Type Hydraulic wet multi-disc
Parking Brake Type Mechanical control on rear axle
Tires
Front 4WD - standard 14.5 - 20

Rear 4WD - standard 16,9 - 28
Loader

Shovel capacity 1,1 m³ (1.4 y³)
Breakout force - lift 56,1 kN (12612 lbf)
Breakout force shovel maximum 81,6 kN (18344 lbf)
Lift height to hinge pin 3670 mm (144.49 in)
ROC (ISO 14397-1) Bucket Application 2905.5 kg (6505 lb)
Backhoe
Maximum bucket breakout 59,1 kN (13277 lbf)

Arm breakout force
Retracted 31,8 kN (7140 lbf)
Extended (with optional extendable arm) 22,4 kN (5036 lbf)
Cab / Canopy
Cab ROPS (ISO 3741) and FOPS (ISO 3449 Level II) type tinted safety glass giving total visibility,
full opening rear-side windows, front and rear windshield wipers, fully adjustable front / rear and up
/ down seat, Fresh air heater / blower, full heat control
Canopy ROPS (ISO 3741) and FOPS (ISO 3449 Level II), fully adjustable front / rear and up / down seat.
Steering
Steering type 2 wheel steer hydrostatic

Power steering Hydrostatic
Turning circle - outer front tire clearance 12,170 mm (39.9 ft)
Turning circle - outer bucket clearance 14,600 mm (47.9 ft)

Capacities
MAXIMUM CAPACITY SERVICE CAPACITY

Engine oil (with filters) 8,4 L (8.9 qt) 8,0 L (8.5 qt)
Cooling system 25,0 L (6.6 U.S. gal) 25,0 L (6.6 U.S. gal)
Fuel tank 140,0 L (37 U.S. gal) 140,0 L (37 U.S. gal)
Hydraulic tank 75,0 L (19.8 U.S. gal) 90,0 L (23.8 U.S. gal)
Hydraulic system 130,0 L (34.3 U.S. gal) 130,0 L (34.3 U.S. gal)
Transmission 19,0 L (5.0 U.S. gal) 14,0 - 16 L (3.7 - 4.2 U.S. gal)
Axle oil
Front 8,0 L (8.5 qt) 5,5 L (5.8 qt)
Rear 16,0 L (4.2 U.S. gal) 9,0 L (2.4 U.S. gal)
Brake oil 0,4 L (0.42 qt) 0,4 L (0.42 qt)

(B750 S/N B45211001-B45211079)
Weights

Operating Weight 8000 kg (17637 lb)

MAIN COMPONENTS
1
8 9
16
8
3
17
2
5
14 NA13488
4 15
18 8 12
9

6
11
13
19
7
10
10 NA13489
1 OPERATOR’S CAB (WITH ROPS / FOPS) [A] 11 BACKHOE ARM

2 LOADER BUCKET 12 BACKHOE BOOM
3 LIFT ARM 13 STABILISERS
4 FRONT AXLE 14 HYDRAULIC OIL TANK (With left side steps)
5 REAR AXLE 15 BATTERY BOX
6 FUEL TANK (With right side steps) 16 ENGINE BONNET
7 BACKHOE BUCKET [B] 17 APPROVED LIFT ARM SUPPORT DEVICE
8 WORK LIGHTS 18 BOOM LOCKOUT
9 MIRRORS 19 BUCKET LINK
10 TYRES
[A] - Roll Over Protective Structure (ROPS) per ISO 3471 and Falling Over Protective Structure (FOPS) per ISO 3449,
Level II.
[B] - Several different buckets and other attachments are available for the Bobcat backhoe loader.


POSITION OF MACHINE
The terms right, left, front and rear are used referring to the operator seated on the driver seat for the loader and backhoe
attachment position.
Loader Attachment Position

RIGHT-HAND SIDE
FORWARD
REAR
LEFT-HAND SIDE

Backhoe Attachment Position
LEFT-HAND SIDE
FORWARD
REAR
RIGHT-HAND SIDE


SAFETY INSTRUCTION
In this manual safety signs are classified according to the relative seriousness of the hazard situation by the use of
the signal word. Two signal words are used: DANGER and WARNING. The signal word alerts you to the existence
and relative seriousness of a hazard and it is essential that you understand these signal words fully.
DANGER: The signal word DANGER on the machine and in the manuals indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING: The signal word WARNING on the machine and in the manuals indicates a potentially hazardous
situation which, if not avoided, could result in death or serious injury.
In addition to these instructions you must follow the safety regulations applicable to your work environment and job site
and any federal, state and local safety requirements.

SAFETY INSTRUCTION (CONT’D) • If no other guidelines are given, perform maintenance
and repairs utilising the following precautions:
General Safety Information
1. Park backhoe loader on firm and level ground. Rest
• Study the Operation & Maintenance Manual before the attachments on the ground.
operating or working on the backhoe loader, make
sure that you have additional information for special 2. Place all control in NEUTRAL position and engage
attachments of your machine, read it and understand park brake.
it!
3. Turn the engine off and remove the ignition key.
• Allow only authorized personnel informed about the
• Before working on the hydraulic circuit, move all
safety rules to operate, service or repair the backhoe
levers and pedals with the ignition key in contact
loader, be sure to observe any minimum applicable
position to release the hydraulic accumulator
age requirement.
pressure and the remaining pressures in the different
• Allow only properly trained personnel to operate or main circuits. In addition, relieve the pressure in the
work on the backhoe loader, make sure to clearly hydraulic tank as described in the Operation &
specify the person who is responsible for set up, Maintenance Manual.
maintenance and repairs.
• Make sure there is no leak in the hydraulic system
• Make sure the operator knows his responsibility and check the machine daily.
regarding the observance of traffic regulations and
• Check the area where you will work before starting to
permit him to refuse any unsafe instructions given by
work. Be certain that all safety systems operate
a third person.
properly.
• Any person still in training should only operate or work
• Secure all loose parts on the backhoe loader.

on the machine under the supervision and guidance
of an experienced person. • Never operate the backhoe loader without a complete
walk around inspection. Check if all warning decals
• Check and observe any person working or operating
are on the machine and if they are legible.
the backhoe loader periodically and check regularly, if
they observe safety instructions and guidelines given • Observe all danger and safety guidelines.
in the Operation & Maintenance Manual.
• For certain applications, the backhoe loader must be
• Wear proper work clothing when operating or working equipped with specific safety equipment. Use the
on the backhoe loader. Ring, watches, bracelets and backhoe loader only, if they are installed and
loose clothings such as ties, scarves, unbuttoned or functioning properly.
unzipped shirts and jackets are dangerous and could
cause injury! Wear proper safety equipment, such as • Never perform any changes, additions or
safety glasses, safety shoes, hard hats, work gloves, modifications on the machine, which could influence
reflector vests and ear protection. the safety, without obtaining written first permission
from the manufacturer. This also applies to the
• Consult your employer or supervisor for specific installation and adjustment of safety devices and
safety equipment requirements and safety safety valves as well as to any welding on load
regulations on the job site. carrying parts.
• Do not carry tools, replacements parts or other • Do not install any equipment or attachments made by
supplies while climbing on or off the backhoe loader. other manufacturers or any which are not specifically
Never use the steering column, control levers or authorized by BOBCAT for installation without first
joysticks as handholds. obtaining the written permission from BOBCAT.
BOBCAT will issue any required technical
• Never jump off the backhoe loader, climb on and off
documentation for approved installations.
the backhoe loader using only the steps, rails and
handles provided. • Should the electrical circuit be modified or additional
components be installed, so the modification must be
• When climbing on or off the backhoe loader, use both
performed according to the national standards and
hands for support and face the machine.
safety regulations. The installation must be
• If needed, use the rear window or right door as an certificated by an approved organization and a copy
escape hatch. of the certification has to be sent to the BOBCAT
company.

SAFETY INSTRUCTION (CONT’D) • Battery must be fully charged to prevent frozen
electrolyte.
Crushing And Burning Prevention
• Always start the engine as described in the Operation
• Never work underneath the backhoe loader unless it & Maintenance Manual.
is safely resting on the ground and / or is properly
blocked and supported. • Clean the machine regularly and remove all debris
which may cause a fire.
• Never use damaged or insufficient wire ropes, slings
• Don’t use flammable cleanser.
or chains. Always wear gloves when handling wire
ropes. • Observe the following recommendations due to be
protected from an explosion
• Never reach into bores during attachment installation
or removal. Never align bores with fingers or hands. 1. Disconnect the negative (-) cable first and reconnect
Use proper alignment tools when installing, changing it last.
or servicing attachments.
2. Never touch battery terminal with a metal object.
• Keep objects away from the radiator fan. Rotating
• Check the electrical system regularly and frequently.
fans will swirl and throw out objects, which can
All defects, such as loose connections, burnt out
become very dangerous and cause severe injury to
fuses and bulbs, burnt or damaged cables must be
yourself and others. repaired immediately by an electrician or specially
trained person.
• Avoid contact with any components containing
coolant. At or near operating temperature, the engine • Before work in an area including flammable gas,

coolant is hot and under pressure and could cause thoroughly ventilate this area.
severe burns.
• Never store flammable fluids on the machine except
• Check the coolant level only after the radiator cap is in storage tanks intended for the backhoe loader’s
cool enough to touch. Remove the radiator cap slowly operation.
to relieve pressure.
• Inspect all component, lines, tubes and hoses for oil
and fuel leaks and / or damage. Replace or repair any
• Do not allow your skin to come in contact with hot oil damaged components immediately. Any oil, which
or components containing hot oil. At or near operating escapes from leaks, can easily cause a fire.
temperature, engine and hydraulic oil is hot and can
be under pressure. • Be certain that all clamps, guards and heat shields
are installed. These components prevent vibration,
• Always wear safety glasses and protective gloves rubbing, chafing and heat build-up. Install tie wraps to
when handling batteries. Keep sparks or open flames fasten hoses and wires, as required.
away!
• Cold start ether is extremely flammable. Use ether
only in ventilated areas and as directed. Never use it
• Never permit anyone to hand guide the bucket or
near heat sources or open flames. Do not permit
grapple into position. anybody to smoke.
• When working in the engine area, make sure loader • Know the location of the backhoe loader’s fire
safety strut is installed. extinguisher and be familiar with its operation. Make
sure you know your local fire regulations and fire
Fire And Explosion Prevention reporting procedures.
• Always turn off the machine while refueling the

backhoe loader.
• Never smoke or allow an open flame in refueling

areas or where batteries are being charged, or where
batteries or flammable materials are stored.
• Battery electrolyte can cause severe injury. If

electrolyte touches your skin, wash the skin. If drunk
by mistake, drink water or milk.

SAFETY INSTRUCTION (CONT’D) • Always take care to avoid torsional strain when
installing a new hose. On high pressure hydraulic
Hydraulic Lines And Hoses hoses, the mounting screws must be first mounted on
both hose ends (full flange or half clamp) and
• Hydraulic lines and hoses may never be repaired! tightened only thereafter.
• All hoses, lines and fittings must be checked daily, but On high pressure hoses having one curved end,
at least every 2 weeks for leaks and any externally always tighten first the screws on the curved hose end
visible damage! Any damaged sections must be and only then the screws on the straight hose end.
replaced immediately! Escaping oil can cause injuries
and fires! Install and tighten the hose clips that may be mounted
on the hose middle only when the both hose ends are
• Even if hoses and lines are stored and used properly, already tightened.
they undergo a natural aging process. For that
reason, their service life is limited. Improper storage, • Always install hoses so to avoid any friction with other
mechanical damage and improper use are the most hoses and parts.
frequent causes of hose failures.
We recommend keeping a distance between hose
The service life of a hose may not exceed six years, and other parts of at least one half of the hose outer
including a storage period of not more than two years diameter. Keep a minimum gap of 1.2 cm (1/2 in) in
(always check the manufacturer's date on the hoses). any case.
Using hoses and lines close to the limit of ranges of After mounting a hose connecting two parts that are
permitted use can shorten the service life (for movable relative to each other, check during the
example at high temperatures, frequent working return to service that the hose is not rubbing fall full
cycles, extremely high impulse frequencies, multi shift movement.

or around the clock operations).
• Hoses and lines must be replaced if any of the

following points are found during an inspection:
1. Damage on the external layer into the inner layer

(such as chaffing, cuts and rips).
2. Brittleness of the outer layer (crack formation of the

hose material).
3. Changes in shape, which differ from the natural shape

of the hose or line, when under pressure or when not
under pressure, or in bends or curves, such as
separation of layers, blister or bubble formation.
4. Leaks.
5. Non observance of installation requirements.
6. Damage or deformation of hose fittings, which might

reduce the strength of the fitting or the connection
between hose and fitting.
7. Any movement of hose away from the fitting.
8. Corrosion on fittings, which might reduce the function

or the strength of the fitting.
9. Storage or service life has been exceeded.
10. When replacing hoses or lines, always use original

replacement parts.
• Route or install the hoses and lines properly. Do not

mix up the connections!

STORAGE
Preparing The Machine For Storage
If the machine is not going to be used for a long period, it is useful to store the machine under a cover and take the
following precautions:
• Clean the machine completely and paint the damaged parts of the machine.
• Grease all greasing points
• Drain the fuel tank and add approximately 10 l of special washing fuel. Run the engine for about 10 minutes until the
residual normal fuel is eliminated. Fill the fuel tank with diesel fuel.
• Check the air filter, clean or replace if necessary.
• Drain the engine oil and replace the filter.
• Drain the cooling system and do not close the drain plugs. Put a label onto the control panel showing that “the cooling
system is empty”.
• Check the electrolyte level. Make sure that the battery is charged. Remove the battery and place it in dry place at room
temperature.

• Place blocks under the axles to prevent tire deformation.
• Lubricate shafts.
• Cover the exhaust with a cloth.
• Engage the parking brake
Preparing The Machine For Work After A Long Period Of Storage
• Fill the cooling system with engine coolant.
• Fill the engine with oil and check the oil level.
• Replace the fuel filter, fill the fuel tank and bleed the fuel system.
• Replace the battery and make sure that it is charged.
• Check the hydraulic oil level.
• Check the front drive axle and reduction gears oil level.
• Check the rear axle and reduction gears oil level.
• Use a specie solvent to clean the hydraulic cylinder rods.
• Check the tire pressures and tightness of wheel nuts.
• Check that the indicator and warning lights on the control panels work properly.
• Start the engine after removing the cloth on the exhaust. Run to the engine 20 minutes.


LUBRICATION AND MAINTENANCE
LIFTING AND BLOCKING THE BACKHOE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
APPROVED LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
TOWING THE BACKHOE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
AXLE TOE-IN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Lubricant And Operating Materials Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Diesel Fuel: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Brake Oil (For B730 S/N B4B611001 - B4B611134) . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6

Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Front Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Rear Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Lubrication Chart (B730 And B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Checking The Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Draining The Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Replace The Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Changing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11
Cleaning The Radiator And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-12
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-12
To Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-13
Replacing The Internal Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-13
To Clean The Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-14
Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-15
The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-16
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-16
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-16
Drain The Contaminant From The Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Drain The Contaminant From The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Clean Fuel Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Replace The Fuel Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-18

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-18
Checking Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-18
Drain Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-19
Add Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-19
Front Drive Axle And Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-20
To Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-20
To Add Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-20
Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-21
To Check Reduction Gear Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-21
To Drain Reduction Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-21
Add Reduction Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-21
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
To Check Rear Axle Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
Clean The Rear Axle Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
Drain Rear Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
Add Rear Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-23
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-23
Checking Brake Fluid Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-24
Add Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-24
Draining The Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-24
Bleeding The Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-24

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-25
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Engine Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Cleaning The Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Replacing The Air Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Cab Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
BACKHOE BOOM / SWING LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Engaging And Disengaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
ENGINE ALTERNATOR / FAN BELT AND AIR CONDITIONER BELT (IF EQUIPPED) 20-80-1
Checking The Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Replacing Fan And Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Maintenance Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Type Of Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
To Replace A Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Wheel Nut Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2
LUBRICATION OF THE BACKHOE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

LIFTING AND BLOCKING THE BACKHOE LOADER Figure 20-10-2
Procedure
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual and signs (decals)
on machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or
servicing. Check for correct function after
adjustments, repairs or service. Untrained operators
P-55955
and failure to follow instructions can cause injury or
death.
W-2408-0801
Lift the rear of the backhoe loader and install jackstands.
Figure 20-10-1 Figure 20-10-3

B-7023 P-36617
Read the removal and installation, disassembly and NOTE: Loader lift arms are raised for photo clarity.
assembly, etc., completely to become familiar with the
procedure before beginning. Lift the front of the backhoe loader and put jackstands
under the axle.
Always park the backhoe loader on a level surface.
Note: Make sure the jackstands do not touch the
Stop the engine. tires.
WARNING
Put jackstands under the front and rear axle before
running the engine for service. Failure to use
jackstands can allow the machine to fall or move and
cause injury or death.
W-2461-0303


APPROVED LIFT ARM SUPPORT DEVICE NOTE: Remove the attachment from the loader
before the lift arms are raised and the
Description approved lift arm support device is installed.
The approved lift arm support device (1) is used to Have the second person remove the two retaining pins
support the lift arms while working on a machine with the (1) and remove the approved lift arm support device (2)
lift arms up. from the storage position. Reinstall the two retainer pins
(1) so they are secured in the storage position.
The operator will enter the machine, fasten seat belt and
WARNING start the engine.
Figure 20-20-2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or B
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407 A

NOTE: For installing the approved lift arm support
device can be performed with just the B
operator. For removing the approved lift arm
support device, a second person is required. S45437
Figure 20-20-1
Raise the lift arms.
Have the second person position the approved lift arm

support device (A) on the lift cylinder rod. Wrap the loop
and hook fastener (B) around the cylinder rod to hold the
approved lift arm support device to the cylinder rod.
The second person should move away from the machine.

After the second person is away from the machine, slowly
1 lower the lift arm until the approved lift arm support
device is tight against the cylinder rod.
2
1 Stop the engine and exit the machine.
Placing The Approved Lift Arm Support Device In The

S45436
Storage Position
Installing The Approved Lift Arm Support Device A second person is required to assist in removing the
approved lift arm support device.
Park the machine on a flat level surface.
Loosen the hook and loop fasteners from the approved
Fully lower the arm and boom and put the attachments
lift arm support device.
flat on the ground.
Put all controls in NEUTRAL. Have the operator enter the machine, fasten seat belt,
make sure the parking brake is engaged and start the
Engage the parking brake. engine.
Stop the engine and exit the machine.

APPROVED LIFT ARM SUPPORT DEVICE (CONT'D)
Description (Cont’d)
Slightly raise the lift arms so the approved lift arm

support device is loose on the cylinder rod.
The second person will need to remove the approved lift

arm support device (A).The second person should move
away from the machine.
Slowly lower the lift arms fully.
Stop the engine and exit the machine.
Remove the two retaining pins (1) and position the

approved lift arm support device (2) back in the storage
position. Install the two retainer pins (1) to secure in the
storage position.

TOWING THE BACKHOE LOADER DANGER: Never allow anyone to stand near
the cable when pulling or towing the backhoe
Procedure loader. Keep the cable tight and free of kinks.
Pull the cable slowly. The cable could snap and
Figure 20-30-1 break if suddenly jerked.
DANGER: Never allow anyone to stand near

the cable when pulling or towing the backhoe
loader. Keep the cable tight and free of kinks.
Pull the cable slowly. The cable could snap and
break if suddenly jerked.
• Only tow the backhoe loader if absolutely necessary,

for example to remove it for repairs from a dangerous
job site.
• The vehicle should have enough capacity for towing

the machine.
1
S45409 • Observe traffic regulations while towing.
• Be sure all towing and pulling devices such as cables,

The vehicle being towed: hooks, and couplers are safe and adequate.

• Always use the towing hooks (1) for towing your • Make sure that the cable or the towing rod is strong
backhoe loader. enough. Be aware that any damage to the machine
• Turn on the hazard warning by pressing the hazard caused by towing is never covered by the
warning switch. manufacturer's warranty.
• Set the parking brake to off.
• Engage travel slowly, and do not jerk. With a slack
• Adjust the travel direction control lever and gear cable, the sudden impact of the load being towed
lever to NEUTRAL position. could snap and break.
• Tie the cable to the tie point to the front weight.
• Keep personnel out of area. If cable breaks while
The vehicle towing the backhoe loader:
under stress, it could cause severe injury
• Turn on the hazard warning by pressing the hazard
warning switch. • During the towing procedure, keep within the required
• Tow the backhoe loader with the first speed transport position, permissible speed and distance.
• Don’t jerk suddenly. • After the towing procedure is completed, return the
IMPORTANT: The speed of vehicle towing the machine to its previous state.
backhoe loader should be 10 km/h and towing
distance shouldn’t be more than 2 km. • Proceed as outlined in the Operation & Maintenance
Manual when putting the backhoe loader back in
WARNING: While traveling downhill, run the service.
engine in first gear.
NOTE: While traveling downhill or climbing uphill, the

maximum angle of inclination is 25°.
Don’t travel at jobsite where inclination angle is more

than 30°.
The backhoe loader should not be towed until absolutely

necessary. If it is possible carry out the repair work at the
location without towing the machine.
Towing is always the responsibility of the operator.


AXLE TOE-IN ADJUSTMENT
Procedure
(See Basic Track Setting on Page 50-20-50.)


LUBRICATION
General Safety Information
It is very important that all guidelines describing lubrication, checking the oil level, replacing the oil are strictly adhered to!
Regular maintenance increases the life of the backhoe loader and improves its reliability.
It is especially important to change the oil regularly and at the intervals noted in the maintenance schedule! Only use
specified lubricants and oil!
When checking or replacing the oil, observe the following:
• Park the machine on level ground, if not otherwise stated, and turn the engine off.
• When working in the engine area, make sure the covers and side doors are secured.
• Only add fuel when the engine is turned off.
• Never smoke or allow an open flame in refuelling areas.
• Cleanliness is especially important when changing engine, gear or hydraulic oil. Before removing fittings or plugs,
make sure the surrounding areas are cleaned. When changing the oil, clean the fill and drain plugs.

IMPORTANT!
Be sure to drain oil into a suitable container and dispose of oil and filter cartridges properly.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

LUBRICATION (CONT’D)
Lubricant And Operating Materials Specifications
NOTES ON LUBRICANT AND OPERATING MATERIALS CHART AND ON LUBRICATION SCHEDULE
The amounts indicated on the lubricant and operating materials chart and on the lubrication schedule are guidelines.
Check level in appropriate aggregate after every oil change or refill.
Diesel Engine Lubricants
COMPONENTS SYMBOL VISCOCITY SAE DIN 51512 SPECIFICATIONS

DEISEL ENGINE
(Turbo Charged)
LUBRICANT












API CG4 / CH4; ACEA E3 / E5

Lubricant regulation for diesel engines is based on the following specifications and regulations:
API Classification: CG-4, CH-4 (American Petroleum Institute)

ACEA (CCMC) Classification: E3, E5 (ACEA: Association des Constrticteurs Europeens de l'Automobile)

Lubricant And Operating Materials Specifications (Cont’d)
Diesel Fuel:
Use only Diesel fuel with a sulfur content of less than 0.2% and complying with one of the following standards:
Authorized Diesel fuel specifications:
DIN EN 590
ASTMD975-89a: 1-Dand2
See completed diesel fuel specification, (See Fuel Specifications on Page 20-50-16.)
The sulfur content in Diesel fuel should be less than 0.2%.
Higher sulfur contents influence oil change intervals and engine life.

Lubricity
By reducing sulfur content, the question of engine fuel lubricity arises. It has been clearly shown that engine fuels with the
maximum allowable sulfur content (0.05% by volume) can cause damage to the injector systems (especially in the case
of distributor injection pumps).
Diesel fuel fluidity in cold climates
When ambient temperature are below 0°C (32°F), Diesel fuels normally used during the summer may suffer a decline in
fluidity due to paraffin separation. The same occurs if Diesel fuels normally used during the winter are used at temperature
below -15°C (5°F).
Often, additive diesel fuel is on offer with operating temperatures down to -20°C (-4°F).

Engine Coolant
Specifications for anti-corrosion and antifreeze protection
Using mixture of antifreeze and anti-corrosion with anti-corrosion additive.
To assure the protection from corrosion of the cooling system, the coolant must contain at least 50% corrosion / coolant
mixture all year round. This protects the cooling system to about - 35°C (- 33°F).
When fluid is added to the coolant mixture, it must be assured that the mixture maintains a 50% antifreeze content.
CAUTION: The percentage of antifreeze should not exceed 60%. A higher concentration would lead to reduced antifreeze
and cooling properties.
The coolant must be changed every 2 years. Before adding new coolant, check the circuit for cleanness and if necessary
flush it with water.
Follow these steps when using concentrated coolant instead of a ready-to-use premix:

• Use a separate container to mix the coolant.
• The correct mixture proportions of coolant to provide a -37°C (-34°F) freeze protection are 50% water and 50%
ethylene glycol. For instance, to get 8 L OR 2 U.S. gal. of mixture, mix 4 L ethylene glycol with 4 L of water OR 1 U.S.
gal ethylene glycol with 1 U.S. gal of water.
• Add premixed coolant to the coolant tank until the coolant level reaches the lower marker on the tank.
Run the engine until it is at operating temperature. Stop the engine. Check the coolant level when cool. Add coolant as
needed.
Close the engine cover.
Interval for coolant change:
Change coolant every year / every 2000 hours which ever occurs first.
engine damage.
I-2124-0497
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze. WARNING
Too much antifreeze reduces cooling system AVOID INJURY OR DEATH
efficiency and may cause serious premature engine Wear safety glasses to prevent eye injury when any
damage. of the following conditions exist:
• When fluids are under pressure.
Too little antifreeze reduces the additives which • Flying debris or loose material is present.
protect the internal engine components; reduces the • Engine is running.
boiling point and freeze protection of the system. • Tools are being used.
W-2019-0907
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature

Hydraulic / Hydrostatic Fluid Chart
TRANSMISSION AND AXLES

Machine Components Brand Specifications Part Number Volume
Transmission - PETROL OFISI ATF-DEXTRON II-D - MAXITRAK TMS OIL 500* 19,0 litre
- MOBIL ATF-DEXTRON III - MOBIL FLUID 426* 5.0 US gal
- PETRONAS API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/ - PETRONAS AMBRA MULTI-G 10W30
SF/SG/SH/SJ/SL OR ACEA,
CATEGORIES A,B,E
VISCOSITY GRADES:SAE 20W-20/30/10W-
30/10W-40/15W-30/ 15W-40/20W-40
BASE OIL API GROUP 1/2/3
Front Axle & Reduction Gear - PETROL OFISI API GL4 - MAXIGEAR EP-X 85W-90LS* 8,0 litre
- MOBIL - MOBIL FLUID 426* 2.1 US gal
- PETRONAS
- PETRONAS AMBRA W90 LS
Rear Axle & Reduction Gear - PETROL OFISI API GL4 - MAXITRAK TMS OIL 500* 16 liter
- MOBIL - MOBIL FLUID 426* 4.2 US gal
- PETRONAS - PETRONAS AMBRA MULTI-G 10W30
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,

sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Hydraulic oil change intervals x

1. Oil changes in preset intervals;
NOTE: Oil changes in preset intervals are only permitted for mineral oils. When using environmentally friendly
hydraulic fluids, oil sample analysis reports must be used to determine the time of the oil change.
a) In standard applications
o p e r a t in g
h o u r s
5 0 0 1 0 0 0 1 5 0 0 2 0 0 0
b) In dust intensive applications
o p e r a t in g
h o u rs
5 0 0 1 0 0 0 1 5 0 0 2 0 0 0
To limit the hydraulic oil contamination when working under extreme dusty conditions
On backhoe loaders working under very dusty conditions • The tank return filter element(s) must be replaced
or with a hydraulic hammer attachment, the every 1000 operating hours.
contamination of the hydraulic oil may be significantly
increased. • The breather filter on the hydraulic tank must be
In order to avoid any premature wear and failure of replaced with a 75 µm fine breather filter.
hydraulic components in consequence of this
contamination reduce the oil change intervals as • This 75 µm breather filter must be replaced every time
described above and, in addition, observe following the hydraulic oil is changed (every 1000 operating
recommendations: hours).

Brake Oil (For B730 S/N B4B611001 - B4B611134)
 PO MAXIMA 10W-40 API SL/CF, ACEA A3/B3/B4

BRAKE PO ATF II
 MOBIL ATF 22
PETRONAS TUTELA GI/A
Intervals for brake oil change: • Brake oil changes every 1000 hours.
Transmission Fluid
Lubricant regulations for transmission oils based on the following specifications and regulations:
 MOBILFLUID 426 ATF-DEXRON II-D

TRANSMISSION ATF-DEXRON III
 
PETRONAS AMBRA Multi-G 10W-30 API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/
SH/SJ/SL OR ACEA, CATEGORIES A,B,E
VISCOSITY GRADES:SAE 20W-20/30/10W-
30/10W-40/15W-30/ 15W-40/20W-40
BASE OIL API GROUP 1/2/3

Intervals for oil change:
• First oil change at: 100 operating hours
• First filter changes at: 1000 operating hours
• Further filter changes every 1000 hours and oil changes every 1000 hours (depending on climate zone and oil quality).
Front Axle Oil
FRONT AXLE AND 

REDUCTION GEAR PO MAXIGEAR EP-X 85W-90LS API GL-4
MOBIL FLUID 426
PETRONAS AMBRA W90 LS

• First oil change at: 500 hours.
• Further oil changes every 1000 hours.
Rear Axle Oil
REAR AXLE AND

REDUCTION GEAR PO MAXITRACK TMS OIL 500 API GL-4
MOBILFLUID 426
PETRONAS AMBRA MULTI-G 10W30

• First oil change at: 500 operating hours.
• Further oil changes every 1000 hours.

Lubrication Chart (B730 And B750)

*
* (For B730
S/N B4B611001 -
B4B611134 ONLY)

LUBRICATION (CONT’D) Draining The Engine Oil
Diesel Engine Maintenance Tools: Combination wrench 16 mm

Checking The Engine Oil Level
To change the oil, bring the engine to operating
temperature.
Figure 20-50-1
Figure 20-50-3
S45294
S45295

Figure 20-50-2
Place an appropriate container under the drain plug,
remove the drain plug and drain the used oil into the
container.
Replace The Oil Filter Element
Maintenance Tools: filter wrench
Figure 20-50-4
S44139
Park the machine on firm, level ground to check the

engine oil level.
Lift the loader attachment, install the approved lift arm

support device and engage the parking brake.
Turn the engine off and wait a few minutes for the oil to
collect in the oil pan. Open the engine bonnet.
The oil should not exceed the upper mark on the dipstick.
If the oil level is below the mark, remove the filler cap and S45296
add oil up to mark on the dipstick.
WARNING: The engine oil is very hot at or near Remove the filter element by using the filter wrench.
operating temperature. Avoid contact with hot Clean the sealing surface on the filter mount. Grease the
oil and components containing oil, since it could new filter sealing surface and place the new filter in the
cause severe burns. filter housing.

Diesel Engine (Cont’d)
WARNING: Don’t use the filter wrench to place

the new filter.
Lightly lubricate the seal with oil and tighten the

filter element using both hands.
Adding Engine Oil
Figure 20-50-5

S45297
Fill the engine with new oil to the upper mark of the
dipstick.
Run the engine for few minutes and check for leaks and
the level again. Close the engine bonnet.

LUBRICATION (CONT’D) Coolant Reservoir
Figure 20-50-7
Cooling System
See Lubrication Chart and Capacities for service times

and quantities. (See Lubrication Chart (B730 And B750)
on Page 20-50-7.) For model B730 (See Capacities on
Page 10-20-3.) and for model B750 (See Capacities on
Page 10-20-6.)
Thermostat Opening 77° - 82°C (170° - 180°F)
Radiator Cap Pressure 0,8 bar (11 psi)
WARNING: At or near operating temperature,

S45286
the engine coolant is hot and under pressure.
Avoid contact with components containing
coolant, since it could cause severe burns. To check the coolant level in the coolant reservoir, turn
Check coolant level only after the cap of the cap of coolant reservoir slowly to relieve pressure.
radiator and coolant reservoir is cool enough to
touch. When the coolant is cold, the coolant level should not
exceed the upper level of the coolant reservoir If
Checking The Coolant Level necessary, remove the radiator cap and add coolant until
Figure 20-50-6 the level reaches the upper level on the coolant reservoir.

Antifreeze and corrosion protection of the coolant
Never add water to the warm engine. Add the proper
coolant mixture to the cooling system on a year round
basis, not just in the cold season.
The backhoe loader is delivered from the factory with a
cooling system protection to -35°C (this corresponds to
about 50% antifreeze). For the cooling system capacity:
see lubrication chart.
S45285
Park the machine on firm, level ground to check the

engine coolant level. Lift the loader attachment, install
the approved lift arm support device and engage the
parking brake lever. Turn the engine off. Remove the
ignition key.
To check the coolant level in the radiator, turn the cap of

the radiator. When the coolant is cold, the coolant level
should reach the lower end of the filler neck under the
cap of the radiator.If it is under it, add the proper coolant
mixture.

LUBRICATION (CONT’D) Important: In order to totally drain the coolant from the
engine (also when the machine has not been used for a
Cooling System (Cont’d) long period of time), the coolant also has to be drained
from the cooling pump.
Also the correct concentration of corrosion inhibitors
Cleaning The Radiator And Adding Coolant
inside the coolant must be maintained permanently.
The concentration has to be checked after each Figure 20-50-8
important coolant make up, and at regular intervals if
smaller coolant quantities are refilled frequently. If
necessary, anti-corrosion additives must be added to the
cooling system.
If it is possible, use clean and soft water at the cooling

system. Adding antifreeze to the coolant prevents
damages of freezing. Anti-corrosion such as sodium
benzoate or sodium nitrite is advised. At the coolant
mixture, the rate of the antifreeze shouldn’t be more than
50%
The proper coolant mixture should be like follows:
Min temperature °C -5 -10 -15 -20 -25 -30

S45285

The rate of 25 30 35 40 45 50
antifreeze %
Fill the cooling system with clean water. Run the engine
The rate of water % 75 70 65 60 55 50 about 10 minutes to stir up possible rust or sediment.
Stop engine and immediately drain water from the
Even if you don’t need to prevent freezing, the coolant system before rust and sediment settle.
mixture is necessary in order to prevent corrosion. If you
don’t use the antifreeze, you should add the proper anti- Close all drain plugs.
corrosion to water. While adding the anti corrosion, you
should observe recommendation of the manufacturer. Add coolant to the radiator tank and coolant reservoir
through the filler cap.
Changing The Coolant
Remove the loader approved lift arm support device and
The coolant in the cooling system has to be changed at lower the loader attachment.
least every 2 years (or every 2000 hours, whichever
comes first). Important: Air must be expelled from cooling system
when system is refilled. Loosen temperature sending unit
Preferably keep the valves for the cab heating circuit fitting at rear of cylinder head or plug in thermostat
closed when changing the coolant. If the coolant in the housing to allow air to escape when filling system.
heating circuit has to be drained too, the heater core Retighten fitting or plug after filling the cooling system.
must be vented correctly when refilling the circuit. The
water flow through the cab heater is possible only with Start the engine, run it at low idle for about 30 seconds.
ignition key in contact position. This mixes the solution uniformly and circulates it through
the entire system.
Draining Coolant
After running engine, check coolant level and entire
Park the machine on firm, level ground to drain the cooling system for leaks.
coolant. Lift the loader attachment; install the approved
lift arm support device. Engage the parking brake lever. Important: When adding coolant, make sure that the
Turn the engine off. Remove the ignition key. radiator tank if filled all the way to the top of the fitting,
add coolant until the level does no longer drop (it is not
Unscrew the cover of the drain valve. Place an possible to overfill the tank if the pressure relief valve is
appropriate container under the drain plug, remove the not removed).
drain plug and drain the used coolant into the container.

LUBRICATION (CONT’D) Check Hydraulic Oil Level
Cooling System (Cont’d) Figure 20-50-10

Clean The Oil Cooler And The Radiator
Maintenance Tools: Combination wrench 10 - 13 - 17 mm

Figure 20-50-9
S45289
The fluid level should be in the middle of the sight gauge.

S45298 Fill up if necessary.
For removing the dust on the oil cooler and radiator use

compressed air. Protect your face when using
compressed air.
For removing the mud on the oil cooler and radiator, use
water.
See maintenance chart for cleaning intervals. (See
Lubrication Chart (B730 And B750) on Page 20-50-7.)
Hydraulic System

Page 10-20-6.).
Maintenance Instruction
When checking the oil level or adding oil,
• Park the machine on level ground.

• Lower the attachments flat on the ground.
• Place all controls in NEUTRAL.
• Engage the parking brake.
• Turn the engine off and exit the machine. Allow the
engine to cool.

LUBRICATION (CONT’D) Figure 20-50-12
To Drain Oil
Maintenance Tools: Combination wrench 22 mm
Figure 20-50-11
S45444
Remove the filter element by filter wrench. Clean the

sealing surface on the filter mount. Lightly lubricate the
seal with oil and tighten the new filter element, using both
S45299 hands.
Replacing The Internal Hydraulic Filter


Figure 20-50-13
container. The oil should be at operating temperature
when draining.
Interval of changing the oil level at normal 1

conditions.
O p e r a ti n g 1
h o u rs
5 0 0 1 0 0 0 1 5 0 0 2 0 0 0 2
Interval of changing the oil level at the dusty

condition
O p e r a tin g
h o u rs
S45300
5 0 0 1 0 0 0 1 5 0 0 2 0 0 0
Maintenance Tools: Filter wrench Maintenance Tools: Combination wrench 10 mm.
Clean the surface around the hydraulic tank flange (2) of

all dirt and debris.
Remove the four bolts (1) from the flange (2).
Remove the flange (2).

Replacing The Internal Hydraulic Filter (Cont’d)
Figure 20-50-14
1 1
1 1
S47105
Remove the six bolts (1) from the flange.

S47104
Pull out the suction strainer (1).
Install a new strainer and reinstall the flange.

To Clean The Suction Strainer 2
Maintenance Tools: Combination wrench 10 mm, Screw 1

driver
3
S47092
To remove the suction filter flange (1) and clean the

strainer (2) or remove and replace the suction strainer (2)
from the flange if damaged.
1
2
3
S47090
Drain hydraulic tank before removing hydraulic suction

strainer.
Place an appropriate container under the hydraulic tank

before removing components to clean the suction
strainer.
To remove the suction strainer, either the hydraulic clamp

(1) and hose (2) must be removed or the four bolts (3)
must be removed for access to the suction filter.

To Clean The Suction Strainer (Cont’d)
Figure 20-50-15
S47091
Remove the plug (1) from inside the hydraulic tank to

drain any additional hydraulic fluid from the tank.

Clean all surface and reinstall all parts.
Adding Hydraulic Oil
Figure 20-50-16
S45300
Add hydraulic oil through the fill cap (1) until oil is at the
center of the sight gauge. (See Check Hydraulic Oil Level
on Page 20-50-12.)

LUBRICATION (CONT’D) Biodiesel Blend Fuel
The Fuel System Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
and quantities. (See Lubrication Chart (B730 And B750) • Cold weather conditions can lead to plugged fuel
on Page 20-50-7.) For model B730 (See Capacities on system components and hard starting.
Page 10-20-6.). • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination that can cause
Fuel Specifications corrosion and plugging of fuel system components.
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as: plugged
Ultra low sulfur diesel fuel must be used in this machine. fuel filters and deteriorated fuel lines.
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur
maximum. • Shorter maintenance intervals may be required, such
as: cleaning the fuel system and replacing fuel filters
U.S. Standard (ASTM D975)
and fuel lines.
Use only clean, high quality diesel fuel, Grade Number
2-D or Grade Number 1-D. • Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
The following is one suggested blending guideline that deterioration of hoses, tubelines, injectors, injector
should prevent fuel gelling during cold temperatures: pump, and seals.

TEMPERATURE GRADE 2-D GRADE 1-D Apply the following guidelines if biodiesel blend fuel is
Above -9°C (+15°F) 100% 0% used:
Down to -21°C (-5°F) 50% 50% • Ensure the fuel tank is as full as possible at all times
Below -21°C (-5°F) 0% 100% to prevent moisture from collecting in the fuel tank.
NOTE: Biodiesel blend fuel may also be used in this • Ensure that the fuel tank cap is securely tightened.
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed • Biodiesel blend fuel can damage painted surfaces,
with ultra low sulfur petroleum based diesel.
remove all spilled fuel from painted surfaces
This biodiesel blend fuel is commonly
marketed as B5 blended diesel fuel. B5 immediately.
blended diesel fuel must meet ASTM
specifications. • Drain all water from the fuel filter daily before
operating the machine.
E.U. Standard (EN590)
• Do not exceed engine oil change interval. Extended
Use only clean, high quality diesel fuel that meets the
oil change intervals can cause engine damage.
EN590 specifications listed below:
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10 • Before machine storage; drain the fuel tank, refill with
ppm) sulfur maximum 100% petroleum diesel fuel, add fuel stabiliser, and
operate the engine for at least 30 minutes.
• Diesel fuel with cetane number of 51.0 and above.
NOTE: Biodiesel blend fuel does not have long term
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain stability and should not be stored for more
no more than seven percent biodiesel mixed than 3 months.
with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

LUBRICATION (CONT’D) Clean Fuel Tank Breather
Drain The Contaminant From The Fuel Filter Figure 20-50-19
Figure 20-50-17
S45304
S45302
Check the fuel tank breather for contamination. Clean if
necessary.
Drain water from the fuel system daily. Place an
appropriate container under the filter, unscrew the tap Replace The Fuel Filter Elements

located under the filter and drain the water until fuel
emerges, then retighten the drain plug Figure 20-50-20
Drain The Contaminant From The Fuel Tank
Figure 20-50-18
S45302
S45303
Place an appropriate container under the fuel tank,

unscrew the drain plug one up two turns and drain the
contaminant from the fuel tank then re-tighten the drain
plug.

LUBRICATION (CONT’D) Transmission
Replace The Fuel Filter Elements (Cont’d) See Lubrication Chart and Capacities for service times
Figure 20-50-21 on Page 20-50-7.) For model B730 (See Capacities on
Page 10-20-3.) and for model B750. (See Capacities on
Page 10-20-6.)

• Park the machine on level ground
• Lift the loader arms and install the approved lift arm
support device. (See APPROVED LIFT ARM
SUPPORT DEVICE on Page 20-20-1.)
• Transmission in NEUTRAL position, N”
• At engine idling speed about 1000 min-1
S45305
At operating temperature of the transmission (about
80°C)
Remove the fuel filter elements. Lightly grease the seal of
the new filter elements and reinstall the elements. After Checking Transmission Oil Level

that, bleed the fuel system.
Figure 20-50-23
Adding Fuel
Figure 20-50-22
S45307
S45446
Install the drain plugs. Add fuel through the filler cap.
Close the filler cap.

LUBRICATION (CONT’D) Replace The Transmission Filter Elements
Checking Transmission Oil Level (Cont’d) Maintenance Tools: Filter wrench
Figure 20-50-24 Figure 20-50-26
S45308
S45310
Remove and clean the dipstick. Insert oil dipstick into the
oil level tube until contact is obtained and take it out Clean the surface of filter. Take care that no dirt or oil
again. sludge can penetrate the circuit. Place an appropriate

container under the filter. Remove the filter by using filter
The level of oil should be between upper mark and below wrench. Lightly grease the seal of the new filter elements,
mark: In cold weather the oil level should be near the screw filter in until contact with the sealing surface is
lower mark and in hot weather it should be near the obtained. Tighten with both hands.
upper mark. If the level is under the lower mark, add oil.
And replace the dipstick. NOTE: While placing new filter do not use the filter
wrench.
Drain Transmission Oil
Add Transmission Oil
Maintenance Tools: extension bar 12,5 square drive
Figure 20-50-27
Figure 20-50-25
S45307
S45309
Add oil through the filler neck, and then check the oil
level. The level of oil should be between upper slot and
Place an appropriate container under the drain plug; below slot If necessary, add oil. Place the dipstick.
remove the drain plug and filler cap. Drain the used oil Remove support and close the bonnet.
into the container. Install the drain plug and filler cap.

LUBRICATION (CONT’D) To Drain Oil
Front Drive Axle And Reduction Gears Maintenance Tools: 12,5 mm (1/2 in) square drive
wrench
and quantities. (See Lubrication Chart (B730 And B750) Figure 20-50-29
Page 10-20-6.)
Front Drive Axle

• Turn the engine off and exit the machine
To Check front axle oil level
S45312
Maintenance Tools: 12,5 mm (1/2 in) square drive
wrench
Place an appropriate container under the drain plug and
Figure 20-50-28 clean the surface area around the drain plug. Remove

the drain plug and drain the used oil into the container.
Install the drain plug.
To Add Oil

wrench.
Figure 20-50-30
S45311
Remove the plug and check that the oil is level with the
orifice. If necessary, fill up. Install the plug.
S45311
Clean the surface area around the fill plug. Remove the
fill plug.
Add oil until the oil is level with the orifice. Install the plug.

Reduction Gears
See Lubrication Chart for oil quality and oil quantities.

• Place all controls in neutral.
To Check Reduction Gear Oil Level

S45410A
Figure 20-50-31 Park the machine that the level mark on the wheel is the
lowest position. Place an appropriate container under the
plug, remove the plug and drain the used oil into the
container. Install the plug.
Add Reduction Gear Oil

wrench.
Figure 20-50-33
S45410
• Park the machine that the level mark on the wheel is

parallel to the ground. Remove the plug and check
that the oil is level with the orifice. If necessary, fill up.
Install the plug.
To Drain Reduction Gear Oil

S45410
wrench.
Park the machine that is the level mark on the wheel is

parallel to the ground. Remove the plug. Fill up and check
that the oil is level with the orifice and install the plug.
NOTE: Repeat the same procedure for the other

reduction gears.

Rear Axle

Page 10-20-6.)
When Checking The Oil Level, Draining Or Adding

Oil:
S45315
• Place all controls in neutral.
• Engage the parking brake. Check the rear axle breather for contamination. Clean if
• Turn the engine off and exit the machine necessary.
Drain Rear Axle Oil

To Check Rear Axle Oil Level
Maintenance Tools: Extension bar 12,5 square drive Figure 20-50-36

Figure 20-50-34
S45316
S45314
Remove the plug and check that the oil is level with the container. Install the drain plug.
orifice. If necessary, fill up. Install the plug.
Clean The Rear Axle Breather

LUBRICATION (CONT’D) Bleeding The Brake System
Add Rear Axle Oil
(For B730 S/N B4B611135 & Above, B750 S/N
B45BM11001 & Above Only)
After draining the hydraulic system or if the brake pedals
Figure 20-50-37 press down more than normal, the brakes must be bled.
Raise the front and rear axles and install jack stands
under the axles.
Lock the left and right the brake pedals together.
Start the engine. Allow to idle about 1 minute.
Press both brake pedals fully approximately twenty times.
A second person will be needed to open the brake bleed
screws on the rear axle to allow air to be removed from
the brake lines.
While the operator slowly presses the brake pedals, the
second person will need to open each of the brake bleed
screws (one at a time) until hydraulic oil, free of air flows
from the bleed screw. Tighten the bleed screw. Repeat
S45316 this procedure until the oil flows from the bleed screw
without any air bubbles.
Add oil until the oil is level with the orifice. Check the level Brake Fluid

and install the plug.
(For B730 S/N B4B611001 - B4B611134)
NOTE: Bleeding is required when rear axle oil is See Lubrication Chart and Capacities for service times
changed. and quantities. (See Lubrication Chart (B730 And B750)
Page 10-20-6.)
When checking the oil level, draining or adding oil,


LUBRICATION (CONT’D) Draining The Brake System
Checking Brake Fluid Reservoir Level (For B730 S/N B4B611001 - B4B611134)
Place a container under the drain plug. Remove drain
(For B730 S/N B4B611001 - B4B611134) plug.
Figure 20-50-38 Install the drain plug.
Fill the brake reservoir with clean brake fluid.Install the

filler cap. Do the same procedure as bleeding the brake
system until clean brake fluid appears at each bleed
screw. Add additional brake fluid as need.
Bleeding The Brake System
(For B730 S/N B4B611001 - B4B611134)

Lock the brake pedals. Loosen the bleeding screw. And
press down until the pedal reaches end of the stroke.
Hold the pedal end of the stroke and tighten the bleeding
screw. Repeat this procedure until the oil flows form the
bleeding screw without any air bubbles.
S45443
The oil level should be between the MIN and MAX mark

on the reservoir.
Add Brake Oil
(For B730 S/N B4B611001 - B4B611134)
Figure 20-50-39
S45443
Add oil through the filler cap. Install the drain plug and
filler cap. Bleed the system.

Service Schedule
Maintenance procedures which are given in the Service Manual can be performed by the owner / operator without any
specific technical training. Maintenance procedures which are not in the Service Manual must be performed ONLY BY
QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.
SERVICE SCHEDULE
Maintenance Interval Service Points Grease Check Clean Drain Replace
every 8 hours daily Loader attachment pivots x
Backhoe attachment pivots x
Front axle pivots x
Hydraulic circuit oil level x
Engine oil level x
Engine coolant level x
Indicator lights and gauges x
Air filter elements x
Bucket teeth for wear x
Windshield washer reservoir level x
every 50 hours weekly Rear cardan shaft joints x
Front cardan shaft joints x

Brake fluid level x
Tyres pressure x
Tightening of the wheel nuts x
Parking brake x
Brake pedal x
Transmission oil level x
Front Axle oil level x
Reduction gear oil level x
Rear axle oil level and breather x
Water separator bowl in the fuel filter x
Cab intake filter x
Fan belt x
first 100 hours Engine oil [1]
Engine oil filter [1]
Transmission oil [1]
Transmission filter [1]
every 250 hours Engine oil x
Engine oil filter x
Engine mounts x
Fuel filter x
Fuel Pre-Filter x
Transmission mounting bolts x
ROPS / FOPS cab (Contact your Bobcat x
Dealer)
Battery x

Service Schedule (Cont’d)
SERVICE SCHEDULE
Maintenance Interval Service Points grease check clean drain replace
first 500 hours Reduction gear oil [1]
Front axle oil [1]
Rear axle oil [1]
every 500 hours Fuel tank x
Transmission oil x
Transmission filter x
Air filter inside elements x
Air filter outside elements x
very 1000 hours Front axle oil x
Reduction gear oil x
Rear axle and oil x
Hydraulic oil x
Hydraulic oil filter (suction) x

Hydraulic oil filter (return) x
Hydraulic breathers x
Alternator x
Starter x
Hydraulic oil filter (mesh) x
Brake oil x x
Machine cleaning x
per year-every 2000 hours Engine coolant x x
Thermostat x
Tork Control x
Transmission filter (suction) x
Engine valve clearance x

As required Tightening of bucket tooth x
Bucket teeth x [2]
Extendable arm bearing pads x [2]
Engine alternator and fan belt x [2]
NOTE:
[1] = First interval only.
X = Repeat interval.
[2] = Change if necessary.

AIR CLEANER SERVICE Maintenance consists of cleaning the primary element
and replacing both the primary and secondary filter
Engine Air Intake System elements. We do not recommend cleaning the secondary
element.
Cleaning the filter elements.....................every 8 hours or
everyday Always check air filter restriction lamps located on the
side control panel.
Replacing the filter primary element........every 500 hours
Seals between filter element and housing can be
Replacing the secondary element...........every 500 hours damaged if the filter element is removed too often. Before
installing the new elements, carefully clean the seal and
WARNING: If you operate the machine in dusty the sealing surface of the filter housing.
terrain, you should reduce the maintenance
intervals.
Figure 20-60-1

S45457
Figure 20-60-2
S44172
For maximum engine protection, the air intake system

must be checked and serviced at regular intervals.
The air cleaner is designed to give maximum protection

at longest maintenance intervals.

AIR CLEANER SERVICE (CONT’D) Figure 20-60-5
Cleaning The Primary Element
If the primary element is dry;
Figure 20-60-3
S45416
1
Carefully remove the primary element. For cleaning, use

low pressure compressed air until there is no more dust
on the primary element. Compressed air pressure should
not exceed the 7 bar.
S45414
WARNING: If you operate the machine in dusty

Park the machine on firm, level ground. Lift the loader terrain, you should reduce the maintenance
attachments, install the approved lift arm support device. intervals.

Engage the parking brake. Turn the engine off and
remove the ignition key. Using the ignition key, unlock the If the primary element is oily;
engine cover (1) and open the engine cover. For cleaning, use warm water and dissolve a small
amount of suitable non-soapy detergent in it, and put the
Figure 20-60-4 filter element in this solution.
Shake it slowly and rinse it with clean water

1
until the detergent and dust have been removed
and water appears clear. Leave it to dry before
installation.
WARNING: Never use compressed air when the filtering

element is wet or moist.
S45415
Remove the cover of air filter by opening the clips (1).

AIR CLEANER SERVICE (CONT’D) Cab Air Intake Filter
Replacing The Air Filter Elements Maintenance Instruction
Figure 20-60-6 Cleaning cab air intake filter............every 50 hours
Figure 20-60-7
S45417
After removing the filter elements, clean inside of the filter

housing and the sealing surface with a damp rag. Do not
S45321

direct compressed air into the housing. Carefully install
the secondary element and then the primary element.
Make sure that they are seated correctly. Install the cover Remove the screws and the cab grille. Removed the cab
and close it by fastening the clips. air intake filter. Clean the filter with compressed air.
Install the filter.
Start the engine, run it at low idle and check that if the air
filter restriction lamp turns off. WARNING: Protect your face when using
compressed air, otherwise a serious accident
Remove the approved lift arm support device and lower may occur.
the loader attachments.


BACKHOE BOOM / SWING LOCK
Engaging And Disengaging
Figure 20-70-1
1
4
6 3
8
7
2
5 S44220
Swing the boom fully to the left or right transport position.

Fully raise the boom and retract the arm.
Park the machine on a flat level surface.
Put all controls in NEUTRAL.
Engage the parking brake.
Stop the engine, remove the start key and exit the
machine.
The lever (1) is used to secure the backhoe boom / swing

lock device (2) in the unlocked position.
To unlock the boom / swing lock for work position:.
Position (3): Move the lever (1) to the unlocked position.
Position (4): Rotate the boom / swing lock device UP to

the unlocked position.
To lock the boom / swing lock in the transport position:
Position (5): Rotate the boom / swing lock device DOWN

to the locked position. The bracket must fit onto the swing
lock pin (7) and into the boom lock plate (8).
Position (6): Move the lever (1) to the locked position.


ENGINE ALTERNATOR / FAN BELT AND AIR Replacing Fan And Alternator Belt
CONDITIONER BELT (IF EQUIPPED)
Maintenance Tools: Combination wrench 10 - 13 mm
Checking The Fan Belt
Release tension on belt by loosening the bolts, and
Maintenance Instruction remove belt from pulleys. Install new belt, making sure
belt is correctly seated in all pulley grooves. Apply
Figure 20-80-1 tension to belt by tightening the bolts. Remove the
approved lift arm support device. Lower the loader
attachments.
S45458

The belt tension is designed to operate within the limit of
hand movement. Depress the fan belt by hand. Check
mounting bracket and the belt length. The length of the
deflection should be 13 - 20 mm (0.5 - 0.8 in.). Inspect
belts for cracks, fraying, or stretched out. Replace new
belt if necessary.


TIRE MAINTENANCE To Replace A Wheel
Maintenance Instruction Maintenance Tools: socket wrench 27 mm for front

wheels, socket wrench 30 mm for rear wheels, ratchet
Checking the pressure of tire............every 50 hours handle - 20 mm square drive, and torque wrench.
Checking the torque...........................every 50 hours
WARNING: Do not perform any welding
Figure 20-90-1 operation near a tire. First remove the tire then
make welding.
WARNING: If a tire becomes flat, it may cause

serious accidents. Check the tire pressure
regularly.
WARNING: When removing the tire always use

inflation cage and never face the tire.
Park the machine on firm, level ground. Loosen the nuts

from the tire. Lift the machine above the ground by using
loader attachments and stabilizers. Engage the parking
S44175 brake. Turn the engine off. Place the blocks under the
axle to provide safety. Take off the nuts and remove the

tire. Install a new tire by carefully observing the
Check the condition of tires and observe the inflation orientation of the tread pattern. Install the nuts and adjust
pressures. Replace if necessary. their torque. Remove the blocks. Start the engine and
lower the machine.
Type Of Tires
DIMENSION PRESSURE
Front 4WD-standard 12.5/80-18 3.7 bar 54 psi
Rear 4WD-standard 16.9-28 2.6 bar 38 psi

TIRE MAINTENANCE (CONT’D)
Wheel Nut Torque Settings
Figure 20-90-2
S44175
Check the wheel nut torque of the tire for correct torque
value.

Front wheel nut............................ 300 N•m (221 ft-lb)
Rear wheel nut............................. 300 N•m (221 ft-lb)

LUBRICATION OF THE BACKHOE LOADER 5. Picot Link (2) (both sides)
Lubrication Locations
6. Tilt Cylinder Base End (2) (both sides)
Lubricate the backhoe loader as specified in the
SERVICE SCHEDULE for the best performance of the Figure 20-100-3
machine. (See Lubrication Chart (B730 And B750) on
Page 20-50-7.)
Always use a good quality lithium based multipurpose

grease when lubricating the machine. Apply the lubricant
until extra grease shows.
Figure 20-100-1
1 7
S45449
2 3
7. Lift Cylinder Rod End (2) (both sides)

Figure 20-100-4
2
S45436
11
Ref Description (# of Fittings)
1. Lift Arm Pivot Pin (2) (both sides)
2. Lift Cylinder Base End (2) (both sides) 9
3. Pivot Link (2) (both sides)
Figure 20-100-2
6
10
S44212
8. Bucket Pivot Pin (2) (both sides)

5
9. Clam Bucket Pivot Pin (2) (both sides) (if equipped)
10. Clam Bucket Cylinder Base End (2) (both sides) (if
equipped)
4
S45448
11. Clam Bucket Cylinder Rod End (2) (both sides) (if
equipped)
4. Pivot Link (2) (both sides)

Lubrication Locations (Cont’d)

17
Figure 20-100-5
12
19
14
18
16 17
13
S45450
S47168
12. Tilt Cylinder Rod End (2) (both sides)

16. Boom Swing Pin (2)
13. Tilt Linkage Pivot Pin (2) (both sides)
17. Boom Pivot (2) (top and bottom)
14. Bucket Linkage pivot Pin (2) (both sides)
18. Swing Cylinder Rod End(2) (both sides)
Figure 20-100-6
19. Swing Cylinder Pivot (4) (Top and Bottom)
Figure 20-100-8
15
20
S44211
S
15. Front Axle (4) (both sides)
20. Boom Cylinder Base End (1)

Figure 20-100-9
25
21
S45452
25. Bucket Cylinder Base End (1)

S45451
Figure 20-100-12
21. Boom Cylinder Rod End (1)

28

Figure 20-100-10
23
27
26
24
29
29
S47167
26. Bucket Cylinder Rod End (1)

22
27. Bucket Pivot (1)
28. Bucket Link Pivot (1)

S44205
29. Bucket Link (4)

22. Arm Cylinder Base End (1)
23. Arm Cylinder Rod End (1)
24. Arm Pivot (1)

Figure 20-100-13
32
30
S45455
30
32. Rear Drive shaft (1)
S45453 Figure 20-100-16
30. Front Drive shaft (2) 33

33

Figure 20-100-14
31
S45456
33. Brake Pedal Pivots (2) (Below Steering Column in

Cab)
S45454
31. Rear Drive shaft (1)

Figure 20-100-17
35
34
36

S47169
34. Stabiliser Cylinder (Rod End) (2)
35. Stabiliser Cylinder (Base Rod End) (2)
36. Stabiliser Pad Pivot (2)


HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Tests and Hydraulic Pressure Test (B730) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Tests and Hydraulic Pressure Test (B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Hydraulic Tank And Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Fixed Displacement Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
ON-OFF Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
ON-OFF Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-10
Unloading Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-17
Steering Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-18
Backhoe Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-19
Steering Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-22
Pilot Pressure Test (B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-23
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-24

RETURN LINE CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Basic Type Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Nut Type Cylinder Montage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-8
Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-12
Loader Bucket (Tilt) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-15
Clampshell Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-18
Backhoe Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-21
Backhoe Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-24
Backhoe Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-27
Backhoe Extendible Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-30
Backhoe Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-33
Backhoe Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-36
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

BACKHOE CONTROL VALVE (B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

BACKHOE CONTROL VALVE (B730) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1

BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1


BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61-1
CLAMP CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62-1

CLAMSHELL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63-1

LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64-1

STABILIZER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65-1

STICK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66-1

SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67-1


TILT CYLINDERS (B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68-1
TILT CYLINDERS (B730) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69-1

BRAKE PEDAL AND BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Removal And Installation (B730 S/N B4511155 & Above) 
(B750 S/N B45211080 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

LOADER CONTROL VALVE (B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1

LOADER CONTROL VALVE (B730) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91-1

STEERING COLUMN AND UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1

HYDRAULIC/HYDROSTATIC SCHEMATIC
B730 (S/N B4B611001 AND ABOVE)
(Shown With Options)
(PRINTED JANUARY 2017)
V-B730 LAAP
LEGEND
1 HYDRAULIC RESERVOIR 17 PORT RELIEF VALVE

BACKHOE ARM CYLINDER (Rod)
Reservoir Capacity . . . . . . . 75 L (19.8 U.S. gal)
. . . . . . . . . . . . . . 225 +/- 5 bar (3263 psi)
System Capacity . . . . . . . . . 130 L (34.3 U.S. gal)
17A PORT RELIEF VALVE
BACKHOE ARM CYLINDER (Base)
2 SCREEN (Suction) . . . . . . . . . . . . . . 275 +/- 5 bar (3989 psi)
3 HYDRAULIC FILTER ELEMENT 18 CHECK VALVE – With Orifice
4 COLD WEATHER BY-PASS . . . . . . . 2,0 bar (29 psi)
19 PORT RELIEF VALVE
AUXILIARY . . . . . . . . . 160 +/- 5 bar (2320 psi)
5 PRETENSION CHECK VALVE . . . . . 4,5 bar (65 psi)
20 RELIEF VALVE – Unload Valve . . 180 +/- 5 bar (2611 psi)
6 Not Used
21 SLOENOID ACTIVATED DIRECTIONAL
7 HYDRAULIC FILL CAP, pressurised with internal filter
CONTROL VALVE
8 OIL COOLER 22 UNLOADER SPOOL
9 RELIEF VALVE . . . . . . . . . . 220 +/- 5 bar (3190 psi)
23 CHECK VALVE
TILT CYLINDER (Rod) . . . . 225 +/- 5 bar (3263 psi)
24 PRIORITY VALVE - Steering
TILT CYLINDER (Base) . . . . 160 +/- 5 bar (2320 psi) 25 GEAR PUMP
64 L/min (16,9 gpm) at High Engine Idle
AUXILIARY (Base) . . . . . . . 240 +/- 5 bar (3480 psi) 26 GEAR PUMP
90 L/min (23,8 gpm) at High Engine Idle
12 PORT RELIEF VALVE 27 LOAD CHECK VALVE
BACKHOE SWING CYLINDER (Rod & Base)
. . . . . . . . . . . . . . 160 +/- 5 bar (2320 psi) 28 RELIEF VALVE - pilot . . . . 27 +/- 2 bar (392 psi)
29 RELIEF VALVE - steering . . 175 +/- 5 bar (2538 psi) (2)
13 Not Used
30 CHECK VALVE (2)
PORT RELIEF VALVE 31 CHECK VALVE

14
BACKHOE BOOM CYLINDER (Rod)
32 CHECK VALVE
. . . . . . . . . . . . . . 225 +/- 5 bar (3263 psi)
14A PORT RELIEF VALVE 33 LOAD CHECK VALVE
BACKHOE BOOM CYLINDER (Base)
. . . . . . . . . . . . . . 275 +/- 5 bar (3989 psi)
34 SOLENOID ACTIVATED DIRECTIONAL CONTROL
15 PORT RELIEF VALVE VALVE – Lift Arm Cylinder
BUCKET CYLINDER (Rod & Base)
. . . . . . . . . . . . . . 225 +/- 5 bar (3263 psi)
VALVE – Tilt Cylinder
16 LOAD CHECK VALVE – Stabiliser Cylinders (2)
36 ACCUMULATOR (OPTIONAL)
37 RELIEF VALVE . . 250 bar (3626 psi) (OPTIONAL)

VALVE – Ride Control
39 DIRECT TO TANK VALVE – Breaker Operation
(OPTIONAL)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in Belgium V-B730 LAAP (1-10-17)
83 of 856
L 39
13
V1 C1
32 AUXILIARY
AUXILIARY HYDRAULIC
STEERING CYLINDERSTEERING CYLINDER AUXILIARY COUPLERS
V2 C2 MALE
33
19
31
FEMALE
L R 31 11
31
31
34
29
15
LIFT ARM 31
30
BUCKET
30
31 31 31 31
31
31
TILT
BOOM
31
17
17A
10A 31
31 35 STABILIZER
10
28
20
31
27 STABILIZER 16
P T LS Dealer Copy -- Not for Resale 14A 14

21
22
23
MP2 31
36
MP1 18
37 ARM
31 31
12
31
18
SWING
31 31
MS 38 38
24
CF EF T2
LS A
7
25 26
1
B
4
8
HYDRAULICL SCHEMATIC
2
B730 (S/N B4B611001 & Above)
S1 (Shown With Options)
D
201.117.567 (1)
(SM 7310058)
Printed JANUARY 2017
Sheet 2 of 2
T5
3
Printed In BELGIUM
84 of 856
HYDRAULIC/HYDROSTATIC SCHEMATIC
B750 (S/N B4BM11001 AND ABOVE)
(Shown With Options)
(PRINTED JANUARY 2017)
V-B750 LAAP
LEGEND
1 HYDRAULIC RESERVOIR 18 ORIFICE

Reservoir Capacity . . . . . . . 75 L (19.8 U.S. gal)
System Capacity . . . . . . . . . 130 L (34.3 U.S. gal) 19 PORT RELIEF VALVE
AUXILIARY . . . . . . . . . 160 +/- 5 bar (2320 psi)
2 SCREEN (Suction) 20 RELIEF VALVE – Unload Valve . . 180 +/- 5 bar (2611 psi)
3 HYDRAULIC FILTER ELEMENT
21 SLOENOID ACTIVATED DIRECTIONAL
4 COLD WEATHER BY-PASS . . . . . . . 2,0 bar (29 psi) CONTROL VALVE
22 UNLOADER SPOOL
5 PRETENSION CHECK VALVE . . . . . 4,5 bar (65 psi)
SLOENOID ACTIVATED DIRECTIONAL 23 CHECK VALVE
6
CONTROL VALVE
7 HYDRAULIC FILL CAP, pressurised with internal filter
24 PRIORITY VALVE - Steering
8 OIL COOLER
25 GEAR PUMP
9 RELIEF VALVE . . . . . . . . . . 220 +/- 5 bar (3190 psi) 64 L/min (16,9 gpm) at High Engine Idle
10 PORT RELIEF VALVE 26 GEAR PUMP

TILT CYLINDER (Base) . . . . 160 +/- 5 bar (2320 psi) 90 L/min (23,8 gpm) at High Engine Idle
27 LOAD CHECK VALVE
TILT CYLINDER (Rod) . . . . 225 +/- 5 bar (3263 psi) 28 RELIEF VALVE - pilot . . . . 27 +/- 2 bar (392 psi)
PORT RELIEF VALVE 29 RELIEF VALVE - steering . . 175 +/- 5 bar (2538 psi) (2)
11
AUXILIARY (Base) . . . . . . . 240 +/- 5 bar (3480 psi) 30 CHECK VALVE (2)
12 PORT RELIEF VALVE 31 CHECK VALVE

BACKHOE SWING CYLINDER (Rod & Base)
. . . . . . . . . . . . . . 160 +/- 5 bar (2320 psi) 32 CHECK VALVE
33 LOAD CHECK VALVE

13 ORIFICE
34 CHECK VALVE – With Orifice
BACKHOE ARM CYLINDER (base) 35 ACCUMULATOR
. . . . . . . . . . . . . . 225 +/- 5 bar (3263 psi)
BACKHOE ARM CYLINDER (Rod) 36 ACCUMULATOR (OPTIONAL)
. . . . . . . . . . . . . . 275 +/- 5 bar (3989 psi)
37 RELIEF VALVE . . 250 bar (3626 psi) (OPTIONAL)
BUCKET CYLINDER (Rod & Base) 38 SOLENOID ACTIVATED DIRECTIONAL CONTROL
. . . . . . . . . . . . . . 225 +/- 5 bar (3263 psi) VALVE – Ride Control
16 LOAD CHECK VALVE – Stabiliser Cylinders (2) 39 DIRECT TO TANK VALVE – Breaker Operation
(OPTIONAL)
17 PORT RELIEF VALVE 40 RELIEF VALVE . . 27 bar (392 psi) (OPTIONAL)
BACKHOE BOOM CYLINDER (Rod)
. . . . . . . . . . . . . . 275 +/- 5 bar (3989 psi) 41 CHECK VALVE
PORT RELIEF VALVE
17A BACKHOE BOOM CYLINDER (Base) 42 SOLENOID ACTIVATED DIRECTIONAL CONTROL
. . . . . . . . . . . . . . 225 +/- 5 bar (3263 psi) VALVE – Joystick Lockout
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in Belgium V-B750 LAAP (1-31-17)
85 of 856
CONTROL VALVE DIRECT TO TANK
L
VALVE
(OPTIONAL)
39
6
32
19
31 AUXILIARY
HYDRAULIC
COUPLERS
AUX MALE
CONTROL 31
FEMALE
VALVE 15
K T1 31
STEERING CYLINDER
V1 C1
BUCKET
31 14 31 14A
L R AUX
31
29 V2 C2 34
33
ARM
11
31 31
31 31
30 30
31
31
TILT
STAB
36 31
16
10A 37
31 10 17 17A
STAB
ARM 31
28
BOOM
31 31 12
38 38
31
31
27 18
9
P T LS
STEERING 20 SWING
VALVE
31
7 31
T2
21
R
A
22 MP2
23
5
1
M1 2
Dealer Copy -- Not for Resale B 4 JOYSTICK

LOCKOUT VALVE
MP1 8 D
BACKHOE
24
MS JOYSTICK
CF EF 3
35 RIGHT
42
MP
LS
41
40
25
26
ISO CONTROL
BHL CONTROL
PATTERN
PATTERN
BACKHOE
JOYSTICK LEFT LOADER JOYSTICK
HYDRAULICL SCHEMATIC
B750 (S/N B4BM11001 & Above)
CLAMP VALVE (Shown With Options)
201.117.568 (1)
(SM 7310058)
Printed JANUARY 2017
Sheet 2 of 2
ISO / BHL
SELECTOR VALVE
86 of 856
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS
WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

Solid Line - Working (Main) Line, Restriction - Affected by Viscosity
Return Line (line conducting fluid (property of resistance to flowing
from working devices to the reservoir) fluid).
and Feed line (main line conductor).
VARIABLE ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
PILOT PRESSURE - Dashed Line -
Pilot Line (Line which conducts TEMPERATURE CONTROL -
control fluid). (Indication of temperature).
DRAIN CIRCUITS - Dotted Line -

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.)

FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FILTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

Connected). electric signal with pressure.
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
PRESSURE SWITCH - Switch

activates when pressure reaches
specified level.
MUFFLER (silencer) - Reduces

noise.

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward CONTROL VALVE WITH DETENT
strokes). (Holds Valve in Position) - device for
maintaining a given position
DOUBLE ACTING HYDRAULIC (mechanical).
CYLINDER, UNEQUAL
DISPLACEMENT - With single piston CONTROL VALVE ACTIVATED BY A
rod. PULL BUTTON (manual).
DOUBLE ACTING HYDRAULIC

CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY A
DISPLACEMENT and CUSHION ON PUSH-PULL BUTTON (manual).
ONE END - With single piston rod.
CONTROL VALVE ACTIVATED BY A

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic

energy.
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
CONTROL VALVE WITH SPRING
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).
MOTOR: To convert hydraulic energy into rotary CONTROL VALVE ACTIVATED BY A

mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).
FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY

BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).


NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for the
allows free flow in one direction only. opening (fully or restricted) or the closing of one or more
flow paths (represented by several squares).
NON-RETURN VALVE (Check Valve) TWO PORTS and CLOSED FLOW

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
LOCK VALVE - hydraulic pressure is

applied to open the valve to allow the
hydraulic cylinder to move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR VALVE

(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.
TOW VALVE - Normally in closed

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

HYDRAULIC SYSTEM
Tests and Hydraulic Pressure Test (B730)
Tests and Hydraulic Pressures Test Point Normal Valve Notes

Engine RPM Low 800 min-1
Engine RPM High 2200 min-1
Oil Temperature 50±10 °C
Transmission system pressure Trans 16+3 bar

Adjusted Hydraulic main system P1 220±5 bar All pressure
pressure adjustment due to
engine’s 1500 rpm
Hydraulic support pump system pressure P2 180±5 bar
Loader Valve
Boom cylinder retract P1 220±5 bar System pressure
Boom cylinder extend P1 220±5 bar System pressure
Bucket cylinder retract P1 225±5 bar

Bucket cylinder extend P1 160±5 bar
Clamp cylinder retract P1 240±5 bar

Clamp cylinder extend P1 220±5 bar System pressure
Backhoe Valve
Boom cylinder retract P1 225±5 bar
Boom cylinder extend P1 275±5 bar
Arm cylinder retract P1 275±5 bar

Arm cylinder extend P1 225±5 bar

Swing cylinder - Left P1 160±5 bar

Swing cylinder - Right P1 160±5 bar
Stabilizer - Left leg P1 220±5 bar System pressure

Stabilizer - Right leg P1 220±5 bar System pressure
Steering system
Steering unit CF 175±5 bar
Turn Right CF 175±5 bar
Turn Left CF 175±5 bar

HYDRAULIC SYSTEM (CONT’D)
Tests and Hydraulic Pressure Test (B750)
Tests and Hydraulic Pressures Test Point Normal Valve Notes

Engine RPM Low 800 min-1
Engine RPM High 2200 min-1
Oil Temperature 50±10 °C
Transmission system pressure Trans 16+3 bar

Adjusted Hydraulic main system P1 220±5 bar All pressure
pressure adjustment due to
engine’s 1500 rpm
Hydraulic support pump system pressure P2 180±5 bar
Loader Valve
Boom cylinder retract P1 220±5 bar System pressure
Boom cylinder extend P1 220±5 bar System pressure

Clamp cylinder retract P1 240±5 bar

Clamp cylinder extend P1 220±5 bar System pressure
Backhoe Valve
Boom cylinder retract P1 225±5 bar
Boom cylinder extend P1 275±5 bar
Arm cylinder retract P1 275±5 bar

Arm cylinder extend P1 225±5 bar

Swing cylinder - Left P1 220±5 bar

Swing cylinder - Right P1 220±5 bar
Stabilizer - Left leg P1 220±5 bar System pressure

Stabilizer - Right leg P1 220±5 bar System pressure
Steering system
Steering unit CF 175±5 bar
Turn Right CF 175±5 bar
Turn Left CF 175±5 bar
Pilot System Pressure Pilot 27+2 bar

HYDRAULIC SYSTEM (CONT’D) Figure 30-20-3
Test Ports
Figure 30-20-1 1
S47017
2
NOTE: This is for 750 models.
S47015
1. Pilot pressure test port 27~30 bar (392 - 435 psi).
1. P1 test port 215~225 bar (3118 - 3263 psi). Figure 30-20-4

2. Steering pressure test port 165~175 bar
(2393 - 2538 psi).
Figure 30-20-2
2 1
S47018
1. P1 adjustment screw.
S47016
1. P1 test port 215~225 bar (3118 - 3263 psi).
2. P2 test port pressure should increase to 165~175 bar

(2393 - 2538 psi) then suddenly drop to 0~5 bar (0 -
73 psi). (when the system pressure reaches 165 bar
(2393 psi) an unloader valve in the control valve
diverts the bigger pump’s flow from system to tank).

HYDRAULIC SYSTEM (CONT’D) Hydraulic Tank And Return Filter
Test Ports (Cont’d) Figure 30-20-6
Figure 30-20-5
P126265
S47019
Hydraulic tank contains the hydraulic oil for the hydraulic
system.
1. P2 adjustment screw.
Figure 30-20-7

S44223
Hydraulic tank has three separate sections.
1. Filter chamber A, all leak oil is collected.
2. Return oil side B, all return oil from the hydraulic

valves is collected.
3. Suction side C, where the oil is drawn by the hydraulic

pumps.
Section B and C are divided by means of the perforated

steel sheet.
Filtered oil flows through the section C which is free from

the foam.

Fixed Displacement Tandem Pump
Figure 30-20-8
S46985
P1 PUMP
Figure 30-20-10
P2 PUMP S46986
The working pump is designed as a gear pump. It is

driven by the diesel engine and installed on the

transmission unit.
Hydraulic pump converts mechanical energy to hydraulic

energy.
The double pump consists of two input units P1 and P2

and designed as a fixed displacement gear pump.
The pump is driven by the transmission with the same

speed of the engine. S44227
The second pump P1 supplies oil to the hydraulic

steering system via the priority valve.
The priority valve diverts excess flow to the loader valve.
This flow summation increases the attachment speed.

HYDRAULIC SYSTEM (CONT’D) Function Of Pretension Check Valve
Blocks Figure 30-20-12
Collector Block
Figure 30-20-11
S44230
The pretension check valve is pre-adjusted in the factory.

P126266
The counter pressure is adjusted by the spring (2) force
which holds the piston (9) in its seat. When the counter

The return oil from the users is collected in the loader pressure is reached to the adjusted value, the piston
valve block (100) and the backhoe valve block (200) and leaves its seat, allowing oil to flow through port T. The
returns to the tank via collector block (2). pressure at port A is maintained to the pre-adjusted
value.
The oil returns to the tank, either via the pretension check
valve 2.2, connections and oil cooler (3). The orifice on the piston allows oil on the spring side to
flow through the tank (to avoid the piston from blockage).
To avoid the pressure peaks in the oil cooler when the
hydraulic oil is cold (high viscosity), the pretension check If the servo pressure is higher than the predefined value,
valve (2.1), which is adjusted to 4.5 bar, pens and allows loosen locknut and turn the adjustment screw counter-
the return oil from the control valve blocks to flow directly clockwise to set the pressure.
to the hydraulic tank (1).
1- Cover 2- Spring 3- O-ring
4- Housing 5- O-ring 6- Seal
7- Support 8- O-ring 9- Piston
A- Inlet Port T - Tank port

Blocks (Cont’d)
Servo Valve Block
Figure 30-20-13

S46987
S44231
Servo valve is a collector and distributor block.
Servo valve supply oils to the joysticks and the backhoe

boom locking valve. The return lines of these
components are connected to the tank via the servo
valve.
The valve is supplied with hydraulic oil via connection (9)

from the distributor block which is also supplied with
hydraulic oil via the axial piston pump.
The cartridge type pressure reducing valve is mounted to

the block. The purpose of this is to limit the servo
pressure to a certain value.
An accumulator is mounted to the block which maintains

the servo pressure makes it possible to apply a limited
times when the engine is turned off or the hydraulic pump
has a failure.

ON-OFF Solenoid Valve
Function
Figure 30-20-15
S46990
All the joysticks are supplied with oil when the solenoid
valve is energized.
S46988

The spool of the solenoid valve closes the ports of A and
B in neutral by means of the spring force.
Figure 30-20-16
S46989
When the solenoid energized, the pin inside the magnet

is forced towards to the spool. The spool moves in the
same direction of the pin allowing the oil to flow from Port
A to Port B.

ON-OFF Pressure Reducing Valve
Adjustment
Figure 30-20-18
S44233
If the pilot pressure is lower than the predefined value,

loosen locknut and turn the adjustment screw clockwise
to set the pressure.
S44232
If the pilot pressure is higher than the predefined value,
loosen locknut and turn the adjustment screw counter-

Remove cap and install the pressure gauge to the test clockwise to set the pressure.
point PILOT for the pilot pressure of the hydraulic
system.
Run the diesel engine at approx. 1000 RPM.
Load the pump slowly by means of actuating one of the

cylinders all the way.
Check the servo pressure.

Loader Control Valve
Port Locations - B730

S47020
PORT LINE MAX PRESSURE

P1 41cc PUMP 220 bar (3191 psi)
P2 EF PORT OF PRIORITY VALVE 165 bar (2393 psi)
T TANK 50 bar (725 psi)
B BACKHOE CONTROL VALVE 220 bar (3191 psi)
M1 SYSTEM PRESSURE GAUGE 220 bar (3191 psi)
M2 UNLOADER PRESSURE (P2) GAUGE 165 bar (2393 psi)
1A BOTTOM SIDE OF TILT CYLINDER 160 bar (2321 psi)
1B ROD SIDE OF TILT CYLINDER 220 bar (3191 psi)
2A BOTTOM SIDE OF LIFT CYLINDER 220 bar (3191 psi)
2B ROD SIDE OF LIFT CYLINDER 220 bar (3191 psi)
3A ROD SIDES OF CLAMSHELL BUCKET’S CYLINDERS 220 bar (3191 psi)
3B BOTTOM SIDES OF CLAMSHELL BUCKET’S CYLINDERS 220 bar (3191 psi)

Loader Control Valve (Cont’d)

S47021

P1 41cc PUMP 220 bar (3191 psi)
P2 EF PORT OF PRIORITY VALVE 165 bar (2393 psi)
B BACKHOE CONTROL VALVE 220 bar (3191 psi)
M1 SYSTEM PRESSURE GAUGE 220 bar (3191 psi)
M2 UNLOADER PRESSURE (P2) GAUGE 165 bar (2393 psi)
1A BOTTOM SIDE OF LIFT CYLINDER 220 bar (3191 psi)
1B ROD SIDE OF LIFT CYLINDER 220 bar (3191 psi)
2A BOTTOM SIDE OF TILT CYLINDER 160 bar (2321 psi)
2B ROD SIDE OF TILT CYLINDER 220 bar (3191 psi)
3A BOTTOM SIDES OF CLAMSHELL BUCKET’S CYLINDERS 220 bar (3191 psi)
3B ROD SIDES OF CLAMSHELL BUCKET’S CYLINDERS 220 bar (3191 psi)

Functions Of The Loader Control Valve And Unloader

B
Valve
Figure 30-20-20
S47024
Feeding B port.
Figure 30-20-23
S47022

A B
Neutral position.
Figure 30-20-21
S47025
Float position.
S47023
Feeding A port.

The Function Of The Loader Control Valve And Unloader

Valve (Cont’d)
Figure 30-20-24
S47026

Anti Shock Valve Operation
Figure 30-20-25
S47027
Anti-Cavitation Valve Operation

HYDRAULIC SYSTEM (CONT’D) Similarly, when the solenoid valve is energized the oil
flows along the same path, cause pressure drop across
Loader Control Valve (Cont’d) the orifice and the spool shifts and opens P2 to the tank.
Oil flow from the loader control valve enters via
The Function Of The Loader Control Valve And Unloader connection the backhoe control valve.
Valve (Cont’d)
Figure 30-20-27
Figure 30-20-26
P2 adjustment relief valve
P2 Unloader solenoid
P1 pump adjustment relief valve
P2 pump connection

P1 pump connection Float Valve Selection
S46991
The loader control valve is monoblock and open

centered. The control valve is combined of the different
elements.
The control valve is pilot operated and controls the S46992

working movements of the backhoe depending on the
lever position.
Primary pressure relief valve which is installed loader
valve protect the hydraulic system against pressure
Oil from P2 enters the valve, flows through the Check
peaks above the adjusted maximum pump working
Valve and combines with the flow from P1.
pressure between pump and control valves.
A drilling in the block feeds oil from the main passage to
Some of user of the control valve is fitted either with a
the end of the unloader spool, through the orifice to the
secondary pressure relief valve integrated suction
relief valve and solenoid valve. When pressure in the
function to avoid from cavitations except clamp (left and
main passage exceeds 180 Bar, the relief valve opens
right).
and oil begins to flow from the main passage through the
orifice and the relief valve to the tank. The pressure drop
Secondary pressure relief valve and protect the working
created across the orifice which is acting on the end of
circuits by limiting the pressure which could appear
the spool exceeds the spring force, allowing the spool to
between the control valve and the users to a preadjusted
shift, opening P2 to the tank. When pressure in the main
value.
passage falls below the setting of the relief valve, it
closes. The flow through the orifice stops, pressure
The purpose of the suction valve which is combined with
equalizes at each end of the spool, the spool is then
the relief valve is to prevent the cavitations which could
shifted to its original position by the spring. Oil from P2
occur during certain working movements, while allowing
passes through the check valve again to combine with
the oil at the tank pressure to flow to the low pressure
the flow from P1 to give full flow to the Loader Control
side of the users.
Valve.

Pressure Relief Valves (PRV) Test
Park the machine on level ground. Make sure that the

attachments are in the road travel position. Lower the
loader bucket.
• Heat the hydraulic oil temperature until it reaches to

50°C.
• Raise the loader and install the safety strut.
• Stop the engine and release the pressure in the S44240

hydraulic system.
Figure 30-20-28 • Raise the boom and control the pressure via
manometer.
B730
NOTE: If the pressure is above or under the
determined value, adjust the main pressure
relief valve (P1).

Remove the manometer.
P1 Test Point
Figure 30-20-31
P126259
Figure 30-20-29
B750
P1 Test Point
P126261
• Attach the manometer (0 - 400 bar) to the test point

P1.
• Make sure that there is anyone around the machine.
• Start up the machine. S46992

Secondary Pressure Relief Valves (SPRV)
• Park the machine on flat, level ground. Make sure that

the attachments are in the road travel position.
• Lower the loader bucket.
• Heat the machine until the hydraulic oil temperature

reaches to 50°C.
S44242
• Stop the engine and release the pressure in the • Remove the secondary pressure relief valve as
hydraulic system. shown in the pictures.
• Attach the manometer (0 - 400 bar) to the test point Figure 30-20-34
P1.

• Turn in the primary pressure relief valve adjusting bolt
one turns clockwise.
• Start up the engine.

Adjustment Bolt
• Activate the related attachment to make the controls
and see the secondary pressure from the test point
P2.
NOTE: If the pressure is lower or higher than the

determined value, park the machine, stop the
engine, release the pressure in the hydraulic
system and remove the secondary pressure S44243
relief valve.
Figure 30-20-32 • Adjust the SPRV.
SPRV
S44241
• Define the SPRV correctly.

HYDRAULIC SYSTEM (CONT’D) • Be sure that the unloader solenoid is not energized.
Unloading Valve Test • Raise the boom and control the pressure in the
manometer.
Park the machine on flat, level ground. Make sure that
the attachments are in the road travel position. Lower the Figure 30-20-37
loader bucket.
• Heat the engine until the hydraulic oil temperature

reaches to 50°C.
• Stop the machine and release the pressure in the

hydraulic system.
Figure 30-20-35
B730 S44240
• Make sure that the pressure in two test points (P1 and

P2 Test Point P2) rises to 180 bar simultaneously.
• When the pressure in test point P2 reaches to 180

bar, discharge valve decreases the pressure of pump
P2 to 0 bar.

determined value, the adjustment of the
discharge valve should be done by the
P126259 adjustment bolt.
Figure 30-20-38
Figure 30-20-36
B750
P2 adjustment bolt
P2 Test Point
S44241
P126262
• Control and adjust the pressure and park the

• Attach the manometers (0 - 400 bar) to the test point machine.
P2.
• Stop the engine and remove the manometers.

Steering Priority Valve
Figure 30-20-39
S44236
Oil from P1 enters the steer priority valve and is diverted

to the controlled flow port CF. Pressure in CF is sensed

through a small drillings in the spool and is directed to the
end of the Spool through an orifice.
When sufficient oil is delivered to the steering unit to

satisfy the steering requirement, pressure in CF rises.
When it exceeds the setting of the spring, the spool
begins to shift. The excess flow is diverted to EF to
combine with the flow from P2 to the loader control valve.
Figure 30-20-40
S46993
A Load Sense hose directs pressure from the steering

unit back in to LS.

Backhoe Control Valve
S47028

P PRESSURE 220 bar (3191 psi)
CL CLAMP CYLINDERS 220 bar (3191 psi)
1A BOTTOM SIDE OF TELESCOPIC ARM’S EXTENSION CYLINDER OR 160 bar (2321 psi)
HAMMER PRESSURE
1B ROD SIDE OF TELESCOPIC ARM’S EXTENSION CYLINDER 220 bar (3191 psi)
2A BOTTOM SIDE OF BUCKET CYLINDER 220 bar (3191 psi)
2B ROD SIDE OF BUCKET CYLINDER 220 bar (3191 psi)
3A ROD SIDE OF BOOM CYLINDER 220 bar (3191 psi)
3B BOTTOM SIDE OF BOOM CYLINDER 220 bar (3191 psi)
4A BOTTOM SIDE OF LEFT STABALIZER CYLINDER 220 bar (3191 psi)
4B ROD SIDE OF LEFT STABALIZER CYLINDER 220 bar (3191 psi)
5A BOTTOM SIDE OF RIGHT STABALIZER CYLINDER 220 bar (3191 psi)
5B ROD SIDE OF RIGHT STABALIZER CYLINDER 220 bar (3191 psi)
6A BOTTOM SIDE OF ARM CYLINDER 220 bar (3191 psi)
6B ROD SIDE OF ARM CYLINDER 220 bar (3191 psi)
7A SWING CYLINDERS 160 bar (2321 psi)
7B SWING CYLINDERS 160 bar (2321 psi)

Backhoe Control Valve (Cont’d)
S47029

P PRESSURE 220 bar (3191 psi)
CL CLAMP CYLINDERS 220 bar (3191 psi)
1A BOTTOM SIDE OF TELESCOPIC ARM’S EXTENSION CYLINDER OR 160 bar (2321 psi)
HAMMER PRESSURE
1B ROD SIDE OF TELESCOPIC ARM’S EXTENSION CYLINDER 220 bar (3191 psi)
2A BOTTOM SIDE OF BUCKET CYLINDER 220 bar (3191 psi)
2B ROD SIDE OF BUCKET CYLINDER 220 bar (3191 psi)
3A BOTTOM SIDE OF ARM CYLINDER 220 bar (3191 psi)
3B ROD SIDE OF ARM CYLINDER 220 bar (3191 psi)
4A BOTTOM SIDE OF LEFT STABALIZER CYLINDER 220 bar (3191 psi)
4B ROD SIDE OF LEFT STABALIZER CYLINDER 220 bar (3191 psi)
5A BOTTOM SIDE OF RIGHT STABALIZER CYLINDER 220 bar (3191 psi)
5B ROD SIDE OF RIGHT STABALIZER CYLINDER 220 bar (3191 psi)
6A ROD SIDE OF BOOM CYLINDER 220 bar (3191 psi)
6B BOTTOM SIDE OF BOOM CYLINDER 220 bar (3191 psi)
7A SWING CYLINDERS 160 bar (2321 psi)
7B SWING CYLINDERS 160 bar (2321 psi)

HYDRAULIC SYSTEM (CONT’D) Secondary pressure relief valve protect the working
circuits by limiting the pressure which could appear
Backhoe Control Valve (Cont’d) between the control valve and the users to a preadjusted
value.
The Function Of The Backhoe Control Valve
The purpose of the suction valve which is combined with
Figure 30-20-41 the relief valve is to prevent the cavitations which could
occur during certain working movements, while allowing
the oil at the tank pressure to flow to the low pressure
side of the users.
S46994

The backhoe control valve is monoblock and open
centered. The control valve is combined of the different
elements.
Oil flow from the loader control valve enters via

connection N the backhoe control valve.
The control valve is mechanically actuated and control

the working movements of the backhoe depending on the
mechanical joystick position.
Figure 30-20-42
S46995
Each user of the control valve is fitted either with a

secondary pressure relief valve integrated suction
function to avoid from cavitations except stabilizers (left
and right).

Steering Pressure Test

Plug (over adjustment bolt)
Park the machine on flat, level ground. Make sure that
the attachments are in the road travel position. Lower the
loader bucket.

reaches to 50°C.
• Stop the machine and release the pressure in the Steering Control Unit
S44245
hydraulic system.
Figure 30-20-43 • Demount the steering control unit.
• Remove the plug.
Figure 30-20-45

Adjustment Bolt
Steering Pressure Test Point (CF)

P126260
• Attach the manometers (0 - 400 bar) to the CF test

point. S44246

• Adjust steering pressure by adjustment bolt.
• Turn the steering one side end.
• Check the steering pressure (175 bar).

determined value (175 bar), the adjustment of
the steering pressure should be done by the
adjustment bolt.

Pilot Pressure Test (B750)
Park the machine on flat, level ground. Make sure that Pilot Valve
the attachments are in the road travel position. Lower the
loader bucket.
Pilot adjustment bolt

reaches to 50°C.
• Stop the machine and release the pressure in the

hydraulic system.
Figure 30-20-46

Hydraulic accumulator (13 bar)
Pilot Pressure Test Point

S46999
P126263
• Untighten the nut.
• Adjust pilot pressure by adjustment bolt.

• Attach the manometers (0 - 50 bar) to the test point
Pilot. • Tighten the nut.
• Check the steering pressure (27 bar).

determined value (27 bar), the adjustment of
the pilot pressure should be done by the
adjustment bolt.

Priority Valve
Figure 30-20-48
1
P136415
Remove the hose (Item 1).

P136413
Figure 30-20-51
Figure 30-20-49

1 1
P136414
P136416
Remove the hoses (Item 1).


Priority Valve (Cont’d)
Figure 30-20-52
P136417

Figure 30-20-53
P136418
Remove the bolts and washers (Item 1).
Remove the priority valve.


RETURN LINE CHECK VALVE Figure 30-21-3
Removal And Installation
Lift and block the backhoe loader.
Stop the engine.
Rotate the battery disconnect switch.

1
Operate the control levers to relieve hydraulic pressure.
Figure 30-21-1
P135623
Remove the hose (Item 1) and the fitting.
Figure 30-21-4

1
P135622
Figure 30-21-2
1
P135622
1 Remove the nuts and bolts (Item 1).
Remove the return line check valve.
P135622
Remove the hoses (Item 1, Item 2).


HYDRAULIC CYLINDERS Figure 30-30-3
Basic Type Cylinder Assembly
Figure 30-30-1
S44249
You can use air for drying the guide.

S44247
Figure 30-30-4
Firstly clean the piston guide with solvent or a chemical

cleaner.

Figure 30-30-2
S44250
Seal parts:
S44248 1) Back-up ring

2) O-ring
3) O-ring
After cleaning, dry the piston guide. 4) Omegat
5) Dust seal
6) O-ring
7) Dust seal
8) Nutring
9) O-ring
10) Guide ring
11) Guide ring
12) Guide ring

HYDRAULIC CYLINDERS (CONT’D) Figure 30-30-7
Basic Type Cylinder Assembly (Cont’d)
Figure 30-30-5
S44253
S44251
Firstly insert the O-ring into the groove then mount the
Prepare the guide and piston end for mounting. Omegat into groove over the O-ring and same groove.
New seal kit montage to guide. Figure 30-30-8
Figure 30-30-6

S44254
S44252
Mounting of omegat.
Firstly, mount back-up ring and O-ring into the guide

surface groove.

Figure 30-30-9
S44257
Mount the guide ring.

S44255
Figure 30-30-12
Use bottom of a screw driver for assist mounting of a

Omegat.

Figure 30-30-10
S44258
Mount the nutring shown.
S44256
Prepare the guide ring for montage.

Figure 30-30-13
S44261
Mount the dust seal with pressure apparatus.

S44259
Piston Montage
Mount the guide ring. Figure 30-30-16

Figure 30-30-14
S44262
S44260
Seat the O-ring into the piston surface groove.
Align the dust seal on the guide.

Figure 30-30-17
S44265
Use apparatus shown for placing the omegat.

S44263
Figure 30-30-20
Insert the O-ring inner side of piston.

Figure 30-30-18
S44266
Place the omegat and align on the guide apparatus

S44264 shown.
Seat the O-ring into the piston surface groove.

Figure 30-30-21
S44269
Place the omegat into groove.
Figure 30-30-24

S44267
Push the omegat through the piston with the insert

apparatus.
Figure 30-30-22
S44270
Use the circular pressure apparatus on the omegat.
S44268
Use a plastic hammer move the omegat to groove.

Figure 30-30-25
S44273
Piston is ready.
S44271
Mount the piston into cylinder shell.
Fit the omegat.

Mount the piston on rod.
Figure 30-30-26
S44272
Mount the guide rings.
Mount the set screw.

Nut Type Cylinder Montage
Figure 30-30-28
S44276
Figure 30-30-31
S44274
In some of the guide seals shown nut type cylinder

montage.

Figure 30-30-29
S44277
Mount back-up ring and O-ring.
S44275
Mount the O-ring, guide ring, seal and omegat inner side
of the guide groove.

Nut Type Cylinder Montage (Cont’d)
Figure 30-30-32
S44280
Use Loctite® on threads.

S44278
Figure 30-30-35
Mount the O-ring inner side of piston.

Figure 30-30-33
S44281
Mount the nut end of the rod.

S44279
Mount the piston on rod.

Figure 30-30-36
S44284
Mount the Teflon™ rings.

S44282
Figure 30-30-39
Place the guide rings on piston.

Figure 30-30-37
S44285
Align and replace the piston into the cylinder shell.

S44283
Select the suitable torque on nut.
Tighten the nut.

HYDRAULIC CYLINDERS (CONT’D)
Figure 30-30-40
S44286
Use Loctite® on bolts.

Figure 30-30-41
S44287
Tighten the guide bolts.
Cylinder is ready.

Loader Lift Cylinder

S44288
1 CYLINDER PIPE LEFT 14 O-RING

2 TEFLON™ RING 15 OMEGAT
3 O-RING 16 ROD
4 BACK-UP RING 17 GREASER
5 NUTRING 18 DUST SEAL
6 TEFLON™ RING 19 BUSHING
7 DUST SEAL 20 DUST SEAL
8 GUIDE 21 BUSHING
9 BOLT 22 GREASER
10 NUT 23 PLUG
11 PISTON 24 LIFT CYLINDER RIGHT
12 TEFLON™ RING 25 LIFT CYLINDER LEFT
13 TEFLON™ RING 26 REPAIR KIT

Loader Lift Cylinder (Cont’d)

S44289
1 CYLINDER PIPE LEFT 12 TEFLON™ RING

2 TEFLON™ RING 13 TEFLON™ RING
3 O-RING 14 O-RING
4 BACK-UP RING 15 OMEGAT
5 NUTRING 16 ROD
6 TEFLON™ RING 17 GREASER
8 GUIDE 19 BUSHING
9 BOLT 20 DUST SEAL
10 NUT 21 BUSHING
11 PISTON 22 GREASER

Loader Lift Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Fix the cylinder (1) very carefully.
Remove the bolts (9) and take the guide (8).
Remove the rod (16) carefully.
Fix the rod (16) from the pin side. Remove the nut (10) with a key.
Remove the piston (11) from the rod (16).
Remove the Omegat (15), Teflon™ rings (12, 13), and O-ring (14).
Remove the guide (8) from the rod (16).
Remove the Teflon™ rings (2, 6), O-ring (3), back-up ring (4), nutring (5) and dust seal (7) from the guide (8).
Check the greasers (17, 22) and if they don’t work, change them.
CHECK
Clean all parts of the cylinder.

Check inside the cylinder (1).
If there is damage in the pipe, renew it.
Check the surface of the rod (16), renew it if there is damage.
Check the linearity of the rod (16).

Check the bushings (19, 21). Change them if necessary.
Check the guide (8). Change it if necessary.
Check the piston (11). Change it if necessary.
ASSEMBLY
After the assembly of the Teflon™ rings (2, 6) to the guide, place the dust seal (7) and nutring (5).
Then, place the O-ring (3) and back-up ring (4).
Grease the guide (8). Pass the rod (16) from the head of the guide (9).
Pass the Omegat (15) on the piston (11).
Grease the O-ring (14) and pass the piston (11).
Grease the Teflon™ rings (12, 13) and pass on the piston (11).
Assemble the piston (11) to the rod (16).
Tighten the nut (10) and fix the piston (11).
Install the rod from the cylinder which is greased by hydraulic oil.
Fix the guide (8) with bolts (9).

Loader Bucket (Tilt) Cylinder

S44290

2 TEFLON™ RING 14 O-RING
3 OMEGAT 15 OMEGAT
4 O-RING 16 TEFLON™ RING
5 BACK-UP RING 17 ROD
8 DUST SEAL 20 GREASER
9 GUIDE 21 BUSHING
10 BOLT 22 TILT CYLINDER
11 NUT 23 REPAIR KIT
12 PISTON

Loader Bucket (Tilt) Cylinder (Cont’d)

S44291
1 CYLINDER PIPE LEFT 12 PISTON

3 OMEGAT 14 O-RING
4 O-RING 15 OMEGAT
5 BACK-UP RING 16 TEFLON™ RING
6 NUTRING 17 ROD
7 TEFLON™ RING 18 DUST SEAL
8 DUST SEAL 19 BUSHING
9 GUIDE 20 GREASER
10 BOLT 21 BUSHING
11 NUT 22 TILT CYLINDER

Loader Bucket (Tilt) Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Fix the cylinder (1).
Remove the bolts (10) and the head of the cylinder (9).
Remove the rod (17).
Remove the Omegat (15), Teflon™ rings (13, 16), and O-ring (14) from the piston.
Remove the Teflon™ rings (2, 7), Omegat (3), O-ring (4), back-up ring (5), nutring (6) and dust seal (8).
CHECK
Clean all parts.

Change the cylinder (1) if necessary.
Check the surface of the rod (17). Change it if necessary.
Check the linearity of the rod (17).

Check the guide (9). If a problem is seen, renew it.
Check the piston (12). If a problem is seen, renew it.
ASSEMBLY
Then, place the Omegat (3), O-ring (4) and back-up ring (5).
Grease the guide (9) and pass the rod (17) from the head of the guide (9).
Grease the O-ring (14) and pass the piston (12).
Make the assembly of the piston (12) to the rod (17).
Pass the rod from the cylinder (1) which is greased by hydraulic oil.

Clampshell Cylinder

S44292
1 CYLINDER PIPE 13 OMEGAT

5 OMEGAT 17 SEGEMENT
6 NUTRING 18 JOINT
9 GUIDE 21 GREASER
10 NUT 22 CLAMP CYLINDER
11 PISTON 23 REPAIR KIT
12 TEFLON™ RING

Clampshell Cylinder (Cont’d)

S44293
1 CYLINDER PIPE 12 TEFLON™ RING

3 O-RING 14 O-RING
5 OMEGAT 16 ROD
6 NUTRING 17 SEGMENT
7 TEFLON™ RING 18 JOINT
9 GUIDE 20 DUST SEAL
10 NUT 21 GREASER
11 PISTON

Clampshell Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Remove the cylinder head (9).
Remove the Teflon™ rings (12, 15), Omegat (14), and O-ring (12) from the piston.
Remove the Teflon™ rings (2, 7), Omegat (5), O-ring (3), back-up ring (4), nutring (6) and dust seal (8).
CHECK
Clean all parts.

If there is a damage in the cylinder (1), renew it.
Check the surface of the rod (16), if there is damage on the surface, renew it.
Check the linearity of the rod (16). If there is a problem, renew it.

ASSEMBLY
Place the Teflon™ rings (2, 7) to the guide after the assembly of the dust seal (8) and nutring (6).
Then, place the Omegat (5), O-ring (3) and back-up ring (4).
Grease the guide (9) and pass the rod (16) from the head of the guide (9) very carefully.
Grease the O-ring (13) and then pass on the piston.
Grease the Teflon™ rings (12, 15) and then pass on the piston (11).
Tighten the nut (10) and then fix the piston (11).
Pass the rod (16) from the cylinder (1) which is greased by hydraulic oil.
Fix the guide (9).

Backhoe Boom Cylinder

S44294

3 O-RING 17 OMEGAT
5 OMEGAT 19 TEFLON™ RING
6 NUTRING 20 ROD
9 GUIDE 23 GREASER
10 BOLT 24 BUSHING
11 SEGMENT 25 REPAIR KIT
12 WASHER 26 BACKHOE BOOM CYLINDER
13 WASHER 27 SCREW
14 PISTON

Backhoe Boom Cylinder (Cont’d)

S44295
1 CYLINDER PIPE 14 PISTON

3 O-RING 16 O-RING
5 OMEGAT 18 TEFLON™ RING
6 NUTRING 19 TEFLON™ RING
7 TEFLON™ RING 20 ROD
9 GUIDE 22 BUSHING
10 BOLT 23 GREASER
11 SEGMENT 24 BUSHING
12 WASHER 25 SCREW
13 WASHER

Backhoe Boom Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Remove the bolts (10) and take the cylinder head (9).
Fix the rod (20).
Remove the Omegat (17), Teflon™ rings (15, 18, and 19), O-ring (12), washers (12, 13) and segment (11) on the piston.
Remove the Teflon™ rings (2, 7), Omegat (5), O-ring (3), back-up ring (4), nutring (6) and dust seal (8) from the guide (9).
CHECK
Clean all parts.

If there is a damage in the cylinder, renew it.
Check the surface of the rod (20). If there is damage on the surface, change it.
Check the linearity of the rod (20). If there is a problem, renew it.

Check the guide. If a problem is seen, change it.
ASSEMBLY
Then, place Omegat (5), O-ring (3) and back-up ring (4).
Grease the guide (9) pass the rod (20) from the head of the guide (9).
Place the Omegat (17) on the piston (14).
Grease the O-ring (16) and then pass it on the piston (14).
Grease the Teflon™ rings (15, 18, 19) and then pass on the piston (14).
Place the washer (12, 13) and segment (11) and fix the piston (14).

Backhoe Arm Cylinder

S44296
1 CYLINDER PIPE 12 O-RING

3 FIBER RING 14 OMEGAT
4 NUTRING 15 GREASER
7 GUIDE 18 BUSHING
8 BOLT 19 DUST SEAL
9 NUT 20 BUSHING
10 PISTON 21 ARM CYLINDER
11 TEFLON™ RING

Backhoe Arm Cylinder (Cont’d)

S44297

2 O-RING 12 O-RING
3 FIBER RING 13 TEFLON™ RING
4 NUTRING 14 OMEGAT
6 DUST SEAL 16 ROD
8 BOLT 18 BUSHING
9 NUT 19 DUST SEAL
10 PISTON 20 BUSHING

Backhoe Arm Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Remove the rod (16) very carefully.
Fix the rod (16) from the pin side and remove the nut (9) with a key.
Remove the Omegat (14), Teflon™ rings (11, 13) and O-ring (12).
Remove the fiber-ring (3), O-ring (2), Teflon™ ring (5), nutring (4) and dust seal (6) from the guide (7).
CHECK
Clean all parts.

Check the surface of the rod (16), if there is damage, renew the cylinder.
Check the linearity of the rod (16). Change it if necessary.

Check the guide (7). If there is a problem, renew it.
Check the piston (10). If a problem is found, change it.
ASSEMBLY
After the assembly of the Teflon™ ring (5) to the guide (7), place the dust seal (6) and nutring (4).
Then, place the fiber ring (3) and O-ring (2).
Pass the omegat (14) on the piston (10).
Grease the O-ring (12) and then pass on the piston (10).
Grease the Teflon™ rings (11, 13) and then pass on the piston (10).

Backhoe Bucket Cylinder

S44298

2 BACK-UP RING 13 O-RING
4 O-RING 15 OMEGAT
5 NUTRING 16 ROD
8 GUIDE 19 GREASER
9 BOLT 20 BUSHING
10 NUT 21 DUST SEAL
11 PISTON 22 BACKHOE BUCKET CYLINDER

Backhoe Bucket Cylinder (Cont’d)

S44299

4 O-RING 15 OMEGAT
5 NUTRING 16 ROD
8 GUIDE 19 GREASER
9 BOLT 20 BUSHING
10 NUT 21 DUST SEAL
11 PISTON

Backhoe Bucket Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Remove the Omegat (15), Teflon™ rings (12, 14) and O-ring (13) on the piston (11).
Remove the guide from the rod (16).
Remove the Teflon™ rings (3, 6), O-ring (4), back-up ring (2), nutring (5) and dust seal (7) from the guide (8).
CHECK
Clean all parts.

Check the surface of the rod (16), if there is damage, renew it.
Check the linearity of the rod (16). If there is a problem, change it.

Check the piston (11) Renew it if necessary.
ASSEMBLY
Then, place the O-ring (4) and back-up ring (2).
Pass the omegat (15) on the piston (11).
Grease the O-ring (14) and then pass on the piston (11).
Grease the Teflon™ rings (12, 14)and then pass on the piston (11).
Assemble the piston (11) to the rod (16).

Backhoe Extendible Arm Cylinder

S44300

3 O-RING 13 OMEGAT
8 GUIDE 18 RUBBER BUMPER
9 NUT 19 EXTENDIBILE ARM CYLINDER
10 PISTON 20 REPAIR KIT

Backhoe Extendible Arm Cylinder (Cont’d)

S44301
1 CYLINDER PIPE 10 PISTON

3 O-RING 12 O-RING
5 NUTRING 14 ROD
8 GUIDE 17 GREASER
9 NUT 18 RUBBER BUMPER

Backhoe Extendible Arm Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Remove the rod (14) from the cylinder (1).
Remove the Teflon™ ring (11), Omegat (13), O-ring (12) from the piston.
Remove the Teflon™-rings (2, 6), O-ring (3), back-up ring (4), nutring (5) and dust seal (7).
CHECK
Clean all parts.

If there is damage in the cylinder (1), renew it.
Check the surface of the rod (14). If there is a damage inside it, change it.

Check the piston (10). If there is a problem, change the piston.
Check the greaser (17). If it doesn’t work, change it.
ASSEMBLY
Then place the O-ring (3) and back-up ring (4).
Grease the O-ring (12) and pass on the piston (10).
Grease the Teflon™ ring (11) and pass on the piston (10).
Pass the rod from the cylinder (1) which is greased by hydraulic oil.
Fix the guide (9).

Backhoe Swing Cylinder

S44302
1 CYLINDER PIPE RIGHT 13 PISTON

5 OMEGAT 18 ROD
6 NUTRING 19 GREASER
9 GUIDE 22 SWING CYLINDER RIGHT
10 SEGMENT 23 SWING CYLINDER LEFT
11 WASHER 24 REPAIR KIT
12 WASHER 25 SCREW

Backhoe Swing Cylinder (Cont’d)

S44303
1 CYLINDER PIPE RIGHT 12 WASHER

2 TEFLON™ RING 13 PISTON
4 O-RING 15 OMEGAT
5 OMEGAT 16 O-RING
6 NUTRING 17 TEFLON™ RING
10 SEGMENT 21 BUSHING
11 WASHER 22 SCREW

Backhoe Swing Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Fix the rod (18) from the pin side.
Remove the Teflon™ rings (14, 17), Omegat (15), O-ring (16), washer (11, 12) and segment (10) from the piston.
Remove the Teflon™-rings (2, 7), Omegat (5), O-ring (4), back-up ring (3), nutring (6) and dust seal (8) from the guide (9).
CHECK
Clean all parts.

Check inside the cylinder (1) if it is worn out or not.
If there is damage in the cylinder (1), renew it.
Check the surface of the rod (18). Renew it if necessary.
Check the bushing (21). Change it if necessary.

Check the guide (9). If a problem is seen, change the guide.
Check the piston (13). If a problem is seen, renew the piston.
ASSEMBLY
Then place the Omegat (5), O-ring (4) and back-up ring (3).
Grease the Teflon™ rings (14, 17), washers (11, 12), segment (10) and pass on the piston (13).
Fix the piston (13).
Fix the guide (9).

Backhoe Stabilizer Cylinder
19
20 1
18
2
4
5 10
3 12
11
6
8 7
9 14
15
13

16
21
17
NA13508S

3 OMEGAT 15 O-RING
5 O-RING 17 BUSHING
6 NUTRING 18 BUSHING
8 DUST SEAL 20 STABILIZER CYLINDER
9 GUIDE 21 REPAIR KIT
10 NUT
11 PISTON
12 SCREW

Backhoe Stabilizer Cylinder (Cont’d)

S44305

3 OMEGAT 14 OMEGAT
5 O-RING 16 ROD
6 NUTRING 17 SEGMENT
7 TEFLON™ RING 18 JOINT
9 GUIDE 20 BOLT
10 NUT 21 LOCK WASHER
11 PISTON 22 WASHER

Backhoe Stabilizer Cylinder (Cont’d)
DISASSEMBLY
Clean the cylinder.

Remove the rod (16) from the cylinder (1) very carefully.
Remove the Teflon™ rings (12, 13), Omegat (14) and O-ring (15) from the piston.
Remove the guide (9), Teflon™-rings (2, 7), Omegat (3), O-ring (5), back-up ring (4), nutring (6) and dust seal (8).
CHECK
Clean all parts.

If there is damage inside the cylinder (1), renew it.
Check the surface of the rod (16), if is damaged, renew it.
Check the linearity of the rod (16), change it if necessary.
Check the guide (9). If there is a problem, change it.
Check the piston(11). If a problem is seen, change it.

Check the joint (18). If a problem is seen, change it.
Check the greaser (19). If it doesn’t work, change it.
ASSEMBLY
Then place the Omegat (3), O-ring (5) and Back-up ring (4).
Grease the guide (9). Pass the rod (16) from the head of the guide (9).
Fix the guide (9).

HYDRAULIC PUMP Figure 30-40-3
Figure 30-40-1
1
2
P136295
Loosen the bolt (Item 1) and remove the clamp (Item 2).
P136293
Figure 30-40-4

1

Figure 30-40-2
2
1
1
P136296
Remove the four bolts (Item 1), flange (Item 2) and the
P136294 hose (Item 3).

HYDRAULIC PUMP (CONT’D)
Removal And Installation (Cont’d)
Figure 30-40-5
P136297
Remove the bolts and washers (Item 1) from both left and
right side of the hydraulic pump.

Remove the hydraulic pump.

BACKHOE CONTROL VALVE (B750) Figure 30-50-3
Install the approved backhoe boom / swing lock.
Stop the engine.
Figure 30-50-1
P135827
Separate the cable from the socket.
NOTE: Mark all hoses for correct installation.
Figure 30-50-4

1
P135823
Remove the nut (Item 1).
Figure 30-50-2
P135826
P135828
Remove the solenoid socket (Item 1).
Remove the twelve hoses (Item 1).

BACKHOE CONTROL VALVE (B750) (CONT’D) Figure 30-50-7
Figure 30-50-5
P135831
1
Figure 30-50-8
P135829

Figure 30-50-6
P135832
1
Figure 30-50-9
P135830
P135833

Figure 30-50-10
P135836

P135834P
135834
Figure 30-50-13
Figure 30-50-11

1
P135837
Remove the hose (Item 1) if the machine has hydraulic

P135835 breaker.
Figure 30-50-14
2
1
P135838
Remove the two bolts (Item 1) and hose clamp (Item 2).

Figure 30-50-15
P135841

P135839
Figure 30-50-18

Figure 30-50-16
1
P135842

P135840
Figure 30-50-19
P135843

Figure 30-50-20
1
1 2
P135846

P135844
Figure 30-50-23
Remove the two bolts (Item 1) and the hose clamp (Item
2).

Figure 30-50-21
1
1
P135847
P135845 Figure 30-50-24
P135848

Figure 30-50-25
1
1
P135851

P135849
Figure 30-50-28

Figure 30-50-26
2
1
P135852
Remove both bolts (Item 1) and remove the throttle (Item

P135850 2).

BACKHOE CONTROL VALVE (B750) (CONT’D)
Figure 30-50-29
P135853
Remove the two bolts and washers (Item 1).

Figure 30-50-30
P135854
Remove the bolt and washer (Item 1).
Remove the backhoe control valve.


BACKHOE CONTROL VALVE (B730) NOTE: Mark all hoses for correct installation.
Removal And Installation Figure 30-51-3
Install the approved backhoe boom / swing lock.
Stop the engine.

1
Figure 30-51-1
P135798
Push down the bellows (Item 1) or pull the bellows up to

reach the forks. (Take off all the bellows).
Figure 30-51-4

1 4
3
P135823
1
2 P135800

Remove the snap rings (Item 1) and pins (Item 2).
Figure 30-51-2 Loosen the nuts (Item 3). Remove the control valve sticks
(Item 4).
Figure 30-51-5
P135827
Separate the cable from the socket.

P135802

Figure 30-51-6
1 1
P135824

P135822
Figure 30-51-9

Figure 30-51-7
P135807

P135806
Figure 30-51-10
P135808
Remove the bolts (Item 1) and clamp (Item 2).

Figure 30-51-11
1 1
1 P135811

P135809
Figure 30-51-14
Remove the bolts (Item 1) and clamp (Item 2).
Figure 30-51-12

1
1
P135812

P135810
Figure 30-51-15
P135813
Remove the bolts (Item 1).

Figure 30-51-16
1
1
P135816

P135814
Figure 30-51-19
Remove the clamp (Item 1).

Figure 30-51-17
P135817

P135815
Figure 30-51-20
P135818

Figure 30-51-21
1 1
1
P135821
Remove the two bolts (Item 1).

P135819
Remove the backhoe control valve.

Figure 30-51-22
P135820
Remove the hose (Item 1 and Item 2).


BOOM CYLINDER Figure 30-60-3
Extend the backhoe arm out and lower the boom to the
ground. Stop the engine. Operate the backhoe control
levers to relieve hydraulic pressure.
WARNING: Hydraulic fluid escaping under pressure

can have sufficient force to enter a person’s
body by penetrating the skin. This can cause
serious injury and possible death if proper
medical treatment by a physician familiar with
this injury is not received immediately. 1
Figure 30-60-1 P135873
Figure 30-60-4

P135871
1 2
Figure 30-60-2 P135874
Remove the nut (Item 1) and the pivot pin retainer bolt
(Item 2).
P135872

BOOM CYLINDER (CONT’D) Figure 30-60-7
Figure 30-60-5
1 P135877
Remove the pivot pin (Item 1).

P135875
Remove the boom cylinder.

Figure 30-60-6
P135876
Remove the pivot pin retainer bolt (Item 1).

BUCKET CYLINDER Figure 30-61-3
Figure 30-61-1
P135885
Remove both nuts (Item 1).

P135883
Figure 30-61-4
Install a hoist and lifting strap to lift and support the

bucket cylinder.

Figure 30-61-2
1 1
P135886
Remove the bolts (Item 1) and the pivot pin.
P135884
Remove the two hoses (Item 1).

BOOM CYLINDER (CONT’D)
Figure 30-61-5
P135887
Remove the bolt (Item 1) and the pivot pin.

Remove the bucket cylinder.

CLAMP CYLINDERS Figure 30-62-3
The removal procedure is the same for both clamp

cylinders.
1
Figure 30-62-1
P135576
Loosen the bolts (Item 1).
Figure 30-62-4
P135574

Install a hoist and lifting strap to support the kingpost and 3
side shift.
Figure 30-62-2 4
1
2
1
P135577
Remove the pipe (Item 1),hose (Item 2), bolts (Item 3)

and the clamp (Item 4).
Figure 30-62-5
P135575
Remove the nuts (Item 1).
P135578
Remove the clamp cylinder.

CLAMP CYLINDERS (CONT’D)
NOTE: As shown below there’s no clamp at the

bottom side of the side shift.
Figure 30-62-6
2
3
P135579

You need to remove the adjustment bolt (Item 1), hose
(Item 2) and loosen the three bolts (Item 3) from both left
and right side of the side shift before removing both
clamp cylinders which positioned on the bottom side of
the side shift.

CLAMSHELL CYLINDER Figure 30-63-3
Remove the front bucket.
Figure 30-63-1
3
2
P136607
Remove the nut (Item 1), pivot pin retainer bolt (Item 2)
1 and pivot pin (Item 3).
P136605 Remove the clamshell cylinder.

Figure 30-63-2
P136606
Remove the nut (Item 1), pivot pin retainer bolt (Item 2)
and pivot pin (Item 3).


LIFT CYLINDERS Figure 30-64-3
Start the engine.
Figure 30-64-1
P136340
Remove the pivot pin retainer bolt (Item 1) and pivot pin
(Item 2).
P136338 Figure 30-64-4

Raise the lift arms and install a hoist and lifting strap to
support the lift cylinder.
Stop the engine.

1
Figure 30-64-2
2
2
P136341
Remove the snap ring (Item 1) and washer (Item 2).
Remove the cylinder.

1
P136339
Remove the two hoses (Item 1) and (Item 2).
NOTE: Mark hoses for correct installation.


STABILIZER CYLINDERS Figure 30-65-3
The removal and installation procedure is the same for

both left and right stabilizer cylinders.
Figure 30-65-1
1 P135631
Install a hoist and lifting apparatus (Item 1) to lift and

support the stabilizer cylinder.
Figure 30-65-4
P135629

Remove the bolt and washer (Item 1) and the cover (Item
2).
1
Figure 30-65-2
P135632
2
Remove the bolt (Item 1).
Figure 30-65-5
P135630P
135872
Remove the pipes (Item 1) and the bolt and washer (Item
2).
P135633
Remove the pin (Item 1).

STABILIZER CYLINDERS (CONT’D) Figure 30-65-8
Figure 30-65-6
P135636
1 Remove the snap ring (Item 1).

P135634
Figure 30-65-9
Remove the wear pads (Item 1).

Figure 30-65-7
P135637

P135635
Figure 30-65-10
Remove the snap ring (Item 1).
P135638
Pull cylinder up and remove the cylinder.

STICK CYLINDER Figure 30-66-3
Set the bucket flat on the work surface.
Figure 30-66-1
P135650
Figure 30-66-4
P135652

Install a hoist and lifting strap to lift and support the stick
cylinder.
2
Figure 30-66-2
P135649
1
Remove the nut (Item 1) and the bolt (Item 2).
Figure 30-66-5
P135651
P135648
Remove the bolt (Item 1) and the cover (Item 2).

STICK CYLINDER (CONT’D) Figure 30-66-8
Figure 30-66-6
P135654

P135656
Figure 30-66-9

Figure 30-66-7
2
1
P135655
Remove the cylinder.

P135653
Remove the nut (Item 1) and bolt (Item 2).

SWING CYLINDERS Figure 30-67-3
Figure 30-67-1
2
1
P135672
Figure 30-67-4
P135670
Remove the nut (Item 1) and pivot pin retainer bolt (Item
2).

Figure 30-67-2
P135673
Remove all the hoses from the distribution block.
P135671 Figure 30-67-5
P135674

SWING CYLINDERS (CONT’D) Figure 30-67-8
Figure 30-67-6
P135677
2
1 Remove both hoses (Item 1).
P135675
Figure 30-67-9
Remove the pipe (Item 1) and the bolts (Item 2).
Figure 30-67-7 2 1

1
3
2 4
1
4
P135678
Remove the grease fittings (Item 1), bolts (Item 2, Item 3)

P135676 and the covers (Item 4).
Figure 30-67-10
Remove the bolt (Item 1) and distribution block (Item 2).
P135679
Remove the bolts (Item 1) and the covers (Item 2).

SWING CYLINDERS (CONT’D)
Figure 30-67-11
2
1
P135680
Remove both bolts and washers (Item 1) and the pins

(Item 2).

Figure 30-67-12
P135681
Remove the support plate (Item 1).
Remove the swing cylinders.


TILT CYLINDERS (B750) Figure 30-68-3
Lower the lift arms to the ground.
Stop the engine. 1
Operate control levers to relieve hydraulic pressure.

this injury is not received immediately. P136487
Figure 30-68-1
IMPORTANT: When making repairs on hydraulic

system, clean the work area before
1 disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and

ports to keep dirt out. Dirt can quickly damage
the system.
Figure 30-68-4
P136494
Figure 30-68-2
P136488
1 Install a hoist and lifting strap to lift and support the

cylinder.
P136495
Remove the connector (Item 1).

TILT CYLINDERS (B750) (CONT’D) Figure 30-68-7
Figure 30-68-5
1
1
P136491

P136489
Figure 30-68-8
Figure 30-68-6

1
1
P136492

P136490
Figure 30-68-9
P136493
Remove the snap ring (Item 1) and the pivot pin (Item 2)
Remove the tilt cylinder.

TILT CYLINDERS (B730) Figure 30-69-2
Lower the lift arms to the ground.
Stop the engine.
Operate control levers to relieve hydraulic pressure.

this injury is not received immediately. P136497
Figure 30-69-1
cylinder.
Figure 30-69-3

1
1
P136496

P136498
IMPORTANT: When making repairs on hydraulic Remove the snap ring (Item 1).
system, clean the work area before
disassembly and keep all parts clean. Always Figure 30-69-4
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
P136499

TILT CYLINDERS (B730) (CONT’D) Figure 30-69-7
Figure 30-69-5
P136502P
1 135877
Remove the snap ring (Item 1) and the pivot pin (Item 2).
P136500
Remove the tilt cylinder.

Figure 30-69-6
P136501

BRAKE PEDAL AND BOOSTER Figure 30-70-3
Removal And Installation (B730 S/N B4511155 &

Above) (B750 S/N B45211080 & Above)
Stop the engine.
Rotate the battery disconnect lever counterclockwise to

disconnect from the system.
Remove the front console.
Figure 30-70-1
1
P135573
Remove the two bolts (Item 1) and the brake pedals.
Figure 30-70-4

1
1
P135571
1
P135572
Figure 30-70-2
Remove the four nuts (Item 1) for removing booster from

the pedal bracket.
P135572

BRAKE PEDAL AND BOOSTER (CONT’D) Figure 30-70-7

If necessary to replace the check valve and accumulator

block;
1
Figure 30-70-5
P135556
If necessary to replace check valve; remove the check

valve itself (Item 1).

Figure 30-70-8
P135556

1
Figure 30-70-6
P135556
If necessary to replace the switch; remove the switch

(Item 1) itself.
P135556
Remove the two bolts and nuts (Item 1) from the plate.

BRAKE PEDAL AND BOOSTER (CONT’D)

Figure 30-70-9
P135556

If necessary to replace the accumulator; remove the
accumulator (Item 1) itself.


HYDRAULIC RESERVOIR Figure 30-80-3
Figure 30-80-1
1 P135602
Remove all the hoses (Item 1) from hydraulic reservoir.

P135600
Figure 30-80-4
Remove the drain plug (Item 1).
Figure 30-80-2

1
P135603
Remove both mounting bolts and washers (Item 1) from

the hydraulic reservoir.
Figure 30-80-5
2
P135601
1
Install a hoist and lifting strap to support the hydraulic
reservoir.
P135604
Remove the bolts (Item 1) and flange (Item 2).

HYDRAULIC RESERVOIR (CONT’D) Figure 30-80-8
Figure 30-80-6
P135607
Remove the cover (Item 1).

P135605
Figure 30-80-9
Remove the cover (Item 1).
Figure 30-80-7

1
P135608
Remove the returning filter (Item 1).

P135606
Figure 30-80-10
Remove the strainer (Item 1).
P135609
Remove the flange (Item 1) then check the filter (Item 2)

for damage and replace if necessary.

HYDRAULIC RESERVOIR (CONT’D)
Figure 30-80-11
P135610
Remove the drain plugs (Item 1).

There’s hydraulic oil in the return filter also. You need to
drain the oil.
For installation, you need to reverse all the processes

from the last step to the first step.


LOADER CONTROL VALVE (B750) Figure 30-90-3
With engine stopped, loader in lowered position, operate

the control levers to relieve hydraulic pressure.
1
Rotate battery disconnect switch.
Figure 30-90-1
P136372
Figure 30-90-4

2
P136370
Remove the cable (Item 1).
Figure 30-90-2 P136373
Figure 30-90-5
1
3
P136371
P136374
Remove the three hoses (Item 1, Item 2, Item 3).

LOADER CONTROL VALVE (B750) (CONT’D) Figure 30-90-9
Figure 30-90-6
1
P136378
Remove the three hoses (Item 1, Item 2, Item 3).

P136375
Figure 30-90-10
Figure 30-90-7

1
P136379
P136376
Remove the three hoses (Item 1).
P136377 P136380

Figure 30-90-12
P136384
Figure 30-90-16
P136381
Remove the fitting (Item 1).

Figure 30-90-13
1 P136385
Figure 30-90-17
P136382
2
Figure 30-90-14
1
P136386
Remove the two hoses (Item 1, Item 2).

P136383

LOADER CONTROL VALVE (B750) (CONT’D)
Figure 30-90-18
P136387

Figure 30-90-19
P136388
Remove the three bolts (Item 1).
Remove the loader control valve.

LOADER CONTROL VALVE (B730) Figure 30-91-3
With engine stopped, loader in lowered position, operate

the control levers to relieve hydraulic pressure.
1
Rotate battery disconnect switch.
Figure 30-91-1
P136357
Remove the snap rings (Item 1).
Figure 30-91-4

P136355
2
Remove the loader control valve sticks (Item 1). 1
Figure 30-91-2
P136358
Remove the pins (Item 1) from the forks. Then loosen the
nuts (Item 2) and remove the sticks.
Figure 30-91-5
P136356
P136359

Figure 30-91-6
1
P136362

P136360
Figure 30-91-9
Figure 30-91-7

1
P136363

P136361
Figure 30-91-10
P136364

Figure 30-91-11
1
P136367

P136365
Figure 30-91-14

Figure 30-91-12
1
P136368
1
Figure 30-91-15
P136366
P136369
Remove the loader control valve.


STEERING COLUMN AND UNIT Figure 30-100-3
Remove front console.
Figure 30-100-1
3 2 1
P135641
Remove the four bolts and washers (Item 1) from the

plate.
1
P135639 Figure 30-100-4
Remove the four bolts (Item 1) from each corner of the

steering column plate (Item 2) and remove the steering
column (Item 3).
Figure 30-100-2
P135642
2
Separate the steering unit (Item 1) from the cab.
Figure 30-100-5
P135640

plate (Item 2) and remove the plate.
P135643
Remove all the hoses from steering unit.


ELECTRICAL SYSTEM
ELECTRICAL SYSTEM - B730 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
ELECTRICAL SYSTEM - B750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-2
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Component Location - ZF In B730 And B750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-1

Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-1
INSTRUMENT CLUSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1



01 30
15
2009
2006
F27-15A
F12-15A
F1- 15A
S1
2MM-KR*YE
1.5MM-KR
3MM-KR
3MM-KR
2MM-BE
2008
3MM-KR
2MM-KR*YE
2007
2MM-SA*YE
2002
2003
2004
2005
1.5MM-GR*SI
6001 E3F E4F E7F E9F
2MM-KR*SA
3MM-YE 6003
2014
1MM-KH
6016
2001
2016
K1 K2 K10 K3
2MM-SI
1MM-KR
1MM-SI 2140 B5
6MM-KR 2015 E1 E3 P2 E4 E5 E6 E7 P3 E8 E9
3MM-YE
1.5MM-SA
3MM-SA
2010 D12
2019
2020
2012
2011 3MM-KR
P1
D11
2141
D1
D2 D10
2017 6015
1MM-KR Dealer Copy -- Not for Resale
D3
G2 D9
M1
70MM-SI
D4
2029
D8
2018
1MM-YE*KR
1MM-YE*BE
3MM-KR
1MM-MR
1MM-YE
1MM-PE
1MM-PE
D5 D7 6003
2021
2022
2023
2024
2025
2026
2027
2028
1MM-BE
D6
+ R1 S4 S5 6002
B1 B2
_ E2 S3a S3b S3c
B3 B4
G1
S6
70MM-SI
B01 B02
S2
1.5MM-BE
1.5MM-BE
2MM-BE
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
2MM-SI
1MM-SI
1MM-SI
70MM-SI
1001
1002
1003
1004
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
31
KR = RED
KH = BROWN
MA = BLUE
MR = PURPLE
ELECTRICAL SCHEMATIC
SI = BLACK YE = GREEN B730 (S/N B4B611001 AND ABOVE)
BE = WHITE GR = GREY
Sheet 1 of 8
SA = YELLOW PE = PINK
(Printed January 2017)
TR = ORANGE A.YE = LIGHT GREEN
Printed In Belgium 201.136.008-R04 (4)
215 of 856
02 30
15
F18 - 15A
F19 - 15A
F4 - 15A
F2 - 15A
6003 6003
2MM-KR*BE
2MM-KR*MA
1MM-KH
2030
1MM-KH
2MM-SA
2123
2031
2032
2MM-KR*SA
1MM-YE*KR 1MM-SI 1MM-SI
E10
2120
1MM-KH
1MM-KH
1MM-KH
S27 S28
6003
2164 2165
S7 S8
1MM-BE*TR
1MM-MA
1MM-BE
1MM-KH*BE
2036
K9
2MM-SA*KR
K8
2MM-SA*KR
1MM-KH*BE
6004
1MM-KH*BE
2038
2039
2040
2035
2.5MM-BE
2MM-BE
2125
2126
K20
2MM-TR*BE
2MM-MA*BE
2037
1MM-BE 1MM-BE
E11 E12
2121
2122
D11 D12
2142
V1 H1 H17 H18 H19 H20 H21 H22

6003 6012
B6
Test İkaz
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1099
1103
1104
1105
1106
1020
1021
1022
1023
1024
1025
1026
1110
1100
1101
1102
1107
1018
31
KR = RED
KH = BROWN
MA = BLUE
MR = PURPLE
Sheet 2 of 8
216 of 856
03 30
15
F16-10A
F15-10A
F11-10A
F17-10A
F20-10A
F8-10A
F7-10A
2MM-KR*BE
2MM-KR
2151 1MM-KR*YE
2056
2065 1MM-KR 6006
6003
2069
2070
1MM-KR
2051
2053
2054
2MM-KR*BE
2MM-KR*BE
2052
1MM-YE*KR 2066 1MM-MA
2MM-KR*BE
1MM-BE*KR
1MM-KR
2067 1MM-YE
1MM-KH
1MM-SA*KR
2075
2068 1MM-GR*BE
2146
S15 S17
K5
2148
2055
2147
2MM-BE*KR
G
2132
2MM-BE*KR
M M
2063
S16 H23
M2 M3
2129
2130
2133
1MM-MA*BE
1MM-KH*SA
1MM-KH
2057
1MM-TR
1MM-YE
1MM-KH
6003
2152
1MM-KH*BE 1MM-BE
2058
2131 1MM-SA
2064
1MM-YE 2MM-KR
1MM-TR
1MM-KH*SA
B8
S19
1MM-TR
1MM-YE S18
K7 K6
2074
2MM-KH*BE 2MM-MA*KR
6003
2059
2061
F21-10A
F22-10A
F23-10A
F24-10A
2073
1MM-MA*KR
1MM-BE*KR
1MM-SA*BE
2072
2149
2150
2071
1MM-KR
2MM-SI*KH 2MM-MA
2060 2062
M M
E21 H2 H3 H4 H5 E14 H6 H7 H8 H9 H11 H12 H13 H14 E15 M4 M5

1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1037
1046
1038
1039
1040
1041
1042
1043
1044
1045
1047
1049
1050
1051
1052
1053
1054
1055
1056
1057
1058
1059
1060
1061
1062
1063
31
KR = RED
KH = BROWN
MA = BLUE
MR = PURPLE
Sheet 3 of 8
217 of 856
04 30
15
F28 - 15A
F14 - 15A
X3
GEAR LEVER
1MM-KR*SA
1MM-SA
2076
6005 1 2 3 4 5 6 7 8 9 10 11 12 6013
2093
KÖR UÇ
1MM-KR
EMPTY
2078
2079
2080
2081
2082
2083
2084
2085
1.5MM-KR
2153
1MM-KR
1MM-MR 1MM-SA*KR
6002
6001 1MM-MA-KR
1.5MM-PE D18
K16 1.5MM-SA D19
1MM-SA*KR
1.5MM-KR*SI
1.5MM-PE
1.5MM-SA
2157
2156
1.5MM-KR*SI
2077
6011
1MM-PE 1MM-SA*KR
2154
2155
D14 D15
1MM-PE
1MM-SA*MR 1MM-SA*KR
1.5MM-SA*KR
1MM-KR*MA
1.5MM-MA
2089
1.5MM-SA
K13 K14 K11 K12 K15

1MM-GR
2087 1.5MM-KR*SI
D16 1MM-PE 1MM-MR
1.5MM-SA*MR
1MM-PE
1MM-YE
1MM-GR
2086
2088
2091
2092
1.5MM-SA 1MM-KH*BE
2090
Y3 Y6 Y5 Y4 Y1 Y2 6004
K4
B9 6012
6010
1MM-SA*MA
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1064
1065
1066
1067
1068
1069
1070
1071
1072
1073
1074
1075
31
KR = RED
KH = BROWN
MA = BLUE
MR = PURPLE
Sheet 4 of 8
218 of 856
05 30
15
F9 - 15A
F6 - 15A
6016
2099
6009
1MM-KR*BE
2MM-GR*YE
1MM-GR*KR
2109
1.5MM-KR*BE
2127
1MM-KR 1MM-KR*SA 6002 1MM-KR
6003 2100 1MM-YE*SI
6003
1MM-KH 6011
1MM-KR*BE
2159
1MM-KH
1MM-GR
S20 S21 K21 K22 K19

E19
1MM-YE*SI
97
20
D23
1MM-MA*KR
2MM-PE
1MM-MA*KR
98 6003
1MM-GR
20 1MM-GR
1MM-YE*SI
1MM-YE*SI
2095
2096
1MM-KR
K23
1MM-MA*SI
1.5MM-GR*KR
D26 D28
2101
2102
1MM-SA*MA
6010 D13 D17
X4
1MM-TR
2162
1MM-BE
2158
F25 - 15A
F26 - 15A
6013
2105
D24 6010 6015
E16 E17
1.5MM-MR*KR
1.5MM-MR*KR
D25
6003
2163
1MM-KH
1MM-GR
2160
2161
2103
2104
2108
V5 V6
S29
Y7 Y8
R2
S22
H15 H16 S23 S24
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
H18
1.5MM-SI
1108
1076
1077
1078
1079
1080
1081
1082
1083
1084
1085
1086
1088
1089
1090
1102
31
Optional Part : EHSS
KR = RED
KH = BROWN
MA = BLUE
MR = PURPLE
Sheet 5 of 8
219 of 856
06 30
15
F29 - 20A
F3 - 15A
F3 15A
6006
2MM-SA*SI
2128
2170
1MM-KR
1MM-MA*BE
3MM-KR
2168
2166
BLOWER
C
FAN
B 0
- +
K24 B13
L M H 1
A/C 1.5MM-BE
2169
yellow-1
black-1
black-1
2MM-SI
TEMP.
CONTROL
2167
K25
B10
İ
A/C
COMPRESSOR
green-black-1
Dealer
M Copy --
M Not for Resale
green-1
İ
TEMP FAN
F31-1A
F32-7A
white-black-1
B11
+
white-1
PRESSURE
TUBE
orange-1
+
red-1
+ B12
R3 Koltuk
Altı
İ
E24 COMPRESOR Unite

-
S30
1MM-SI
X5
1MM-SI
1MM-SI
1MM-SI
1109
1110
1096
1092
31
Optional Part : - AIR CONDITION - FUEL HEATER
KR = RED
KH = BROWN
MA = BLUE
MR = PURPLE
Sheet 6 of 8
220 of 856
B750LA– BACKHOE LOADER H5 Turn Signal Lamp BR
WIRE DESCRIPTION H6 Right Front Parking Lamp
15 Plus(+) Downstream of Battery H7 Left Front Parking Lamp
30 Input from (+) Battery Terminal Direct H8 Right Rear Parking Lamp
31 (-) Battery Terminal or Ground, Direct H9 Left Rear Parking Lamp
B01 Magnetic Sensor- Left H11 Left Low Beam Headlamp
B02 Magnetic Sensor- Right H12 Right Low Beam Headlamp
B1 Oil Pressure Warning Sensor H13 Left High Beam Lamp
B2 Engine Temperature Sensor H14 Right High Beam Lamp
B3 Transmission Temperature Sensor H15 Left Brake Lamp
B4 Fuel Level Sensor H16 Right Brake Lamp
B5 Warning Horn H17 Right Front Working Lamp
B6 Transmission Pressure Sensor H18 Left Front Working Lamp
H19 Right Rear Working Lamp
B8 Front Horn H20 Right Rear Working Lamp
B9 Backup Alarm H21 Left Rear Working Lamp
B10 Radio H22 Left Rear Working Lamp
B11 Left Speaker
B12 Right Speaker H23 Cab Light
B13 Antenna K1 Main Relay
D1 thru D26 Diodes K2 Starter Relay
E1 Alternator Charge-Indicator Lamp K3 Engine Heater Relay
E2 Heater Indicator Lamp K4 Gear Timer Relay
E3 Oil Pressure Indicator Lamp K5 Hazard Warning Signal Flasher
E3F Below Stabilizer Warning Lamp K6 High Beam Headlamp Relay
E4 Engine Temperature Indicator Lamp K7 Low Beam Headlamp Relay
*E4F Brake System Pressure Lamp (Options) K8 Front Working Lamp Relay
E5 Transmission Temperature Indicator Lamp K9 Rear Working Lamp Relay
E6 Air Filter Indicator Lamp K10 Starter Warning Relay
E7 Fuel Indicator Lamp K11 Forward Relay
*E7F Water In The Fuel Lamp (Options) Dealer Copy -- Not for Resale
K12 Backward Relay
E8 Brake Hydraulic Oil Level Indicator Lamp K13 Gear Relay - I
E9 General Warning Lamp K14 Gear Relay - II
E10 Transmission Pressure Indicator Lamp K15 3 and 4 Gear Pump Unloader Relay
E11 Pump Valve Indicator Lamp K16 Transmission Unloader Replay
E12 Beacon Indicator Lamp
E14-E21 Hazard Warning Signal Indicator Lamp
E15 High Beam Indicator Lamp K19 4X4 Relay
E16 Differential Lock Indicator Lamp K20 Pump Unloader Relay
E17* Ride Control Indicator Lamp(EHSS) K21 Brake Lamps Relay
E18 4x4 Indicator Lamp K22 Transmission Unloader When Brake
E19 Parking Brake Indicator Lamp K23 4X4 Replay
*K24 Additional A.C Unıt
K25 Rear Window resistance Relay
E24 Rear Window resistance Lamp M1 Starter Motor
F1…F29 Fuses M2 Front Wiper Motor
G1 Battery M3 Front Windshield Washer Motor
G2 Alternator M4 Rear Windshield Washer Motor
H1 Beacon Lamp M5 Rear Wiper Motor
H2 Turn Signal Lamp FL P1 Tachometer with LCD Hourmeter
H3 Turn Signal Lamp RL P2 Engine Temperature Indicator
H4 Turn Signal Lamp FR P3 Fuel level Indicator
R1 Resistant
Sheet 7 of 8
221 of 856
R2 Resistant Between the 86 pin of Starter Warning Relay (K10) and 4TH pin of the
R3 Resistant 6001
Gear Lever (X3)
S1 Starter Switch
S2 Battery Switch Between the 8TH pin of Gear Lever (X3) and 86 pin of the 4X4 Relay
6002
S3a Motor Stop Switch (K19) and Warning Horn (B5) 2ND pin.
S3b Motor Stop Switch(Fuel Pump sensor) Between the 8TH pin of Test Switch (S6) and 8TH pin of the Beacon
S3c Motor Stop Switch(Engine Advance sensor)
S4 Air Filter Switch Switch (S8) and 1ST pin of the Transmission Pressure Sensor (B6) and
S5 Brake Hydraulic Oil Level Sensor 8TH pin of the Magnetic Switch (S10) and 8TH pin of the Parking Lamb
S6 Test Switch Switch (S16) and 2ND pin of the Fuse (F21) and 8TH pin of the
S7 Pump Unloader Valve switch
Windshield and Wiper Switch (S18) and 8TH pin of the Differential Lock
S8 Beacon Switch 6003
Switch (S20) and 8TH pin of the Ride Control System Switch (S21) and
8TH pin of the 4x4 Switch (S24) and 8TH pin of the Joystick Locking
switch (S26) and 8TH pin of the Front Working Light Switch (S27) and 8TH
S14RF Front joystick- right front switch-transmission unloader pin of the Rear Working Light Switch (S28) and 3RD pin of the Cigarette
S14RR Front joystick- right rear switch- Pump unloader lighter (X4) and Tachometer with LCD Hourmeter (P1)
S14LF Front joystick- left front switch- opening bucket Between the 86 pin of Pump Unloader Relay (K20) and 1ST pin of the
S14LR Front joystick- left rear switch- opening bucket
Right Rear Joystick (S12) and 87 pin of the 3 and 4 Gear Pump unloader
S15 Hazard Warning Switch 6004
S16 Parking Lamb Switch Relay (K15) and Front joystick- right rear switch- Pump unloader
S17 Horn, Windshield, Signal Switch (S14RR)
S18 Windshield and Wiper Switch Between the pin of Front joystick-right front switch-transmission unloader
S19 Cab Light Switch 6005
S20 Differential Lock Switch (S14RF) and 86 pin of the Transmission Unloader Replay (K16)
*S21 Ride Control System Switch Between the 2ND pin of Left Rear Joystick (S11) and 1ST pin of the Cab
S22 Brake Switch - 1 6006
Light (H23) and Tape Recorder
S23 Brake Switch - 2
S24 4x4 Switch 6007 Empty
Resale the 2ND pin of Magnetic Switch (S10) and 2ND pin of the
Between
Dealer Copy -- Not for
S26 Joystick Locking switch 6009
Differential Lock Switch (S20)
S27 Front Working Light Switch
S28 Rear Working Light Switch Between the 87 pin of Transmission Unloader When Brake (K22) and 85
S29 Parking Brake Switch 6010 pin of the Forward Relay (K11) and 2ND pin of the Parking Brake
S30 Rear Window resistance Switch Indicator Lamp (E19)
V1 Pump Unloader Valve
Between the 86 pin of Forward Relay (K11) and 86 pin of the
V3 Opening Bucket Valve 6011
V4 Closing Bucket Valve Transmission Unloader When Brake (K22)
*V5 *Smoot Ride Control System Valve Between the 85 pin of Backward Relay (K12) and 1ST pin of the
*V6 *Smoot Ride Control System Valve 6012
Transmission Pressure Sensor (B6)
V7 Joystick Locking Valve
X3 Gear Lever Between the 7TH pin of Gear Lever (X3) and 2ND pin of the 4x4 Switch
6013
X4 12 V power Port (S24)
*X5 Heater + AC Between the 2ND pin of Parking Brake Indicator Lamp (E19) and 2ND pin
Y1 Connector(forward solenoid) 6015
Y2 Connector(rear solenoid) of the Test Switch (S6)
Y3 Connector (Shift Control solenoid) Between the 1 pin of Parking Brake Indicator Lamp (E19) and 1ST pin of
ST
Y4 Connector (Shift Control solenoid) 6016

the Warning Horn (B5)
Y5 Connector (Shift Control solenoid)
Y7 Connector (Differential Locking solenoid) * Optional.
Y8 Connector (4x4 solenoid)
Sheet 8 of 8
222 of 856
01 30
15
2009
2006
F27-15A
F12-15A
F1- 15A
S1
2MM-KR*YE
1.5MM-KR
3MM-KR
3MM-KR
2MM-BE
2008
3MM-KR
2MM-KR*YE
2007
2MM-SA*YE
2002
2003
2004
2005
1.5MM-GR*SI
6001 E3F E4F E7F E9F
2MM-KR*SA
3MM-YE 6003
2014
1MM-KH
6016
2001
2016
K1 K2 K10 K3
2MM-SI
1MM-KR
1MM-SI 2140 B5
2015 E1 E3 P2 E4 E5 E6 E7 P3 E8 E9
6MM-KR
3MM-YE
1.5MM-SA
3MM-SA
2010 D12
2019
2020
2012
2011 3MM-KR
P1
D11
2141
D1
D2 D10
2017 6015
1MM-KR
D3
M1 G2 Dealer Copy -- Not for Resale D9
70MM-SI
D4
2029
D8
2018
1MM-YE*KR
1MM-YE*BE
3MM-KR
1MM-MR
1MM-YE
1MM-PE
1MM-PE
D5
D7 6003
2021
2022
2023
2024
2025
2026
2027
2028
1MM-BE
D6
+ R1 S4 S5 6002
B1 B2
_ E2 S3a S3b S3c
B3 B4
G1
S6
70MM-SI
B01 B02
S2
1.5MM-BE
1.5MM-BE
2MM-BE
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
2MM-SI
1MM-SI
1MM-SI
70MM-SI
1001
1002
1003
1004
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
31
KR = RED MA = BLUE
KH = BROWN MR = PURPLE ELECTRICAL SCHEMATIC
SI = BLACK YE = GREEN B750 (S/N B4BM11001 AND ABOVE)
BE = WHITE GR = GREY Sheet 1 of 8
SA = YELLOW PE = PINK (Printed January 2017)
Printed In Belgium TR = ORANGE A.YE = LIGHT GREEN 201.136.009-R05 (5)
223 of 856
02
30
15
F27 - 15A
F10 - 15A
F4 - 15A
F2 - 15A
1.5MM-KR*MA
2030
2MM-SA
6009
2034
2031
2032
2033
2MM-KR*SA
6005
1.5MM-KR*MA
1MM-YE*KR
E10 6003
1MM-KH
1MM-KH
1MM-SA*BE
1MM-KH
1MM-KH
6003
R-L R-R
S7 S8 S11 S12 S10
1MM-BE*TR
1MM-KH*BE
6004
6006
6007
1MM-MA*SA
2143
2036
2044
1MM-BE
S14LF S14RF
2MM-SA*KR
2MM-SA*KR
1MM-KH*BE
S14LR S14RR
6004 B7
1MM-KH*BE
2038
2039
2040
2035
K20 Dealer Copy -- Not for Resale
1MM-KH*BE
2144 K18
1MM-MA*SA
2MM-TR*BE
2045
1MM-MA*BE
2037
1MM-BE 1MM-BE
E11 E12
1MM-MA*BE
D27
1MM-PE*MA
D11 D12 D28
2142
2043
N
6004
V1 H1 E23 S13
6003 6012
B6
Test İkaz
V3 V4
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-BE
1MM-SI
1MM-SI
1MM-SI
1MM-MR
1020
1021
1022
1023
1024
1025
1026
1030
1031
1018
31
KR = RED MA = BLUE
224 of 856
03 30
15
F16-10A
F15-10A
F11-10A
F17-10A
F20-10A
F8-10A
F7-10A
2MM-KR*BE
2MM-KR
2151 1MM-KR*YE
2056
2065 1MM-KR 6006
6003
2069
2070
1MM-KR
2051
2053
2054
2MM-KR*BE
2MM-KR*BE
2052
1MM-YE*KR 2066 1MM-MA
2MM-KR*BE
1MM-BE*KR
1MM-KR
2067 1MM-YE
1MM-KH
1MM-SA*KR
2075
2068 1MM-GR*BE
2146
S15 S17
K5
2148
2055
2147
2MM-BE*KR
G
INDICATOR LEVER
2132
2MM-BE*KR
M M
2063
S16 H23
M2 M3
2129
2130
2133
1MM-MA*BE
1MM-KH*SA
2057
1MM-KH
1MM-TR
1MM-YE
1MM-KH
6003
2152
1MM-KH*BE 1MM-BE
2058
2131 1MM-SA
2064
1MM-YE 2MM-KR
1MM-TR
1MM-KH*SA
Dealer Copy -- Not for Resale B8
S19
1MM-TR
1MM-YE S18
K7 K6
2074
2MM-KH*BE 2MM-MA*KR
6003
2059
2061
F21-10A
F22-10A
F23-10A
F24-10A
2073
1MM-MA*KR
1MM-BE*KR
1MM-SA*BE
2072
2149
2150
2071
1MM-KR
2MM-SI*KH 2MM-MA
2060 2062
M M
E21 H2 H3 H4 H5 E14 H6 H7 H8 H9 H11 H12 H13 H14 E15 M4 M5

1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1037
1046
1038
1039
1040
1041
1042
1043
1044
1045
1047
1049
1050
1051
1052
1053
1054
1055
1056
1057
1058
1059
1060
1061
1062
1063
31
KR = RED MA = BLUE
225 of 856
04 30
15
F28 - 15A
F14 - 15A
X3
GEAR LEVER
1MM-KR*SA
1MM-SA
2076
1 2 3 4 5 6 7 8 9 10 11 12 6013
2093
6005
1MM-KR
2078
2079
2080
2081
2082
2083
2084
2085
1.5MM-KR
2153
1MM-KR
1MM-MR 1MM-SA*KR
6002
6001 1MM-MA-KR
1.5MM-PE D18
K16 1.5MM-SA D19
1MM-SA*KR
1.5MM-KR*SI
1.5MM-PE
2154 1.5MM-SA
2157
2156
1.5MM-KR*SI
2077
6011
1MM-PE 1MM-SA*KR
2155
D14 D15
1MM-PE
1MM-SA*MR 1MM-SA*KR
1.5MM-MA
1.5MM-SA*KR
1MM-KR*MA
1.5MM-SA
2089
K13 K14 K11 K12 K15
1MM-GR
2087 1.5MM-KR*SI
D16 1MM-PE 1MM-MR
1.5MM-SA*MR
1MM-PE
1MM-YE
1MM-GR
2086
2088
2091
2092
1.5MM-SA 1MM-KH*BE
2090
Y3 Y6 Y5 Y4 Y1 Y2 6004
K4
B9 6012
6010
1MM-SA*MA
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1064
1065
1066
1067
1068
1069
1070
1071
1072
1073
1074
1075
31
KR = RED MA = BLUE
Printed In Belgium A.YE = LIGHT GREEN 201.136.009-R05 (5)
TR = ORANGE
226 of 856
05 30
15
F6 - 15A
F5 - 15A
2099
6009
1MM-KR*BE
1MM-GR*KR
2MM-KR*MA 2113
2109
6016
1.5MM-KR*BE
6003
1MM-KR 1MM-KR*SA
1MM-KR 1MM-KH
6003 2100 1MM-YE*SI 6002
6003
1MM-KH 6011
1MM-KR*BE
2159
1MM-KH 2MM-KR*YE
1MM-GR
S20 S21 K21 K22 K19 P S26

E19
1MM-YE*SI
97
20
D23
1MM-MA*KR
2MM-PE
1MM-MA*KR
98
2114
2115
1MM-GR
1MM-GR
20
1MM-GR*SI
1MM-YE*SI
1MM-YE*SI
2095
2096
1MM-KR
1MM-MA*SI
K23
D26
2101
2102
D28 1MM-SA*MA
1MM-GR D13 D17
6010 1MM-TR
2162
1MM-BE
F25 - 15A
F26 - 15A
2158
1MM-GR-KR
2105
6013
E16 E17
D24
Dealer Copy -- Not for Resale 6010 6015
K17
1.5MM-MR*KR
1.5MM-MR*KR
D25
6003
2163
1MM-GR*KR
2108
1MM-KH
2107
1.5MM-GR
2161
2103
2160
2104
1MM-GR
2116
2117
V5 V6
S29
Y7 Y8 V7
S22
H15 H16 S23 S24 E20
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
1MM-SI
H18
1076
1077
1078
1079
1080
1081
1082
1083
1084
1085
1086
1088
1089
1090
1093
1095
1094
1097
31
Optional Part : EHSS
KR = RED MA = BLUE
227 of 856
06 30
15
F18 - 15A
F19 - 15A
F29 - 20A
F3 - 15A
F9 - 15A
F3 - 15A
6006
6003 6003
2MM-KR*BE
1.5mm-SA*Sİ
2MM-GR*YE
2MM-KR*MA
1MM-KH
1MM-KH
2MM-SA*SI
2127
2128
2123
2170
1MM-KR
3MM-KR
1MM-MA*BE
1MM-SI 1MM-SI 2168
2166
2120
C B 0
S27 S28
2164
1MM-MA
2165 K24 B13
1MM-BE L M H 1
1.5MM-BE
K25
2169
yellow-1
black-1
black-1
2MM-SI
AIR CONDITIONING
6003 (IF EQUIPPED)
2167
K9 B10
K8
1.5MM-GR*KR
X4
green-black-1
green-1
M
2.5MM-BE
2MM-BE
2125
2126
F31-1A
F32-7A
white-black-1
B11
+
2MM-MA*BE
1mm-TR*Sİ
0.75mm-TR*Sİ
1.5mm-KR
white-1
2121
2122
PRESSURE
TUBE
orange-1
red-1
R2 + + B12
R3 S30
H17 H18 H19 H20 H21 H22 Altı
E24
COMPRESOR
1.5MM-SI
1099
1103
1104
1105
1106
1108
1109
1110
1101
1110
1100
1102
1107
1202
1203
1204
1205
1096
1092
31
Optional Part : - AIR CONDITION - FUEL HEATER
KR = RED MA = BLUE
Printed In Belgium A.YE = LIGHT GREEN 201.136.009-R05 (5)
TR = ORANGE
228 of 856
WIRE DESCRIPTION H5 Turn Signal Lamp BR
15 Plus(+) Downstream of Battery H6 Right Front Parking Lamp
30 Input from (+) Battery Terminal Direct H7 Left Front Parking Lamp
31 (-) Battery Terminal or Ground, Direct H8 Right Rear Parking Lamp
B01 Magnetic Sensor- Left H9 Left Rear Parking Lamp
B02 Magnetic Sensor- Right H11 Left Low Beam Headlamp
B1 Oil Pressure Warning Sensor H12 Right Low Beam Headlamp
B2 Engine Temperature Sensor H13 Left High Beam Lamp
B3 Transmission Temperature Sensor H14 Right High Beam Lamp
B4 Fuel Level Sensor H15 Left Brake Lamp
B5 Warning Horn H16 Right Brake Lamp
B6 Transmission Pressure Sensor H17 Right Front Working Lamp
B7 Rear Horn H18 Left Front Working Lamp
B8 Front Horn H19 Right Rear Working Lamp
B9 Backup Alarm H20 Right Rear Working Lamp
B10 Tape Recorder H21 Left Rear Working Lamp
B11 Left Speaker H22 Left Rear Working Lamp
B12 Right Speaker H23L thru
Cab Light
B13 Antenna H23R
D1 thru D26 Diodes K1 Electricity Main Relay
E1 Alternator Charge-Indicator Lamp K2 Starter Relay
E2 Heater Indicator Lamp K3 Engine Heater Relay
E3 Oil Pressure Indicator Lamp K4 Gear Timer Relay
E3F Below Stabilizer Warning Lamp K5 Hazard Warning Signal Flasher
E4 Engine Temperature Indicator Lamp K6 High Beam Headlamp Relay
K7 Low Beam Headlamp Relay
*E4F Brake System Pressure Lamp (Options)
K8 Front Working Lamp Relay
E5 Transmission Temperature Indicator Lamp
K9 Rear Working Lamp Relay
E6 Air Filter Indicator Lamp
K10 Starter Warning Relay
E7 Fuel Indicator Lamp
K11 Forward Relay
*E7F Water In The Fuel Lamp (Options)
K12 Backward Relay
E8 Brake Hydraulic Oil Level Indicator Lamp
E9-E9F General Warning Lamp
Dealer CopyK13
-- Not for Resale
Gear Relay - I
K14 Gear Relay - II
E10 Transmission Pressure Indicator Lamp
K15 3 and 4 Gear Pump Unloader Relay
E11 Pump Valve Indicator Lamp
K16 Transmission Unloader Replay
E12 Beacon Indicator Lamp
K17 Joystick System Locking Relay
E14-E21 Hazard Warning Signal Indicator Lamp K18 Tilt Automatic Relay
E15 High Beam Indicator Lamp K19 4X4 Relay
E16 Differential Lock Indicator Lamp K20 Pump Unloader Relay
E17* Ride Control Indicator Lamp(EHSS) K21 Brake Lamps Relay
E18 4x4 Indicator Lamp K22 Transmission Unloader When Brake
E19 Parking Brake Indicator Lamp K23 4X4 Replay
E20 Joystick Locking Indicator Lamp *K24 Additional A.C Unıt
E23 Tilt Automatic Lamp K25 Rear Window resistance Relay
E24 Rear Window resistance Lamp M1 Starter Motor
F1 thru F29 Fuses M2 Front Wiper Motor
G1 Battery M3 Front Windshield Washer Motor
G2 Alternator M4 Rear Windshield Washer Motor
H1 Beacon Lamp M5 Rear Wiper Motor
H2 Turn Signal Lamp FL P1 Tachometer with LCD Hourmeter
H3 Turn Signal Lamp RL P2 Engine Temperature Indicator
H4 Turn Signal Lamp FR P3 Fuel level Indicator
R1 Resistant
KR = RED MA = BLUE
SI = BLACK YE = GREEN
BE = WHITE GR = GREY B750 (S/N B4BM11001 AND ABOVE)
SA = YELLOW PE = PINK Sheet 7 of 8
Printed In Belgium (Printed January 2017)
TR = ORANGE A.YE = LIGHT GREEN 201.136.009-R05 (5)
229 of 856
R2 Resistant Between the 86 pin of Starter Warning Relay (K10) and 4TH pin of the
6001
R3 Resistant Gear Lever (X3)
S1 Starter Switch Between the 8TH pin of Gear Lever (X3) and 86 pin of the 4X4 Relay
6002
S2 Battery Switch (K19) and Warning Horn (B5) 2ND pin.
S3a Motor Stop Switch Between the 8TH pin of Test Switch (S6) and 8TH pin of the Beacon
S3b Motor Stop Switch(Fuel Pump sensor) Switch (S8) and 1ST pin of the Transmission Pressure Sensor (B6) and
S3c Motor Stop Switch(Engine Advance sensor) 8TH pin of the Magnetic Switch (S10) and 8TH pin of the Parking Lamb
S4 Air Filter Switch Switch (S16) and 2ND pin of the Fuse (F21) and 8TH pin of the
S5 Brake Hydraulic Oil Level Sensor Windshield and Wiper Switch (S18) and 8TH pin of the Differential Lock
6003
S6 Test Switch Switch (S20) and 8TH pin of the Ride Control System Switch (S21) and
S7 Pump Unloader Valve switch 8TH pin of the 4x4 Switch (S24) and 8TH pin of the Joystick Locking
S8 Beacon Switch switch (S26) and 8TH pin of the Front Working Light Switch (S27) and 8TH
S10 Magnetic Switch pin of the Rear Working Light Switch (S28) and 3RD pin of the Cigarette
S11 Left Rear Joystick lighter (X4) and Tachometer with LCD Hourmeter (P1)
S12 Right Rear Joystick Between the 86 pin of Pump Unloader Relay (K20) and 1ST pin of the
S13 Tilt Automatic Sensor Right Rear Joystick (S12) and 87 pin of the 3 and 4 Gear Pump unloader
6004
S14RF Front joystick- right front switch-transmission unloader Relay (K15) and Front joystick- right rear switch- Pump unloader
(S14RR)
S14RR Front joystick- right rear switch- Pump unloader
Between the pin of Front joystick-right front switch-transmission unloader
S14LF Front joystick- left front switch- opening bucket 6005
(S14RF) and 86 pin of the Transmission Unloader Replay (K16)
S14LR Front joystick- left rear switch- opening bucket
Between the 2ND pin of Left Rear Joystick (S11) and 1ST pin of the Cab
S15 Hazard Warning Switch 6006
Light (H23) and Tape Recorder
S16 Parking Lamb Switch
6007 Empty
S17 Horn, Windshield, Signal Switch
Between the 2ND pin of Magnetic Switch (S10) and 2ND pin of the
S18 Windshield and Wiper Switch 6009
Differential Lock Switch (S20)
S19L-S19R Cab Light Switch
Between the 87 pin of Transmission Unloader When Brake (K22) and 85
S20 Differential Lock Switch
6010 pin of the Forward Relay (K11) and 2ND pin of the Parking Brake
*S21 Ride Control System Switch Indicator Lamp (E19)
S22 Brake Switch - 1 Between the 86 pin of Forward Relay (K11) and 86 pin of the
S23 Brake Switch - 2 6011
Transmission Unloader When Brake (K22)
S24 4x4 Switch Between the 85 pin of Backward Relay (K12) and 1ST pin of the
S25 Hand Brake Switch 6012
Transmission Pressure Sensor (B6)
S26 Joystick Locking switch
Dealer Copy
6013-- Not for Resalethe 7TH pin of Gear Lever (X3) and 2ND pin of the 4x4 Switch
Between
S27 Front Working Light Switch (S24)
S28 Rear Working Light Switch Between the 2ND pin of Parking Brake Indicator Lamp (E19) and 2ND pin
S29 Parking Brake Switch 6015
of the Test Switch (S6)
S30 Rear Window resistance Switch Between the 1ST pin of Parking Brake Indicator Lamp (E19) and 1ST pin of
V1 Pump Unloader Valve 6016
the Warning Horn (B5)
V3 Opening Bucket Valve
V4 Closing Bucket Valve * Optional.
*V5 *Smoot Ride Control System Valve
*V6 *Smoot Ride Control System Valve
V7 Joystick Locking Valve
X3 Gear Lever
X4 Cigarette lighter
*X5 Heater + AC
Y1 Connector(forward solenoid)
Y2 Connector(rear solenoid)
Y7 Connector (Differential Locking solenoid)
Y8 Connector (4x4 solenoid)
KR = RED MA = BLUE
KH = BROWN MR = PURPLE
SI = BLACK YE = GREEN ELECTRICAL SCHEMATIC
PE = PINK
B750 (S/N B4BM11001 AND ABOVE)
SA = YELLOW Sheet 8 of 8
Printed In Belgium TR = ORANGE A.YE = LIGHT GREEN (Printed January 2017)
201.136.009-R05 (5)
230 of 856
ELECTRICAL SYSTEM - B730
Fuses

V-1626
FUSE DESCRIPTION FUSE DESCRIPTION

REF AMP REF AMP
TOP FUSE BOX BOTTOM FUSE BOX
1 ENGINE STOP 15 1 HORN 15
2 BEACON LAMP, SIDE SHIFT LOCK (If 15 2 PARKING LIGHTS SWITCH, HAZARD 15
Equipped), EHSS (If Equipped) WARNING SWITCH
3 REAR WINDOEW HEATER 20 3 CAB LIGHTS 10
4 PUMP UNLOAD RELAY, TRANS PRESS 15 4 FRONT WORK LIGHTS 15
RELAY, REAR JOYSTICKS
5 JOYSTICK LOCKING, PUMP UNLOAD 15 5 REAR WORK LIGHTS, FIXING SENSOR 20
SWITCH
6 4X4, BRAKE RELAY 15 6 ISO / STD PATTERN CHANGE VALVE (If 10
Equipped)
7 FRONT WIPER 15 7 RIGHT PARKING LIGHTS 10
8 HEADLIGHT SWITCH, SIGNAL LIGHTS 15 8 LEFT PARKING LIGHTS 10
9 12 V POWER PORT 15 9 LOW BEAM 15
10 TRANS UNLOAD JOYSTICK BUTTON 10 10 HIGH BEAN 15
11 REAR WIPER, RADIO 10 11 RIGHT BRAKE LIGHTS 10
12 SIDE WARNING LIGHTS, GAUGES 10 12 LEFT BRAKE LIGHTS 10
13 BOOM LOCKING (If Equipped), FUEL 15 13 DIFF LOCK, TILT, FRONT WARNING 15
HEATER (If Equipped) LIGHTS
14 F-N-R RELAYS, BUZZER 15 14 GEAR LEVER 15

ELECTRICAL SYSTEM - B730 (CONT’D)
Relays

V-1626
REF RELAY DESCRIPTION REF RELAY DESCRIPTION

1 MAIN 13 GEAR 1
2 STARTER 14 GEAR 2
3 ENGINE HEATER 15 GEARS 3 AND 4, PUMP UNLOAD
4 GEAR TIMER 16 TRANSMISSION UNLOAD
5 HAZARD FLASHER 17 JOYSTICK SYSTEM LOCKING
6 HIGH BEAM 18 TILT AUTOMATIC
7 LOW BEAM 19 4X4
8 FRONT WORKING LAMPS 20 PUMP UNLOAD
9 REAR WORKING LAMPS 21 BRAKE LAMPS
10 STARTER WARNING 22 TRANSMISSION UNLOADER WHEN
BRAKE
11 FORWARD 23 TRANS PRESS.
12 BACKWARD

ELECTRICAL SYSTEM - B750
Fuses

V-1626
FUSE DESCRIPTION FUSE DESCRIPTION

REF AMP REF AMP
TOP FUSE BOX BOTTOM FUSE BOX
1 ENGINE STOP 15 1 HORN 15
2 BEACON LAMP, SIDE SHIFT LOCK (If 15 2 PARKING LIGHTS SWITCH, HAZARD 15
Equipped), EHSS (If Equipped) WARNING SWITCH
3 REAR WINDOEW HEATER 20 3 CAB LIGHTS 10
4 PUMP UNLOAD RELAY, TRANS PRESS 15 4 FRONT WORK LIGHTS 15
RELAY, REAR JOYSTICKS
5 JOYSTICK LOCKING, PUMP UNLOAD 15 5 REAR WORK LIGHTS, FIXING SENSOR 20
SWITCH
6 4X4, BRAKE RELAY 15 6 ISO / STD PATTERN CHANGE VALVE (If 10
Equipped)
7 FRONT WIPER 15 7 RIGHT PARKING LIGHTS 10
8 HEADLIGHT SWITCH, SIGNAL LIGHTS 15 8 LEFT PARKING LIGHTS 10
9 12 V POWER PORT 15 9 LOW BEAM 15
10 TRANS UNLOAD JOYSTICK BUTTON 10 10 HIGH BEAN 15
11 REAR WIPER, RADIO 10 11 RIGHT BRAKE LIGHTS 10
12 SIDE WARNING LIGHTS, GAUGES 10 12 LEFT BRAKE LIGHTS 10
13 BOOM LOCKING (If Equipped), FUEL 15 13 DIFF LOCK, TILT, FRONT WARNING 15
HEATER (If Equipped) LIGHTS
14 F-N-R RELAYS, BUZZER 15 14 GEAR LEVER 15

ELECTRICAL SYSTEM - B750 (CONT’D)
Relays

V-1626
REF RELAY DESCRIPTION REF RELAY DESCRIPTION

1 MAIN 13 GEAR 1
2 STARTER 14 GEAR 2
3 ENGINE HEATER 15 GEARS 3 AND 4, PUMP UNLOAD
4 GEAR TIMER 16 TRANSMISSION UNLOAD
5 HAZARD FLASHER 17 JOYSTICK SYSTEM LOCKING
6 HIGH BEAM 18 TILT AUTOMATIC
7 LOW BEAM 19 4X4
8 FRONT WORKING LAMPS 20 PUMP UNLOAD
9 REAR WORKING LAMPS 21 BRAKE LAMPS
10 STARTER WARNING 22 TRANSMISSION UNLOADER WHEN
BRAKE
11 FORWARD 23 TRANS PRESS.
12 BACKWARD

ELECTRICAL SYSTEM Backhoe Control Valve
Component Location Figure 40-20-2
Starter
Figure 40-20-1
1
2
S47031
2
1. Sideshift locking solenoid.
S47030
2. Backhoe control valve body.

1. Actuator. Solenoid is active when the side-shift lock is triggered to
“1” position, and sideshift is ready to use.
2. Body.
Sideshift Locking Valve
12 V Perkins starters are used in our machines.
Figure 40-20-3
Starter operates with the electrical energy supplied by
battery and it is the prime mover of the engine.
When starter key is brought to “III” start position, current

first enters to actuator of the starter and actuator gives
current to windings inside body part. By this way, rotor of
the starter turns and it gives first movement to the
engine.
S47032
Situated on the backhoe control valve.

ELECTRICAL SYSTEM (CONT’D) Clamshell Control Valves
Component Location (Cont’d) Figure 40-20-6
Pump Unloader Valve
Figure 40-20-4
1
2
S47036
1. Clamshell control valve block.

S47034
2. Clamshell opening solenoid.

Situated on loader control valve. 3. Clamshell closing solenoid.
Regulation Block Situated under the chassis.
Figure 40-20-5 Brake System Pressure Switch
Figure 40-20-7
1 2
S47035
1. Regulation block.
2. Regulation valve solenoid.
It’s the block providing joystick system to operate, the

system is locked by triggering joystick locking switch.
P135556
Situated under chassis, on check valve and accumulator

block.

ELECTRICAL SYSTEM (CONT’D) Fuel Pump Sensor
Indicator Socket
Figure 40-20-8
S47039
Transfer Pump Actuator

S47037
Figure 40-20-11

Figure 40-20-9
S47040
S47038
Indicator socket used for warning when air filter is

clogged.

ELECTRICAL SYSTEM (CONT’D) Engine Oil Pressure Sensor
Transfer Pump
Figure 40-20-12
S47043
Engine Temperature Sensor

S47041
Figure 40-20-15

Stop Solenoid
Figure 40-20-13
S47044
S47042
Situated on the fuel pump.

ELECTRICAL SYSTEM (CONT’D) Crab Steering Valves
Heater Socket
Figure 40-20-16
1 3
S47048
1. Steering unit.
S47045
2. Crosswise.

Fuel Level Sensor 3. Parallel.
Figure 40-20-17
S47046

ELECTRICAL SYSTEM (CONT’D) Figure 40-20-21
Component Location (Cont’d)
Right Control Panel
Figure 40-20-19
S47051
Fuel level gauge indicates the level of fuel in fuel tank.
CALIBRATION
S47049
FUEL LEVEL 0/4 1/2 4/4
RESISTANCE 300 121 9

Figure 40-20-20
S47050
Engine heat gauge shows temperature of engine coolant.
CALIBRATION
TEMPERATURE (°C) 40 80 120
RESISTANCE 1170 +/- 268 +/- 83 +/-%10
%10 %10

ELECTRICAL SYSTEM (CONT’D)
Component Location - ZF In B730 And B750
Gear Lever ZF
Figure 40-20-22

S47053
OUTPUT
DIGITAL INPUT DIGITAL OUTPUT SELECTION OF SPEED RANGE GEAR
DIRECTION
PIN PIN F N R 1 2 3 4
ED1 (VP) 1 AD4 F 5 X
AD5 R 6 X
AD6 N 4 X
ED2 (VP) 9 AD1 B3 7 X X
AD2 B2 3 X X
AD3 B1 2 X X
AD7 B4 8 X

Component Location - ZF In B730 And B750 (Cont’d)
Solenoid Matrix ZF
Figure 40-20-23

S47054
SOLENOID UNDER CURRENT

FORWARD REVERSE NEUTRAL
GEAR 1 2 3 4 1 2 3 N
Y1 X X X X
Y2 X X X
Y5 X X X
Y4 X X X X
Y6 X
Y3 X X X X
ENGAGE KV KV K4 K4 KR KR KR
CLUTCHES K1 K2 K1 K2 K1 K2 K3

ELECTRICAL SYSTEM (CONT’D) Upper Solenoids ZF
Component Location - ZF In B730 And B750 (Cont’d) Figure 40-20-26
Transmission Heat Sensor ZF

4
Figure 40-20-24 2
5
S47058
1. Pressure sensor.
S47056
2. Y1 (Forward).

When transmission oil temperature rises to 120°C, 3. Y2 (Reverse).
sensor is activated by heat and it warns the operator by
blinking the warning lamp. 4. Y3
Transmission Pressure Sensor ZF 5. Differential lock.
Figure 40-20-25 Upper Solenoids ZF
Figure 40-20-27
3 2
1
S47057
4
S47059
1. Y5
2. Y4
3. Y6
4. 4X4


BATTERY Figure 40-30-3
Figure 40-30-1
1 2
1
P135569
Loosen the nuts (Item 1) and remove the clamps (Item 2)

P135567 from the battery. Then remove the battery lines.
Figure 40-30-4
Remove the bolts and washers (Item 1).

Figure 40-30-2
P135570
P135568 Remove the battery.
Remove the nut (Item 1) and battery cable (Item 2).


FUSE Figure 40-40-3
Fuse Location
Figure 40-40-1
P136199
Remove the four screws (Item 1).

P136201

Figure 40-40-2
There’s a fuse arrangement decal under the relay panel

cover.
Figure 40-40-4
P136200
Remove the fuse panel cover (Item 1).
P136202
Fuse arrangement.

FUSE (CONT’D) Figure 40-40-6
Fuse Location (Cont’d)
Figure 40-40-5

P136204
The fuse system.

P136203

RELAY Figure 40-41-3
Relay Location
Figure 40-41-1
P136476
Remove the three screws (Item 1) and relay panel cover

(Item 2). P136478

Figure 40-41-2
Relay arrangement.
Figure 40-41-4
P136477
P136479
There’s a relay arrangement decal under the relay panel

cover.
The relay system.


INSTRUMENT CLUSTERS Figure 40-50-3
Figure 40-50-1
1 1
1 1
P136317
Remove the screws (Item 1) from each corner of the

P136315 indicator board (Item 2). Remove the indicator board.
Figure 40-50-4
Remove four screw caps (Item 1).

Figure 40-50-2
1
1
P136318
P136316 Remove the connector (Item 1).
Remove four screws (Item 1) which are placed on each

corner of the instrument clusters.

INSTRUMENT CLUSTERS (CONT’D) Figure 40-50-7
Figure 40-50-5
1 1
P136321
Remove the connectors (Item 1).

P136319
Figure 40-50-8
Remove the four screws (Item 1) from each corner of the

A/C control panel. Remove the A/C control panel.

Figure 40-50-6
P136322
1
P136320 Figure 40-50-9
P136323

Figure 40-50-10
P136326

P136324
Figure 40-50-13

Figure 40-50-11
1 1
P136327
Remove the buttons (Item 1).

P136325
Figure 40-50-14
P136328

Figure 40-50-15
P136331
Remove the starter switch (Item 1).

P136329
Figure 40-50-18

Figure 40-50-16
1
1
2
P136332

P136330
Figure 40-50-19
P136332

INSTRUMENT CLUSTERS (CONT’D)
Figure 40-50-20
P136333


AXLES
SAFTEY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
FRONT AXLE - B730 AND B750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-18
FRONT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-21-1

REAR SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-22-1

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

REAR AXLE - B730 AND B750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Lubrication And Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Service Brake - Brake Wear Measurement On The ZF-Axle MT-B 3070 . . . . . . . . . 50-40-4
Instructions For The Displacement Resp. Emergency Towing Of The Vehicle . . . . . 50-40-6
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-7
Disassembly - Output Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-9
Service Brake (Multi-Disc Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-14
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-17
Disassembly - Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-22
Disassembly - Parking Brake “Multi-Disc Brake” . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-25
Disassembly - Parking Brake “Disc Brake” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-28
Reassembly - Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-29
Reassembly - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-36
Assembly Service Brake (Multi-Disc Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-45
Reassembly - Output Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-53
Parking Brake Version “Multi-Disc Brake” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-58
Reassembly Of Parking Brake Version “Disc Brake” . . . . . . . . . . . . . . . . . . . . . . . 50-40-65
Completion Of Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-68
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Bleeding The Brake Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-4


SAFTEY INSTRUCTIONS
General Safety Recommendations
IMPORTANT: Before proceeding with any operations please read this chapter very carefully.
Safety precautions
Correct use and repair of BOBCAT products and of their components is very important for safety and reliability.
Recommendations and all described procedures given in this manual have been experimented and hence are effective
operational methods. Please follow every procedure. Use the text as well as the illustrations. Certain procedures show
use of special tools, designed so that the operations can be carried out in a clear and correct manner.
It is impossible to advise every working method or know all possible methodologies for carrying it out or to predict risky
consequences of each operation. Hence, performing procedures or using instruments which have not been advised could
be dangerous for the operator / mechanic as well as the vehicle.
Danger
Safety goggles must be worn while carrying out every assembly or disassembly operation.

Safety Symbols
Recognize Safety Information
This is the safety alarm symbol; whenever you find it in the manual or see it on the machine, you are being warned about
potential danger of accidents or harm to personnel. Follow the do’s and don’t’s to operate in total safety.
Understanding Written Warnings
Written warning (DANGER, WARNING or CAUTION) is used along with an alarm symbol on the machine. DANGER or
WARNING signs are used near danger zones, while CAUTION sign indicates general precaution.

SAFETY INSTRUCTIONS (CONT’D)
General Safety Recommendations (Cont’d)
Follow Safety Instructions!
Read all suggestions given in this instruction manual very carefully. Unauthorized changes could endanger the
functioning, work safety and work span. If you do not understand this instruction manual, contact the nearest sales
representative.
Safety Maintenance Rules
• Operate in a clean and dry environment.

• Do not lubricate, handle or adjust the group underway.
• Keep your hands, feet and clothing away from moving parts.
• Always be prepared for fires. Keep the extinguisher and the first aid kit within reach.
• Keep the phone numbers of a doctor, an ambulance, a hospital and the fire department within reach
near the telephone set.
• Wear suitable clothing and protection such as overalls, safety gloves and ear safety devices.
• Use suitable ear protection, like ear plugs, to keep out noise and prevent injury to the ears. A prolonged 
exposure to noise can damage your hearing.

• The operator must be very careful with the equipment. Do not use headphones to listen music while you are working
on the product or on the group.
Residual Risk Elimination
• Risk of squashing and shearing due to the presence of moving parts
WARNING: Carry out all maintenance operations when the machine is stationary.
• Risk due to inhalation of poison gases that can be produced by heating the varnishes during any welding.
WARNING: Use work stations equipped with dust and fume discharging systems. Let the fumes disperse for at
least 15 minutes, before welding or reheating, or working on the group again.
• Risk of fire due to the solvents used and to the oil in the machine.
WARNING: Keep away any heat sources from the working area. When solvents or paint removers are used, they
should be removed with soap and water, before welding. Remove any containers of solvent, paint remover or any
other inflammable products from the working area.
• Risk due to fall, drop or violent ejection of objects or oil.
WARNING: These residual risks and the suitable relative procedures to eliminate them completely are pointed
out, in detail, in the assembly and disassembly procedures. During maintenance, follow carefully all the safety
procedures indicated in the manual.

FRONT AXLE - B730 AND B750
Description
Front-Rear Axle
1
2 3
4 6
5
S47072

1. Bevel gear.
2. Service brake.
3. Hot oil inside flow to wheel side in order to be cooled

by passing through axle center and brakes by the help
of oil lines.
4. Oil lines.
5. Cooled oil returns to axle from this point.
6. Some of the oil passes to the wheel from this point.

FRONT AXLE - B730 AND B750 (CONT’D) Figure 50-20-2
Disassembly
ZF - Multisteer Steering Axle MS-B 3025
Figure 50-20-1
S45477
3
Loosen the screw plug and drain oil from the axle.
4
Figure 50-20-3
S47071
The axle identification plate is located on axle housing.

1. Axle type.
2. Vehicle producer spare part code.
3. Serial number.
4. ZF spare part code.
Disassembly Output S45478
Figure 50-20-1
Loosen the screw plug and drain oil from the planetary
carrier.
Identification Plate
Figure 50-20-4
S45476
Fix the axle to the assembly truck.

S45479
(S) Assembly truck C77AS34
(S) Fixtures C77AS35
(S) Fixing bracket C77AS36 Loosen the cylindrical screws and pull the planetary
carrier from the hub.

Disassembly (Cont’d)
Figure 50-20-5
S45482
Loosen the locking screws.

S45480
Figure 50-20-8
Disengage the retaining ring.
Figure 50-20-6

S45483
Pull the ring gear with a three-armed puller from the

S45481 knuckle housing from the bushes.
(S) Pressure piece C77AT28

Pull off the planetary gear with the cylindrical roller
bearing.

Figure 50-20-9
S45486
Force both bearing outer rings out of the hub and remove
S45484 the O-ring (see arrow).
Figure 50-20-12
Pull the hub with a two-armed puller from the knuckle
housing.

NOTE: Pay attention to the releasing bearing inner

ring.
Figure 50-20-10
S45487
Pull the bearing inner ring from the knuckle housing.
(S) Rapid grip C77AT29

S45485
Force the cassette type sealing out of the hub.

Figure 50-20-13
S45490
Loosen the hexagon screws on both bearing bolts.

S45488
Figure 50-20-16
Loosen the hexagon nut.
Figure 50-20-14

S45491
Use a lever to remove both bearing bolts from the

S45489 knuckle housing.
Press the tie rod with a forcing device (S) out of the
knuckle housing.
(S) Forcing device C77AT30

Figure 50-20-17
S45494
Force the retaining ring apart and pull the sun gear shaft
S45492 from the double U-joint shaft.
(S) Pliers C77AT32

Press the bearing inner ring and the shaft seal ring with
the cut-off device (S) from the bearing bolt. Figure 50-20-20

(S) Cut-off device C77AT31
Figure 50-20-18
S45495
Disengage the retaining ring out of the annular groove of

S45493 the double U-joint shaft.
Separate the knuckle housing with the double U-joint

shaft from the axle housing.

Figure 50-20-21
S45498
Disengage the retaining ring and press the releasing ball

S45496 bearing out of the knuckle housing.
Figure 50-20-24
Press the double U-joint shaft out of the knuckle housing.
(S) Extracting tool C77AT33

Figure 50-20-22
S45499
If necessary provide the bushes with threads (M12) and

use a striker (S) to pull them out of the housing.
S45497
(S) Striker C77AT36
Pull the shaft seal out of the housing hole.
(S) Internal extractor C77AT34

(S) Counter support C77AT35

FRONT AXLE - B730 AND B750 (CONT’D)
Figure 50-20-25
S45500
Press the double U-joint shaft out of the knuckle housing.
(S) Extracting tool C77AT33

Figure 50-20-26
S45501
Pull the shaft seal out of the housing hole.


Disassembly Steering
Figure 50-20-27
S45504
Loosen the hexagon screws.
Figure 50-20-30
S45502
Disengage the retaining ring.

WARNING: The axial joint is mounted with
Loctite® (type #243).
Figure 50-20-28
S45505
Force the complete steering cylinder out of the axle

housing holes.
S45503
Separate the tie rod from the piston rod.

Figure 50-20-31
S45508
Push or force the plug into the cylindrical tube, until it is

S45506 possible to unsnap the retaining ring (see sketch below).
Figure 50-20-34
Unsnap the ring and remove the releasing flange.
(S) Pliers C77AT32

Figure 50-20-32
S45633
Comment on sketch:
S45507 1. Cylindrical tube
2. Retaining ring
Unsnap the retaining ring.
3. Plug
4. Piston rod

Figure 50-20-35
S45509
Unsnap the retaining ring.
Figure 50-20-36

S45510
Force the piston rod with the plug out of the cylindrical
tube.
Then remove all sealing elements from piston rod, plug

and cylindrical tube.

Disassembly Input
Figure 50-20-37
S45513
Lift the differential out of the axle housing.
Figure 50-20-40
S45511
Secure the axle housing with the lifting device and loosen

the screw joint.
Then separate the axle housings.
Figure 50-20-38
S45514
Pull the bearing outer ring with a striker out of the bearing
hole and remove the shim lying behind.
S45512
Pull the bearing outer ring with a striker out of the bearing
hole and remove the shim lying behind.
Remove the O-ring (see arrow).

Figure 50-20-41
S45517
Press the screen sheet with the cut-off device (S) from
S45515 the yoke.
(S) Cut-off device C77AT31

Loosen the hexagon nut and remove the shim lying
behind. Figure 50-20-44

(S) Clamping fork C77AS49
Figure 50-20-42
S45518
Force the input pinion out of the axle housing.

S45516
NOTE: If the pinion bearing should not be replaced,
special care must be taken that the outer
Pull the yoke from the input pinion. bearing inner ring is always in contact
position with the bearing outer ring when
forcing the input pinion out.

Figure 50-20-45
S45521
Use a lever to remove the shaft seal ring from the axle
S45519 housing and remove the releasing roller bearing.
Figure 50-20-48
Remove spacer ring and bush.
Figure 50-20-46

S45522
S45520 Pull the bearing outer ring out of the outer bearing hole.
(S) Internal extractor C77AS42

Pull the roller bearing from the input pinion and remove (S) Counter support C77AS43
the releasing shim.
(S) Grab sleeve C77AT37

(S) Basic device C77AS5

Figure 50-20-49
S45523
Force the bearing outer ring out of the inner bearing hole.
Figure 50-20-50

S45524
If necessary, pull both bushes out of the axle housing.


Disassembly Limited Slip Differential DZ-250 / Differential

D-250
Figure 50-20-51
S45527
Press crown wheel from differential carrier and cover.
Figure 50-20-54
S45525

Pull both roller bearings from the differential carrier.

(S) Basic device C77AS51
Figure 50-20-52
S45528
Version: DZ-250
Lift the axle bevel gear with pressure disc and disc
package out of the differential carrier.
Version: D-250
Lift the axle bevel gear with thrust washer and constant
spacer out of the differential carrier.
S45526
Use a press to fix the differential and loosen the

cylindrical screws.
NOTE: Cylindrical screws are mounted with Loctite®

(type #243).

Figure 50-20-55
S45529
Insert the slotted pin into the differential shaft until

contact is obtained.

Figure 50-20-56
S45530
Pull the differential shaft out of the housing and remove

the releasing single parts.
Then force the slotted pin out of the differential shaft.

Reassembly
Reassembly Differentials (DZ-250 and D-250)
Reassembly Limited Slip Differential DZ-250
Setting of the axial play of both axle bevel gears =

0,00 - 0,15 mm [Figure 50-20-57] through [Figure 50-
20-61].
WARNING: In order to achieve a correct

measuring result, the single parts must first be
mounted without lubricant. S45532
Figure 50-20-57 Insert the pre-assembled axle bevel gear into the
differential carrier.
Figure 50-20-59

S45531
Preassemble the single parts as described on the sketch S45533

left.
1. Axle bevel gear Insert both axle bevel gears with thrust washers into the
differential carrier and fix them with a differential shaft.
2. Pressure disc
NOTE: Pay attention to the radial installation position
3. Outer discs of the thrust washers.
4. Inner discs
WARNING: Mount the pressure disc with the

coated face showing to the outer disc.

Reassembly (Cont’d)
Figure 50-20-60
S45536
Use a slotted pin to fix the differential shaft.

S45534
NOTE: Pay attention that the installation depth of
differential carrier and differential shaft is the
Check the axial play of the axle bevel gear. same (see sketch below).
NOTE: In case of deviations from the necessary axial Figure 50-20-63

play correct with the corresponding outer
discs (s=1,4 mm or s=1,5 mm).
Figure 50-20-61
S45537
Comment on sketch:
S45535
1. Differential carrier
Separate the single parts again after setting has been 2. Slotted pin
completed.
3. Differential shaft
Then oil all single parts as specified in the lubrication and
maintenance instruction and reassemble them.
WARNING: Thickness and coating of the disc

package may no more be changed.

FRONT AXLE - B730 AND B750 (CONT’D) Insert the pre-assembled axle bevel gear into the
Figure 50-20-66
Figure 50-20-64
S45540
S45538
Mount two adjusting screws (S) and install the cover.

Pre-assemble the second axle bevel gear with identical
coating and thickness. (S) Adjusting screws C77AT13

1. Axle bevel gear Figure 50-20-67
2. Pressure disc
3. Outer discs
4. Inner discs
NOTE: Mount the pressure disc with the coated face

showing to the outer disc.
WARNING: Thickness and coating of the disc

package must be identical on both sides of the
differential assembly.
S45541
Figure 50-20-65
Heat the crown wheel and mount until contact position
with the differential carrier is obtained.
S45539

Figure 50-20-68
S45542
Use a press to fix the differential and fix the crown wheel
with cylindrical screws.

Tightening torque (M10 - 10,9) MA = 68 N•m
WARNING: Wet the thread of the cylindrical

screws with Loctite® (type #243).
Figure 50-20-69
S45543
Heat both roller bearings and mount until contact is

obtained.
NOTE: Adjust bearing after cooling down.

Reassembly Differential D-250
Figure 50-20-70
S45546
Insert both axle bevel gears with thrust washers into the
differential carrier and fix them with the differential shaft.
S45544 NOTE: Pay attention to the radial installation position

of thrust washers and differential shaft.
Pre-assemble the single parts as shown on the left Figure 50-20-73

sketch.
1. Axle bevel gear
2. Thrust washer
3. Constant spacer
NOTE: Oil all single parts as specified in the

corresponding lubrication and maintenance
instruction.
Figure 50-20-71
S45547
Fix the differential shaft with a slotted pin.
NOTE: Pay attention that the installation depth of

differential carrier and differential shaft (see
sketch below) is the same.
S45545
Insert the pre-assembled axle bevel gear into the


Figure 50-20-74
S45550
Insert the pre-assembled axle bevel gear into the

S45548 differential carrier.
Figure 50-20-77
Comment on sketch:
1. Differential carrier

2. Slotted pin
3. Differential shaft
Figure 50-20-75
S45551
Mount two adjusting screws (S) and install the cover.
(S) Adjusting screws C77AT13
S45549
Preassemble the second axle bevel gear.
1. Axle bevel gear
2. Thrust washer
3. Constant spacer

Figure 50-20-78
S45554
Heat both roller bearings and mount them until contact is

S45552 obtained.
NOTE: Adjust the bearing after cooling down.

Heat the crown wheel and mount until contact position
with the differential carrier is obtained.

Figure 50-20-79
.S45553
Use a press to fix the differential and fix the crown wheel
with cylindrical screws.
WARNING: Wet the thread of the cylindrical

screws with Loctite® (type #243).

Reassembly Input
NOTE: If crown wheel or input pinion are damaged,

both parts must be replaced together. When
reinstalling a complete bevel gear set, pay
attention that input pinion and crown wheel
have identical mating numbers.
Installation of Input Pinion
Figure 50-20-81
S45556
Undercool the bearing outer ring and insert until contact

position with the bearing hole is obtained.
(S) Driver tool C77AS52

(S) Handle C77AS53

S45555
Undercool the outer bearing outer ring (see arrow) and

use the assembly fixture (S) to bring it into contact
position with the bearing hole.
(S) Assembly fixture C77AT40

(S) Pressure rings C77AT41

Determine the thickness of the shim to obtain a

correct contact pattern.
NOTE: Perform the following measuring operations

with utmost accuracy. Inaccurate
measurements result in a defective contact
pattern and require to disassemble and
reassemble the input pinion one more time.
Figure 50-20-83
S45559
Determine dimension III (bearing width).
Dimension III e.g. 30,35 mm

CALCULATION EXAMPLE “A”:
Dimension II 97,00 mm
Dimension III + 30,35 mm

Leads to X = 127,35 mm
CALCULATION EXAMPLE “B”:
Dimension I 130,55 mm
S45557
Dimension X - 127,35 mm
Difference = shim s = 3,20 mm
Read dimension I on the axle housing.
Dimension I e.g. 130,55 mm Figure 50-20-86
Figure 50-20-84
S45560
S45558
Insert the determined shim e.g., s = 3,20 mm.
Read dimension II (pinion dimension).
Dimension II e.g. 97,00 mm

Figure 50-20-87
S45561
Heat the roller bearing and mount until contact is

obtained.
NOTE: Adjust the bearing after cooling down.

Setting of the rolling torque of the input pinion

bearing 1,0 - 3,0 N•m (without shaft seal ring).
Figure 50-20-88
S45564
Press the screen sheet (see arrow) onto the yoke until
NOTE: The shaft seal ring is only mounted after

S45562 acceptance of the contact pattern.
Figure 50-20-91

Mount bush (1) and spacer (2), e.g. s = 6,40 mm).
NOTE: Experience has shown that the required

rolling torque is reached when reusing the
shims being removed during disassembly
(e.g. s = 6,40 mm). A later check of the rolling
torque, however, is absolutely necessary.
Figure 50-20-89
S45565
Mount the yoke and fix it with disc and hexagon nut.
Tightening torque MA = 450 N•m
S45563 NOTE: First use the old hexagon nut (self securing),
which has been removed during disassembly.
Insert the pre-assembled input pinion into the axle WARNING: While tightening, rotate the input
housing and mount the heated roller bearing until contact pinion several times in both directions.
is obtained.

Figure 50-20-92
S45566
Check the rolling torque (1,0 - 3,0 N•m without shaft seal
ring).

NOTE: With new bearings try to achieve the upper
value of the rolling torque.
WARNING: In case of deviations from the

necessary rolling torque correct with a
corresponding spacer ring [Figure 50-20-88],
as specified below.
Insufficient rolling torque - mount a thinner spacer ring.
Excessive rolling torque - mount a thicker spacer ring.

Setting of the backlash of crown wheel set and

bearing preload of the differential.
Backlash = 0,12 - 0,24 mm
Bearing preload = 0,10 - 0,15 mm

(corresponds to a bearing rolling torque of 3 - 4 N•m)
NOTE: Pivot the axle housing 90°.
Figure 50-20-93
S45569
Insert the pre-assembled differential into the axle

housing.
Figure 50-20-96

S45567
Insert the shim e.g. s = 0,90 mm (recommended value)

into the bearing hole and adjust the bearing outer ring
until contact is obtained.
S45570
Figure 50-20-94
Mount the bearing outer ring.
NOTE: Rotate differential and bearing outer ring in

both directions, in order to assure that the
rollers are positioned correctly.
S45568
Cover some drive and coast flanks with marking ink.

Figure 50-20-97
S45572
Determine dimension II, between the mounting face of

S45571 the axle housing (part II) and the contact face of the
bearing outer ring.
Align the differential centrically and determine dimension

Dimension II e.g. 8,80 mm
I, between the mounting face of the axle housing and the
front face of the bearing outer ring. CALCULATION EXAMPLE “C”:

Dimension I 9,50 mm
Dimension I e.g. 9,50 mm
Dimension II - 8,80 mm
(S) Straightedge C77AS56 Difference = 0,70 mm
Required bearing preload + 0,10 mm
NOTE: Take several measuring points to find the e.g.
average value.
Leads to shim - 127,35 mm
Difference = shim s = 0,80 mm
Figure 50-20-99
S45573
Insert the determined shim e.g. s = 0,80 into the bearing

hole and adjust the bearing outer ring until contact is
obtained.

Figure 50-20-100
S45576
Tighten the axle housing parts with hexagon screws until

S45574 contact is obtained.
Tightening torque (M16 - 10.9) MA = 280 N•m

Mount the axle housing (part II) with the lifting device.
Figure 50-20-103
NOTE: Provisionally mount the axle housing without

O-ring.
Figure 50-20-101
S45577
Pivot the axle housing 90° and fix the torsion bar (S) with
S45575 the cone connection (S) in the hole of the cover
(differential).
Check the gap between the two axle housings with a (S) Torsion bar C77AT67
feeler gauge. (S) Cone connection C77AT68
NOTE: If the shim (according to calculation example

C, s = 0,80 mm) has been determined
correctly, the gap width is approx. 0,10 mm.
WARNING: Take several measuring points to

find the average value.

Figure 50-20-104
S45579
Insert the differential again into the axle housing after

S45578 checking the contact pattern.
Figure 50-20-106
Place the dial indicator right-angled through the oil drain
hole at a tooth flank of the crown wheel and check the
backlash.

NOTE: Provisionally mount the axle housing without
O-ring.
WARNING: In case of deviations from the

necessary backlash (0,12 - 0,24 mm) correct
with the corresponding shims. [Figure 50-20-
93]
1. Insufficient backlash – mount a thicker shim. The

shim to determine the bearing preload, [Figure 50-
S45580
20-99] must be accordingly thinner.
2. Excessive backlash – mount a thinner shim [Figure Grease the O-ring (see arrow) and mount it to the axle
50-20-93]. The shim to determine the bearing preload housing (part II).
[Figure 50-20-99] must be accordingly thicker.
Then mount the axle housing (part II) until contact is
Check the contact pattern: obtained.
Rotate the yoke to roll the crown wheel several times in

both directions over the input pinion.
Then separate the axle housings and remove the

differential again. Compare the received contact pattern
with contact pattern examples.
WARNING: In case of a contact pattern

deviation it is imperative to correct the
measuring failures which occurred when
determining the shim.

Figure 50-20-107
S45581
Finally tighten the axle housing with hexagon screws.

Mount the Shaft Seal Ring (Yoke)
Figure 50-20-108
S45584
Mount the yoke and finally tighten with disc and “new“
hexagon nut (self securing).
S45582 Tightening torque MA = 450 N•m

Loosen the hexagon nut and pull the yoke from the input

pinion.
Figure 50-20-109
S45583
Mount the shaft seal ring with the seal lip showing to the
oil chamber.
(S) Driver tool C77AT44
NOTE: Use the specified driver (S) to obtain the exact

installation position of the shaft seal ring.
WARNING: Just before the assembly wet the

outer diameter of the shaft seal ring with spirit
and fill the space between seal and dust lip with
grease.

FRONT AXLE - B730 AND B750 (CONT’D) NOTE: Right before the assembly wet the outer
diameter of the shaft seal ring with spirit and
Reassembly (Cont’d) fill the space between the seal lips with
grease.
Reassembly Output Mount The Knuckle Housing
Figure 50-20-113
Figure 50-20-111
S45587
S45585
Mount both bearing outer rings until contact position with

Flush-mount the bush into the axle housing. the pivot bearing holes is obtained.

(S) Driver tool C77AT45 (S) Driver tool C77AT48
(S) Handle C77AS53 (S) Driver tool C77AS52
(S) Handle C77AS53
NOTE: Pay attention to the radial installation
position, the latching / cross joint of the bush Figure 50-20-114
must be showing upwards (12 o’clock) in
installed condition.
Figure 50-20-112
S45588
Insert the bushes until contact position with the holes of

S45586 the knuckle housing is obtained.
(S) Mandrel C77AT49

Flush mount the shaft seal ring into the axle housing with
the seal lip showing to the oil chamber.
(S) Driver tool C77AT46


Figure 50-20-115
S45591
Insert the cassette type seal ring into the knuckle

S45589 housing.

Insert the ball bearing into the knuckle housing until
contact position is obtained. NOTE: The use of the specified driver tool (S)
ensures that the installation position of the

Figure 50-20-116 cassette type ring is correct.
WARNING: Right before the assembly wet the

outer diameter of the cassette type seal ring
with spirit.
S45590
Fix the ball bearing with a retaining ring.

Mount the Double U-joint Shaft
Figure 50-20-118
S45594
Fix the double U-joint shaft with a retaining ring.
Figure 50-20-121
S45592
Insert the double U-joint shaft into the knuckle housing.

(S) Mandrel C77AT49
NOTE: Right before the assembly wet the cassette

type seal ring with spirit.
Figure 50-20-119
S45595
Insert the retaining ring into the groove of the double U-

joint shaft.
S45593
Pull the double U-joint shaft into the knuckle housing until

NOTE: Place the internal extractor (S) into the groove

of the double U-joint shaft.

Figure 50-20-122
S45596
Insert the sun gear shaft into the double U-joint shaft,
until the retaining ring engages into the annular groove
(see arrow).

Mount The Pivot Bearing
Figure 50-20-123
S45599
Bring the knuckle housing into correct position at the axle

housing.
S45597 NOTE: Thereby mount the double U-joint shaft into

the axle housing until the teeth of the joint
fork are mounted to the differential (axle bevel
Press the shaft seal ring over the collar of the bearing gear).

bolt.
Figure 50-20-126
NOTE: The use of the specified driver tool (S)

ensures that the installation position of the
shaft seal ring is correct.
Figure 50-20-124
S45600
Fix the knuckle housing with pre-assembled bearing bolts

[Figure 50-20-126] and [Figure 50-20-127].
Insert the roller bearing with long-term lubricant (e.g.

grease Renolit 283 EP 2).
S45598
NOTE: Just before the assembly wet the shaft seal
ring with spirit.
Press the roller bearing onto the bearing bolts until
contact position is obtained.
Then wet the collar of the bearing bolts (see arrow) with
anti-corrosive agent (Weicon Anti-Seize).

Figure 50-20-127
S45601
Figure 50-20-128

S45602
Fix both bearing bolts with hexagon screws.

Mount The Hub
Figure 50-20-129
S45605
Press the cassette type seal with the label “OUT SIDE”
showing outwards (upwards) into flush position with the
hub.
S45603
Press the wheel bolts into the hub until contact position is NOTE: The use of the specified driver tool (S)

obtained. ensures that the installation position of the
cassette type seal ring is correct.
(S) Wheel bolt puller – basic tool C77AT54
(S) Insert (M22x1.5) C77AT55 WARNING: Just before the assembly wet the
outer diameter of the cassette type seal ring
NOTE: The special tool (S) is only intended for repair with spirit.
solutions when replacing single wheel bolts
with mounted hub. Figure 50-20-132
Figure 50-20-130
S45606
S45604
Heat the roller bearing and mount until contact position
with the knuckle housing is obtained.
Press the wheel bolts into the hub until contact position is
obtained.

Figure 50-20-133
S45609
Mount the ring gear and pre- tighten with the old retaining
S45607 screws (which have been removed during disassembly)
until contact position is obtained.
Mount the pre-assembled hub. Then loosen the retaining screws again and finally
tighten the ring gear with “new” retaining screws.
NOTE: Right before the assembly wet the seal lips of

the shaft seal ring with spirit. Tightening torque MA = 90 N•m
Figure 50-20-134 Figure 50-20-136
S45608 S45610
Heat the roller bearing and mount until contact position is Insert the O-ring (see arrow) into the annular groove of
obtained. the hub and grease.

FRONT AXLE - B730 AND B750 (CONT’D) NOTE: Mount the bearing inner ring with the large
radius showing to the planetary carrier
Reassembly (Cont’d) (downwards).
Mount The Planetary Carrier Figure 50-20-139
Figure 50-20-137
S45613
S45611
Fix the planetary gear with a retaining ring.
Insert the cylindrical roller bearing into the planetary gear Figure 50-20-140

– for this purpose press the cylindrical roller bearing
through the packaging sleeve until the snap ring engages
into the annular groove of the planetary gear.
NOTE: The packaging sleeve is used as assembly

aid.
1. Cylindrical roller bearing
2. Packaging sleeve
3. Snap ring
4. Planetary gear
S45614
Figure 50-20-138
Mount the planetary carrier and fix it with cylindrical
screws.
NOTE: Prior to putting the axle into operation, fill it

with oil. For this purpose stick to the ZF
lubrication and maintenance instructions.
S45612
Heat the bearing inner ring and mount the planetary gear
until contact position is obtained.

Reassembly Steering
Figure 50-20-141
S45617
Pre-assemble the plug as shown on the sketch.
1. Plug
S45615
2. Dual ring
Pre-assemble the cylindrical tube as shown on the 3. Rod seal

sketch.
4. Scraper
1. Cylindrical tube
Figure 50-20-144
2. Rod seal
3. Scraper
Figure 50-20-142
S45618
Push the pre-assembled piston rod into the cylindrical

tube until contact position is obtained.
S45616
NOTE: Slightly oil all seal elements before inserting
the piston rod.
Pre-assemble the piston rod as shown on the sketch.
1. Piston rod
2. Guide ring
3. Piston seal
4. Spacer part

Figure 50-20-145
S45621
Use the piston rod to bring the plug in contact position

S45619 with the retaining ring.
Figure 50-20-148
Push the pre-assembled plug into the cylindrical tube,
until the retaining ring (see sketch below) can be
mounted.

NOTE: Slightly oil all seal elements before inserting
the plugs.
Figure 50-20-146
S45630
Fill the space (X) between plug and cylindrical tube with
grease.
Comment on sketch:
S45620 1. Retaining ring
2. Plug
Engage the retaining ring into the groove of the
cylindrical roller. 3. Piston rod
NOTE: Installation position, see also sketch 8. 4. Space grease filling
X. Space grease filling

Figure 50-20-149
S45622
Use a retaining ring to fix the plug.
Figure 50-20-150

S45623
Mount the flange and fix with a ring.
(S) PliersC77AT32

Mount the Steering
Figure 50-20-151
S45626
Screw hexagon nut and ball joint to the axial joint.
NOTE: Operation must be implemented on both tie

S45624 rods.
Figure 50-20-154
Wet the contact faces (cylindrical tube / axle housing, see

arrows) with anti-corrosion agent (Weicon Anti-Seize).
Figure 50-20-152
S45627
Fix the pre-assembled tie rod to the piston rod.

S45625
Mount the pre-assembled steering cylinder into the holes WARNING: Wet the thread of the axial joint with
of the axle housing. Loctite® (Type #243).
Then fix the steering cylinder with hexagon screws.

Figure 50-20-155
S45628
Mount the tie rod to the joint housing and fix with “new”
hexagon nut (self-securing).

Output torque MA = 100 N•m
Tightening rotation angle α = 180° +45°
NOTE: First tighten the hexagon nut with a tightening

torque of 100 N•m ±15%. Then mark the
position of the hexagon nut and retighten with
a rotation angle of 180° +45°.
Figure 50-20-156
S45629
Flush mount the bushes on both sides into the axle

housing.

(S) Handle C77AS53

Basic Track Setting

S45631
Bring the piston rod into central position. Check track setting (0°):
Setting of dimension X = 121,75 mm (measured between Determine dimension A1.

front face / steering cylinder and front face / axial joint). Turn both outputs by 180° – Dimension A2 must be
identical with dimension A1.
CAUTION: The axial position of the piston rod Dimension “Y” = distance between wheel center and rim
may no more be changed during track setting. flange.
Then fix both tie rods (axial joint) with hexagon nut (3).
Mount the straightedges (1) in horizontal and central axis
position. Fix the measuring device (2) to the yoke. Tightening torque MA = 300 N•m
Loosen the hexagon nut (3) and set the length of the tie
rod (axial joint), until “0°” (= track setting of “zero” mm)
can be read on the measuring device (2).
NOTE: For a toe-in and toe-out setting, which might

be required, stick to the vehicle
manufacturer’s specification.
CAUTION: Carry out setting on both output

sides.
Comment on sketch:
1. (S) Straightedges C77AT58
2. (S) Measuring device C77AT59
3. Hexagon nut
X. Setting dimension 121,75 mm

Setting of Steering Angle
CAUTION: If track setting should be carried out,

the setting of the steering angle should only be
carried out after completion of the track setting.

S45632
Mount the straightedge (1) in horizontal and central axis Leakage test of the steering.
position.
Fix the measuring device (2) to the yoke. Use a HP pump to check the steering for leakage in both
Pivot the output until the steering angle (e.g. 52°) can be steering directions.
read on the measuring device (2). Build up test pressure p = 200 bar (thereby bleed the
Then bring the stop screws (3) into contact position with pressure chamber).
the axle housing and lock them with hexagon nuts. Then close the connection to the HP pump with a shut-off
valve.
Tightening torque (M14X1,5) MA = 150 N•m During a 20 second testing time a pressure decrease of
max. 5 bar is permitted.
NOTE: The value of the required steering value can
be taken from the vehicle manufacturer’s Test medium:
specifications. Engine oils SAE 10W
MIL-L 2104 C / MIL-L 46152
CAUTION: Carry out the setting on both output
sides. (S) HP pump C77AS59
(S) Threaded coupling C77AS66
Comment on sketch:
1. (S) Straightedges C77AT58
2. (S) Measuring device C77AT59
3. Stop screws


FRONT SHAFT Figure 50-21-3
Install a jack stand to support the front shaft.
Figure 50-21-1
P136191
1
Figure 50-21-4
P136189

Figure 50-21-2
1
P136192
Figure 50-21-5
P136190
Remove the four bolts (Item 1) and both clamps (Item 2).
P136193
Remove the front shaft.


REAR SHAFT Figure 50-22-3
Figure 50-22-1
1 2
P136466
Remove the four bolts (Item 1) and both clamps (Item 2).
Remove the rear shaft.

P136464
Install a jack stand to support the rear shaft.
Figure 50-22-2
P136465
Remove the six flange mounting bolts (Item 1).


SAFETY INSTRUCTIONS
Safety Precautions
Correct use and repair of BOBCAT products and of their components is very important for safety and reliability.
use of special tools, designed so that the operations can be carried out in a clear and correct manner.
It is impossible to advise every working method or know all possible methodologies for carrying it out or to predict risky
consequences of each operation. Hence, performing procedures or using instruments which have not been advised could
be dangerous for the operator / mechanic as well as the vehicle.
Danger
Safety goggles must be worn while carrying out every assembly or disassembly operation.

Safety Symbols

General Safety Recommendations (Cont’d)
representative.
- Operate in a clean and dry environment.

- Do not lubricate, handle or adjust the group underway.
- Keep your hands, feet and clothing away from moving parts.
- Always be prepared for fires. Keep the extinguisher and the first aid kit within reach.
- Keep the phone numbers of a doctor, an ambulance, a hospital and the fire department within reach
- Wear suitable clothing and protection such as overalls, safety gloves and ear safety devices.
- Use suitable ear protection, like ear plugs, to keep out noise and prevent injury to the ears. A prolonged

The operator must be very careful with the equipment. Do not use headphones to listen music while you are working on
the product or on the group.
- Risk of squashing and shearing due to the presence of moving parts

Warning: Carry out all maintenance operations when the machine is stationary.
- Risk due to inhalation of poison gases that can be produced by heating the varnishes during any welding.
Warning: Use work stations equipped with dust and fume discharging systems. Let the fumes disperse for at least 15
minutes, before welding or reheating, or working on the group again.
- Risk of fire due to the solvents used and to the oil in the machine.
Warning: Keep away any heat sources from the working area. When solvents or paint removers are used, they should be
removed with soap and water, before welding. Remove any containers of solvent, paint remover or any other inflammable
products from the working area.
- Risk due to fall, drop or violent ejection of objects or oil.

Warning: These residual risks and the suitable relative procedures to eliminate them completely are pointed out, in detail,
in the assembly and disassembly procedures. During maintenance, follow carefully all the safety procedures indicated in
the manual.

REAR AXLE - B730 AND B750
Preface
This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be
made on ZF-units.
Due to the continuous technical improvement of the product, however, the maintenance of the unit at your disposal might
require both deviating work steps and differing setting and testing data.These lubrication and maintenance instructions are
based on the unit’s state-of-the-art at the time of printing. They were prepared with utmost care in order to avoid errors.
ZF Passau GmbH, however, shall not be liable for any possible errors in figures or descriptions. ZF Passau GmbH
reserves the right to replace these lubrication and maintenance instructions by a successive edition at any time without
advance notice. Upon request, ZF Passau GmbH will advise, which edition is the latest one.
The owner and the user shall be responsible for complying with the safety instructions and for implementing the
maintenance work according to the specified guidelines.
ZF Passau GmbH shall not be liable for any incorrect installation, improper handling, insufficient maintenance, improperly
and incompetently performed work and any consequential damage resulting thereof.

REAR AXLE - B730 AND B750 (CONT’D)
Lubrication And Maintenance Instructions
Oil grade
Approved oils for ZF axles MT-B 3070 see ZF List of Lubricants TE-ML 05. The ZF list of lubricants is being continuously
updated and can be obtained or viewed as follows:
Oil change
Precondition for a prescribed oil change is a horizontal axle installation position in each direction! Place vehicle in
horizontal position. Carefully clean drain plug, filler plug and level check plug prior to opening! Only drain the oil
immediately after a longer vehicle operation (axle / oil at operating temperature).
Figure 50-40-1

S45634
Legend
1. Oil drain hole (7/8“-14 UNF 2B) MA = 30 N•m
2. Oil drain hole (7/8“-14 UNF 2B) MA = 30 N•m
3. Oil filler hole / oil level check hole (7/8“-14 UNF 2B) MA = 30 N•m
Oil drain from axle
Loosen drain plugs (1) and drain the oil from the axle.
Oil drain from output units
To prevent any injury due to a possible pressure build-up in the oil circuit of the planetary carrier when opening the oil drain
plug and the oil filler plug (2) –Bring drain hole to the upper position (12 o’clock position) and turn out oil drain plug and oil
filler plug (2),carefully. Then bring drain hole to lower position (6 o’clock position) – drain oil from both outputs.
Waste oil to be disposed of ecologically and according to legal requirements!

Lubrication And Maintenance Instructions (Cont’d)
Oil filling of axle
Provide drain plugs (1 and 2) with new O-ring and install it. Fill in oil to overflow on the filler hole (3). Tightening torque (7/
8“-14 UNF 2B) MA = 30 N•m
Oil quantity
app. 16,0 ltr
Check
Check oil level after some minutes and refill until the prescribed level has been achieved and remains constant. Provide
filler plugs and level check plug (3) with new O-ring and install them. Tightening torque (7/8“-14 UNF 2B) MA = 30 N•m.
Oil change interval
In this connection refer to specification in the ZF list of lubricants TE-ML 05
Oil level check

Check oil level every month, in particular, however, when a vehicle has been put into service with new or repaired axles
or axle parts.
Brake
The following oils are approved for the pneumatic brake actuation or for brake operations through an accumulation system.
- Motor oils SAE 10 W acc. to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
- ATF – oils type A, Suffic A, Dexron of II D

REAR AXLE - B730 AND B750 (CONT’D) Figure 50-40-3
Service Brake - Brake Wear Measurement On The ZF-

Axle MT-B 3070
Attention:
The lining wear measurement on the service brake
(multi-disc brake) provides only limited information about
the total state of the disc package – without disassembly
of the output unit. Carry out lining wear measurement at
least once per year, in particular, however, if braking
behavior has changed, like
• Brake noises
• Reduced braking power
• Reduced braking power S45635
• Changed deceleration
• Changed brake oil level
• Changed braking pressure If dimension “X” < 4,5 mm, replace the lined /
inner discs on both output sides
Figure 50-40-2
Then install screw plug (check hole)– fitted with new O-
ring. Tightening torque (7/8“-14 UNF 2B) MA = 30 N•m

Just for the axle type with PARKING BRAKE
VERSION “MULTI DISC BRAKE“: Notes on vehicle
dislocation and emergency towing
The parking brake (multi-disc brake) is spring actuated. If

the pressure cannot be built up by the vehicle (e.g. motor
standstill) for hydraulically breathing the parking brake, it
is necessary to activate the mechanical emergency
breathing as follows for towing or dislocating the vehicle
Loosen locknut of adjusting screws (arrows) and turn in

S45636 hex screws evenly until preload of the cup spring is
compensated and the disc pack is released.
Wear measurement - service brake (multi-disc brake) NOTE: Evenly turning in the two hex screws prevents
the brake piston from twisting.
The wear measurement must be carried out on both
output sides!
For this purpose remove the screw plug, actuate the

brake and determine dimension “X” using a feeler gauge.
Feeler gauge 5870 200 113
Dimension “X” = Thickness of lined / inner disc

REAR AXLE - B730 AND B750 (CONT’D) Adjust installation dimension “Y” = 29 + 2,0 mm - [Figure
50-40-5]- on both adjusting screws! Tightening torque M
Service Brake - Brake Wear Measurement On The ZF
- Axle MT-B 3070 (Cont’d) 10x1 MA = 46 N•m
Some of the following pictures may not show exactly your
Figure 50-40-4 axle, but the indicated operations are correct anyway.
Figure 50-40-5
S45637
S45638
Important:

Any time the parking brake has been actuated due to
an emergency braking (e.g. caused by a hydraulic Attention:
system failure on the vehicle), replace the discs of The vehicle manufacturer’s specifications are
the parking brake! binding for the maximum towing speed and the
permitted towing distance, also taking the legal
Ensure operability of the parking brake after directions into account!
dislocating the vehicle or after repair work. For this
purpose turn both hex screws (arrows) evenly back
to their initial position and lock by hexagon nuts.

Instructions For The Displacement Resp. Emergency

Towing Of The Vehicle
The parking brake will be preloaded (closed) by means of

spring force. If a pressure build up from the engine side
(e.g. engine standstill) for the release of the hydraulic
parking brake is not possible, the mechanical emergency
release for the towing, resp. the displacement of the
vehicle must be activated as follows.
Figure 50-40-6
S45640
Important:
After the realized displacement of the vehicle, the
functionality of the parking brake has to be restored. For
this purpose, turn both hex head screws (Arrows) evenly
back again into the start position, and lock them by
means of hex nuts

NOTE: Pay attention to the installation dimension = 29 +
mm [Figure 50-40-7].
S45639
Attention:
As far as the permitted towing speed as well as the
Loosen both locknuts of the adjusting screws (Arrow) and towing distance is concerned, the Specifications of the
screw hex head screws evenly in until the preload force of Vehicle Manufacturer are binding, under consideration of
the compression springs will be neutralized. resp. the the legal conditions.
plate pack is released.
NOTE: The even application of the two hex head screws

prevents a misalignment of the brake piston!

REAR AXLE - B730 AND B750 (CONT’D) Examples Of Gear-Tooth-Contact Patterns For The
Gleason Gear-Tooth System
Technical Data
Ideal tooth-contact pattern i.e. pinion distance is
Axle arrangement Rear axle correct
Final drive Planetary gear drive
Coast side (concave)
Service brake Hydr. Controlled multi-disc
brake with automatic Adjuster/ Figure 50-40-8
Type HLB 232 x 154/3
Parking brake Multi-disc brake (release
through hydr. pressure
Differential type DHK-750, with hydr. controlled
100%-Lock
Adjustment Values
Final Drive
Rolling moment - Output shaft T La =l ? 5 - 3N•m*)
bearing
End play - Sun-gear shaft 0,5. - 1,7 mm
End play - Planetary carrier 0,1 - 0,4 mm
S45641

Drive Side (convex)
Drive - Differential
Figure 50-40-9
Bearing rolling moment - T = 0,5 - 1,0 N•m (without
Drive pinion sealing ring)
Bearing rolling moment - T = 3 - 4 N•m (corresponds to
Differential a bearing preload of 0,10 -
0,15 mm)
Torque limit of the hex nut 600 N•m
on the drive flange
Backlash - Crown wheel 0,15 - 0,25 mm
set
Note Ref*:At the reassembly, determine the total rolling

moment of the output shaft (inclusive of shaft
seal). Tges = Twdr = TLa.
S45642

REAR AXLE - B730 AND B750 (CONT’D) Pinion distance must be decreased
Technical Data (Cont’d) Figure 50-40-13
Pinion distance must be increased
Figure 50-40-10
S45644
Figure 50-40-14
S45643

Figure 50-40-11
S45646
Figure 50-40-15
S45645
Figure 50-40-12
S45648
S45647

Disassembly - Output Unit
Figure 50-40-16
S45651
Mount axle on assembly truck. (Illustration shows axle

S45649 version “A”)
Assembly truck C77AS34

AZ-Axle MT-B 3070 “Disc brake”
Fixtures C77AS35
Parking brake-version

Fixing bracket C77AS36
1. Input
2. Axle drive housing Figure 50-40-19
3. bearing housing
4. Axle housing
5. Output unit
6. Parking brake
Figure 50-40-17
S45652
Remove screw plug (arrow) and drain oil from the axle.
S45650
Parking brake-version “multi-disc brake”
Legend to [Figure 50-40-17]

1. Input
2. Axle drive housing
3. Bearing housing
4. Axle housing
5. Output unit
6. Parking brake

Disassembly - Output Unit (Cont’d)
Figure 50-40-20
S45654
Loosen both hex screws (arrows) of planetary carrier

S45653 fixing.
Figure 50-40-23
Just for axle version “A” (parking brake = multi-disc
brake):

To rotate the output (oil drain hole in 6 o’clock position –
[Figure 50-40-21]) equalize the brake fixing on the axle
which was removed from the vehicle by turning in the two
emergency breathing screws (arrows).
NOTE: Turn in both emergency breathing screws

evenly.
Figure 50-40-21
S45655
Take up planetary carrier by means of a lifting strap and

pull it off the hub.
S45656
Remove screw plug (arrow) and drain oil from both

output units

Figure 50-40-24
S45659
Pull out sun gear shaft and remove O-ring (arrow).

S45657
Figure 50-40-27
Snap out retaining ring.

Figure 50-40-25
S45660
Loosen locking screws of internal gear bolting.

S45658
Pull off planetary gear.
Disassemble the remaining planetary gears in the same

way.

Figure 50-40-28
S45663
Warning: To ensure functioning replace shaft

S45661 seal (cassette-type sealing) after any
disassembly of hub - see [Figure 50-40-31]!
Insert two adjusting screws (M 14 – see arrows) and Pull hub off the axle housing using a pressure piece and
press internal gear evenly off the axle housing by means a two-armed puller.

of puller screws.
NOTE: Pay attention that releasing bearing inner ring
Figure 50-40-29 does not drop.
S45662
If required – remove bushings from internal gear. For this

purpose fit bushings with thread and pull them out by
means of a striker.

Figure 50-40-31
S45664
Lift off shaft seal (arrow) with lever and remove both
bearing outer rings from hub.

Figure 50-40-32
S45665
Pull bearing inner ring off the axle housing.
Grab sleeve C77AS39

REAR AXLE - B730 AND B750 (CONT’D) Warning: Loosen screws (axle housing /
bearing housing / axle drive housing - crown
Service Brake (Multi-Disc Brake) wheel side.
Figure 50-40-33 Figure 50-40-35
S45666 S45668
Legend to [Figure 50-40-33] Take up axle housing by means of a lifting strap, insert
1. Service brake (multi disc brake) two adjusting screws (M 16) – see arrows – and separate

— 1a = Crown wheel side axle housing from bearing housing.
— 1b = Side opposite of crown wheel
2. Differential NOTE: Pay attention that releasing O-rings do not
3. Differential lock (100% lock) drop.
5. Bearing housing (crown wheel side) Adjusting screws C77AS40
6. Axle housing (crown wheel side) Assembly lever C77AS41
7. Bearing housing (side opposite of crown wheel)
8. Axle housing (side opposite of crown wheel) Figure 50-40-36
Figure 50-40-34
S45669
S45667
Remove cpl. stub shaft (with inner disc carrier) from axle
The description below shows the disassembly of the housing.
service brake on the axle housing (crown wheel
side). The service brake on the other axle housing
(side opposite of crown wheel) must be
disassembled in the same way to a large extent.
Secure axle by means of a support, see arrow!

Service Brake (Multi-Disc Brake) (Cont’d)
Figure 50-40-37
S45672
Remove O-rings (arrows 1 and 2).

S45670
Figure 50-40-40
Unsnap retaining ring and pull inner disc carrier from the
stub shaft.

Figure 50-40-38
S45673
Loosen screws and remove cpl. ring.
S45671
Take disc package out of axle housing.

Service Brake (Multi-Disc Brake) (Cont’d)
Figure 50-40-41
S45676
Remove sealing elements from axle housing and piston –

S45674 see arrows.
Figure 50-40-44
Equalize cup spring preload by a press, unsnap retaining
ring and remove washer.

Figure 50-40-42
S45677
S45675
Press off piston by means of compressed air, remove

washer and cup spring behind.

REAR AXLE - B730 AND B750 (CONT’D) Warning: Secure axle by means of support,
see arrow!
Differential
Loosen screws (axle housing / bearing housing / axle
Figure 50-40-45 drive housing - crown wheel side).
Figure 50-40-47
S45678
S45680
Differential with 100% lock

If it is necessary to dismantle the differential and/or Take up axle housing by means of lifting strap, insert two
the input pinion, separate the axle housing assembly adjusting screws (M 16) – see arrows – and separate
(crown wheel side) from bearing housing / axle drive axle housing from bearing housing.
housing.
NOTE: Pay attention that releasing O-rings do not
Legend to [Figure 50-40-45] drop.
1. Differential
2. differential lock (100% lock) Adjusting screws C77AS40
4. Bearing housing (crown wheel side) Assembly lever C77AS41
5. Bearing housing (side opposite of crown wheel)
6. Axle housing (crown wheel side) Figure 50-40-48
7. Axle housing (side opposite of crown wheel)
Figure 50-40-46
S45681
Remove bearing housing.
S45679 Warning: Pay attention that releasing O-rings do not

drop!

Differential (Cont’d)
Figure 50-40-49
S45684
Remove sealing elements (arrows) from bearing housing.
S45682 Figure 50-40-52
Press off piston by means of compressed air and remove

O-ring (arrow).
Figure 50-40-50
S45685
Take cpl. locking slide out of differential. Remove O-rings

(arrows).
S45683
Remove bearing outer ring and shim (Differential bearing

preload).

Figure 50-40-53
S45688
Take up planetary carrier by means of lifting strap and

S45686 pull it off the hub.
Figure 50-40-56
Single parts of locking slide.

1. Locking slide
2. Compression spring
3. Axial needle cage
Figure 50-40-54
S45689
Pull off sun gear shaft and stub shaft.
Warning: Pay attention that releasing differential does

not drop!
S45687
Remove both hex screws (arrows) of planetary carrier

fixing (output on side opposite of crown wheel).
Some of the following pictures may not show exactly your

axle, but the indicated operations are correct anyway.

Figure 50-40-57
S45692
Pull off bearing inner ring.

S45690
Grab sleeve C77AS47
Bring axle in upright position and lift differential out of the Basic tool C77AS48
axle.
Figure 50-40-60

Internal extractor C77AS42
Eye nut C77AS44
Figure 50-40-58
S45693
Loosen screws.
S45691
Pull off bearing inner ring.
Grab sleeve C77AS45

Basic tool C77AS46

Figure 50-40-61
S45696
Remove bearing outer ring and the shim behind

S45694 (backlash).
Warning: Mark shim (position.bearing allocation).

Separate differential carrier halves and remove single
parts.

Figure 50-40-62
S45695
Separate crown wheel from differential carrier.

Disassembly - Input
Figure 50-40-64
S45699
Work steps [Figure 50-40-66] and [Figure 50-40-69].

S45697
Only applicable for parking brake version “multi-disc
brake”.
The below description shows the disassembly of the
input on the axle with parking brake version “multi- Remove hex screws of brake housing bolted connection

disc brake” – disassembly procedure of the input on and loosen the two hex nuts evenly (brake housing is
the axle with parking brake version “disc brake” is subject to compression spring preload).
largely the same, however, the cpl. brake caliper with
brake disc must be removed first – for this purpose Figure 50-40-67
refer to chapter “6. Disassembly parking brake
version – disc brake “.
Warning: Secure axle by means of a support - see arrow!

Figure 50-40-65
S45700
Take off the cpl. brake housing cover.
S45698
Fix input flange using a clamping fork, loosen hex nut and
pull off input flange.
Difficult disassembly! Hex nut has been located with
locking compound (Loctite®), if required, heat up hex nut
with hot air blower
Clamping fork C77AS49
If required - lift off shaft seal with lever.

Disassembly - Input (Cont’d)
Figure 50-40-68
S45703
Press off input pinion by means of two-armed puller - pay

S45701 attention that releasing bearing inner ring does not drop.
NOTE: The input pinion can also be dismantled on

Remove disc carrier. the disassembled brake housing.

Figure 50-40-69 Figure 50-40-71
S45702 S45704
Remove compression springs. Remove spacer ring (arrow) from input pinion and pull off
bearing inner ring.
Grab sleeve C77AS50

Basic tool C77AS51

Disassembly - Input (Cont’d)
Figure 50-40-72
S45707
Only applicable for parking brake version “multi-disc

S45705 brake”.
Loosen cyl. screws, turn in two adjusting screws (M 16) –

Drive internal bearing outer ring off the housing hole. see arrows – and separate brake housing by means of
- pay attention that releasing shim (contact pattern / slight hits with a plastic hammer.

bevel gear set) does not drop.
Adjusting screws (M 16) C77AS55
NOTE: Mark shim (strength / position and bearing
allocation).
Figure 50-40-75
Figure 50-40-73
S45708
S45706
Only applicable for parking brake version “disc brake”.

Pull out external bearing outer ring.
Loosen cyl. screws, turn in two adjusting screws
(M16) and separate brake housing (arrow) by means of
Internal extractor C77AS42 slight hits with a plastic hammer
Counter support C77AS43

Disassembly - Parking Brake “Multi-Disc Brake”
Figure 50-40-76
S45711
Remove hex screws of brake housing bolted connection

S45709 and loosen the two hex nuts evenly (brake housing is
subject to compression spring preload).
Disassembly of parking brake version “multi-disc Figure 50-40-79

brake” was shown as part of the whole disassembly

of the axle – disassembly, however, can also be made
on the fully mounted axle.
Warning: Secure axle by means of a support - see

arrow!
Fix input flange using a clamping fork, loosen hex nut and
pull of input flange.
NOTE: Difficult disassembly! Hex nut has been

located with locking compound (Loctite®), if
required, heat up hex nut with hot air blower.
Clamping fork C77AS49 S45712
Figure 50-40-77
Take off the cpl. brake housing cover.
S45710
If required - lift off shaft seal with lever.


(Cont’d)
Figure 50-40-80
S45715
Press piston out of brake housing cover by means of

compressed air.
S45713
Figure 50-40-83
Remove disc carrier.

Figure 50-40-81
S45716
Take disc package out of brake housing cover.

S45714
Remove compression springs.


(Cont’d)
Figure 50-40-84
S45719
If required, disassemble brake housing
S45717 For this purpose, the cpl. differential must be dismounted

first –in this connection see parts of section 
“3. Disassembly differential”.
Remove sealing elements - see arrow - from the grooves

of the brake housing cover. Press-off input pinion using a two-armed puller – pay
attention that releasing bearing inner ring does not drop.
Figure 50-40-85
Figure 50-40-87
S45718
S45720
Pull off both bolts (with O-ring).

Loosen cyl. screws, turn in two adjusting screws (M 16) –
Remove O-ring (arrow). see arrows – and separate brake housing by means of
slight hits with a plastic hammer.

Disassembly - Parking Brake “Disc Brake”
Figure 50-40-88
S45723
Pull off input flange (1).

S45721
Remove shaft seal (2).
NOTE: Loosen both hex screws (1) and remove brake NOTE: Disassembly of brake housing is shown in
caliper assembly (2). “Disassembly - Input”.

For further work steps regarding disassembly of
brake linings as well as the brake caliper refer to
“original by Knott“.
Figure 50-40-89
S45722
Remove brake disc (1).
Fix input flange (2) by means of clamping fork and loosen

hex nut (3).
Difficult disassembly!
Hex nut has been located with locking compound
(Loctite®), if required, heat up hex nut with hot air blower.

Reassembly - Input
Figure 50-40-91
S45725
The figure above shows the INPUT in the axle type

S45724 with parking brake version “Disc brake”.

The figure above shows the INPUT in the axle with 1. Pinion
parking brake version “multi-disc brake”. 2. Crown wheel

3. Inner roller bearing
Legend to [Figure 50-40-91] 4. Shim *contact pattern)
1. Input pinion 5. Adjust. ring (rolling torque)
2. Crown wheel 6. Outer roller bearing
3. Inner roller bearing 7. Shaft seal
4. Shim (contact pattern) 8. Flange
5. Adjust. ring (rolling torque) 9. Washer
6. Outer roller bearing 10. Hex nut
7. Disc Carrier 11. Brake disc
8. Shaft Seal 12. Axle drive housing
9. Washer 13. Brake housing
10. Hex nut 14. Brake caliper
11. Flange
12. Axle drive housing NOTE: The description below shows the reassembly
13. Brake housing of the input on the axle with parking brake
14. Brake housing cover version “multi-disc brake” – reassembly of
the input on axle with parking brake version
“disc brake” is largely the same.

Reassembly - Input (Cont’d)
Figure 50-40-93
S45727
Insert bearing outer ring until contact is obtained.

S45726
Driver C77AT65
Determine shim for pinion position required to obtain Grip C77AS53

an optimum contact pattern on the bevel gear set

(crown wheel / pinion). Figure 50-40-95
Insert shim (e.g. “S” = 1,60 mm) into hole of brake

housing.
NOTE: We would recommend to reinstall the shim

found during disassembly (e.g. “S” = 1,60 mm
– refer to disassembly instructions, [Figure
50-40-99]) into the inner bearing hole / pinion
bearing.
NOTE: As an alternative, e.g. when assembling new

parts (pinion or roller bearing) – a basic
setting of the required pinion position can be
made as described below [Figure 50-40-99] to
[Figure 50-40-102]. S45728
Warning: The contact pattern required on the bevel gear

set, however, is decisive. Any deviation - see Insert bearing outer ring until contact is obtained.
contact pattern check on Figure no. X, demands
a correction of the pinion position by a Driver C77AT65
corresponding shim! Grip C77AS53

Figure 50-40-96
S45731
[Figure 50-40-98] axle with parking brake version

S45729 “disc brake”.
Mount pre-assembled brake housing and fix with cylinder

Apply sealing agent (Loctite® #574) to contact face of screws.
brake housing / axle drive housing.

NOTE: Ensure a correct installation position of brake
NOTE: Area around oil return hole (arrow) must fully housing.
be wet by sealing agent.
Tightening torque (M 16 - 8,8) MA = 195 N•m
Figure 50-40-97
Figure 50-40-99
S45730
S45732
[Figure 50-40-97] axle with parking brake version

“multi disc brake”. Basic setting of pinion position
[Figure 50-40-99] to [Figure 50-40-102]
Mount pre-assembled brake housing and fix with cylinder
screws Read dimension “I” = dimension for production / axle
drive housing (from axle center line to bearing contact /
NOTE: Ensure a correct installation position inner bearing hole) from brake housing (position – see
regarding oil return hole location. arrow).
Tightening torque (M 16 - 8,8) MA = 195 N•m Dimension “I” e.g. 165,04 mm

Figure 50-40-100
S45734
Read pinion dimension (distance standard dimension =

S45733 127.0) from pinion, in case of a + or – deviation of the
distance standard dimension caused by production, the
actual value is indicated on the pinion
Just for assembly of a “new” brake housing
[Figure 50-40-99] to [Figure 50-40-100]: eg.:

Determine dimension “X” (contact face / brake housing to Pinion dimension ? without + or – deviation = 127,0 mm
locating face tapered roller bearing) of brake housing Pinion dimension ? with a + 0.1 deviation = 127,1 mm
“OLD” and brake housing “NEW”. Pinion dimension ? with a – 0.1 deviation = 126,9 mm
NOTE: Any difference caused by production must be Dimension “II” (pinion dimension) e.g. 126,90 mm
taken into consideration accordingly in
dimension “I” see [Figure 50-40-99]:

REAR AXLE - B730 AND B750 (CONT’D) Rolling torque setting of input pinion bearing
Reassembly - Input (Cont’d) Figure 50-40-103
Figure 50-40-102
S45736
S45735
Mount heated bearing inner ring until contact is obtained
and re-adjust after cooling-down.
Determine dimension “III” bearing width, making sure that Install spacer ring (s = optional).
the rollers are located without clearance (rotate bearing

inner ring in both directions several times – roller setting). NOTE: We recommend to reinstall the spacer ring
Since the installed roller bearing is subject to a preload in found during disassembly (e.g. s = 16,8 mm).
installation position, deduct an experience value of – 0,05
mm. If the originally mounted shim (contact pattern / bevel
Dimension “III” = e.g. 36,60 mm – 0,05 mm = 36,55mm gear set) - see [Figure 50-40-93] was replaced, also
install a spacer ring adjusted by the same correction
CALCULATION EXAMPLE e.g.: value.
Dimension “I” 165,04 mm
Dimension “II + III” (126.90 + 36.55) 163,45 mm
Result 1,59 mm
Required shim “S 1,60 mm

Figure 50-40-104
S45738
Insert pre-assembled input pinion, mount heated bearing

S45737 inner ring until contact is obtained.
Figure 50-40-106
NOTE: However, the required bearing rolling torque
is decisive, for assembly of

• “New” rolling bearing ? 1,5 - 3,0 N•m (without
shaft seal)
• “Old” rolling bearing ? 0,5 - 1,0 N•m (without shaft
seal)
Try to achieve upper value (“Old” = reinstalled rolling
bearing).
Any deviation from the required rolling bearing – see

bearing rolling torque check [Figure 50-40-108] –
demands a correction of the bearing rolling torque by a
corresponding spacer ring.
S45739
Mount disc carrier (arrow – just for axle version with

parking brake version “multi-disc brake”) – Pay
attention to installation position.
Install flange.

Figure 50-40-107
S45741
Check rolling torque of pinion bearing!

S45740 Required bearing rolling torque when using
• “New” rolling bearing ? 1,5 - 3,0 N•m (without

Fix flange with washer and hex nut. shaft seal)
• “Old” rolling bearing ? 0,5 - 1,0 N•m (without shaft

NOTE: During tightening rotate pinion in both seal)
directions several times (roller setting).
Try to achieve upper value (“Old” = reinstalled rolling
Tightening torque (M30x1,5) MA = 600 N•m bearing).
NOTE: If results of contact pattern check are positive,

mount shaft seal and input flange according
to the descriptions in - axle with parking brake
version - “multi-disc brake”.

REAR AXLE - B730 AND B750 (CONT’D) Assembly instructions:
Reassembly - Differential Figure 50-40-111
Figure 50-40-109
S45744
S45742
Locate slotted pin(s) with slot in direction of force (arrow).
Legend to [Figure 50-40-109] NOTE: In case of double slotted pins - bring the slots
in a 180° degrees offset position to each

1. Differential other.
2. Shim (backlash)
3. Shim (diff. bearing rolling torque) To figure
4. Differential lock (100% lock)
5. Bearing housing (side opposite of crown wheel) 1 = Differential carrier
6. Bearing housing (crown wheel side) 2 = Slotted pin
7. Multi-disc brake - service brake (crown wheel side) 3 = Slotted pin (just for version with double slotted pins)
8. Multi-disc brake - service brake (side opposite of X = direction of force
crown wheel)
9. Axle housing Figure 50-40-112
11. Axle housing
Figure 50-40-110
S45745
Insert thrust washer and axle bevel gear into differential

S45743 carrier half I.
Install slotted pins (arrows) into differential carrier half –

observing the assembly instructions [Figure 50-40-129].

Reassembly - Differential (Cont’d)
Figure 50-40-113
S45748
Position axle bevel gear (arrow) on differential spider.

S45746
Fix thrust washer with grease (assembly aid), in
differential carrier half II.
Legend to [Figure 50-40-113].
Figure 50-40-116

1. Differential spider
2. Spider gear
3. Thrust washer
Figure 50-40-114
S45749
Position pre-assembled differential carrier half II on

differential carrier half I.
S45747
NOTE: Ensure radial installation of both differential
carrier halves - punch-marked AF-no. (see
Mount spider gears and thrust washers on differential arrow) corresponds to radial position
spider and insert in differential carrier half. marking.
NOTE: Ensure radial installation position of thrust

washers.
Tab to show straight upwards (see arrows).

Figure 50-40-117
S45752
Install both bearing inner rings.

S45750
NOTE: Use suitable support (arrow) - differential
must not be supported on bearing cage.
Position crown wheel on slotted pins and press onto
differential carrier until contact is obtained. Figure 50-40-120

Figure 50-40-118
S45753
S45751
Cover some tooth flanks of crown wheel with marking ink
(for contact pattern check - [Figure 50-40-130]).
Fix differential by means of a press and connect
differential carrier halves with cylinder screws
Tightening torque (M 12 - 12,9) MA = 135 N•m

Figure 50-40-121
S45756
NOTE: For the following determination of dimension

S45754 pay attention to an exact contact of the
bearing outer ring and a correct positioning of
the differential.
Bring axle into vertical position.
Determine dimension “A” - from mounting face / axle

Insert shim (backlash) into hole of axle housing and drive housing to front face / bearing outer ring (take
locate bearing outer ring until contact. measurements at several points and find out mean
value).
We would recommend to reinstall the shim found during
disassembly – refer to disassembly instructions, [Figure Dimension “I” e.g. 6,64 mm
50-40-127] - (e.g. s = 1,70 mm).
Straightedge C77AS56
NOTE: The required backlash, however, is decisive
for the shim(s), to be used.
Figure 50-40-122
S45755
Insert preassembled differential.
Internal extractor C77AS42

Eye nut C77AT66
Position bearing outer ring on bearing inner ring, until all

rollers are located without clearance.

Figure 50-40-124
S45758
S45757 Insert determined shim (e.g. s = 1,40 mm) into hole of

bearing housing and locate bearing outer ring until
contact.
Determine dimension “II” – from mounting face / bearing
housing to bearing hole / bearing outer ring contact. Figure 50-40-126

Dimension “Z” e.g 5,35 mm
Calculation Example
Dimension “I” e.g 6,64 mm

Dimension “II” e.g -5,35 mm
Difference 1,29 mm
Bearing preload + 0,10 mm
Result = 1,39 mm
Required shim(s) = 1,40 mm
A bearing preload of 0,10 mm corresponds to a bearing S45759
rolling torque of appr. 1,0 - 4,0 N•m, if new bevel roller

bearings are used! Mount preassembled bearing housing (without O-rings).
Bring it to contact position and fix provisionally with hex
screws (3x with washer, L = 70 mm).
NOTE: Rotate differential in both directions several

times - roller setting (also see [Figure 50-40-
127].
Tightening torque (M 16 - 8,8) M A = 195 N•m

Figure 50-40-127
S45761
Place dial indicator (3) at right angles to the straight edge

S45760 (1) within a distance corresponding to the outer diameter
of the crown wheel (r = app. 126 mm) and check
backlash.
Check of backlash and of bevel gear set contact pattern
Backlash 0,15 - 0,25

Insert cylinder screw (2) into internal extractor (1) and fix
straightedge (3) and internal extractor in the hole of the NOTE: Any deviation from the required backlash
differential carrier. requires its correction with corresponding
shim(s) – see [Figure 50-40-127].
NOTE: Internal extractor must not be positioned in
the axle bevel gear. A correction of the shim / backlash also requires a
counter-correction of shim / diff. bearing rolling
Internal extractor C77AS42 torque.
Cylinder screw (M20) C77AS58
Figure 50-40-129
Straightedge C77AS57
S45762
For contact pattern check, roll input pinion against crown

wheel in both directions (drive and coast side
engagement).

Figure 50-40-130
S45765
Mount planetary carrier, and insert stub shaft into the

S45763 planetary carrier (service brake).
NOTE: Pay attention to mounted O-ring (arrow).

Mount preassembled bearing housing (without O-rings).
Bring it to contact position and fix provisionally with hex Figure 50-40-133

screws (3x with washer, L = 70 mm).

times - roller setting (also see [Figure 50-40-
128].
Figure 50-40-131
S45766
Fix planetary carrier with hex screws.
NOTE: Insert hex screws with locking compound

(Loctite® #243).

S45764
Place sun gear shaft and stub shaft into the planetary
carrier (output opposite to crown wheel).

Figure 50-40-134
S45770
Insert locking slide with mounted compression spring.

S45767
Figure 50-40-137
Relocate differential, and insert stub shaft into the axle

bevel gear.

Figure 50-40-135
S45771
Mount axial needle cage on locking slide.
S45769 NOTE: Fix axial needle cage with grease - assembly

aid.
Install adjusting screws (1) and fix both O-rings (2) with
grease (assembly aid) into the countersinks of the axle
drive housing.
Adjusting screws/M16 (1 set = 2 pcs.) C77AS40

Figure 50-40-138
S45773
Oil sealing surface and insert piston.
S45772 Figure 50-40-141
Oil both grooved rings (1 + 2) and place into annular

grooves of the bearing housing - paying attention to the

installation position (see detailed figure).
Install O-ring (3).
Figure 50-40-139
S45774
Press piston to contact position.

Figure 50-40-142
S45768
Legend to detailed figure.
1. Grooved ring
2. Grooved ring
3. O-ring
4. Bearing housing
S45775
Mount preassembled bearing housing.
NOTE: Check leakage of 100% lock.

Assembly Service Brake (Multi-Disc Brake)
Figure 50-40-143

S45776
1. Service brake (multi-disc brake) 11. Ring

— 1a = crown wheel side (CS) 12. Disc Carrier
— 1b = side opposite of crown wheel (SOC) — 12a = Disc carrier (CS)
— 12b = Disc carrier (SOC)
2. Axle housing (CS) 13. Retaining ring
3. Bearing housing (CS) — 13a = retaining ring (CS)
4. Differential assembly — 13b = (SOC)
— 4a = Differential 14. Retaining ring
— 4b = Crown wheel 15. Slotted pin
— 4c = 100% lock 16. Cup spring
17. Washer
5. Axle drive housing 18. Washer
6. Bearing housing (SOC) 19. Cup Spring
7. Axle housing (SOC) 20. Piston
8. Grooved ring 21. Disc package
9. Back-up ring — 21a = Disc package (CS)
10. Cylinder screw — 21b = Disc Package (SOC)
NOTE: Below, the reassembly of the service brake on the axle housing (CS = crown wheel side) is shown.
NOTE: For reassembly of the service brake on the other axle housing (SOC = side opposite of crown wheel)
proceed in the same way.

Assembly Service Brake (Multi-Disc Brake) (Cont’d)
Figure 50-40-144
S45779
Insert sealing elements (4 + 5) [Figure 50-40-146] into

S45777 annular groove (arrow) of piston (6).
NOTE: Pay attention to installation position of

Insert sealing elements (2 + 3 - [Figure 50-40-144] into sealing elements.
annular groove (arrow) of the axle housing.

Flush-mount slotted pins (7) (front face) into piston (6), or
NOTE: Pay attention to installation position of the relocate - if not dismantled.
sealing elements.
Figure 50-40-145
S45778
Legend to [Figure 50-40-144], [Figure 50-40-145] and

[Figure 50-40-146]
1. Axle housing
2. Back-up ring
3. Grooved ring
4. Grooved ring
5. Back-up ring
6. Piston
7. Slotted pins

Figure 50-40-147
S45782
Oil grooved rings and sealing surfaces of axle housing

S45780 and piston.
Mount pre-assembled piston (1).

Legend to [Figure 50-40-147] and [Figure 50-40-148]
Figure 50-40-150

1. Axle housing
2. Cup spring
3. Washer
4. Piston
5. Ring
6. Cup spring
7. Washer
8. Retaining ring
Figure 50-40-148
S45783
Push piston to contact position using a two-armed puller

and a pressure plate.
NOTE: Pay attention to the slotted pins placed in the

piston.
NOTE: Ensure that position of located slotted pins

S45781 does not change - pressure plate may only
touch piston front face.
Locate cup spring (2) – paying attention to correct

installation position (see figure no. X) - and washer (3)
into axle housing (1).

Figure 50-40-151
S45786
Insert preassembled ring and fix with cylinder screws.

S45784
NOTE: Install cylinder screws with locking
compound (Loctite® #262).
Mount cup spring (6) – paying attention to correct
installation position - and washer (7) on ring (5). Tightening torque (M8 - 8,8) MA = 23 N•m

Figure 50-40-152
S45785
Press down cup spring preload using a press, and snap

in retaining ring (8).

Figure 50-40-154
S45789
Mount disc carrier – paying attention to correct

S45787 installation position –and snap in retaining ring.
Figure 50-40-157

1. Outer discs
2. Inner discs (lined discs)
Figure 50-40-155
S45790
Insert pre-assembled stub shaft until all inner discs are

mounted.
S45788
Locate disc package – taking the disc arrangement into

consideration.
NOTE: Fix outside disc with grease - assembly aid.

Figure 50-40-158
S45793
Take up cpl. axle half by means of a lifting strap and

S45791 position it on bearing housing / axle drive housing – and
insert stub shaft into gearing of the axle bevel gear
(differential).
Mount sun gear shaft to inserted stub shaft – assembly
aid (for central position of stub shaft). NOTE: Pay attention to O-rings installed in the axle

drive housing and in the axle housing.
Figure 50-40-159
Figure 50-40-161
S45792
S45794
Fix both O-rings (1) with grease (assembly aid) into

countersinks of the axle housing. Bring axle housing equally to contact position and fix it by
means of hex screws.
Oil O-ring (2) and install on the axle housing.
times – roller setting.

Figure 50-40-162
S45796
Disc clearance test of service brake

S45795
The brake must fully be breathed for obtaining an
objective test result of the disc clearance!
Leakage test of multi-disc brake
NOTE: Pressurize brake by HP pump with p = 60 bar

Mount breather valve (arrow) and connect HP-pump. – 10 bar , then release brake and check disc
HP pump 5870 287 007 clearance “X” using a feeler gauge – [Figure
50-40-164].
Threaded coupling (9/16”-18UNF) 5870 950 115
Oil collector bottle 5870 286 072 Disc clearance “X” nom. = 0,4 - 0,75 mm
Completely breathe brake prior to test start! NOTE: If the required disc clearance “X” is not
obtained, assembly was not carried out
Leakage test properly, and another disassembly and
Build up test pressure p = 60 bar – 10 bar and close shut- reassembly is imperative.
off valve of HP pump (maintain pressure).
A pressure drop of max. 3 bar is allowed during a 2
minute testing time.
Test media
Motor oils SAE-10W;MIL-L 2104 C; MIL-L 46152
API-CC, CD, SC, SD, SE,
ATF-oils: type A; Suffic A; Dexron of II D

Figure 50-40-164
S45798
Leakage test of differential lock (100% lock)

S45797
Prior to starting the test, bleed pressure chamber and
then check 100% lock.
NOTE: Bring axle housing equally to contact position
and fix it by means of hex screws. Rotate Test:

differential in both directions several times – Build up test pressure p = 13 bar and close shut-off valve
roller setting. of HP pump
Tightening torque (M 16 - 8,8) M A = 195 N•m No pressure drop is allowed during a 2 minute
testing time!
(S) HP pump C77AS59
1. Piston
2. Outer disc (S) Threaded coupling (7/16-20 UNF) C77AS60
3. Inner disc (lined disc)
4. X = Disc clearance (0,4 - 0,75 mm) Test media
Motor oils SAE-10W;MIL-L 2104 C; MIL-L 46152
API-CC, CD, SC, SD, SE,
ATF-oils: type A; Suffic A; Dexron of II D

Reassembly - Output Unit
Figure 50-40-166
S45802
Install both bearing outer rings of hub bearing until

S45800
NOTE: Hub must not be supported on wheel bolts.

Driver tool C77AS62

1. Axle housing
Handle C77AS63
2. Hub
3. Shaft seal
4. Roller bearing (hub bearing) WARNING: To ensure functioning, always
5. Internal gear use a “new” shaft seal when reassembling
6. Planetary gears the hub – also refer to disassembly [Figure
7. Planetary carrier 50-40-181].
8. Sun gear shaft
Figure 50-40-167
S45801
Mount wheel bolt.

Reassembly - Output Unit (Cont’d)
Figure 50-40-169
S45805
Mount heated bearing inner ring until contact.

S45804
Figure 50-40-172
NOTE: Apply sealing agent to contact face shaft seal

/ hub (Loctite® #574).

Mount shaft seal observing the correct installation
position.
labeling OUT-SIDE showing upwards / outwards and the

correct offset “X” –see detailed figure
Figure 50-40-170
S45806
NOTE: Just before fitting, wet the contact face shaft

seal / axle housing with spirit - assembly aid.
Lifting bracket C77AS38
S45799
1. Hub
2. Shaft seal
3. X = installation dimension 5 mm
Driver tool C77AS64

Figure 50-40-173
S45808
Finally fix internal gear with “new” locking screws.

S45807
NOTE: Locking screws are permitted for one-time
use only.
If disassembled - insert bushings into the internal gear
until contact is obtained. Tightening torque (M14 12,9) MA = 250 N•m

Figure 50-40-174 Figure 50-40-176
S45808
S45810
Mount preassembled internal gear and equally bring to Just for new parts assembly:
contact position using the “old” locking screws (from
disassembly). Insert cylinder roller bearing into the planetary gear – by
pressing the roller bearing into the planetary gear by the
NOTE: Rotate hub in both directions several times – assembly sleeve (arrow) until the snap ring engages into
roller setting. the annular groove of the planetary gear.

1 = Planetary gear
2 = Roller bearing (with bearing inner ring / cylinder
rollers / axial washers and snap ring)
3 = Assembly sleeve

Figure 50-40-177
S45813
If disassembled - insert stop pin (arrow).

S45811
Figure 50-40-180
Heat pre-assembled planetary gear (bearing inner ring)

and install until contact, with large radius / bearing inner

ring showing downwards (arrow).
NOTE: Adjust bearing inner ring / planetary gear after

cooling down.
Figure 50-40-178
S45814
Oil O-ring (Arrow 1) and install on collar of hub.
S45812
Snap in retaining ring.
WARNING: Check contact position of

retaining ring on groove base and re-adjust!
NOTE: For assembly of the other planetary gears

proceed in the same way.

Figure 50-40-181
S45817
Fix planetary carrier with hex screws.

S45815
NOTE: Insert hex screws with locking compound
(Loctite® #243).
Take sun gear shaft (see arrow -2 / figure-no. 14) out of
axle housing and insert in the preassembled planetary Tightening torque (M12 - 8,8) MA = 55 N•m

carrier – assembly aid.
Figure 50-40-182
WARNING: Prior to putting into operation fill the
axle with oil for this purpose stick to the ZF-lubrication
and maintenance instructions
(ZF-order no.: 5871 519 902)

In general, observe the vehicle manufacturer’s
regulations and instructions
S45816
Take up pre-assembled planetary carrier by means of

lifting strap and mount it on the hub –installing stub shaft
into sun gear shaft.

Parking Brake Version “Multi-Disc Brake”
Figure 50-40-184
S45819

S45818
1. Brake housing cover
2. Grooved ring
For reassembly of the brake housing (1) see 3. Grooved ring
reassembly description of the input pinion. 4. Piston

5. Bolt
Insert all compression springs (2 and 3) into the holes of 6. O-ring
the brake housing (1). 7. Hex screw
8. Hex nut
NOTE: Just for assembly of new parts, or if 9. O-ring
dismantled:
Install slotted pins (4) – with slots of slotted Figure 50-40-186
pins in a 180° offset position – and stud bolts
(5).
NOTE: Insert stud bolts with locking agent (Loctite®

#262).
S45820
Oil both grooved rings (arrow) and insert them into the
brake housing cover – observing the installation position,
see [Figure 50-40-186].

Parking Brake Version “Multi-Disc Brake” (Cont’d)
Figure 50-40-187
S45823
Insert disc package into the brake housing cover –

S45821 observing the disc arrangement [Figure 50-40-188]
starting with an outer disc.
Insert both bolts (arrows) with O-ring into the brake Figure 50-40-190
housing cover – observing the installation position, see

[Figure 50-40-185].
Figure 50-40-188
S45824
Oil sealing surface of piston and of brake housing cover

S45822 and press piston into the brake housing cover to contact
position.
Legend to [Figure 50-40-188] to [Figure 50-40-189] WARNING: Press in piston without tilting--
risk of damage to grooved rings and piston.
1. Outer discs (steel discs)
2. Inner discs (lined discs)

Figure 50-40-191
S45827
Bring brake housing cover to contact position evenly by

S45825 hex nuts and hex screws, then fix it finally.
NOTE: Hereby install disc carrier accordingly, to

Mount pre-assembled brake housing cover and fix with ensure all inner discs remain mounted.
hex nuts (arrows).

Figure 50-40-192
S45826
Insert disc carrier so that all discs (inner discs) are

mounted.
NOTE: Ensure a correct installation position of the

disc carrier – countersink / input flange
contact to show outwards (arrow).

Figure 50-40-194
S45830
Insert shaft seal (2) – observing installation dimension

S45828 X (see detailed figure “Z“).
Contact surface (outer diameter) of shaft seal:
Shaft seal / input flange • If rubber-coated, wet with spirit (assembly aid)
• If made of metal, apply sealing agent (Loctite® #574)

Legend to [Figure 50-40-194] and [Figure 50-40-198] Grease shaft seal around the sealing and dust lip.
(grease e.g. “PETAMO GHY 133 N” ZF-order no 0671
1. Brake housing cover 190 099)
2. Shaft Seal
3. Screen sheet Pay attention to a plane installation position of the
4. Input flange shaft seal – use the specified driver tool to ensure an
5. Washer exact installation position of the shaft seal!
6. Hex nut
7. Input pinion Driver Tool C77AS65
“Z” = Detailed figure - installation dimension / shaft seal
X = install dim. 3,5 + 0,5 mm

Figure 50-40-196
S45833
WARNING: Secure axle by using a support

S45831 tube (arrow) - risk of accident.
Fix flange with washer (5) and hex nut (6).

Just for new parts assembly:
Mount screen sheet (3) on input flange (4) and bring to While tightening rotate pinion in both directions several

contact position. times (roller setting).
NOTE: Install hex nut with locking compound
NOTE: Ensure correct installation position of screen (Loctite® #262).
sheet– also see [Figure 50-40-194] and Tightening torque (M30x1,5) MA = 600 N•m
detailed figure “Z”. Install screen sheet
without deforming it – use suitable driver tool. Figure 50-40-199
Figure 50-40-197
S45834
S45832
WARNING: Check break-away torque of
multi-disc brake. Secure axle by using a
Mount pre-assembled input flange. support [Figure 50-40-198].
Fix locating piece (arrow) on input flange and check
break-away torque of parking brake (do not place torque
wrench on hex nut of input flange fixing).
Break-away torque of parking brake = min. 1000 N•m.
WARNING: In case of a proper parking brake
functioning, a break-away (slipping) of <
1000 N•m is not allowed!

REAR AXLE - B730 AND B750 (CONT’D) Leakage Test Of Multi-Disc Brake
Parking Brake Version “Multi-Disc Brake” (Cont’d) Figure 50-40-202
Setting Of Emergency Breathing Of Multi-Disc Brake
Figure 50-40-200
S45837
Mount breather (1) and screw plug (2).

S45835
NOTE: Install screw plug with sealing agent –
Loctite® #574.

Legend to [Figure 50-40-200] to [Figure 50-40-201]: Tightening torque (1-breather) MA = 6 N•m
1. Brake housing cover Tightening torque (2-screw plug) MA = 25 N•m
2. Hex Screw
3. Hex Nut Check
Prior to staring the test, bleed pressure chamber and
Y = Installation dimension ? 29 + 2 mm then pressurize multi-disc brake several times.
Figure 50-40-201
S45836
Install both emergency breather screws, observing the

installation dimension “Y” – see [Figure 50-40-200]
Tightening torque (M10x1) MA = 46 N•m

Leakage Test Of Multi-Disc Brake (Cont’d)
Figure 50-40-203
S45838

Build up test pressure p =13 bar and close shut-off valve
of HP-pump.
NOTE: A pressure drop of max < 1 bar is permissible

during a 4-minute test duration.
Test media
Motor oils SAE-10 W corresponds,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE.
ATF-oils type A, Suffic A Dexron of II D.
HP pump C77AS59
Reducing Adapter C77AS68
(7/8” to G 1/4”)
Threaded Coupling C77AS67
(G 1/4”)
WARNING: Prior to putting into operation fill

the axle with oil – for this purpose stick to the
ZF-lubrication and maintenance instructions
WARNING: (ZF-order no.: 5871 519 902)!In

general, observe the vehicle manufacturer’s
regulations and instructions!

Reassembly Of Parking Brake Version “Disc Brake”
Setting Of Emergency Breathing Of Multi-Disc Brake
Figure 50-40-204
S45841
Shaft seal / input flange.

S45840
1. Brake housing cover
2. Shaft Seal

For reassembly of brake housing (1) refer to reassembly 3. Screen sheet
procedure of input pinion described in INPUT 4. Input flange
reassembly. 5. Hex screws
6. Input pinion
Mount breather (2) into the brake housing. 7. Washer
8. Hex nut
Tightening torque (breather) MA = 6 N•m 9. Brake disc
10. Brake caliper
11. Washer
12. Hex screw
“Z” = Detailed figure - installation dimension / shaft seal
X = install dim. 3,5 + 0,5 mm


(Cont’d)
Figure 50-40-206
S45843
Driver Tool C77AS72
Just for assembly of new parts, or if disassembled:

S45842
Insert hex screws (5) into the input flange (4). Mount
screen sheet (3)on input flange (4) and bring to contact
Insert shaft seal (2) – observing installation dimension position.

X (see detailed figure “Z“) Observe installation position of screen sheet.
NOTE: During assembly, screen sheet must not be
Contact face (outer diameter) of shaft seal: deformed – use suitable driver tool.
• if rubber-coated: wet with spirit (assembly aid).
• If made of metal: apply sealing (Loctite® #574) Figure 50-40-208
Grease shaft seal around the sealing and dust lip.
NOTE: Observe a plane installation position of the

shaft seal using the specified driver tool (A)
ensures an exact installation position of the
shaft seal.
S45844
NOTE: Secure axle by means of a support (arrow) –

risk of accident.
Mount pre-assembled input flange (4), fix with washer (7)
and hex nut (8).
Fix input flange using a clamping fork, and rotate in both
directions several times while tightening the hex nut -
(roller setting / pinion bearing).
Install hex nut with locking compound (Loctite® #262).
Tightening torque (M30x1,5) MA = 600 N•m


(Cont’d)
Figure 50-40-209
S45845
Mount brake disc (9) – observe installation position - and

fix with tube and hex nut (arrows) – transportation lock.

Figure 50-40-210
S45846
Fix brake assembly (10) with washer (11) and hex screw
(12).
Tightening torque (M16x1,5 - 10,9) MA = 300 N•m
NOTE: Regarding assembly, functional
characteristics, maintenance and setting
instructions for the brake assembly (10). See
original documents of component
manufacturer (Knott).
ZF-lubrication and maintenance instructions
WARNING: (ZF-order no.: 5871 519 902)! In
general, observe the vehicle manufacturer’s

Completion Of Axle
Figure 50-40-211
S45848
NOTE: Fit screw plugs (arrow) of both output units

S45847 with new O-ring and mount them.
Tightening torque (7/8“ – 14 UN) MA = 30 N•m

Check axle regarding leakage.

1. Oil Drain Plug
2. Oil Filter / level check plug WARNING: Max. test pressure = 0.5 bar must
3. Brake control plug not be exceeded here – risk of damage!
4. Identification Plate
Mount air connection into brake control hole of axle
Fit all screw plugs with new O-ring and install them.
housing.
Pressurize axle with a test pressure of = 0,5 bar – and
close shut-off valve.
Just for assembly of new parts or if disassembled:
Fix identification plate with grooved pins.

Completion Of Axle (Cont’d)
Figure 50-40-213
S45849
NOTE: No pressure drop is allowed during a 3-minute

testing time.

Air Connection C77AS69
Connection Plug C77AS70
Reducing Adapter C77AS68
(7/8” to G 1/4”)
Remove air connection, then fit screw plug with new O-

ring and install it.

ZF-lubrication and maintenance instructions!
In general observe the vehicle manufacturer’s
Warning: Bleeding process is required when rear axle

oil is changed.


SERVICE BRAKE
Description
Figure 50-50-1
Right Brake Breather
S47079
Figure 50-50-2

Left Brake Breather
S47080
There are two bleed screws, one located on each side of

the rear axle.
Air trapped in the brake lines may cause a spongy feel

and/or delayed activation of the service brake.
Use the following procedure to remove air from the brake

circuit.

SERVICE BRAKE (CONT”D) Figure 50-50-5
Bleeding The Brake Circuitry
Figure 50-50-3
S47083
Have an assistant sit in the operator’s seat.

S47081
NOTE: Hydraulic fluid will be forced from the bleed
screws during the following procedure.
Use a container / hose to collect the fluid.
Start the engine and wait about 1 minute.

Figure 50-50-4
Latching the brake pedals together, apply the latched
pedals and fully stroke the booster push rods
approximately twenty times.
Start to permit the air out by loosening the nipples while

all air removed.
After that screw nipples and latch the pedals.
Repeat this procedure until the oil flows from the bleeding
screw without any air bubbles.
When finished test for proper brake operation.
S47082 Test Procedure
Start engine, move backhoe and loader attachments to

Start with the brake that is furtherest from the master travel position as described in operation manual. Make
cylinder. sure machine on flat surface, not on any slope.
Remove the cap from the bleed screw and connect the Separate brake pedals by; Raise the pin, slide it to the
hose / container to collect the fluid. left, turn it downwards.
Press left brake pedal only and release parking brake.
Select THIRD gear, and put direction lever in FORWARD

position.
Slowly increase engine speed by pressing engine

accelerator pedal.
Machine should stay stationary in full engine speed.

SERVICE BRAKE (CONT”D)
Test Procedure (Cont’d)
Release engine accelerator pedal and engage parking

brake.
Release left brake pedal.
Repeat same process for right brake pedal.
Machine should stay stationary in full engine speed.
Engage parking brake and lock brake pedals by; Raise

the pin, slide it to right, turn it downwards.
If machine start to move while pressing left / right brake

pedals, park machine as described in operation manual.
And contact your service / dealer.

SERVICE BRAKE (CONT”D)
Brake System Troubleshooting
POSSIBLE
PROBLEM SOLUTION
REASON
Brake system pressure warning light Brake system hose Check brake system hose that connects transmission to
illuminates when engine is working. ruptured. check valve and accumulator block for damage. Replace
damaged hose. Bleed brake system if required.
Check valve Check check valve mechanism. Replace check valve
problem mechanism if needed.
Cable or socket Check cables that connects pressure switch to brake
problem system relay (K26 for B730 & B750).
Relay problem Check brake system relay (K26 for B730 & B750) if
working correctly, replace relay if needed.
Pressure switch Check brake system pressure switch which is
problem. located on check valve and accumulator block.
Replace pressure switch if needed.
Brake system pressure warning light There is low Limited pressure can be stored in accumulator. If
illuminates when engine is not pressure in brake used 4-6 times it is normal to get warning.

working. accumulator. Check if problem continues when engine is working.
Brake system pressure warning light Insufficient Check transmission oil level. Add transmission oil if
and transmission pressure warning transmission oil. needed.
light illuminate when engine is Transmission do Check transmission for any problem and solve
working. not supply problem.
enough pressure
for brake system.
Brake pedal effort is too high. There is no Check brake system hoses for damage. Find and
sufficient replace damaged hose. Bleed brake system if
pressure for brake required.
system. Check transmission for any problem and solve problem if
any.
Check check valve mechanism. Replace check valve
mechanism if needed.
There is problem Check booster unit for any problem. Replace
with booster unit. booster unit if needed.
Insufficient braking performance. Problem with rear Control rear axle brake discs. Replace discs if
axle. needed. Bleed brake system if required.
Brake system Check brake system hoses that connects booster
hose ruptured or unit to rear axle brake ports for leaks or damage.
leaks. Bleed brake system if required.
Tyres worn out. Replace machine's tyres if tyres are worn out.

TRANSMISSION
MANUAL USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Agreements And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Typographic Agreements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Recommendations For Repair Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Transmission Installation On The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

TRANSMISSION - B730 AND B750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Serial Number Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Measuring Points For Pressure Oil And Temperature . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7

Solenoid / Gear Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-9
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-50


MANUAL USE Measurements
Maintenance This manual indicates all measurements in International

System (SI). Use the following conversion table to
CONSULT THIS MANUAL THOROUGHLY, as proper convert Imperial Measure.
functioning and good efficiency of mechanical organs
depends mostly on constant and correct routine General Description
maintenance ensuring product integrity and expected life
duration. In case of any damages or anomalies, quick The machine should be checked and/or repaired only by
intervention of specialized personnel can avoid future qualified technicians, acquainted with its peculiar
impairment and lengthen the working life. features and well aware of all safety instructions. Before
performing any operation it is advisable to carry out unit
Repair cleaning accurately by removing oil / grease
encrustations and accumulation. All disassembled
The disassembly / assembly procedures have been mechanical parts must be cleaned accurately with
outlined for a total product overhauling. They have also suitable products to avoid possible damage. Parts should
been described in sequence through photographs with be replaced if damaged, worn out, cracked, seized, etc.
relevant explanation for specific interventions, thus as they could affect proper working.
obtaining a complete and safe guide for each and every
phase of an operation. Operation description presumes Rotating parts (bearings, gears, shafts) and that of
that the unit has already been removed from the vehicle. hardware / fasteners (O-ring, oil seals) should be
The manual supplied by the vehicle manufacturer should examined carefully, as they are subject to major stress,
be consulted in case of a overhauling or maintenance wearing and aging. We highly advise to replace
intervention requiring the removal of the machine. tightening parts during very teardown or repair. In case of

replacement of one part of the bevel gear set this
Agreements And Definitions operation requires the replacement of the other part too.
Use appropriate spare parts, nuts and bolts to avoid any
Agreements other problems. Moreover, use metric tools for metric
nuts and bolts and Imperial tools for the others. Some
Illustrations like pictures, drawings and components of repairs are destructive for some axle components.
this manual are NOT in scale, because of limited space Carefully reading and thorough understanding of these
and editing limits, therefore they are NOT reliable to instructions will avoid damage to other components
obtain values about size or weight. Illustrations are unnecessarily.
supposed to point out the correct methods to working on
the machine and its components, therefore they could not
display exactly the same elements.
Definitions
Left side: it is the left side of the unit considering the

vehicle running conditions.
Right side: it is the right side of the unit considering the

vehicle running conditions.
Typographic Agreements
NOTE: The notes, pointed out externally to the text

they refer, include important information.
Warning: Warning indications point out the procedures,

whose partial or complete non-observance can damage
the machine or the connected equipment.
Danger: Danger indications point out the procedures,

whose partial or complete non-observance can injure the
operator.

MANUAL USE (CONT’D) Oil Drain
Recommendations For Repair Operations Before disassembly, oil should be drained out.
Before starting any disassembly and assembly Warning: Disposal of used oil must be done according to
operations, read carefully the following laws.
recommendations.
Cleaning
Shafts Seals
Wash all moving parts (gears, bearings, etc.) accurately
Respect the following recommendations during shaft seal with diesel fuel or kerosene. Avoid gasoline and watery
assembly: alkaline solutions. Do not wash with steam or hot water,
as it will be very difficult to eliminate surface humidity. Dry
- Clean shaft very carefully and ensure that the part in all parts with a rag or air jet to avoid scratching from
contact with the shaft seal is not damaged, cut or out of abrasive residuals. All surfaces should be covered with
roundness. lubricant so as to protect it from future oxidation.
- Assemble the seals so that the lip is fitted towards the oil
side. Checks
- Assemble the seals so that the lip is fitted towards the oil
side. Examine accurately all bearings, external rings which
- Lubricate seal lips (use oil) and fill 3/4 of seal cavity with may be still stuck in their position and pivot pins on which
grease. rolls rotate. Replace those which are worn out or
- Use appropriate drivers. Do not use a hammer directly damaged. Gears should not be spoiled and teething
on the seals. should not be excessively worn out. Teeth smoothing

- Do not damage the seals while assembling the shaft. should not be deteriorated. Check all grooves: assure
that they are not worn out or damaged. Replace spoiled
O-Rings parts with original spare parts. Replace seals on rotating
shafts, before reassembly.
Lubricate adequately before inserting them at the right
place and avoid o-ring rolling while inserting the shaft. Ends Of Flanges And Tools
Adjusting Shims Be careful when hammering tool or flange ends, in order

to avoid jeopardizing functionality and integrity of either
Use appropriate adjusting shims and measure each one the tools or the components on which you are operating.
separately. Complete group measurement or stampings
on the shims are not always reliable: check. Reassembly Methods
Bearings In order to reassemble the group, an appropriate fixture

must be used. In order to position the group, to
It’s advisable to heat up bearings to 80°C - 90°C before disassemble and reassemble the ring gear and to
assembling them onto their respective shafts or to cool support the gear housing, a lifting system is needed. To
them (dry ice) before inserting them into corresponding make disassembling and assembling operations easier,
bore. Always use suitable extractors to remove the use a group assembly drawing.
bearings. Before reassembling the bearings, clean,
check and lubricate them. Lubricant Use
Split Pins In order to lubricate the CARRARO transmissions

correctly and to reach the exact operation temperature, it
Before assembling elastic pins, make sure that the notch is important to use the recommended lubricants (Section
is oriented towards the stressing force. Spiral elastic pins C.4), keeping their level constant as indicated in this
do not need orientation. manual.
Sealing
Use sealing as advised by specifications. Ensure that

parts to be sealed are clean, dry and completely grease
free.

MANUAL USE (CONT’D)
Transmission Installation On The Machine
Figure 70-10-1
S44640
In order to avoid the damage of the pump seal ring (1), it

is recommended to fit by hand the converter (2) on the
transmission (3) TLB (the two converter tang drivers (4)
which drag the pump may cut the seal ring lip). Then
connect transmission and converter to machine motor
flywheel using the flex plate screws and the SAE 3 motor
bellhousing screws.


SAFETY INSTRUCTIONS
Safety Precautions
Correct use and repair of CARRARO products and of their components is very important for safety and reliability.
use of special tools, designed so that the operations can be carried out in a clear and correct manner. Special tools must
be used when a particular operation is being carried out. It is impossible to advise every working method or know all
possible methodologies for carrying it out or to predict risky consequences of each operation. Hence, performing
procedures or using instruments which have not been advised could be dangerous for the operator / mechanic as well as
the vehicle.
Danger
Safety goggles must be worn while carrying out every assembling or disassembling operations.

Safety Symbols

representative.
General Precautions
Observe safety instructions, accident prevention rules and all general safety regulations in each and every step at work.
Before going ahead with maintenance or repair work ensure that all the tools, the supporting bench, stands, levers,
extractors and spanners are in good condition so that the work can be carried out easily. Risks to various parts and
components will also be reduced in this way and working condition for the operator will also be safer. CARRARO SpA
declines any responsibility in case of an accident or damage resulting due to changes made arbitrarily on product. The
product is used for any other purpose different from the one foreseen, than CARRARO SpA declines any responsibility.
In this case all consequences will be at the customer’s expense.
- Operate in a clean and dry environment.

- Do not lubricate, handle or adjust the group underway.
- Keep your hands, feet and clothing away from moving parts.
- Always be prepared for fires. Keep the extinguisher and the first aid kit within reach.

- Keep the phone numbers of a doctor, an ambulance, a hospital and the fire department within reach
- Wear suitable clothing and protection such as overalls, safety gloves and ear safety devices.
- Use suitable ear protection, like ear plugs, to keep out noise and prevent injury to the ears. A prolonged
The operator must be very careful with the equipment. Do not use headphones to listen music while you are working on
the product or on the group.
- Risk of squashing and shearing due to the presence of moving parts

Warning: Carry out all maintenance operations when the machine is stationary.
- Risk due to inhalation of poison gases that can be produced by heating the varnishes during any welding.
Warning: Use work stations equipped with dust and fume discharging systems. Let the fumes disperse for at least 15
minutes, before welding or reheating, or working on the group again.
- Risk of fire due to the solvents used and to the oil in the machine.
Warning: Keep away any heat sources from the working area. When solvents or paint removers are used, they should be
removed with soap and water, before welding. Remove any containers of solvent, paint remover or any other inflammable
products from the working area.
- Risk due to fall, drop or violent ejection of objects or oil.

Warning: These residual risks and the suitable relative procedures to eliminate them completely are pointed out, in detail,
in the assembly and disassembly procedures. During maintenance, follow carefully all the safety procedures indicated in
the manual.

TRANSMISSION - B730 AND B750
Serial Number Plate Location
S47088 S47087
Preface
This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be

made on ZF units.
This documentation describes a ZF series product with a design level valid at the date of edition.
Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal may require both
deviating work steps and differing setting and testing data.
We would therefore recommend you to entrust masters practical and theoretical training is constantly updated in
and servicemen with the work on your ZF product whose our training school.
The Service Stations established by ZF Friedrichshafen all over the world offer you:
1. Permanently trained staff 3. State-of-the-art genuine ZF spare parts
2. Specified equipment, e.g. special tools
All work is done there with utmost care and reliability.
In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms of the
currently applicable contractual conditions.
Any damage resulting from work which is done in an improper and unprofessional manner by third parties and any
consequential costs incurred shall be excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.

TRANSMISSION - B730 AND B750 (CONT’D)
General
The Service Manual covers all work required for disassembly and the relating reassembly.
When repairing the transmission, ensure utmost cleanliness and that the work is done in a professional manner.
Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing
parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use suitable pulling devices for
removing parts being tightly installed on the shafts, such as bearings, bearing rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools which have been developed for
this purpose. Prior to re installation of the parts, clean contact faces of housings and lids from residues of seals. Remove
any burrs or similar irregularities with an oil stone. Clean housings and end covers, in particular corners and angles, with
a suitable detergent. Damaged or heavily worn parts must be replaced, with an expert assessing whether parts subject to
normal wear during operation, such as bearings, thrust washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with worn or broken
sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies remain in the housing. Check
the lube oil holes and grooves regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation.

NOTE: Only a heating furnace or an electric drier is permitted to be used for heating up parts such as bearings,
housings, etc.! Parts fitted in heated state must be readjusted after cooling down to ensure a perfect
contact.
Caution: When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual.
Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.
The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible
malfunction.
Never wash discs having organic friction linings (e.g. paper discs - adverse effect on lining adhesion).
Only dry cleaning is permitted (leather cloth).

Schematics
Configuration 4 WG-94 Without Front Wheel Drive
13
1
12
2
11
10
3
9
4 8

5
6
7
S45851
1 Converter
2 Flexplate for direct mount
3 Transmission pump
4 Converter bell
5 Clutch shaft K2
6 Way of installation front wheel drive
7 Clutch shaft K3
8 Output flange
9 Clutch shaft K1
10 Clutch shaft K4
11 PTO; coaxial, engine-dependent (Central shaft) PTO
12 Input shaft / clutch shaft Clutch shaft KR
13 Clutch shaft KV

Schematics (Cont’d)
Configuration 4 WG-94 With Front Wheel Drive
13
1
12
2
11
10
3
9
4 8

5
6
7
S45852
1 Converter
2 Flexplate for direct mount
3 Transmission pump
4 Converter bell
5 Clutch shaft K2
6 Front wheel drive
7 Clutch shaft K3
8 Output flange
9 Clutch shaft K1
10 Clutch shaft K4
11 PTO; coaxial, engine-dependent (Central shaft) PTO
12 Input shaft / clutch shaft Clutch shaft KR
13 Clutch shaft KV

Transmission Schematics Gear Schematics
KV
KV
AN/KR PTO
AN/KR
K4
K4
K1 K1
K2/AB

AN/K2
K3
VA
K3
VA
S45853 S45854
AN/KR Input / KV clutch Directional clutch

KV KV clutch Directional clutch
K1 K1 clutch Gear clutch
K2/AB K2 clutch / output Gear clutch
K3 K3 clutch Gear clutch
K4 K4 clutch Directional clutch
VA Front wheel drive
PTO Power take-off; coaxial, engine-dependent

S45855

S45856

Measuring Points For Pressure Oil And Temperature

S45857
S45858

Measuring Points For Pressure Oil And Temperature (Cont’d)

S45859
51 Before the converter – opening pressure 11+2 bar (159 + 29 psi) M10x1
53 Clutch - Forward KV 16+3 bar (232 + 44 psi) M10x1
55 Clutch - Reverse KR 16+3 bar (232 + 44 psi) M10x1
56 Clutch K1 16+3 bar (232 + 44 psi) M10x1
63 Temperature after the converter 100° C; short-term 120° C M14x1,5
67 System pressure 16+3 bar (232 + 44 psi) M10x1
68 Parking brake PB 16+3 bar (232 + 44 psi) 9/16“ - 18 UNF
69 Differential lock DL 16+3 bar (232 + 44 psi) 3/4“ - 18 UNF
70 Front wheel drive WD 16+3 bar (232 + 44 psi) M10x1
13 Connection Parking brake (rear axle) 9/16“ - 18 UNF
14 Connection towards return line into transmissions sump 9/16“ - 18 UNF
15 Connection towards heat exchanger 7/8“ 14 UNF
16 Connection from heat exchanger 7/8“ 14 UNF
35 Inductive transmittern speedometer (Option) M18x1,5
Y1 - Y6 Control Valves
YWD Front wheel drive
YDL Differential lock (rear axle)
YPB Parking brake (rear axle)

Solenoid / Gear Activation
SOLENOID UNDER CURRENT

FORWARD REVERSE NEUTRAL
GEAR 1 2 3 4 1 2 3 N
Y1 X X X X
Y2 X X X
Y5 X X X
Y4 X X X X
Y6 X
Y3 X X X X
ENGAGE KV KV K4 K4 KR KR KR
CLUTCHES K1 K2 K1 K2 K1 K2 K3
KV Forward
Clutch

Input KR
Reverse Clutch
K4 Forward
Clutch
Output / K2
Range Clutch K1 Range
Clutch
K3 Range
Clutch MFWD
Clutch
S47093
GEAR
1 KV + K1
2 KV + K2
3 K4 + K1
4 K4 + K2
1R KR + K1
2R KR + K2
3R KR + K3 (WG94)

Hydraulic Schematic
S47094

TRANSMISSION - B730 AND B750 (CONT’D) Figure 60-30-5
Disassembly
Transmission 4 WG-94
Figure 60-30-3
1 3
2
1
S45862
Loosen hexagon screw (1) and remove cover (2) and

seal (3).
1 1 S45860 NOTE: If an oil filler tube with oil dipstick is installed

instead of the cover (2), these two parts must
be removed.

Attach transmission to the assembly truck by means of
holding fixtures (1) and clamping angles (2). Figure 60-30-6
(S) Assembly truck C77AS34

(S) Holding fixtures C77AT10
(S) CLAMPING ANGLES C77AT11
NOTE: Drain oil prior to starting disassembly.
Figure 60-30-4
S45863
Separate ZF fine filter (1) from the filter head by means of

a belt wrench.
1
(S) Belt wrench C77AT12
S45861
Remove screw plug (1).
WARNING: Disposal of oil according to legal

requirements!
NOTE: Shows the mounting provision for oil filler

tube with oil dipstick (option).

Figure 60-30-7
S45864
Loosen cylindrical screws (2) and separate filter head (1)

from the transmission housing.

Figure 60-30-8
S45865
Remove both O-rings (1) out of the annular groove of the

filter head.

TRANSMISSION - B730 AND B750 (CONT’D) NOTE: Version with inductive sensor (option).
Disassembly (Cont’d) Figure 60-30-10
Solenoid Valves, Inductive Sensor, Screw Plugs And

Nozzles (Orifices)
Figure 60-30-9
2
3
1 4
1
S45867
Loosen inductive sensor (1).
NOTE: Remove O-ring.

Figure 60-30-11
6
7
8
9 S45866
Loosen cylindrical screws, remove bracket and pull

solenoid valves off the holes.
NOTE: Mark solenoid valves (different versions).
1 Y1 (control valve)
S45868
2 YPB (parking brake - rear axle)
3 YDL (differential lock - rear axle)
Pull output flange (1) off the output shaft.
5 Y2 (control valve) NOTE: Remove all screw plugs and nozzles (orifices).
9 YWD (front wheel drive)

Disassembly Of Engine Connection, Main Pressure

Valve And Converter Safety Valve 1 2
Engine Connection
Figure 60-30-12
2
1
S45871
Loosen bolted connection between converter bell-

housing / housing (1) and transmission pump / housing
(2).
3 Figure 60-30-15

S45869
Loosen hexagon screws (1) and separate flexplate (2) 1

from converter (3).
Figure 60-30-13
S45872
Loosen screw plug, measuring point 63“(1).
NOTE: Remove O-ring.
S45870
Pull off converter (1) by hand.

2
Disassembly Of Engine Connection, Main Pressure S
1
Valve And Converter Safety Valve (Cont’d)
Figure 60-30-16
S45875
If required, remove both cylindrical pins (1).
Remove filter (2).
S45873 NOTE: Transmission pump cannot be separated from

the housing until the 4 cylindrical screws of

the housing inner side have been loosened.
Separate converter bell-housing from the mounting face
of the transmission housing by means of slight hits with a WARNING: Fit adjusting screws to ensure
plastic hammer. that the transmission pump is centered at the
housing after the 4 cylindrical screws have
Figure 60-30-17 been
(S) Adjusting screws (M10) C77AT13
S45874
Remove converter bell-housing by means of assembly

lever.
NOTE: Difficult disassembly due to fixing by

cylindrical pins.

Disassembly Of Engine Connection, Main Pressure

Valve And Converter Safety Valve (Cont’d)
1
Main pressure valve and converter safety valve
Figure 60-30-19
1
2
3
4
S45877
5
Functional check of converter safety valve (1). Use a
screwdriver to check the movability of the ball in the
valve.
NOTE: If the valve is okay, it does not need to be

removed.

S45876
NOTE: Valve assembly is installed in the housing -
not visible.
Loosen screw plug (1) and remove main pressure valve
(control pressure valve).
Main pressure valve consists of:
1. Screw plug
2. O-ring
3. Piston
4. Spacer ring
5. Compression spring

TRANSMISSION - B730 AND B750 (CONT’D) Separate housing front part from transmission housing
rear part by means of lifting device (approx. 1 cm).
Use the plastic hammer to reset the output shaft (1) of
Removal Of Clutches, Central Shaft And Disassembly Of the front wheel drive to its initial position, thus separating
Transmission Pump the screen sheet (2) from the shaft of the clutch.
Removal of clutches (S) Eye bolts assortment C77AT14
Figure 60-30-21 Figure 60-30-23

S45878
Force out cylindrical pins (1).
Loosen bolted connection (2) of housing front and rear

part.
Figure 60-30-22
S45880
Remove screen sheet (1) and separate transmission

housing front part by means of lifting device.
S45879

Removal Of Clutches, Central Shaft And Disassembly Of

Transmission Pump (Cont’d)
Figure 60-30-24
S45883
Slightly lift clutch (K2) and remove clutch (K1).
Figure 60-30-27
S45881

Designation of clutches:
KV Forward clutch (directional clutch)

KR Reverse clutch (directional clutch)
K1 K1 clutch (gear clutch)
K4 K4 clutch (directional clutch)
VA Front wheel drive clutch S45884
Figure 60-30-25
Lift KV and KR clutch off the bearing outer rings jointly
and then remove them one after the other.
S45882
Remove K4 clutch.

1
2
Removal Of Clutches, Central Shaft And Disassembly Of
Transmission Pump (Cont’d)
Figure 60-30-28
S45886
Snap out retaining ring (1) and remove central shaft (2).
Figure 60-30-30

3
S45885 1
Jointly remove VA, K2 and K3 clutch together with screen

sheet (1).
Use the lifting device to jointly lift VA and K3 clutch S45887

together with K2 clutch, and then remove the
components one after the other.
Snap out rectangular ring (1).
(S) Eyebolts C77AT15
Press ball bearing (2) off the central shaft (3).

TRANSMISSION - B730 AND B750 (CONT’D) Remove all bearing outer rings (3) from the housing front
part.
NOTE: If, contrary to the ZF recommendation, the
Removal Of Clutches, Central Shaft And Disassembly Of tapered roller bearings of clutches and input
Transmission Pump (Cont’d) are not replaced, it is imperative to ensure the
previous pairing (bearing outer ring / bearing
Figure 60-30-31 inner ring).
NOTE: Bearing outer ring and bearing inner ring must

2 be marked.
1
S45888

Remove O-rings (1).
Remove all bearing outer rings (2) from the housing rear
part.

tapered roller bearings of clutches are not
replaced, it is imperative to ensure the
previous pairing (bearing outer ring / bearing
inner ring).
NOTE: Bearing outer ring and bearing inner ring must

be marked.
Figure 60-30-32
1
2
S45889
Loosen the cylindrical screws (1) and remove suction

tube (2).

Disassembly Of Transmission Pump

1
2
Figure 60-30-33
S45892
Remove O-ring (1).
Loosen cylindrical screws (2).

S45890
Figure 60-30-36

Loosen cylindrical screws (3 and 4) and remove
transmission pump.
WARNING: Pay attention so that the 1

transmission pump does not drop!
2
Figure 60-30-34
3
4
S45893
1
Check transmission pump:
1. Stator hollow shaft

2. Inner rotor
3. Outer rotor
4. Pump housing
S45891
NOTE: In case of wear marks in the pump housing,
stator hollow shaft or on the inner and outer
Remove transmission pump (1). rotor, the complete transmission pump must
be replaced.

Disassembly Of Transmission Pump (Cont’d)
Figure 60-30-37
S45894

Remove shaft seal ring (1) from the pump housing (2).

1
Disassembly Clutches - KR Clutch / Input 2
Figure 60-30-38
S45897
Remove bearing inner ring (1), axial bearing assembly

(2) and inner disc carrier (3).
S45895 Figure 60-30-41

Figure 60-30-39
S45898
1
Remove needle cage (1).
S45896
Pull off bearing inner ring with inner disc carrier (1).

Disassembly Clutches - KR Clutch / Input (Cont’d)
Figure 60-30-42
1 3
2 1
S45901
Remove end plate (1), disc package (2) and plate

assembly with cup springs (3) from the disc carrier.
S45899 Figure 60-30-45

Remove axial bearing assembly (1). 1
Figure 60-30-43
S45902
Remove retaining ring (1) at axial bearing contact.
S45900
Remove snap ring (1).


1
Figure 60-30-46
S45905
By means of compressed air (see arrow), press piston (1)

off the shaft / disc carrier and remove it.
S45903 Figure 60-30-49

Preload compression spring and remove snap ring (1). 1
(S) Assembly aid C77AT16
Figure 60-30-47
2
1
2
S45906
Remove both O-rings (1 and 2).
S45904
Remove spring cup (1) and compression spring (2).

1A
Figure 60-30-50 1B
1C 1
1
1D
S45909
NOTE: The input shaft (1) cannot be disassembled. It

is supplied by the spare parts service only as
a complete assembly which consists of:
S45907
1A - Ball
1B - Helical gear

Snap out rectangular rings (1). 1C - Disc carrier
1D - Input shaft
Figure 60-30-51
S45908
Pull tapered roller bearing (inner ring) off the shaft.
(S) Grab sleeve C77AT17

(S) Basic tool C77AS51

1
Disassembly Clutches - KV Clutch 2
Figure 60-30-53
3
1
S45912

S45910 Figure 60-30-56

Snap out rectangular ring (1). 1
Figure 60-30-54
1
S45913
S45911

Disassembly Clutches - KV Clutch (Cont’d)
Figure 60-30-57
1 3
2
1
S45916

S45914 Figure 60-30-60

Figure 60-30-58
S45917
S45915

1
Figure 60-30-61
S45920

S45918 Figure 60-30-64

Preload compression spring and remove snap ring (1).
1
Figure 60-30-62
2
1
S45921
S45919

Disassembly (Cont’d) 1A
1B
Figure 60-30-65
1C
1
1
1D
1E
S45924
NOTE: The clutch (1) cannot be disassembled. It is

supplied by the spare parts service only as a
complete assembly which consists of:
S45922
1A - Retaining ring
1B - Helical gear

Snap out rectangular ring (1). 1C - Helical gear
1D - Disc carrier
Figure 60-30-66 1E - Shaft
S45923

(S) Basic tool C77AT19

Disassembly Clutches - K1 Clutch 1

2
Figure 60-30-68
S45927
1
S45925 Figure 60-30-71

1
Figure 60-30-69
S45928
1
S45926

Disassembly Clutches - K1 Clutch (Cont’d)
Figure 60-30-72
1
3
2
1
S45931
Remove end plate (1), disc package (2) and cup springs
(3) from the disc carrier.
S45929 Figure 60-30-75

Remove axial bearing assembly (1).
Figure 60-30-73
S45932
S45930

1
Figure 60-30-76
S45935

S45933 Figure 60-30-79

1
2
Figure 60-30-77
S45936
S45934


1A
Figure 60-30-80
1
1 1B
1C
S45939
NOTE: The clutch (1) cannot be disassembled! It is

S45937
1A - Helical gear
1B - Disc carrier

Snap out rectangular ring (1). 1C - Shaft
Figure 60-30-81
S45938


1
Disassembly Clutches - K2 Clutch 2
Figure 60-30-83
3
S45942

S45940 Figure 60-30-86

Snap out rectangular ring (1). 2 1
Figure 60-30-84
1 S45943
Remove needle cage (1) and bushing (2).
S45941

Figure 60-30-87
2
1
S45946
S45944 Figure 60-30-90

Figure 60-30-88
S45947
S45945

1
Figure 60-30-91
S45950

S45948 Figure 60-30-94

Preload cup springs and remove snap ring (1).
(S) Assembly aid C77AT16 1

Figure 60-30-92
2
1
2
S45951
S45949
Remove axial washer (1) and cup springs (2).

1A
Figure 60-30-95
1B
1 1
1C
1D
S45954
NOTE: The clutch (1) cannot be disassembled! It is

S45952
1A - Ball
1B - Helical gear

Snap out rectangular rings (1). 1C - Shaft
1D - Disc carrier
Figure 60-30-96
S45953


Disassembly (Cont’d) 1
Disassembly Clutches - K3 Clutch
2
Figure 60-30-98
3
1
S45957

S45955 Figure 60-30-101

2 1
Figure 60-30-99
1 S45958
Remove needle cage (1) and bushing (2).
S45956

Figure 60-30-102
1 3
2
1
S45961
S45959 Figure 60-30-105

Figure 60-30-103
1
1
S45962
S45960 (S) Assembly aid C77AT16

Disassembly Clutches - K3 Clutch (Cont’d) 1

Figure 60-30-106
1 2
S45965
Figure 60-30-109
S45963

Figure 60-30-107
S45966
S45964


Figure 60-30-110
S45967


Figure 60-30-111
1A
1
1B
1C
S45968

1B - Shaft
1C - Disc carrier

Disassembly (Cont’d) 1
Disassembly Clutches - K4 Clutch
2
Figure 60-30-112
3
1
S45971

S45969 Figure 60-30-115

Snap out rectangular ring (1). 1
Figure 60-30-113
1
S45972
S45970

Figure 60-30-116
1
3
2
1
S45975

S45973 Figure 60-30-119

Figure 60-30-117
S45976
S45974

1
Figure 60-30-120
1
S45979

S45977 Figure 60-30-123

1
Figure 60-30-121
2
1
S45980
S45978

Disassembly Clutches - K4 Clutch (Cont’d) 1A
Figure 60-30-124 1B
1 1
1C
1D
S45983

S45981
1A - Retaining ring
1B - Helical gear

Snap out rectangular ring (1). 1C - Disc carrier
1D - Shaft
Figure 60-30-125
S45982


1
Disassembly Clutches - Front Wheel Drive (VA)
Figure 60-30-127
S45986
Remove running disc (1).
Figure 60-30-130
S45984

Figure 60-30-128 1
S45987
Pull off inner disc carrier (1).
S45985


Disassembly Clutches - Front Wheel Drive (VA) (Cont’d)
Figure 60-30-131
1
S45990
Preload cup springs and remove snap ring (1).

S45988
Figure 60-30-134

1
Figure 60-30-132
2
S45991
2
Remove washer (1) and cup springs (2).

1 S45989
Remove end plate (1) and disc package (2) from the disc
carrier.

Disassembly Clutches - Front Wheel Drive (VA) (Cont’d)

1A
Figure 60-30-135
1
1
1B
S45994

S45992
1A=Shaft
1B=Disc carrier

Figure 60-30-136
S45993


Reassembly
2
Assembly Of Clutches - KR Clutch / Input 1
Figure 60-30-138
1A
1B
1C
1
S45997
1D Mount bearing inner ring (1) until contact is obtained.
Mount bearing inner ring (1) until contact is obtained.

S45995
WARNING: Wear protective gloves.


NOTE: The input shaft (1) is supplied by the spare
parts service only as a complete assembly
which consists of: NOTE: Adjust bearing inner ring after cooling-down.
1A - Ball Figure 60-30-141

1C - Disc carrier
1D - Input shaft
1
Figure 60-30-139
S45998
Insert both O-rings (1 and 2) into the piston grooves and

oil them.
S45996
1. 40x3
Heat up bearing inner ring (approx. 120°C). 2. 104.5x3

Reassembly (Cont’d) 2
1
Assembly Of Clutches - KR Clutch / Input (Cont’d)
Figure 60-30-142
S46001
Mount compression spring (1) and spring cup (2).
Figure 60-30-145
S45999

Insert piston (1) into the disc carrier.
NOTE: Pay attention to the installation position, see 1

[Figure 60-30-142].
Figure 60-30-143
S46002
By means of the assembly aid, preload compression

spring under a hand-operated press until the retaining
ring 40x1.75 (1) can be snapped in.
S46000
Use a hand-operated press to place piston into the disc

carrier by means of the assembly aid.

Figure 60-30-146
1 2
1
3
S46005
Install outer and inner discs alternately into the disc

carrier (3) as shown in Figure 11, starting with an outer
disc and ending with an inner disc.
S46003
Legend:

Mount plate assembly with cup springs (1), with the open 1. Outer discs (10 pcs)
side showing towards the piston.
2. Inner discs (10 pcs)
NOTE: Installation position of plate see also Figure
10. 3. Input shaft assembly
Figure 60-30-147 Figure 60-30-149
2 1 2
3 1
S46004 S46006
Fit plate (1) according to sketch (see arrow). Mount end plate (1) with the flat side showing towards the
disc package and fix it by means of snap ring (2) (e.g.
Legend: thickness = 2,5 mm / recommended value).
1. Plate assembly with cup springs NOTE: Pay attention to the installation position of the
end plate.
2. Compression spring with spring cup and retaining ring
3. Piston with O-rings
4. Input shaft assembly

Figure 60-30-150
1
S46009
Snap retaining ring 40x1.75 (1) into the groove.
NOTE: Contact for axial bearing see [Figure 60-30-

S46007 153].
Figure 60-30-153

Equally press on end plate with F (approx. 18 N to 20 N =
1,8 kg to 2,0 kg) and set dial indicator to “zero”. 3
2
Figure 60-30-151 1
S46010
Mount running disc 40x60x3.5 (1), axial needle cage

S46008 40x60x3 (2) and axial washer 40x60x1 (3) and oil them.
NOTE: Mount running disc (1), with the chamfer

Then press end plate against the snap ring (upwards) showing towards the retaining ring.
and read the disc clearance.
NOTE: Disc clearance: 2,0 - 2,3 mm.
NOTE: In case of deviations, the disc clearance must

be corrected with an appropriate snap ring
(optional thickness = 2,0 - 3,5 mm / available in
steps of 0,25 mm).

2
1
Figure 60-30-154
S46013
Mount axial washer 40x60x1 (1), axial needle cage

40x60x3 (2) and running disc (3) 40x60x3.5 and oil them.
S46011 NOTE: Mount running disc (3), with the chamfer

showing towards the tapered roller bearing.

Mount needle cage 40x45x17 (1) and oil it. Figure 60-30-157
Figure 60-30-155
L R
1
S46014
S46012
Heat up bearing inner ring (approx. 120°C).
Mount inner disc carrier until contact is obtained.
Install inner discs by short ccw/cw rotations of the inner

disc carrier (1).

Figure 60-30-158
2 1
S46015

Fit rectangular ring 30x2 (2).
NOTE: Adjust bearing inner ring after cooling-down.
Figure 60-30-159
S46016
NOTE: Check closing and opening of the clutch by

means of compressed air at the hole (see
arrow).
Closing and opening of the clutch must be clearly

audible.

2 1
Assembly Of Clutches - KV Clutch
Figure 60-30-160
1A
1B
1C 1
S46019
1D
1E Fit rectangular ring 30x2 (2).

S46017

NOTE: The clutch (1) is supplied by the spare parts
service only as a complete assembly which NOTE: Adjust bearing inner ring after cooling-down.
consists of:
Figure 60-30-163
1C - Helical gear
1D - Disc carrier
1E - Input shaft 2
Figure 60-30-161
1
S46020

oil them.
1. 40x3
S46018
2. 104.5x3

2
Assembly Of Clutches - KV Clutch (Cont’d) 1
Figure 60-30-164
S46023
Figure 60-30-167
S46021

NOTE: Pay attention to the installation position, see

[Figure 60-30-164].
1
Figure 60-30-165
S46024

ring 40x1,75 (1) can be snapped in.
S46022


Assembly Of Clutches - KV Clutch (Cont’d)
Figure 60-30-168
2
1
1
3
S46027

carrier (3) as shown in [Figure 60-30-170], starting with
an outer disc and ending with an inner disc.
S46025
Legend:

NOTE: Installation position of plate see [Figure 60-
30-169]. 3. Clutch assembly
Figure 60-30-169 Figure 60-30-171
2 1 2
1
3
S46026 S46028
disc package and fix it by means of snap ring (2) (e.g.
Legend: thickness = 2,5 mm / recommended value).
end plate.

Figure 60-30-172 1
S46031

S46029 175].
Figure 60-30-175

Equally press on end plate with F (approx.18 N to 20 N =
Figure 60-30-173 2
1
S46032



steps of 0,25 mm).

Assembly Of Clutches - KV Clutch (Cont’d) 2
Figure 60-30-176 1
S46035



Figure 60-30-177
L R
1
S46036
S46034

disc carrier (1).

Figure 60-30-180
2
1
S46037

Figure 60-30-181
S46038

arrow).

audible.

2
Assembly Of Clutches - K1 Clutch 1
Figure 60-30-182
1A
1
S46041
1B

1C Fit rectangular ring 30x2 (2).
S46039

consists of:
Figure 60-30-185
1C - Shaft
Figure 60-30-183 2
S46042

oil them.
S46040
1. 40x3

2
Assembly Of Clutches - K1 Clutch (Cont’d)
1
Figure 60-30-186
S46045
Figure 60-30-189
S46043


[Figure 60-30-186].
Figure 60-30-187 1
S46046

S46044


TRANSMISSION - B730 AND B750 (CONT’D) 4. Clutch assembly
Reassembly (Cont’d) Figure 60-30-192
Figure 60-30-190
1
2
3 1
S46049

S46047 carrier (3) [Figure 60-30-192], starting with an outer disc
and ending with an inner disc.

Mount cup spring 112x75x2.55 (1), with the convex side Legend:
showing towards the piston.
1. Outer discs (10 pcs)
NOTE: Installation position of cup spring see also
[Figure 60-30-191]. 2. Inner discs (10 pcs)
Figure 60-30-191 3. Clutch assembly
Figure 60-30-193
2 1
2
3
S46048
S46050
Install cup spring (1) according to sketch.
Legend: Mount end plate (1) with the flat side showing towards the
disc package and fix it by means of snap ring (2) 
1. Cup spring 112x75x2,55 (convex side towards the (e.g. thickness = 2,5 mm / recommended value).
piston)
NOTE: Pay attention to the installation position of the
2. Compression spring with spring cup and retaining ring end plate.


1
Figure 60-30-194
S46053

S46051 197].
Figure 60-30-197

Figure 60-30-195 2
1
S46054
Mount running disc 40x60x3,5 (1), axial needle cage



(optional thickness = 2,0 - 3,5 mm /available in
steps of 0,25 mm).

Assembly Of Clutches - K1 Clutch (Cont’d) 2
Figure 60-30-198 1
S46057

40x60x3 (2) and running disc (3) 40x60x3,5 and oil them.


Figure 60-30-199
L R
S46058
S46056

disc carrier (1).

Figure 60-30-202
2
1
S46059

Figure 60-30-203
S46060

arrow).

audible.

Assembly Of Clutches - K2 Clutch

2
Figure 60-30-204 1
1A
1B
1C
1
S46063
1D Mount bearing inner ring (1) until contact is obtained.
Fit rectangular ring 50x2,5 (2).

S46061

consists of:
Figure 60-30-207
1A - Ball
1B - Shaft
1C - Helical gear
1D - Disc carrier
2
Figure 60-30-205
S46064

oil them.
S46062 1. 40x3
2. 115x3

1
2
Figure 60-30-208
S46067
Mount cup spring package (1) and axial washer (2).
NOTE: Installation position of cup springs see

S46065 [Figure 60-30-210].
Figure 60-30-211


3 2
[Figure 60-30-208]. 4
Figure 60-30-209
5
S46068
Fit cup springs according to the sketch.
Legend:
S46066
1. Clutch
Use a hand-operated press to place piston into the disc 2. Piston with O-rings
3. Cup springs (7 pcs)
4. Axial washer (40x60x1)
5. Retaining ring (40x1.75)

Reassembly (Cont’d) 2 1

3
Figure 60-30-212
S46071
Install cup spring (1) according to sketch.
Legend:
1. Cup spring 122.7x87x2.55 (convex side showing

towards the piston)
S46069

By means of the assembly aid, preload cup springs under
a hand-operated press until the retaining ring 40x1.75 (1) 3. Piston with O-rings
can be snapped in.
4. Clutch assembly
Figure 60-30-215
Figure 60-30-213
2
1
S46072
S46070

Mount cup spring 122.7x87x2.55 (1), with the convex carrier (3) as shown in [Figure 60-30-215], starting with
side showing towards the piston. an outer disc and ending with an inner disc.
NOTE: Installation position of cup spring see also Legend:

[Figure 60-30-214].
3. Clutch assembly

Reassembly (Cont’d) F
Figure 60-30-216
2
1
S46075
Then press end plate against the snap ring (upwards)

S46073 NOTE: Disc clearance: 2,0 - 2,5 mm.

Mount end plate (1) with the flat side showing towards the be corrected with an appropriate snap ring
disc package and fix it by means of snap ring (2)  (optional thickness = 2,0 - 3,5 mm / available in
(e.g. thickness = 2,5 mm / recommended value). steps of 0,25 mm).
NOTE: Pay attention to the installation position of the Figure 60-30-219

end plate.
1
Figure 60-30-217
S46076
S46074 Snap retaining ring 40x1.75 (1) into the groove.
NOTE: Contact for axial bearing - see [Figure 60-30-

Equally press on end plate with F (approx.18 N to 20 N = 219].
1,8 kg to 2,0 kg) and set dial indicator to “zero”.

L R
Figure 60-30-220 1
3
2
1
S46079

S46077 disc carrier (1).
Figure 60-30-223

Mount running disc 40x60x3,5 (1), axial needle cage
40x60x3 (2) and axial washer 40x60x1 (3) and oil them.
3
2
showing towards the retaining ring. 1
Figure 60-30-221
2 1
S46080


S46078 showing towards the tapered roller bearing.
Mount needle cage 40x45x17 (1) and busing (2) and oil
them.

Figure 60-30-224
S46083

arrow).
S46081
audible.

Figure 60-30-225
2 1
S46082

2 1
Figure 60-30-227
1A
2
1
1
1B
S46086
1C Fit rectangular ring 30x2 (2).

S46084

consists of:
Figure 60-30-230
1C - Shaft
Figure 60-30-228 1
S46087

oil them.
S46085
1. 40x3

2
Figure 60-30-231
S46090
Figure 60-30-234
S46088


[Figure 60-30-231].
Figure 60-30-232 1
S46091

S46089


Figure 60-30-235
2
1 1
3
S46094

S46092
Legend:
Mount cup spring 112x75x2.55 (1), with the convex side 1. Outer discs (9 pcs)

showing towards the piston.
[Figure 60-30-236]. 3. Clutch assembly
Figure 60-30-236 Figure 60-30-238
2 1 2
1
3
S46093 S46095
Install cup spring (1) according to sketch. Mount end plate (1) with the flat side showing towards the
Legend: (e.g. thickness = 2,5 mm / recommended value).
1. Cup spring 112x75x2.55 (convex side towards the NOTE: Pay attention to the installation position of the
piston) end plate.
4. Clutch assembly

2
1
Figure 60-30-239
S46098

35x52x2 (2) and axial washer 35x52x1 (3) and oil them.

showing towards the retaining ring.

Equally press on end plate with F (approx. 18 N to 20 N = Figure 60-30-242
Figure 60-30-240
2 1
S46099
S46097 Mount needle cage 35x42x18 (1) and busing (2) and oil
them.


steps of 0,25 mm).

Figure 60-30-243
L R
1
S46102
Figure 60-30-246
S46100
2 1


disc carrier (1).
Figure 60-30-244
3
2
1
S46103
S46101



Figure 60-30-247
S46104

arrow).

audible.

2
1
Figure 60-30-248
1A
1B
S46107
1C
1D Fit rectangular ring 30x2 (2).

S46105

consists of:
Figure 60-30-251
1C - Disc carrier
1D - Shaft
1
Figure 60-30-249
S46108

oil them.
S46106 1. 40x3
2. 104.5x3

1
Figure 60-30-252
S46111
Figure 60-30-255
S46109


[Figure 60-30-252]. 1
Figure 60-30-253
S46112

S46110


Figure 60-30-256
2
3 1
1
S46115

S46113
Legend:

[Figure 60-30-257]. 3. Clutch assembly
Figure 60-30-257 Figure 60-30-259
2 1
2
1
3
S46114 S46116
Legend: (e.g. thickness = 2,5 mm / recommended value).
end plate.
4. Clutch assembly


1
Figure 60-30-260
S46119
NOTE: Contact for axial bearing - see [Figure 60-30-

S46117 262].
Figure 60-30-263

Figure 60-30-261 2
1
S46120



steps of 0,25 mm).


1
Figure 60-30-264
1
S46123



Figure 60-30-265
L R
S46124
S46122

disc carrier (1).

Figure 60-30-268
2
1
S46125

Figure 60-30-269
S46126

arrow).

audible.

Assembly Of Clutches - Front Wheel Drive (VA)
Figure 60-30-270
1A
1
S46129
1B

S46127

service only as a complete assembly which Figure 60-30-273
consists of:
1A - Shaft
1B - Disc carrier
1
Figure 60-30-271
S46130
NOTE: Oil both sealing lips.

S46128
[Figure 60-30-273].

3 4
Assembly Of Clutches - Front Wheel Drive (VA) (Cont’d) 2
Figure 60-30-274
5
S46133
Fit cup springs according to sketch.
Legend:
1. Clutch
S46131 2. Piston
3. Cup springs (7 pcs)

4. Washer
5. Retaining ring (50x2)
Figure 60-30-275
Figure 60-30-277
S46132
S46134
Mount cup spring package (1) and washer (2).

By means of the assembly aid, preload cup springs under
NOTE: Installation position of cup springs see a hand-operated press until the retaining ring 50x2 (1)
[Figure 60-30-276]. can be snapped in.

TRANSMISSION - B730 AND B750 (CONT’D) NOTE: Pay attention to the installation position of the
end plate.
Figure 60-30-280
Assembly Of Clutches - Front Wheel Drive (VA) (Cont’d)
Figure 60-30-278
F
2
1
3
S46137
S46135 Equally press on end plate with F (approx. 18 N to 20 N =


Install outer and inner discs alternately into the disc Figure 60-30-281
an outer disc and ending with an inner disc. F
Legend:
3. Clutch assembly
Figure 60-30-279
2
S46138
1

steps of 0,25 mm).
S46136
Mount end plate (1) with the flat side showing towards the
(e.g. thickness = 2,5 mm / recommended value).

Figure 60-30-282
L R
1
S46141
Figure 60-30-285
S46139

Mount inner disc carrier until contact is obtained. 1

disc carrier (1).
Figure 60-30-283
1
S46142
S46140
Mount running disc 40x60x3,5 (1).

Figure 60-30-286
S46143

arrow).

audible.

S
Reinstallation and reassembly of transmission pump, oil
suction tube and oil filler tube, control pressure and
converter safety valve, coarse filter and clutches
Reassembly Of Transmission Pump 1
Figure 60-30-287
2
1
S46145
2
With the sealing lip showing downwards, carefully insert
the shaft seal 55x75x8 (1) into the pump housing (2) until
3 contact is obtained.
NOTE: Fill space between sealing lip and dust lip

4 with grease.

S46144 NOTE: Outer diameter:
If rubber-coated: wet with spirit.
If made of metal: apply sealing agent Loctite®
NOTE: In case of wear marks in the pump housing, #574.
stator hollow shaft, inner rotor, outer rotor
and on the sliding bearing, the pump Figure 60-30-289
assembly must be replaced.
Legend:
1. Stator hollow shaft

2
2. Inner rotor
1
3. Outer rotor
4. Pump housing with sliding bearing
S46146
Fit outer rotor (1) and inner rotor (2).
NOTE: The driver pins of the inner rotor (see arrows)

are to be fitted in upward direction.

TRANSMISSION - B730 AND B750 (CONT’D) Oil suction tube and oil filler tube
Reassembly Of Transmission Pump (Cont’d)
Figure 60-30-290
1
2
1
S46149
Mount O-ring 30x3 (1) onto the suction tube (2) and
S46147 grease it.
Figure 60-30-293

Fit stator hollow shaft (1).
Figure 60-30-291
1 2
2
S46150
S46148 Fix suction tube (1) with cylindrical screws M8x16 (2).
Tightening torque M8 - 8,8x16 MA = 23 N•m

Fix stator hollow shaft radially with two cylindrical screws
(1).
NOTE: Do not tighten the cylindrical screws – just

turn them in until contact is obtained and then
turn them back by approx. ½ rotation.
Place O-ring (2) 135x3 into the annular groove and

grease it.

TRANSMISSION - B730 AND B750 (CONT’D) Reinstallation Of Converter Safety Valve
Reassembly Of Transmission Pump (Cont’d)
Figure 60-30-294 S
2
S46153
1
Insert valve (1) with drift (S) into the housing until contact
S46151 is obtained.
(S) Drift C77AT24

Insert tube (1) into the transmission housing by means of
driver tool (S).
(S) Driver too C77AT23
NOTE: Use the driver tool to obtain the correct offset.
NOTE: Apply Loctite® (type #574) onto the surface

(2).
Coarse Filter
Figure 60-30-295
S46152
Insert filter (1).

Reassembly Of Main Pressure Valve (Control Pressure

Valve)
Figure 60-30-297
3 1
S46154

Insert main pressure valve (1).
Main pressure valve consists of:

2 - Piston
3 - Spacer ring (2 pcs) recommended value 5 mm
4 - Compression spring
NOTE: The main pressure 16 + 3 bar is determined by

means of the spacer rings.
NOTE: Gradation of available spacer rings see spare

parts list.
Figure 60-30-298
S46155
Fit screw plug M22x1,5 (1) with O-ring 19x2.

1
Reinstallation Of Transmission Pump
2
Figure 60-30-299
S
1 S46158
Fix converter bellhousing (1) with cylindrical screws

M10x30 (2).
S46156 Tightening torque (M10 - 8,8x30) MA = 46 N•m
Figure 60-30-302

Fit two adjusting screws (S) and position converter
bellhousing (1) equally until contact is obtained.
NOTE: Pay attention to the hole pattern.

1
NOTE: Wet mounting face with Loctite® (type #574). S
Figure 60-30-300
1
S46159
Fit two adjusting screws (S) and mount preassembled

pump (1).
NOTE: Pay attention to the hole pattern.
S46157
Force the cylindrical pins 12x24 (1) into the holes (blind
holes) until contact is obtained.

Reinstallation Of Transmission Pump (Cont’d)
Figure 60-30-303
S46160

Position transmission pump with 3 cylindrical screws (1)
M8x60 (3x120° offset position) equally until contact is
obtained.
ATTENTION: Do not damage (shear off) the O-ring.
Fix transmission pump with cylindrical screws M8x60 (1).
Tightening torque (M8 - 8,8x60) MA = 23 N•m
Figure 60-30-304
1
2
S46161
Fix pump with cylindrical screws (1 and 2).

1 - M 8x16
2 - M 8x35
Tightening torque M 8 - 8,8x16 MA = 23 N•m
Tightening torque M 8 - 8,8x35 MA = 23 N•m

Reinstallation Of Clutches
Figure 60-30-305
S46162

Insert all bearing outer rings (1) into the bearing holes of
both housing parts. [Figure 60-30-305] and [Figure 60-
30-306].
NOTE: Place bearing outer rings into the bearing

holes using assembly grease.
Figure 60-30-306
S46163

tapered roller bearings of clutches and input
are not replaced, it is imperative to ensure the
previous pairing (bearing inner ring / bearing
outer ring).

TRANSMISSION - B730 AND B750 (CONT’D) Reinstallation Of K2 And K3 (Version With Front Wheel
Drive)
Figure 60-30-308
Reinstallation Of K2 And K3 (Version Without Front
Wheel Drive)
Figure 60-30-307

S46165
Align and grease rectangular rings 50x2,5 (4) and

rectangular rings 30x2 (6), as well as those of the front
wheel drive.
Hold K3 clutch (5) and front wheel drive (1) by means of

S46164
the lifting device, position K2 clutch (2) and screen sheet
(3) at K3 clutch (5), and then jointly insert the assembly.
Align rectangular rings 50x2,5 (6) and rectangular ring
30x2 (7) and grease them. (S) Eyebolts C77AT15
Hold K3 clutch (3) by means of the lifting device, position NOTE: Bolts (8) of the screen sheet must be fixed into
K2 clutch (2) and screen sheet (1) at K3 clutch (3), and the pilot holes (7).
then jointly insert the assembly.
(S) Eyebolts C77AT15
NOTE: Bolts (4) of the screen sheet must be fixed into

the pilot holes (5).

TRANSMISSION - B730 AND B750 (CONT’D) Reinstallation Of KV And KR
Reinstallation Of K1
Figure 60-30-309
2
1
1
4
2
3
S46167
Align and grease rectangular rings 50x2,5 (4) and

S46166 rectangular ring 30x2 (3).
Jointly position KV clutch (1) and KR clutch (2).

Align and grease rectangular ring 30x2 (2).
Position K1 clutch (1).

TRANSMISSION - B730 AND B750 (CONT’D) Version without front wheel drive:
Reinstallation Of K4 3
2 4 5
Figure 60-30-311 6
1 7
S46169
Place O-rings (5 and 7) into the hole and grease them.

S46168 Align and grease rectangular rings (1, 2, 3, 4 and 6).
1 Rectangular ring 30x2 (KV clutch)

Align and grease rectangular ring 30x2 (1).
2 Rectangular ring 30x2 (K4 clutch)
Position K4 clutch (2). 3 Rectangular ring 35x2 (KR clutch)
5 O-Ring 15x2
7 O-Ring 21.89x2.62

Reinstallation Of K4 (Cont’d)
Version with front wheel drive:
Figure 60-30-313
6 1
3
2 4 5 7
1 8
S46170

Place O-rings (5 and 8) into the hole and grease them.
Align and grease rectangular rings (1, 2, 3, 4 and 7).
S46171
1 Rectangular ring 30x2 (KV clutch)
2 Rectangular ring 30x2 (K4 clutch) Use the lifting device to carefully bring the transmission
3 Rectangular ring 35x2 (KR clutch) housing front part into contact position.
NOTE: Bolts (1) of the screen sheet must be fixed into
5 O-Ring 15x2 the pilot holes.
6 O-Ring 21.89x2.62
7 ---------------------------- (front wheel NOTE: Wet mounting face with Loctite® (type #574).
drives)

Reinstallation Of K4 (Cont’d)
Figure 60-30-315
2 1
2
S46172

Hand-tighten the transmission housings crosswise with
2 cylindrical screws (1).
Fit cylindrical pins 12x24 (2) centrically to the mounting

face.
Figure 60-30-316
3 2
1
S46173
Fix transmission housing front and rear part by means of

cylindrical screws (1 and 2).
Fit bracket (3).
Cylindrical screw (1) M10x30 (14x)

Cylindrical screw (2) M10x50 (10x)

1 2
Reassembly of rear axle output flange and screw plug at
measuring point “63” after the converter, and sealing of
version with and without front wheel drive
5
Reassembly Of Rear Axle Output Flange 3
Figure 60-30-317
S 4
S46175
Installation situation - rear axle output
1. Shaft seal 60x90x8
2. Screen sheet

3. Closing cover
S46174
4. Output flange
Use driver tool (S) to fit the shaft seal 60x90x8 (1) until 5. K2 clutch shaft
contact position, with the sealing lip showing towards the
oil sump see [Figure 60-30-318]. 6. Transmission housing
(S) Driver tool C77AT26 Figure 60-30-319

with grease.
NOTE: Wet rubber-coated outer diameter with spirit.
S46176
Press closing cover (3) into the flange (4) until contact is
obtained see [Figure 60-30-319].
NOTE: Apply Loctite® (type #518) to the closing

cover.
NOTE: Use suitable pressure piece; closing cover

must not be deformed.

TRANSMISSION - B730 AND B750 (CONT’D) Sealing of version with front-wheel-drive
Reassembly Of Rear Axle Output Flange (Cont’d)
Figure 60-30-320 S
2
4
S46179
Use driver tool (S) to fit the shaft seal 40x62x7 (1) until
S46177 contact position, with the sealing lip showing towards the
oil sump [Figure 60-30-323].

Press screen sheet (2) onto the flange (4) until contact is (S) Driver tool C77AT27
obtained [Figure 60-30-320].
NOTE: Use suitable pressure piece; screen sheet with grease.
must not be deformed.
NOTE: Wet rubber-coated outer diameter with spirit.
Figure 60-30-321
S46178
Mount output flange (4) until contact position [Figure 60-

30-321].

TRANSMISSION - B730 AND B750 (CONT’D) Sealing of version without front-wheel-drive
Figure 60-30-323 S
4
2
3
S46182
Use the driver tool (S) to place screen sheet (1) into the
1 S46180 transmission housing (2) until contact is obtained see
[Figure 60-30-326].

Installation situation - sealing of version with front- (S) Driver tool C77AT27
wheel-drive
Figure 60-30-326
1. Shaft seal 40x62x7
2. Screen sheet
2
3. VA clutch shaft
4. Transmission housing
1
Figure 60-30-324
2 S46183
3
Installation situation - sealing of version with front-

wheel-drive
1. Screen sheet
2. Transmission housing
S46181
Use the driver tool (S) to install screen sheet (2) onto the
VA clutch shaft (3) until contact position see [Figure 60-
30-323].

Reassembly of screw plug at measuring point “63”
Figure 60-30-327
S46184

Fit screw plug M14x1.5 (1) with new O-ring 11x2 (2).

Reinstallation Of Nozzles (Orifices), Screw Plugs, 2

Solenoid Valves, Inductive Sensor And Mounting
Provision For Oil Filler Tube
Reinstallation Of Nozzles (Orifices)
Figure 60-30-328
1 3
S46186
Fit nozzles for the gear clutches K1, K2 and K3.

1 1. Nozzle (K1) M10x1 Ø1.4
2. Nozzle (K2) M8 Ø1.7

3. Nozzle (K3) M8 Ø1.4
S46185
Tightening torque M8 MA = 10 N•m
Fit nozzle M10x1 Ø 1.55 (1) for the directional clutches Tightening torque M10x1 MA = 10 N•m
KV, KR and K4.
Tightening torque MA= 10 N•m

TRANSMISSION - B730 AND B750 (CONT’D) Reinstallation Of Solenoid Valves
Reinstallation Of Screw Plugs

3
1
Figure 60-30-330
2 3
2
3 S46188
Insert solenoid valves (1 and 2) into the transmission

S46187 housing and fix them by means of bracket and cylindrical
screw M6x12 (3).

Install all screw plugs with O-rings. 1. Solenoid valve - parking brake - rear axle
1. Screw plug 3/4 -16 UNF; O-ring 16,36x2,21 (2x) 2. Solenoid valve - differential lock – rear axle
2. Screw plug M10x1; O-ring 8x1,5 (36x) Tightening torque M6 - 8,8 MA = 9,5 N•m
3. Screw plug 9/16 -18 UNF; O-ring 11,89x1,98 (3x) Figure 60-30-332
Tightening torque 3/4 -16 UNF MA = 28 N•m

Tightening torque M10x1 MA = 6 N•m 1
Tightening torque 9/16 -18 UNF MA = 15 N•m
2
S46189
Insert solenoid valve Y2 (1) into the transmission housing

and fix it by means of bracket and cylindrical screw
M6x12 (2).
Tightening torque M6 - 8,8 MA = 9,5 N•m

Reinstallation Of Solenoid Valves (Cont’d)
Figure 60-30-333
3 1
2
1
3
2
S46192
Insert solenoid valve Y5 (1) into the transmission housing

and fix it by means of bracket and cylindrical screw M
6x12 (2).
S46190

Insert solenoid valves Y1 (1) and Y3 (2) into the Figure 60-30-336
transmission housing and fix them by means of bracket
and cylindrical screw M6x12 (3).
Figure 60-30-334
2
3
1
3
S46193
Insert solenoid valves Y6 (1) and Y4 (2) into the

1
transmission housing and fix them by means of bracket
and cylindrical screw M 6x12 (3).
2
S46191
Insert solenoid valve YWD (1) into the transmission

housing and fix it by means of bracket and cylindrical
screw M6x12 (2).

TRANSMISSION - B730 AND B750 (CONT’D) Mounting Provision For Oil Filler Tube (Option)
Reinstallation Of Inductive Sensor (Option)
Figure 60-30-337
3
2
1
2 1
S46195
Fix closing cover (2) and seal (3) with hexagon screws
S46194 (1).

Install inductive sensor (1) with O-ring 15x2 (2).

Reassembly Of PTO
Figure 60-30-339
2
3
S46196

Press ball bearing 45x75x16 (1) onto the pump shaft (2)
until contact is obtained.
Fit rectangular ring 50x2.5 (3).
Grease and centrically align rectangular ring.
Figure 60-30-340
S46197
Mount pump shaft (2) until contact is obtained and fix it

by means of retaining ring 75x2.5 (1).

Reassembly Of Engine Connection
Figure 60-30-341
S46200
Tighten hexagon screws (1).

S46198
WARNING: Fix converter axially. Risk of injury.

Mount converter (1) until contact is obtained.
Figure 60-30-342
4
3
S46199
Position 1 washer each / thickness=1,0 mm (4x) (1) onto

the flexplate mounting webs (4x).
Place flexplates (2).
NOTE: Pay attention to the installation position.

Spot-welded reinforcing discs of the flexplate
to be arranged towards the outside - see
arrows.
Mount washer (3) onto the hexagon screw M10x16 (4)

and fix flexplates.

Reassembly Of Filter And Oil Drain Plug
Figure 60-30-344
S46203
NOTE: The ZF filter (1) has to be fitted as follows:

- Slightly oil the seal
- Turn in the filter until contact with the sealing
S46201 surface is obtained, and then tighten it by
hand with approx. 1/3 to 1/2 rotation.

Place O-rings 34.2x3 (1) into the holes and grease them. Figure 60-30-347
Figure 60-30-345
2 2
1
S46204
S46202
Fit oil drain plug 7/8 - 14 UN 2A (1).
Attach filter head (1) with cylindrical screws M8x30 (2). Tightening torque (7/8 - 14 UN 2A) MA = 30 N•m
Tightening torque (M8 - 8,8X30) MA = 23 N•m
Fix identification plate (2) by means of 4 grooved pins
3x5.

Reassembly Of Filter And Oil Drain Plug (Cont’d)
Figure 60-30-348

S46205
Before putting the transmission into operation, fill it

with oil according to Operation Manual.

ENGINE SERVICE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Engine Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Engine Lift Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Viton Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
POWERPART Recommended Consumable Products . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Basic Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Data And Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
Thread Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-20
Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-21
Specific Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-22
Compression Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-25
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1


Atomiser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Rocker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2
Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-4
Valve Tip Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-6
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-11
Valve And Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-14
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-17
Inspection And To Correct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-20
PISTON AND CONNECTING ROD ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Big End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-2
Piston And Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-4
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-7
Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-8
Piston And Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-10
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-11
Partially Finished Small End Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-12
Piston Cooling Jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-13

CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-2
Rear End Oil Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
To Remove And To Fit A Wear Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-11
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-13
Balancer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-17
TIMING CASE AND DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Timing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Mechanical Fuel Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Electronic Fuel Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Idler Gear and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-9
Heavy Duty Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-12
Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-14
Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-15
Timing Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-18
Crankshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-21

Camshaft and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-22
CYLINDER BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

To Set Number 1 Piston To TDC On The Compression Stroke . . . . . . . . . . . . . . . . 70-80-2
To Check The Timing Of The Bosch VP30 Fuel Injection Pump . . . . . . . . . . . . . . . . 70-80-3
To Check The Timing Of The Bosch EPVE Fuel Injection Pump . . . . . . . . . . . . . . . 70-80-4
To Adjust The Timing Of The Bosch EPVE Fuel Injection Pump . . . . . . . . . . . . . . . 70-80-5
To Check The Timing Of The Delphi DP210 Fuel Injection Pump . . . . . . . . . . . . . . 70-80-7
To Check The Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
ASPERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Turbocharger Side Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Turbocharger Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Open Engine Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Natural Aspirated Engine Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Closed Engine Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-10

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Lubrication System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Canister Type Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Element Type Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Dipstick Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-8
Oil Strainer And Suction Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Lubricating Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Cold Start Advance Unit (KSB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-3
Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5
Atomizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-6
Fuel Lift Pump And Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-9
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-11
Bosch VP30 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-12

Bosch EVPE Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-17
Delphi DP210 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Coolant Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-6
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-10
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-10
Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-11
Coolant Bypass Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-13
Oil Cooler / Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-14
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2
Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Starting Aid (Glow Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-7
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-9
Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-11
Voltage Load Protection Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-13
Programming A New ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-14
Speed And Timing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-15
Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-16
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-18
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-20
AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
Adaptor For A Hydraulic Pump Or A Steering Pump . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
Exhauster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-160-1

List Of Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-160-1

REAR HAND THROTTLE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-170-1
Cable Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-170-1
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-180-1

Cable Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-180-3
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-190-1
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-200-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-200-1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-210-1

GENERAL INFORMATION WARNING: This indicates that there is a
possible danger to the person.
Introduction
This Workshop Manual has been written to provide Caution: This indicates that there is a possible danger to
assistance in the service and overhaul of Perkins 1100 the engine.
Series 4 cylinder engines. It should be used in
conjunction with normal workshop practice and NOTE: Is used where the information is important, but
information contained in current service bulletins. there is not a danger.
Mention of certain accepted practices therefore, has
been purposely omitted in order to avoid repetition. For
overhaul procedures the assumption is made that the
engine is removed from application.
The engine conforms with USA (EPA/CARB) stage 2 and

EEC stage 2 emissions legislation for agriculture,
construction and industrial applications.
Most of the general information which is included in the

relevant has not been repeated in this workshop manual
and the two publications should be used together.
Where the information applies only to certain engine

types, this is indicated in the text.

The details of some operations will be different according
to the type of fuel injection pump which is fitted. The
specific pump type used can be found by reference to the
manufacturer’s identification plate on the pump body but,
generally, the type of pump fitted is as shown below:
• Delphi- DP210 Series
• Bosch- VP30
• Bosch- EPVE
When reference is made to the “left” or “right” side of the

engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available and a list of

these is given in Special tools. Reference to the relevant
special tools is also made at the beginning of each
operation.
POWERPART recommended consumable products are

listed under “POWERPART recommended consumable
products”. Reference to the relevant consumable
products is also made at the beginning of each operation.
Data and dimensions are included in Specifications.
Read and remember the “Safety precautions”. They are

given for your protection and must be used at all times.
Danger is indicated in the text by two methods:

GENERAL INFORMATION (CONT’D) Figure 70-10-2
Engine Views
Figure 70-10-1
5
1
2
3
6
4
7
S45017
5. Alternator
S45016
6. Turbocharger
1. Fuel Lift Pump 7. Starter

2. Fuel Filter
3. Water Pump
4. Fuel Pump

Engine Identification
The Perkins 1100 series 4 cylinder engines have been

designed for industrial, construction and agricultural
applications. There are a range of four cylinder engines
with or without electronics, available in naturally
aspirated, turbocharged and air to air charge cooled
models.
In this Workshop Manual, the different models are

indicated by their code letters. The first two letters of the
engine number are indicated below:
RK Naturally aspirated S45018
RF Naturally aspirated, electronic

RG Turbocharged Figure 70-10-4
RH Turbocharged, electronic
RJ Turbocharged, charge cooled
RK Turbocharged, charge cooled, electronic

The Perkins 1100 Series 4 cylinder engines have
been designed for agricultural, industrial and
construction applications.
The correct identification of the engine is by the full

engine number.
The engine number is stamped on a label which is

fastened to the left side (A2) of the cylinder block. An
example of an engine number is: S45462
RE......*U.......*
If a short engine has been fitted in service, two engine
If you need parts, service or information for your engine, serial numbers and a TPL number are stamped on the
you must give the complete engine number to your engine serial number label (B3).
Perkins Dealer / Distributor. If there is a number in the
area of the label marked TPL No, then this number must The engine serial number plate (B) contains the following
also be given to your Perkins Dealer / Distributor. information:
Other identification labels fitted to the engineer include: • TPL number (1).
• A label (A1) with the fuel injection pump part numbers. • Type (2).
• An emissions legislation label (A3), (A6), (A7) and • Serial number (3).
(C1) can be fitted in four different positions on the
engine. • List number (4).
• A “Ether” warning label (A5) is fitted on the intake

manifold.
• A “Caution please read label” (A4) is screen printed

into the atomizer cover.

GENERAL INFORMATION (CONT’D) Safety Precautions
Engine Identification (Cont’d) These safety precautions are important. You must
refer also to the local regulations in the country of use.
Figure 70-10-5
Some items only refer to specific applications.
• Only use these engines in the type of application for

which they have been designed.
• Do not change the specification of the engine.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been split. Material which

has been contaminated by fuel must be move to a
safe place.
• Do not put fuel in the tank while the engine runs

S45463 (unless it is absolutely necessary).
• Do not clean, and lubricating oil, or adjust the engine

while it runs (unless you have had the correct training;
even then extreme care must be used to prevent

injury).
• Do not make adjustments that you do not understand.
• Ensure that the engine does not run in a location

where it can cause a concentration of toxic emissions.
• Other persons must be kept at a safe distance while

the engine or auxiliary equipment is in operation.
• Do not permit loose clothing or long hair near moving

parts.
• Keep away from moving parts during engine

operation.
WARNING: Some moving parts cannot be seen

clearly while the engine runs.
• Do not operate the engine if a safety guard has been

removed.
• Do not remove the filler cap, or any component of the

cooling system while the engine is hot and while the
coolant is under pressure because dangerous hot
coolant can be discharged.
• Do not allow sparks or fire near the batteries

(especially when the batteries are on charge)
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the skin
and especially to the eyes.

GENERAL INFORMATION (CONT’D) • Turbochargers operate at high speed and at high
temperatures. Keep fingers, tools and items away
Safety Precautions (Cont’d) from the inlet and outlet ports of the turbocharger and
prevent contact with the hot surfaces.
• Do not allow sparks or fire near the batteries
(especially when the batteries are on charge) • Do not clean an engine while it runs. If cols cleaning
because the gases from the electrolyte are highly fluids are applied to a hot engine, certain components
flammable. The battery fluid is dangerous to the skin on the engine may be damaged.
and especially to the eyes.
• Fit only genuine Perkins parts.
• Disconnect the battery terminals before a repair is
made to the electrical system.
• Only one person must control the engine.
• Ensure that the engine is operated only from the

control panel or from the operator’s position.
• If your skin comes into contact with high-pressure

fuel, obtain medical assistance immediately.
• Diesel fuel and lubricating oil (especially used

lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a special

solution to protect the skin.
• The combustible material of some components of the

engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this
burnt material to come into contact with the skin or
with the eyes, see “Viton seals” for safety precautions.
• Do not wear clothing which is contaminated by

lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.
• Discard used lubricating oil in a safe place to prevent

contamination.
• Ensure that the control lever of the transmission drive

is in the “out-of-drive” position before the engine is
started.
• Use extreme care if emergency repairs must be made

in adverse conditions.
• Read and use the instructions relevant to “Engine lift

equipment”.
• Always use a safety cage to protect the operator

when a component is to be pressure tested in a
container of water. Fit safety wires to secure the
plugs, which seal the hose connections of a
component which is to be pressure tested.
• Do not allow compressed air to contact your skin. If

compressed air enters your skin, obtain medical help
immediately.

Engine Lift Equipment
The maximum weight of the engine without coolant,

lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment of the
maximum capacity listed below is used:
Four cylinder engines 600 kg (1320 lbs)
NOTE: Use lift equipment or obtain assistance to lift

heavy engine components such as the
cylinder block, cylinder head, balancer unit,
flywheel housing, crankshaft and flywheel.
Before the engine is lifted:
• Always use lift equipment of the approved type and of

the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown in
(A) is used, to provide a vertical lift directly above the
engine lift brackets (A1). Never use a single lift
bracket to raise an engine.

• Check the engine lift brackets for damage and that
they are secure before the engine is lifted. The torque
for the set screws for the engine lift brackets is 44 N•m
(33 lbf-ft) 4,5 kgf m.
S45019
• To prevent damage to the rocker cover, ensure that

there is clearance between the hooks and the rocker
cover.

GENERAL INFORMATION (CONT’D) If theses cautions are ignored, the engine or certain
components could be damaged, fail to operate and also
Viton Seals make the manufacturer’s warranty invalid.
Some seals used in engines, and in components fitted to

engines, are made of Viton. Viton is used by many
manufacturers and is a safe material under normal
conditions of operation.
If Viton is burned, a product of this burnt material is an

acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with
the eyes.
If it is necessary to come into contact with components

which have been burnt, ensure that the precautions
which follow are used:
• Ensure that the components have cooled.
• Use neoprene gloves and discard the gloves safely

after use.
• Wash the area with calcium hydroxide solution and

then with clean water.
• Disposal of components and gloves which are

contaminated must be in accordance with local
regulations.
If there is contamination of the skin or eyes, wash the

affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15 - 60 minutes.
Obtain immediate medical attention.
Safety Cautions When an Engine in Cleaned
Care should be taken, when an engine is cleaned with a

high pressure cleaning system.
Cautions:
• Do not wash an engine while it runs or while it is hot.

If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
• Leave the engine to cool for at least one hour and

disconnect the battery connections before cleaning.
• Do not wash any part of the fuel injection pump (FIP),

cold start device, electrical shut off solenoid (ESOS)
or electrical connectors.
• Ensure that the alternator, starter motor and any other

electrical components are shielded and not directly
cleaned by the high pressure cleaning system.

GENERAL INFORMATION (CONT’D) POWERPART Lay-Up 2
POWERPART Recommended Consumable Products Protect the inside of the engine and of other closed
systems. Part number 162811.
Perkins have made available the products recommended
below in order to assist in the correct operation, service POWERPART Lay-Up 3
and maintenance of your engine and your machine. The
instructions for the use of each product are given on the Protects outside metal parts. Part number 1734115.
outside of each container. These products are available
from your Perkins Dealer / Distributor. POWERPART Metal repair putty
POWERPART Antifreeze Designed for external repair of metal and plastic. Part
number 21820126.
Protect the cooling system against frost and corrosion.
Part number 21825166. POWERPART Pipe sealant and sealant primer
POWERPART Atomizer thread sealant To retain and seal pipe connections with coarse threads.
Pressure systems can be used immediately. Part number
To seal the threads of the atomizer into the cylinder 21820122.
head. Part number 21825474.
POWERPART Radiator stop leak
POWERPART Easy Flush
For the repair of radiator leaks. Part number 21820127.
Cleans the cooling system. Part number 21825166.

POWERPART Red rubber grease
POWERPART Gasket and flange sealant
Providers lubrication for the fitting of O-rings. Part
To seal flat faces of components where no joint is used. number 21820221.
Especially suitable for aluminum components. Part
number 21820518. POWERPART Retainer (high strength)
POWERPART Gasket remover To retain components that have an interference fit. Part
number 21820638.
An aerosol for the removal of sealants and adhesives.
Part number 21820116. POWERPART Retainer (oil tolerant)
POWERPART Graphite To retain components that have an interference fit, but is

in contact with oil. Part number 21820603.
To improve the grip of worn tools and fasteners. Part
number 21820129. POWERPART Safety cleaner
POWERPART Hydraulic thread seal General cleaner in an aerosol container. Part number
21820128.
To retain and seal pipe connections with fine threads.
Especially suitable for hydraulic and pneumatic systems. POWERPART Silicone adhesive
Part number 21820121.
An RTV silicone adhesive for application where low
POWERPART Industrial grade super glue pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and
Instant adhesive designed for metals, plastics and movement of the joint occurs. Part number 21826038.
rubbers. Part number 21820125.
POWERPART Silicone RTV sealing and jointing
POWERPART Lay-Up 1 compound
A diesel fuel additive for protection against corrosion.

Part number 1772204.

GENERAL INFORMATION (CONT’D)
POWERPART Recommended Consumable Products

(Cont’d)
Silicone rubber sealant that prevents leakage through

gaps. Part number 1861108.
POWERPART Stud and bearing lock
To provide a heavy duty seal to components that have a

light interference fit. Part number 21820119 or 21820120.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is

necessary. Part number 21820117 or 21820118.
POWERPART Universal jointing compound
Universal jointing compound that seals joints. Part

number 1861117.


SPECIFICATIONS
Basic Engine Data
Number Of Cylinders
RE,RF,RG,RH,RJ,RK 4
Cylinder arrangement In Line
Cycle Four stroke
Direction of rotation Clockwise from the front
Induction System
RE,RF Naturally aspirated
RG,RH Turbocharged
RJ,RK Turbocharged, charge cooled
Combustion system Direct injection
Normal Bore
RE,RF,RG,RH,RJ,RK 105 mm (4.133 in)
Stroke 105 mm (5.00 in)
Compression Ratio
RE,RF 19.3:1

RG,RH,RJ,RK 18.2:1
Cubic Capacity
RE,RF,RG,RH,RJ,RK 44,4 liters (268 in3)
Firing Order
RE,RF,RG,RH,RJ,RK 1, 3, 4, 2
Valve Tip Clearance (Cold)

Inlet 0,20 mm (0.008 in)
Exhaust 0,45 mm (0.018 in)
Lubrication Oil Pressure(1)

RE,RF,RG,RH,RJ,RK 300 kPa (43 lbf/in2) 3,0 kgf/cm2
(1) Minimum at maximum engine speed and normal engine temperature

SPECIFICATIONS (CONT’D)
Data And Dimensions
NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which
are shown are those which are mainly used in the factory. The information applies to all engines, unless
an engine type code is shown.
Cylinder Head
Angle of Valve Seat

Intake 30° (120° included angle)
Exhaust 30° (120° included angle)
Leak test pressure 200 kPa (29 lbf/in2) 2,04 kgf/cm2
Head thickness 117,95 - 118,05 mm (4.643 - 4.647 in)
RZ and Rmax To Be Measured To DIN EN ISO 4287
Surface finish of head face for cylinder head joint Rz < 15um Rmax < 20um
Permissible Wave Depth

Wt <2,0 mm with a wave distance Wd ≤ 4 um
Diameters of Parent Bore for Valve Guide

Intake 13,000 - 13,027 mm (0.5118 - 0.5129 in)
Exhaust 13,000 - 13,027 mm (0.5118 - 0.5128 in)
Minimum permissible thickness after head face has been 117,20 mm (4.614 in)
machined

Data And Dimensions (Cont’d)
Maximum Permissible Distortion Of Cylinder Head Face
A1 0,03 mm (0.0012 in)

A2 0,05 mm (0.0019 in)
A3 0,05 mm (0.0019 in)
A4 0,03 mm (0.0012 in)

S45020

Intake Valves
Diameter of valve stem 8,953 - 8,975 mm (0.3525 - 0.3533 in)

Clearance in valve guide 0,025 - 0,069 mm (0.001 - 0.0027 in)
Maximum Permissible Clearance in Valve Guide

Production limit 0,069 mm (0.0027 in)
Service limit 0,13 mm (0.005 in)
Diameter of valve head 46,20 - 46,45 mm (1.819 - 1.829 in)
Angle of valve face 30°
Full length 128,92 - 129,37 mm (5.076 - 5.093 in)
Seal arrangement Stem seal with integral seating washer
Depth of Valve Head Below the Face of Cylinder Head

Production limit, RE and RF 0,58 - 0,84 mm (0.023 - 0.033 in)
Service limit, RE and RF 1,09 mm (0.043 in)

Production limit, RG,RH,RJ,RK 1,58 - 1,84 mm (0.062 - 0.072 in)
Service limit, RG,RH,RJ,RK 2,09 mm (0.082 in)
Exhaust Valves
Diameter of valve stem 8,938 - 8,960 mm (0.3519 - 0.3528 in)

Clearance in valve guide 0,040 - 0,84 mm (0.0016 - 0.033 in)
Maximum Permissible Clearance In Valve Guide

Production limit 0,84 mm (0.003 in)
Diameter of valve head 41,51 - 41,75 mm (1.634 - 1.644 in)
Angle of valve face 30°
Full length 128,92 - 129,37 mm (5.075 - 5.093 in)
Seal arrangement Stem seal with integral seating washer
Depth of Valve Head Below the Face of Cylinder Head

Production limit, RE and RF 0,53 - 0,81 mm (0.021 - 0.032 in)
Service limit, RE and RF 1,06 mm (0.042 in)
Production limit, RG,RH,RJ,RK 1,53 - 1,81 mm (0.060 - 0.071 in)
Service limit, RG,RH,RJ,RK 2,06 mm (0.081 in)

Models RE And RF
Intake
A1 9,910 - 10,040 mm (0.3902 - 0.3953 in)
A2 47,820 - 47,845 mm (1.8827 - 1.8837 in)
A3 Radius 0,38 mm (0.015 in) maximum
Exhaust
A1 9,910 - 10,040 mm (0.3901 - 0.3951 in)
A2 42,420 - 42,445 mm (1.6701 - 1.6711 in)
Models RG, RH, RJ And RK
Intake
A1 10,910 - 11,040 mm (0.4295 - 0.4346 in)

A2 47,820 - 47,845 mm (1.8827 - 1.8837 in)
Exhaust
A1 10,910 - 11,040 mm (0.4295 - 0.4346 in)
A2 42,420 - 42,445 mm (1.6701 - 1.6711 in)
S45021

Models RE And RF
Intake
A1 1,5 mm (0.06 in)

A2 20 mm (0.80 in)
A3 6,8 - 7,1 mm (0.267 - 0.279 in)
A4 100 mm (3.94 in)
A5 38,10 - 38,30 mm (1.500 - 1.507 in)
A6 46,25 - 46,50 mm (1.820 - 1.830 in)
A8 Radius 1,5 mm (0.06 in)
A10 8,77 - 8.80 mm (0.345 - 0.346 in)
Exhaust
A1 1,5 mm (0.06 in)

A2 20 mm (0.80 in)
A3 7,2 - 7,5 mm (0.283 - 0.295 in)
A4 100 mm (3.94 in)
A5 34,38 - 34,38 mm (1.353 - 1.361 in)
A6 41,75 - 42,00 mm (1.643 - 1.653 in)
A10 8,77 - 8.80 mm (0.345 - 0.346 in)
S45022

Valve Guides
Inside diameter of partially finished guide 8,250 - 8,350 mm (0.3248 - 0.3287 in)
Inside diameter of finished guide 9,000 - 9,022 mm (0.3543 - 0.3552 in)
Outside Diameter
Intake 13,034 - 13,047 mm (0.5131 - 0.5137 in)
Exhaust 13,034 - 13,047 mm (0.5131 - 0.5137 in)
Interference fit of valve guide in cylinder head 0,007 - 0,047 mm (0.0003 - 0.0019 in)
Full length 51,00 - 51,50 mm (2.008 - 2.028 in)
Protrusion from bottom of recess for valve spring 12,35 - 12,65 mm (0.486 - 0.498 in)
Valve Springs
Fitted Length
Models RE and RF 33,5 mm (1.319 in)

Models RG,RH,RJ and RK 34,5 mm (1.358 in)
Load at Fitted Length

Models RE and RF 254 N (57 lbf) 26,0 kgf
Models RG,RH,RJ and RK 229 N (51 lbf) 23,0 kgf
Number of active coils 3.8
Number of damper coils 0
Direction of coils Right hand
Tappets
Diameter of tappet stem 18,987 - 19,012 mm (0.7480 - 0.7485 in)

Diameter of tappet bore in cylinder block 19,050 - 19,082 mm (0.7500 - 0.7513 in)
Clearance of tappet in cylinder block 19,050 - 19,082 mm (0.7500 - 0.7513 in)
Rocket Shaft
Outside diameter 24,962 - 24,987 mm (0.9828 - 0.9837 in)
Rocker Levers And Bushes
Diameter of parent bore for rocker lever 25,013 - 25,051 mm (0.9848 - 0.9863 in)
Clearance between rocker lever bore and rocker shaft 0,026 - 0,89 mm (0.0010 - 0.0035 in)
Maximum permissible clearance between rocker lever bore 0,17 mm (0.007 in)
and rocker shaft

Pistons
Type “Fastram” combustion bowl, re-entrant angle 80°

(turbocharged), 70° (naturally aspirated)
Diameter of bore for gudgeon pin 39,703 - 39,709 mm (1.5631 - 1.5633 in)
Height of piston above top face of cylinder block 0,21 - 0,35 mm (0.008 - 0.0137 in)
Width of Groove for Top Ring

Engine types RE and RF 2,58 - 2,60 mm (0.1015 - 0.1023 in)
Engine types RG, RH, RJ and RK Tapered
Width of groove for second ring 2,54 - 2,56 mm (0.0999 - 0.1007 in)
Width of groove for third ring 3,52 - 3,54 mm (0.1385 - 0.1393 in)
Piston Cooling Jets
Valve open pressure 150 - 250 kPa (22 - 36 Ibf/in2) 1,5 - 2,5 kgf/cm2

Piston Rings
Top Compression Ring

Engine types RE and RF Barrel face, molybdenum insert, rectangular
Engine types RG, RH, RJ and RK Barrel face, molybdenum insert, keystone
Second compression ring Taper face, cast iron, internal bottom chamfer
Oil scraper ring Two piece coil spring loaded, chromium faced
Width of Top Ring

Engine types RG, RH, RJ and RK Tapered
Width of second ring 2,47 - 2,49 mm (0.097 - 0.098 in)
Width of third ring 3,47 - 3,49 mm (0.1366 - 0.1374 in)
Clearance of Top Ring in Groove

Engine types RG, RH, RJ and RK Wedge
Clearance of second ring in groove 0,05 - 0,09 mm (0.002 - 0.003 in)
Clearance of third ring in groove 0,03 - 0,07 mm (0.0011 - 0.0027 in)
Gap of top ring 0,30 - 0,55 mm (0.0118 - 0.0216 in)
Gap of second ring 0,70 - 0,95 mm (0.0275 - 0.0374 in)
Gap of third ring 0,30 - 0,55 mm (0.0118 - 0.0216 in)

Connecting Rods
Type ‘H’ shape section, wedge shape small end

Location of cap to connecting rod Fracture split
Diameter of parent bore for big end 67,21 - 67,22 mm (2.6460 - 2.6465 in)
Diameter of parent bore for small end 43,01 - 43,03 mm (1.693 - 1.694 in)
Length grades F, G, H, J, K, L
Length between centers (parent bores) 219,05 - 219,10 mm (8.624 - 8.626 in)
Big End Bearings
Type
Naturally aspirated engines 8x Steel back, tin / aluminum bearing material
Turbocharged engines bearing cap 4x Steel back, tin / aluminum bearing material
Turbocharged engines bearing rod 4x Steel back, loaded bronze bearing material
Width 31,55 - 31,88 mm (1.240 - 1.255 in)
Thickness at center of bearings 1,835 - 1,842 mm (0.072 - 0.0725 in)

Bearing clearance 0,030 - 0,081 mm (0.0012 - 0.0032 in)
Available undersize bearings 0,25 mm (-0.010 in); -0,50 mm (-0.020 in); 0,75 mm
(-0.030 in)
Gudgeon Pins
Production
Type Fully floating
Clearance fit in piston boss 0,003 - 0,015 mm (0,0001 - 0,0006 in)
Small End Bushes
Type Steel back, lead bronze

Inside diameter 39,723 - 39,738 mm (1.5638 - 1.5645 in)
Surface finish grade Ra 0,8 micrometer
Clearance between bush in small end and gudgeon pin 0,023 - 0,044 mm (0.0009 - 0.0017 in)

Crankshaft
Diameter of main journals 76,159 - 76,180 mm (2.9984 - 2.9992 in)

Maximum wear and ovality on journals and crank pins 0,04 mm (0.0016 in)
Width of center journal 44,15 - 44,22 mm (1.738 - 1.741 in)
Width of all other journals 39,24 - 39,34 mm (1.545 - 1.549 in)
Diameter of crank pins 63,47 - 63,49 mm (2.499 - 2.500 in)
Width of crank pins 40,35 - 40,42 mm (1.589 - 1.591 in)
Diameter of flange 135,27 - 135,32 mm (5.3257 - 5.3277 in)
Depth of recess for spigot bearing 20,40 - 20,60 mm (0.8031 - 0.8112 in)
Bore of recess for spigot bearing 46,96 - 46,99 mm (1.8488 - 1.8488 in)
Crankshaft end-float 0,05 - 0,38 mm (0.002 - 0.015 in)
Maximum permissible end-float 0,51 mm (0.020 in)
Fillet radii of journals and crank pins 3,68 - 3,96 mm (0.145 - 0.156 in)
Undersize journals and crank pins - 0,25 mm (-0.010 in); -0,51 mm (-0.020 in); 0,76
mm (-0.030 in)
Crankshaft Heat Treatment

Induction hardened Part number 3131D074, 4114A006
Nitrocarburised Part number 3131D072, 4114A005
Crankshaft Overhaul
NOTE: Nitrocarburised crankshafts must be hardened again each time they are machined. These crankshafts
must be Nitrocarburised or, if this process is not available, they can be nitrided for 20 hours. If neither
process is available a new crankshaft, or a “new for old” crankshaft, must be fitted.
NOTE: Check the crankshaft for cracks before and after it is ground. Demagnetize the crankshaft after it has been
checked for cracks.
NOTE: After the crankshaft for cracks before and after it is ground. Demagnetize the crankshaft after it has been
checked for cracks.
NOTE: After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.
NOTE: Surface finish and fillet radii must be maintained and require Ra 0.4 um.

Crankshaft Overhaul (Cont’d)
The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:
Item 0,25 mm 0,51 mm 0,76 mm

(0.010 in) (0.020 in) (0.030 in)
1 75,909 - 75,930 mm (2.9884 - 75,649 - 75,670 mm 75,399 - 75,420 mm
2.9892 in) (2.9784 - 2.9792 in) (2.9684 - 2.9692 in)
2 63,220 - 63,240 mm (2.4889 - 62,960 - 62,982 mm 62,708 - 62,728 mm
2.4896 in) (2.4788 - 2.4796 in) (2.4688 - 2.4696 in)
3 39,47 mm (1.554 in) max. --- ---
4 37,44 mm (1.474 in) max. --- ---
5 44,68 mm (1.759 in) max. --- ---
6 40,55 mm (1.594 in) max. --- ---
7 Do not machine --- ---
8 Do not machine --- ---
9 3,68 - 3,69 mm (0.1448 - 0.1452 --- ---

in)
Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro inches). Surface finish for the seal area
of the crankshaft palm must be 0,4 - 1,1 microns (16 - 43 micro inches).
S45023

Crankshaft Overhaul (Cont’d)
With the crankshaft on mountings at he front and rear journals, the maximum run-out (total indicator reading) at the
journals must not be more than shown below:
Journal Maximum run-out

1 Mounting
2 0,08 mm (0.0031 in)
3 0,15 mm (0.0059 in)
4 0,08 mm (0.0031 in)
5 Mounting
Run-out must not be opposite. The difference in run-out between one journal and the next must not be more than 0,10 mm
(0,004 in).
Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter must not be more than 0,05
mm (0,002 in) total indicator reading.

Main Bearings
Type Steel back with, tin / aluminum bearing material

Bearing Width
All bearings 31,62 - 31,88 mm (1.244 - 1.255 in)
Bearing thickness at center -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); 0,76 mm
(-0.030 in)
Bearing Clearance
All bearings 0,057 - 0,117 mm (0.0022 - 0.0046 in)
Bearing thickness at center 2,083 - 2,089 mm (0.0820 - 0.823 in)
Crankshaft Thrust Washers
Type Steel back bearing material

Position Each side of center main bearing
Thickness
Standard 2,26 - 2,31 mm (0,089 - 0,091 in)
Oversize 2,45 - 2,50 mm (0,096 - 0,098 in)
Balancer Unit
Number of teeth on gear of drive shaft 17

Backlash from gear of drive shaft to idler gear 0,097 - 0,17 mm (0.0038 - 0.0066 in)
Diameter of bore for idler gear 37,197 - 37,212 mm (1.5431 - 1.5437 in)
Diameter of hub of idler gear 37,152 - 37,162 mm (1.4626 - 1.4630 in)
End-float of idler gear 0,12 - 0,27 mm (0.0047 - 0.0106 in)
Number of teeth on idler gear 44

Lubricating Oil Pump On The Balancer
Type Differential rotor, gear driven

Number of Lobes
Inner rotor 4
Outer rotor 4
Clearance of outer rotor to body 0,13 - 0,23 mm (0.005 - 0.009 in)
Clearance of inner rotor to outer rotor 0,05 - 0,20 mm (0.0020 - 0.0079 in)
End Clearance
Inner rotor 0,032 - 0,125 mm (0.0013 - 0.0049 in)
Outer rotor 0,032 - 0,125 mm (0.0013 - 0.0049 in)
Timing Case And Drive Assembly
Camshaft
Diameter of number 1 journal 50,711 - 50,737 mm (1.9965 - 1.9975 in)

Cam Lift
Intake for models RE, RF 7,382 - 7,482 mm (0.2906 - 0.2946 in)
Intake for models RG, RH, RJ, RK 7,031 - 7,13 mm (0.2768 - 0.2807 in)
Exhaust for models RE, RF 7,404 - 7,504 mm (0.2914 - 0.2954 in)
Exhaust for models RG, RH, RJ, RK 7,963 - 8,063 mm (0.3135 - 0.3174 in)
Maximum permissible ovality and wear on journals 0,05 mm (0.21 in)
End-float
Production limits 0,10 - 0,55 mm (0.004 - 0.022 in)
Service limits 0,60 mm (0.023 in)
Width of spigot for thrust washer 5,64 - 5,89 mm (0.222 - 0.232 in)
Camshaft Thrust Washer
Type 360°
Depth of recess in cylinder block for thrust washer 5,54 - 5,64 mm (0.218 - 0.222 in)
Thickness of thrust washer 5,486 - 5,537 mm (0.216 - 0.218 in)
Relationship of thrust washer to front face of cylinder block -0,154/-0,003 mm (-0.0006/-0.0001 in)
Camshaft Gear
Number of teeth 68
Diameter of bore 34,92 - 34,95 mm (1.3750 - 1.3760 in)
Outside diameter of the camshaft hub 34,90 - 34,92 mm (1.3741 - 1.3747 in)

Fuel Pump Gear Electronic Engines
Number of teeth 68
Bore 29,995 - 30,021 mm (1.417 - 1.419 in)
Fuel Pump Gear Mechanical Engines
Number of teeth 68
Bore 36,00 - 36,06 mm (1.1809 - 1.1819 in)
Crankshaft Gear
Number of teeth 34
Diameter of bore 47,625 - 47,650 mm (1.8750 - 1.8760 in)
Diameter of hub for gear on crankshaft 47,625 - 47,645 mm (1.8750 - 1.8758 in)
Transition fit of gear on crankshaft -0,020/+0,020 mm (-0,0008/+0,0008 in)
Idler Gear And Hub

Number of teeth 73
Diameter of bore of gear 57,14 - 57,18 mm (2.2495 - 2.2512 in)
- with roller bearings 72,35 - 72,36 mm (2.8482 - 2.8489 in)
Width of gear and split bush assembly (fitted in position) 30,14 - 30,16 mm (1.186 - 1.187 in)
Inside diameter of flanged bushes (fitted in position) 50,78 - 50,80 mm (1.9999 - 2.000 in)
Outside diameter of hub 50,70 - 50,74 mm (1.9990 - 1.9999 in)
- with needle roller bearings 49,975 - 49,988 mm (1.967 - 1.968 in)
Clearance of bushes on hub 0,04 - 0,1 mm (0.0016 - 0.0039 in)
Timing Gear Backlash Values
Production limits 0,10 - 0,20 mm (0.004 - 0.008 in)

with needle roller bearings 0,10 - 0,75 mm (0.0039 - 0.295 in)
Oil pump gear (with oil pump idler) 0,046 - 0,106 mm (0.0018 - 0.0041 in)
Oil pump idler gear (with crankshaft gear) 0,094 - 0,160 mm (0.0037 - 0.0063 in)
Crankshaft gear (with idler gear) 0,064 - 0,124 mm (0.0025 - 0.0049 in)
Camshaft gear (with idler gear) 0,052 - 0,107 mm (0.0020 - 0.0042 in)
Power take off LHS (PTO) gear (with idler gear) 0,112 - 0,172 mm (0.0044 - 0.0068 in)
Fuel injection pump gear (with idler gear) 0,054 - 0,109 mm (0.0021 - 0.0043 in)
Coolant pump gear (with fuel injection pump gear) 0,073 - 0,133 mm (0.0028 - 0.0052 in)

Cylinder Block Assembly
Cylinder block
Height between top and bottom faces 441,073 - 441,374 mm (17.3657 - 17.3769 in)
Diameter of cylinder bore 105,000 - 105,025 mm (4.1338 - 4.1348 in)
Diameter of first oversize cylinder bore 105,500 - 105,525 mm (4.1535 - 4.1545 in)
Diameter of second oversize cylinder bore 106,000 - 106,025 mm (4.1732 - 4.1742 in)
Maximum permissible cylinder bore wear 0,15 mm (0.0059 in)
Diameter of parent bore for main bearing 80,416 - 80,442 mm (3.1660 - 3.1670 in)
Camshaft Bore Diameter
Number 1 (for bush) 55,563 - 55,593 mm (2.188 - 2.189 in)

Number 2 50,546 - 50,597 mm (1.990 - 1.992 in)
Number 3 50,038 - 50,089 4mm (1.969 - 1.972 in)
Turbocharger

The make and type and part number of turbocharger fitted is marked on the turbocharger identification plate. that is fitted
to the turbocharger body.
As a general guide, the make and type of turbocharger fitted is: Garrett GT25.
Waste-gate test pressure for rod movement of 1.00 mm (0.039 in)
Turbocharger Waste-gate pressure

part number (kPa) (Ibf/in²) (kgf/cm²)
(+/- 5) (+/- 0.72) (+/- 0.05)
2674A200 100 14.5 1,01
2674A201 110 15.9 1,12
2674A202 128 18.5 1,30
2674A209 100 100 1,01
2674A211 128 18.5 1,30
2674A215 128 18.5 1,30
2674A223 136 19.7 1,38
2674A224 136 19.7 1,30
2674A225 136 19.7 1,38
2674A226 100 14.5 1,01
2674A227 128 18.5 1,30

Lubrication System
Canister Type Oil Filter

Type Full flow, screw-on type canister
Pressure to open bypass valve in filter 80 - 120 kPa (16 - 24 Ibf/in2)
Element Type Oil Filter

Type Full flow, replaceable element
Pressure to open bypass valve in filter 130 - 170 kPa (26 - 12 Ibf/in2)
Lubricating Oil Pump
Type Differential rotor, gear driven

Number of Lobes
Inner rotor 5
Outer rotor 6
Clearance of outer rotor to body 0,152 - 0,330 mm (0.0059 - 0.0129 in)

End Clearance
Inner rotor 0,038 - 0,089 mm (0.0014 - 0.0035 in)
Outer rotor 0,025 - 0,076 mm (0.0010 - 0.0029 in)
Idler Gear For Lubricating Oil Pump
End float 0,050 - 0,275 mm (0.0019 - 0.0108 in)

Inside diameter of bush (fitted) 16,012 - 16,038 mm (0.6303 - 0.6314 in)
Outside diameter of idler shaft 15,966 - 15,984 mm (0.6285 - 0.6292 in)
Clearance of bush of idler gear on shaft 0,028 - 0,072 mm (0.0011 - 0.0028 in)
Oil Pressure Relief Valve Oil Pump
Diameter of bore for plunger 19,250 - 19,300 mm (0.7578 - 0.7598 in)

Outside diameter of plunger 19,186 - 19,211 mm (0.75553 - 0.7563 in)
Clearance of plunger in bore 0,039 - 0,114 mm (0.0015 - 0.0044 in)
Length of spring (fitted) 59,8 mm (2.3543 in)
Load on spring (fitted) turbocharged with lubricating oil cooler 121 N (27.1 Ibf) 12,0 kgf
Load on spring (fitted) naturally aspirated without lubricating oil 90,9 N (20.1 Ibf) 9.2 kgf
cooler

Oil Pressure Relief Valve (Balancer)
Diameter of bore for 14,52 - 14,54 mm (0.5716 - 0.5724 in)

Outside diameter of plunger 14,46 - 14,48 mm (0.5692 - 0.5700 in)
Clearance of plunger in bore 0,04 - 0,08 mm (0.0015 - 0.0031 in)
Length of spring (fitted) 45 mm (1.77 in)
Load on spring (fitted) Turbocharged 77 - 84 N (17.3 - 18.9Ibf) 7,8 - 8,5 kgf
Load on spring (fitted) Naturally aspirated oil cooled 70 - 77 N (15.7 - 17.3 Ibf) 7,1 - 7,8 kgf
Load on spring (fitted) Naturally aspirated non oil cooled 59 - 65 N (13.3 - 14.6Ibf) 6,0 - 6,6 kg
Cooling System
Coolant Pump
Type Centrifugal gear driven
Outside diameter of shaft 21,425 - 21,438 mm (0.8435 - 0.8440 in)
Diameter of bore of drive gear 21,375 - 21,400 mm (0.8415 - 0.8425 in)
Interference fit of drive gear on shaft 0,025 - 0,063 mm (0.0009 - 0.0024 in)
Diameter of bore of impeller 11,943 - 11,971 mm (0.4701 - 0.4712 in)

Outside diameter of shaft for impeller 11,997 - 12,008 mm (0.4723 - 0.4727 in)
Interference fit of impeller on shaft 0,026 - 0,065 mm (0.0010 - 0.0025 in)
Diameter of bore for bearing 39,989 - 40,014 mm (1.5743 - 1.5753 in)
Diameter of bearing 39,989 - 40,000 mm (1.5743 - 1.5747 in)
Interference fit of bearing in pump body (transition fit) +0,025/-0,011 mm (0.0009/-0.0005 in)
Dimension of impeller boss to front face of pump body (fitted) 7,030 - 7,33 mm (0.276 - 0.288 in)
Dimension of gear from rear flat face of pump body (fitted) 31,60 - 32,10 mm (1.244 - 1.263 in)
Fan Drive Housing

Bore of housing for bearing 61,986 - 62,005 mm (2.4403 - 2.4411 in)
Outside diameter of bearing 61,987 - 62,000 mm (2.4404 - 2.4409 in)
Interference fit of bearing in housing 0,014 - 0,018 mm (0.0006 - 0.0007 in)
Outside diameter of shaft 25,002 - 25,011 mm (0.9843 - 0.9846 in)
Maximum permissible end-float of shaft 0,200 mm (0.0079 in)
Thermostat
Type
Single Wax element, bypass blanking
Part number Nominal temperature stamped “Start to open” “Fully open” Minimum valve
on thermostat bypass valve temperature temperature lift fully open
2485C034 82 8C 79/84 8C 93 8C 10 mm

Fuel System
Bosch Fuel Injection Pump

Type Bosch VP30 electronic, pin timed, with a locking
screw
Direction of rotation from drive end Clockwise from drive end
Bosch Fuel Injection Pump

Type EPVE, with a locking screw
Delphi Fuel Injection Pump

Type DP210, with a locking screw
Fuel Lift Pump

Type Electrically operated
Method of drive Electric motor 12v / 24v
Blue Fuel Filter

Type Single element
Green Fuel Filter

Type Replaceable paper element
Atomizer Service Settings
Color code Holder Nozzle Set and reset pressure

atm (Ibf/in²) MP
Yellow 2645A321 2645A611 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Blue 2645A321 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Red 2645A322 2645A613 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Black 2645A322 2645A614 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
White 2645A322 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Flywheel And Housing
Limits for flywheel housing run-out and alignment (total indicator reading)
Diameter of housing flange bore Maximum limit (total indicator reading)

mm in mm in
410 16.14 0,25 0.010

Electrical Equipment
NOTE: The information which follows is general and can change with specific applications
Alternators
Make and type Denso
Starter Motors
Voltage
Denso P95RL 12V 3.0 kW rhs
Denso R4.5 24V 4,5 kW rhs
Number of teeth on pinion 10
Maximum starter cable resistance at 200 DC (680 8F)

12V 0.0017 ohms
24V 0.0034 ohms
Starting Aids

Type Glow plugs
Voltage 12V or 24V

Thread Sealant
When set screws or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant must be
used to prevent leakage.
Micro encapsulated anaerobic sealant (M.E.A.S.) fasteners have been introduced instead of jointing compounds or other
sealants when the fasteners are fitted in through holes into oil or coolant passages. The identification of these fasteners.
as supplied, is by a red, blue, or other color sealant around the fastener threads.
With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head I cylinder block etc. Ensure that the
threaded holes have a 1,59 mm (0.0625 in) 45° chamfer, to ensure that when the new fasteners are fitted the M.E.A.S.
sealant is not removed. If the fasteners have to be removed and fitted again. the threads must be cleaned and a suitable
sealant used.
NOTE: New set screws have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If
the set screws are to be used again, clean the old sealant from the male and female threads and apply new
sealant, (POWERPART Threadlock and Nutlock) to the set screws.

Standard Torque Values
Most of the torque values on the engine are standard. Special torque values are listed in the separate special torque
tables. The standard torque values listed in the tables below can be used when a special torque is not necessary.
The torque values below apply to components lubricated with a little clean engine oil before they are fitted.
Standard Torques For Set Screws And Nuts
Thread size Torque

N•m Ibf ft Kgf m
M6 x 1,00 9 7 0,9
M8 x 1,25 22 16 2,2
M10 x 1,50 44 32 4,5
M12 x 1,25 78 58 8,0
M14 x 2,00 124 92 13,0
M16 x 2,00 190 140 19,3
Standard Torques For Studs (Metal End)

Thread size Torque
N•m Ibf ft Kgf m
M6 x 1,00 5 4 4
M8 x 1,25 11 8 1,1
M10 x 1,50 18 13 1,8
M12 x 1,75 25 18 2,5
Standard Torques For Pipe Unions, Plugs, And Adaptors
Thread size Torque

inches N•m Ibf ft Kgf m
1/8 PTF 9,5 7 0,9
1/4 PTF 17 12 1,7
3/8 & 1/2 PTF 30 22 3,0
3/4 PTF 45 33 4,6

Specific Torque Values
The torque values below apply to components lubricated with a little clean engine oil before they are fitted.
Specific Torques For Set Screws And Nuts
Description Thread size Torque

N•m Ibf ft Kgf m
Cylinder head assembly
Set screw cylinder head See Operation 3-10
Torx screw, rocker shaft M8 35 26 3,5
Locknut, rocker lever adjustment 3/8 UNF 27 20 2,7
Fastener, rocker cover M6 9 7 0,9
Set screw, heatshield to cover M6 9 7 0,9
Set screw, exhaust manifold to cylinder head M10 33 24 3,3
Piston and connecting rod assemblies
Set screw, fracture split connecting rod See Operation 4-2
Crankshaft assembly

Set screws, main bearings 5/8 UNF 245 180 25
Set screw, crankshaft pulley 7/16 UNF 115 85 12
Allen screws, bridge piece to cylinder block M6 16 12 1,6
Torx screw, rear end oil seal housing M8 22 16 2,2
Set screws, balancer to cylinder block M10 54 39 5,5
Timing case and drive assembly
Set screw, camshaft gear M12 95 70 9,7
Set screw, PTO blanking plate plastic M10 22 16 2,2
Set screw, plastic oil filler M8 22 16 2,2

Specific Torque Values (Cont’d)

N•m Ibf ft Kgf m
Cylinder block
Plug, compressor oil feed M10 35 26 3,5
Plug, oil rail rear face 7/8 UNF 35 26 3,5
Plug, front feet M12 27 20 2,7
Plug, turbocharger feed M10x1 9 7 0,9
Plug, coolant drain 1/4 NSPM 9 7 0,9
Fuel system
Nuts, high-pressure fuel pipes M12 245 180 25
Set screw, atomiser clamp M8 245 180 25
Nut, fuel injection pump 10 gear (mechanical) M14 245 180 25
Set screws, gear 10 fuel injection pump M8 245 180 25
electronic
Set screw, timing case to fuel injection pump M8 245 180 25

Locking screw on shaft of Bosch fuel injection M10 245 180 25
pump
Locking screw in run position of Bosch fuel M10 245 180 25
injection pump
Locking screw on shaft of DP 210 fuel injection M12 245 180 25
pump
Locking screw in run position of DP 210 fuel M12 245 180 25
injection pump
Lubrication System
Plug, lubricating oil sump G 3/4 245 180 25
Oil inspection valve M10 x 1 115 85 12
Oil inspection valve plug M10 x 1 16 12 1,6
Nut, dipstick tube M16 22 16 2,2
Element oil filter 31/2ACME 54 39 5,5
Cooling System
Set screws, fan drive housing to cylinder head M10 95 70 9,7
Set screws, fan drive pulley 10 hub M8 22 16 2,2
Set screws, fan M8 22 16 2,2

Specific Torque Values (Cont’d)

N•m Ibf ft Kgf m
Flywheel and housing
Engine types RE, RF, RG, RJ and RH 1/2 UNF 105 77 10,7
Set screws. flywheel to crankshaft
Engine type RK 1/2 UNF 115 85 11,7
Set screws, flywheel to crankshaft
Set screws, cast iron flywheel housing to M10 44 32 4,5
cylinder block
- Head stamped 8.8 M12 7 55 7,6
- Head stamped 10.9 M10 63 46 6,4
- Head stamped 10.9 M12 115 85 11,7
Set screws, flywheel housing to cylinder block M10 70 52 7,1
(paper joint)
Aspiration System
Nuts, turbocharger to manifold M10 47 35 4,8

Banjo bolt, turbo feed M10x1 22 16 2,2
Fastener, breather pipe to cylinder head M6 9 7 2,0,9
Electrical equipment
Sensor, engine oil pressure M12 x 1,5 10 7 1,0
Plug, engine oil pressure M12 x 1,5 12 9 1,2
Sensor, inlet manifold temperature M18 20 15 2,0
Plug, inlet manifold temperature M18 20 15 2,0
Sensor, inlet manifold pressure M12 10 7 1,0
Plug, inlet manifold pressure M12 10 7 1,0
Sensor, coolant temperature M18 20 15 2,0
Plug, coolant temperature M18 20 15 2,0
Set screw, ECM plug to ECM M5 6 4 0,6
KSB 1/2 PTF 30 22 3,0
Glow plug to cylinder head M10 18 13 1,8
Nut, bus-bar to grow plug M4 2 1 0,2
Nut, alternator pulley:
- CAV AC5RA and AC5RS
- Thin nut A127, and Motorola pulley, 22 mm
A/F
- Thick nut A127, and Motorola pulley, 24 mm M16 80 59 8,1
A/F
- Bosch 55A
- Bosch 55A
- Butec 5524
Nut, starter motor M10 44 32 4,5

Compression Test Data
Tests have shown that many factors affect compression

pressures. Battery and starter motor condition, ambient
conditions and the type of gauge used can give a wide
variation of results for a given engine.
It is not possible to give accurate data for compression
pressure, but tests have shown that the results should be
within 2000 - 3500 kPa (300 - 500 Ibf/in²) 21,0 - 35,0 kgf/
cm² for diesel engines.
Compression tests should only be used to compare

between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 Ibf/in2) 3,5 kgf/
cm² then those cylinders may be faulty.
Compression tests should not be the only method used
to show the condition of an engine, but they should be
used together with other symptoms and tests.
How to do a compression test
Caution: Before the compression test, ensure that the

battery is in good condition and that it is fully
charged. Also ensure that the starter motor is in
good condition.
1. Ensure that the valve tip clearances are set correctly.

(See Valve Tip Clearances on Page 70-30-6.)
2. Remove the atomisers. (See Atomizers on Page 70-

110-6.)
3. Fit a suitable gauge into the atomiser hole of the

cylinder to be tested.
WARNING: Ensure that the engine cannot

start.
4. Operate the starter motor and record the pressure

indicated on the gauge for each cylinder.


CYLINDER HEAD Atomiser Cover
General Description Figure 70-30-1
In a diesel engine there is little carbon deposit and for this

reason the number of hours run is no indication of when
to overhaul a cylinder head assembly. The factors which
indicate when an overhaul is necessary are how easily
the engine starts and its general performance.
The cast iron cylinder head is fastened to the cylinder

block by flanged head set screws. The cylinder head
gasket is a multi-layer construction. The individual inlet
and exhaust ports are designed to assist air swirl and
improve air flow.
The intake manifold is integral within the cylinder head,

and the rocker cover also contains the engine breather S45024
pipe.
The cylinder head assembly has two overhead valves Removal

fitted for each cylinder. Each overhead valve is held in
place by a single coil spring, cap, and two collets. The 1. Remove the atomiser cover set screws (A1) and
face angle of the intake and the exhaust valves are both remove the atomiser cover (A2).

30°. The cylinder head has steel valve seat inserts fitted
for both the intake and the exhaust valves, and these can Installation
be renewed. The angles of the valve seats in the-cylinder
head for the intake and the exhaust valves are both 30°. 1. Fit the atomiser cover (A2) and tighten the set screws
The valves move in sintered steel valve guides which can (A1) to 9 N•m (7 Ibf ft) 0,9 kgf m.
also be renewed. The exhaust valve guides have a
counterbore to prevent seizure of the valve stem caused
by a build up of carbon under the head of the valve. Each
valve stem is fitted with a synthetic rubber oil seal.
The overhead valves are operated by a rocker shaft

assembly fitted to the top of the cylinder head and under
a composite rocker cover. The forged steel rocker levers
are operated by cold drawn push rods with hardened
heads. The rocker shaft is secured to the cylinder head
by sintered steel brackets between each pair of valves.
The rockers and valve gear are lubricated by an oil now
from the hollow rocker shaft that receives a reduced oil
flow from the camshaft oil feed.
Tappet adjustment is achieved by adjustment screws and

locknuts at the Push rod end of each rocker lever.

CYLINDER HEAD (CONT’D) Figure 70-30-3
Rocker Cover
Figure 70-30-2
S45026
3. Fit a new joint (A1) to the rocker cover.

S45025
Figure 70-30-4
Removal

NOTE: If a top mounted turbocharger is fitted, the
heat shield must be removed first.
1. Remove the atomiser cover. (See Atomiser Cover on

Page 70-30-1.)
2. Remove the breather pipe. (See Open Engine

Breather on Page 70-90-8.) or (See Natural Aspirated
Engine Breather on Page 70-90-9.)
3. Release the fasteners (A), remove the rocker cover

and discard the joint. S45027
Installation
4. Check the condition of the fasteners (B), renew as
NOTE: Reflective heat shields fitted to the rocker required.
covers must be kept clean and free from dust,
all or paint. If the surface of the heat shield is 5. Clean the seal face of the cylinder head and fit the
not shiny, the component that is protected by rocker cover.
the heat shield could be damaged.
1. If the rocker cover has an oil filler, check the condition

of the O-ring, renew as required.
2. Ensure that the rocker cover and the groove for the
joint are clean and free from oil and grease.

CYLINDER HEAD (CONT’D)
Rocker Cover (Cont’d)
Installation (Cont’d)
Figure 70-30-5
S45028

6. Secure the rocker cover to the cylinder head with the
fasteners and tighten in sequence (C) to 9 N•m (7 Ibf
ft) 0,9 kgf m.
7. Fit the breather pipe. (See Open Engine Breather on

Page 70-90-8.) or (See Natural Aspirated Engine
Breather on Page 70-90-9.)

CYLINDER HEAD (CONT’D) Installation
Rocker Arm NOTE: Ensure that the machined square is facing

upwards before the rocker arm is fitted and
Special Requirements that the longest Torx screw is fitted in (A2).
Description Part Number 1. Check that the push rods fit correctly in the sockets of
rocker arm tool 27610227 the tappets and ensure that the rocker arm tools are
correctly fitted between each pair of rocker levers
(A1). Fit the rocker arm. Check that the ends of the
Removal
adjustment screws fit correctly in the sockets of the
push rods.
Page 70-30-1.)
2. Fit the Torx screws for the rocker shaft and tighten the
Torx screws 35 N•m (26 Ibf ft) 3,6 kgf m; begin with
2. Remove the rocker cover. (See Rocker Cover on
the inner Torx screws and work outwards.
Page 70-30-2.)
3. Set valve tip clearance. (See Valve Tip Clearances on
3. Fit the rocker arm tools between each pair of rocker
Page 70-30-6.)
levers (A1).
4. Fit the rocker cover. (See Rocker Cover on Page 70-
4. Release evenly and gradually the Torx screws of the
30-2.)
rocker shaft; begin with the end Torx screws and move
toward the center. Remove the Torx screws and lift off
5. Fit the atomiser cover. (See Atomiser Cover on Page

the rocker arm.
70-30-1.)
Figure 70-30-6
S45029

CYLINDER HEAD (CONT’D) Assembly
Rocker Arm (Cont’d) 1. Ensure that the oil holes in the rocker shaft and in the
rocker levers are not restricted.
Disassembly
2. Lubricate the components with clean engine
1. Remove the circlips from both ends of the rocker lubricating oil before assembly. Assemble the
shaft. Ensure that the ends of the rocker shaft are not components in the correct order. Fit the circlips to the
damaged. ends of the rocker shaft.
2. Dismantle the assembly and make a note of the

position of each component to ensure that they can
be assembled in the same position.
Figure 70-30-7

S45030
Inspection
1. Clean and inspect all the components for wear and

any other damage.
2. Check the clearance of the rocker levers on the rocker

shaft. If the clearance is greater than 0,13 mm (0.005
in), renew the rocker lever and/or the rocker shaft.

CYLINDER HEAD (CONT’D) NOTE: The correct torque for the locknut on the
adjusting screws is 27 N•m (20 lbf ft) 2,8 kgf m.
Valve Tip Clearances
Figure 70-30-9
To Check And To Adjust
The valve tip clearances are checked between the top of

the valve stem and the rocker lever (A), with the engine
cold. The correct clearance for intake valves is 0,20 mm
(0.008 in) and 0,45 mm (0.018 in) for exhaust valves. The
valve positions are shown at (B).
The sequence of valves from number 1 cylinder is shown

in the table below.
NOTE: Number 1 cylinder is the furthest cylinder

from the flywheel end of the engine.
Figure 70-30-8 S45032
2. Set the valves (B3 and 84) of number 2 cylinder as

indicated above for number 4 cylinder. Then check /
adjust the clearances of the valves (B5 and B6) of

number 3 cylinder.
3. Set the valves (B1 and B2) of number 1 cylinder. Then

check / adjust the clearances of the valves (B7 and
B8) of number 4 cylinder.
4. Set the valves (B5 and B6) of number 3 cylinder. Then

check / adjust the clearances of the valves (B3 and
B4) of number 2 cylinder.
S45031
NOTE: After the valve tip clearances have been
adjusted, lubricate the rocker arm with clean
1. Rotate the crankshaft in the normal direction of engine oil. Apply particular attention to the
rotation until the intake valve (B7) of number 4 rocker shaft bearing surfaces, valve tips;
cylinder has just opened and the exhaust valve (B8) push rod sockets and the push rods so that
of the same cylinder has not closed completely. the oil will drain to lubricate the cam
Check the clearances of the valves (B1 and B2) of followers.
number 1 cylinder and adjust them, if necessary.
Cylinder 1 2 3 4
and Valve 1 2 3 4 5 6 7 8
Number
Valve I E I E I E I E
I = Intake
E = Exhaust

CYLINDER HEAD (CONT’D) Caution: Ensure that the valve spring is compressed
squarely or damage can occur to the valve stem.
Valve Springs
NOTE: Do not over compress the valve springs so
To Change The Valve Springs (with Cylinder Head Fitted) that coils are touching.
Special Requirements 6. Compress the valve spring and remove the collets.
Ensure that the valve spring is compressed squarely
Special Tools or damage to the valve stem can occur.
Description Part Number
Caution: Do not rotate the crankshaft while the valve
Valve Spring Compressor 21825666 spring is removed.
Set screw adaptor used 27610235
with 21825666 7. Release the valve spring compressor and remove the
valve spring, cap and valve seal. NOTE: The valve
NOTE: Steps 1 - 11 refer to a change of valve spring stem seal must only be used once.
for a single cylinder.
8. Ensure that the new valve stem seal is clean, not
WARNING: Wear eye protection during this damaged and that the spring is present and correctly
operation. located on the seal.
9. Lubricate the valve stem with clean engine oil. Fit the
1. Remove the atomiser cover. (See Atomiser Cover on valve stem seal onto the valve guide and ensure that,
Page 70-30-1.) the seal and the seating washer are correctly located.

2. Remove the rocker cover. (See Rocker Cover on 10. Put the new valve spring in position, ensure that the
Page 70-30-2.) larger diameter is against the cylinder head.
3. Rotate the crankshaft in the normal direction of 11. Fit the valve spring cap.
rotation until the intake valve of the relevant cylinder Caution: Ensure that the valve spring is compressed
has just opened and the exhaust valve has not fully squarely or damage can occur to the valve stem.
closed. In this position the piston will be at
approximately top dead center (TDG). NOTE: Do not over compress the valve springs so
that coils are touching.
4. Remove the rocker arm. (See Rocker Arm on Page
70-30-4.) 12. Fit the valve spring compressor, compress the valve
spring and fit the collets. Remove the valve spring
Figure 70-30-10 compressor.
13. Fit the rocker arm. (See Rocker Arm on Page 70-30-
4.)
14. Check the valve tip clearances. (See Valve Tip
Clearances on Page 70-30-6.)
30-2.)
S45033
5. Fit the valve spring compressor (A1) and the adaptor

(A2).

Valve Springs (Cont’d)
To Change The Valve Springs (With Cylinder Head

Fitted) (Cont’d)
NOTE: If other or all of the valve springs are to be

changed, they can be changed two cylinders
at a time. The sets of cylinders are 1 and 4, 2
and 3.
If the rocker arm has been removed, piston TOC can be

found as follows:
1. Fit the valve spring compressor and compress the

valve springs to open the valve.
2. Rotate the crankshaft by hand in the normal direction

of rotation until the piston touches the valve.
NOTE: Ensure that the collets are fully located before
the pressure is released on the valve spring
compressor.

3. Continue to rotate the crankshaft, and at the same
time, release pressure on the valve spring
compressor until the piston is at TOC (B).
S45034

CYLINDER HEAD (CONT’D) 11. Remove the atomiser leak-off hoses.
Removal 12. Remove the atomisers. (See Atomizers on Page 70-

110-6.). Fit suitable covers to the nozzles and the
1. Drain the cooling system. open connections.
2. Disconnect the battery terminals. 13. Remove the bus-bar and glow plugs.
3. Remove the air filter / cleaner hose at the intake 14. Release the set screws of the coolant bypass pipe at
manifold. the timing case. Remove the coolant bypass pipe
from the cylinder head.
4. For engines fitted with a boost control device, remove
the boost control pipe that is fitted between the intake 15. Disconnect the coolant temperature sensor / sender
manifold and the top of the fuel injection pump. unit.
5. For engines fitted with a turbocharger, disconnect all 16. Remove the rocker cover. (See Rocker Cover on
connections to the turbocharger and remove the Page 70-30-2.)
turbocharger. (See Turbocharger Side Mount on
Page 70-90-3.) 17. Remove the rocker arm. (See Rocker Arm on Page
70-30-4.)
Figure 70-30-12
18. Remove the push rods.
Figure 70-30-13

S45035
6. Release the exhaust manifold fasteners in the reverse

S45036
sequence to that shown in (A).
7. Remove the low-pressure fuel pipes which are fitted 19. Release the cylinder head set screws evenly and
between the fuel injection pump and the fuel lift pump gradually in the reverse sequence to that shown in
with integral fuel filter. (B).
8. Remove the fuel lift pump with integral fuel filter.
Caution: Where access to the fuel injection pump outlet

unions is possible, ensure that a separate
spanner is used to prevent movement of the fuel
injection pump outlets when the connections of
the high-pressure pipes are released. Fit suitable
covers to all open connections on the fuel
injection pump.

Page 70-30-1.)
10. Remove the high-pressure fuel pipes.

Removal (Cont’d)
Figure 70-30-14
S45037
20. Check the set screws for distortion with a straight

edge (C1) held along the set screw (C2). If there is a

visual reduction in the diameter of the thread that has
not been in engagement with the cylinder block, the
set screw must be discarded.
Caution: Do not use a lever to separate the cylinder

head from the cylinder block, as this may damage the
face of either the cylinder head or the cylinder block.
21. Remove the cylinder head and put it on a surface that

will not damage the bottom face of the cylinder head.
22. Remove the cylinder head gasket.

CYLINDER HEAD (CONT’D) 4. Apply a small amount of lubricant to the threads and
the thrust faces of the cylinder head set screws.
Installation Engage the seven short set screws in positions 2, 5,
6, 7, 8. 9, 10, then remove the guide studs (A1). Fit the
Special Tools three long set screws in positions 1, 3, 4.
Figure 70-30-16
Angle gauge (to tighten 21825607
cylinder head set screws)
1. With a suitable cleaner, clean thoroughly the bottom

face of the cylinder head and the top face of the
cylinder block. Hard carbon and corrosion can be
removed with a hard plastic or hard wood scraper.
Ensure that the top face of the cylinder block and the
bottom face of the cylinder head are free from
scratches or other damage and there is no debris in
the cylinder bores, see “Cylinder head”.
NOTE: The engines have two location pins (A2), one

at each end of the cylinder head, pressed into
the cylinder block to hold the cylinder head S45039
and cylinder head gasket in the correct
position when the cylinder head is fitted.

5. Tighten the set screws to 50 N•m (37 Ibf ft) 5,1 kgf m
NOTE: To prevent damage to the cylinder head in the sequence shown in (B).
gasket, ensure that the location pins are
pressed in the cylinder block before the 6. Tighten the set screws to 100 N•m (74Ibf ft) 10,0 kgf
cylinder head is fitted. m in the sequence shown in (B).
NOTE: The cylinder head gasket must be fitted 7. Tighten the set screws, in the correct sequence, a
without jointing compound. further part of a turn according to the length of the set
screws. Short set screws (S) must be turned a further
Figure 70-30-15 225°. Long set screws (L) must be turned a further
270°. A special tool (C) can be used for this operation.
S45038
2. Fit a new cylinder head gasket in the correct position.
3. To ensure the cylinder head is fitted into the correct

position, fit two suitable M15 guide studs (A1). Put the
cylinder head in position. Ensure that the two location
pins are fully engaged in the cylinder head.

CYLINDER HEAD (CONT’D) 9. Fit the rocker arm. (See Rocker Arm on Page 70-30-
4.)
10. Set the valve tip clearances. (See Valve Tip
Figure 70-30-17 Clearances on Page 70-30-6.)
11. Fit the atomisers. (See Atomizers on Page 70-110-

6.).
12. Fit the atomiser leak-off hoses.
13. Fit the glow plugs and bus-bar. (See Starting Aid
(Glow Plug) on Page 70-140-7.)
14. Fit the high-pressure fuel pipes; tighten the

connection nuts to 22 N•m (16 Ibf-ft) 2,2 kgf m.
Caution: Where access to the fuel injection pump outlet

unions is possible; ensure that a separate
S45040 spanner is', used to prevent movement of the fuel
injection pump outlets when the connections of
the high “pressure pipes” are tightened.
Fit the tool between the socket and the handle. Position
the stop (C1) against a suitable protrusion on the cylinder 15. Fit the fuel lift pump with integral fuel filter and the

head to prevent movement of the degree dial in a bracket. Fit the low-pressure fuel pipes between the-
clockwise direction. Rotate the pointer to align with the fuel-injection pump and the fuel lift pump with integral
relevant angle on the degree dial for the length of set fuel filter.
screw. Tighten the set screw until the pointer on the tool
is aligned with the zero position on the degree dial. 16. Fit the coolant bypass pipe, see operation 12 - 13.
Figure 70-30-18
S45041
If no tool is available, make a suitable mark on the

cylinder head in line with a corner of each set screw (D).
Make another mark, at the correct angle (counter-
clockwise). on the edge of the flange of each fastener
according to the length of the set screw. Tighten each set
screw in the correct sequence until the marks on the
flange are next to, and in line with, the marks on the
cylinder head.
8. Put the push rods in position. Ensure that the end of

each push rod fits correctly in the tappet socket.

CYLINDER HEAD (CONT’D) 23. For engines fitted with a boost control device, fit the
boost control pipe between the intake manifold and
Installation (Cont’d) the top of the fuel injection pump.
Figure 70-30-19 24. Fit the electrical connection to the coolant

temperature sensor / sender unit.
25. Connect the coolant outlet and the hoses for the cab
heater. Tighten the clips.
26. Fin the cooling system.
27. Connect the air filter / cleaner.
28. Connect the battery.
29. Eliminate air from the fuel system. See Operation 11

- 8.
S45042 30. Start the engine and run it at low speed. Check that oil
flows from the holes in the rocker levers. If the oil flow
is correct, fit the rocker cover.
17. Fit two suitable temporary studs (E1) then fit the
exhaust manifold joint (E2). NOTE: It is not necessary to tighten the cylinder head

set screws again with the engine hot or after a
Figure 70-30-20 limited period in service.
S45043
18. Fit the exhaust manifold and the fasteners, lightly

tighten the fasteners 1 and 2 (F).
19. Remove the two temporary studs, fit the remaining

fasteners and lightly tighten.
20. Evenly and gradually tighten the exhaust manifold

fasteners to 33 N•m (24 Ibf ft) 3,4 kgf m in the
sequence shown (F).
21. For engines fitted with turbochargers, fit the

turbocharger. (See Turbocharger Side Mount on
Page 70-90-3.)
22. Connect the electrical connection to the cold start

device.

Valve And Valve Springs
Removal
Special Requirements
Special Tools
Valve Spring Compressor 21825666
Set screw adaptor used with 2182566 27610235
WARNING: Wear eye protection during this

operation.
1. Remove the cylinder head. (See Removal on Page

70-30-9.)
2. Clean the bottom face of the cylinder head and check

the depth of the heads of the valves below the face of
the cylinder head. (See Valve And Valve Springs

(Cont’d) on Page 70-30-15.) S45044
3. Make a suitable mark on the heads of the valves to

ensure that the valves can be fitted in their original
positions, if they are to be used again.
Caution: Ensure that the valve springs are compressed

squarely or the valve stem can be damaged.
NOTE: Do not over compress the valve springs so

that coils are touching.
4. Use the valve spring compressor and the relevant

adaptor to compress the valve spring (A3) and
remove the collets (A1).
5. Release the valve spring compressor and remove the

valve spring cap (A2), valve spring and valve stem
seal (A4).
6. Repeat steps 4 and 5 for the other valves.

Valve And Valve Springs (Cont’d)
Installation
Special Tools
Valve Spring Compressor 21825666
Set screw adaptor used with 2182566 27610235
WARNING: Wear eye protection during this

operation.
Caution: Valves must not be lapped, as the special heat

resistant layer on the face of the valve will be
destroyed.
Caution: If inlet valves are badly worn or damaged, they

must be replaced.
S45044
NOTE: The intake valve has a larger diameter head

than the exhaust valve.
1. Lubricate the valve stem (A5) with clean engine oil

and fit the valves in their respective guides
NOTE: The valve stem seal must only be used once.
2. Fit new valve stem seals (A4) on the valve guides.

3. Put the valve springs in position, ensure that the
larger diameter is against the cylinder head. Fit the
valve spring cap (A2).
Caution: Ensure that the valve springs are compressed
squarely or the valve stem can be damaged.
4. Use the valve spring compressor and the relevant

adaptor to compress the valve spring (A3) and fit the
collets (A1).

CYLINDER HEAD (CONT’D) 6. Check that the seat faces of the valves are not badly
burnt or damaged. Seat faces of valves which are
Valve And Valve Springs ((Cont’d) damaged can be ground on a special machine. When
new valves are fitted, the valve depths must be
Inspection checked after the valve springs are fitted.
Special Requirements 7. Check that the load on the valve springs is correct at
their fitted length, refer to the relevant Data and
Special Tools dimensions for the 'Valve guides and valve springs”.
Fit new valve springs at every complete engine
overhaul.
Gauge, Valve Depth 21825496
Dial Gauge for use with 21825496 21825617
1. Ensure that the heads of the valves and the bottom

face of the cylinder head are clean.
2. Put the valve depth gauge on the face of the cylinder

head and zero the dial gauge.
Figure 70-30-23

S45046
3. Carefully put the valve depth gauge in position over

the head of each valve (A) and make a note of the
measurement. The maximum depth, in service, is
given in the relevant Data and dimensions for the
“intake and exhaust valves”.
4. If a valve is below the depth limit, check the valve

depth with a new valve in position. If the valve depth
is still below the limit the valve seat insert must be
renewed. (See Inspection And To Correct on Page
70-30-20.)
5. Check the valves for cracks. Check the stems of the

valves for wear and for correct fit in their valve guides.
Caution: Valves must not be lapped, as the special heat

resistant layer on the face of the valve will be
destroyed. If inlet valves are badly worn or
damaged they must be replaced.

Valve Guides
Inspection
Figure 70-30-24
S45047

To check the valve guides for wear. The maximum
permissible clearance (A5) with a valve lift of 15,0 mm
(0.6 in), between the valve stem and the bore of the guide
is 0,22 mm (0.009 in) for intake valves and 0,25 mm
(0.010 in) for exhaust valves. If the clearance, with a new
valve fitted, is more than the limit, then a new valve guide
(A4) must be fitted.
It is recommended that the procedure given below is

used to check the valve guide clearance:
1. Put a new valve in the valve guide.
2. Put a dial test indicator with a magnetic base (A1)

onto the face of the cylinder head.
3. With the valve lifted 15,0 mm (0.6 in) and the gauge
(A2) in contact with the edge of the valve head (A3),
move the valve radially away from the gauge. With the
valve held in this position. set the gauge to zero.
4. Move the valve radially across the axis of the cylinder

head towards the gauge. Make a note of the reading
on the gauge. If the reading is equal to or greater than
the data given above, a new valve guide (A4) must be
fitted.

CYLINDER HEAD ASSEMBLY (CONT’D) 4. Hold the top handle (A1) and turn the bottom handle
(A2) clockwise to pull the valve guide out of the
Valve Guides (Cont’d) cylinder head.
Removal
Special Tools
Gauge, Valve Depth 21825478
Adaptor used with 21825478 21825479
Figure 70-30-25

S45048
1. Fit the adaptor (A4) into the remover / replacer tool

(A3).
2. With the adaptor fitted to the tool, put the spacer (A5)
in position on the tool. Pass the adaptor (A4) through
the valve guide (A6) and put the spacer and tool in
position on the valve seat.
3. Fit the attachment (A7) to secure the adaptor to the

valve guide.

Valve Guides (Cont’d)
Installation
Special Tools
27610234
NOTE: The partially finished valve guides are reamed

and the valve seats are cut in one operation
with a special tool. The valve seat and the
guide are cut in one operation to ensure the
concentricity of the valve seat to the valve
guide. This will ensure a good seal between
the guide and its seat. New valves and new
valve seat inserts must be fitted each time a
new valve guide is fitted. Valves must not be
lapped. If all or most of the original valve
guides need to be renewed it may be cost

effective to overhaul or exchange the cylinder
head.
1. Clean the parent bore in the cylinder head for the

valve guide.
2. Lubricate the outer surface of the new valve guide

(A6) with clean engine lubricating oil.
S45049
3. Fit the adaptor (A5) into the remover / replacer tool
(A3).
6. Hold the top handle (B1) and turn the bottom handle
4. With the adaptor fitted to the tool, put the spacer (A4) (B2) clockwise to pull the valve guide until the
in position on the tool. Pass the adaptor through the distance piece contacts the cylinder head.
cylinder head and put the spacer and tool assembly in
position on the valve seat. 7. When the valve guide is fitted correctly, the top of the
valve guide will have a protrusion (B9) of 12,35 - 12,65
5. Put the valve guide in position on the adaptor and fit mm (0.486 - 0.498 in) above the valve spring seat.
the adaptor (B7). Fit the attachment (B8) to secure the
valve guide to the adaptor. 8. Ream the valve guide to the finished size. (See
Inspection And To Correct on Page 70-30-20.)

CYLINDER HEAD (CONT’D) 11. Before any work is done on the valve seats, new valve
guides must be fitted. (See Valve Guides on Page 70-
Inspection And To Correct 30-17.)
1. Remove the cylinder head assembly. (See 12. Badly damaged valve seats can be corrected by use
CYLINDER HEAD on Page 70-30-1.) of the cutter tool, (See Inspection And To Correct on
Page 70-30-20.) or new inserts can be fitted. (See
2. Remove the thermostat housing. (See Thermostat on Inspection And To Correct on Page 70-30-20.)
Page 70-120-3.)
3. Inspect the cylinder head for signs of gas or coolant

leakage.
4. Remove the valve springs and the valves. (See Valve

And Valve Springs on Page 70-30-14.)
5. Clean the face of the cylinder head and the passages

for coot ant and for lubricating oil. The coolant jacket
can be cleaned with a special solvent which must be
used in accordance with the manufacturer's
instructions.
6. Test the cylinder head for leaks at the pressure given

in the relevant Data and dimensions for the “Cylinder

head”.
7. When the cylinder head is thoroughly clean, check it

for cracks. Inspect carefully the areas around the
valve seats and around the holes for the atomiser
nozzles.
Caution: Remove only the minimum material and ensure

that the thickness of the cylinder head will not be
less than 117,20 mm (4.614 in) after the cylinder
head has been machined.
8. The bottom face of the cylinder head can be

machined if there is distortion, or deep scratches, see
step 9.
9. Use a straight edge and feeler gauges to check the

cylinder head for distortion. Refer to the relevant Data
and dimensions for the “Cylinder head”.
If the distortion is more than the given limit, the bottom

face can be machined. Refer to the relevant Data and
dimensions for the “Cylinder head” the surface grade
finish of the cylinder head face.
Caution: Remove only the minimum material and ensure

that the thickness of the cylinder head will not be less
than 117,20 mm (4.614 in) after the cylinder head has
been machined.
10. Check the valve seats for wear and for damage.

Inspection and to Correct (Cont’d)
To Correct A Valve Seat With A Valve Seat Cutter
Special Tools
Cutter (30°) for Inlet and Exhaust
Valve 27610030
Seats and Valve Guide Reamer
Caution: Valves must not be lapped.
NOTE: The partially finished valve guides are reamed

and the valve seats are cut in one operation
with a special tool. The valve seat and the
guide are cut in one operation to ensure the
concentricity of the valve seat to the valve
guide. This will ensure a good seal between
the guide and its seat. New valves and new

valve seat inserts must be fitted each time a
new valve guide is fitted. Valves must not be
lapped. If all or most of the original valve S45051
guides need to be renewed it may be cost

effective to overhaul or exchange the cylinder 4. Fit the reamer / cutter assembly into the valve guide.
head. Ensure that the valve seat cutter is not allowed to fall
onto the seat as this can damage the blades.
1. Before any work is done on the valve seats, new valve Carefully turn the handle in a clockwise direction (B3)
guides must be fitted. (See Valve Guides on Page 70- and gradually move the reamer into the valve guide
30-17.) until the valve guide is reamed to the finished size. A
lubricant is not necessary.
Caution: Ensure that the correct cutter is fitted, for 30°
valve seats. 5. Continue to turn the handle in a clockwise direction to
cut the valve seat. Remove only the minimum material
Caution: Ensure that the valve seat cutter is not allowed to ensure a good valve seat. Keep the seat as narrow
to fall onto the seat as this can damage the as possible.
blades.
6. When the seat is cut, remove the reamer / cutter
NOTE: The intake valve has a larger diameter head assembly. Remove any debris from the area of the
than the exhaust valve. valve guide, valve seat and the port.
2. Select the relevant valve seat cutter, 30° (A2) and the 7. Fit the valve. (See Valve And Valve Springs on Page
valve guide reamer (A1). Set the blades of the cutters 70-30-14.)
to the diameter of the valve seat to be cut, see “Intake
and exhaust valves”. 8. Check that the valve depth is within limits. refer to the
relevant Data and dimensions for the “Intake and
NOTE: The blades of the reamer must not cut the exhaust valves”.
valve guide when the seat is cut.
NOTE: If a valve seat has become too damaged or too
3. Fit the cutter onto the reamer and push the handle worn to correct, a valve seat insert can be
fully onto the reamer. Ensure that the flat part of the fitted. (See Inspection And To Correct on
reamer shank is towards the Allen screw. Tighten the Page 70-30-20.) If all or most of the original
Allen screw to secure the reamer to the handle. valve seat inserts need to be renewed, it may
be cost effective to overhaul or exchange the
cylinder head.

Inspection and to Correct (Cont’d)
To fit valve seat inserts
1. Remove the valve guide (See Valve Guides on Page

70-30-17.) and clean the bare into which the guide is
to be fitted.
2. Fit new partially finished valve guides. (See Valve

Guides on Page 70-30-17.)
3. With the bore of the new partially finished valve guide

used as a pilot, machine the recess in the cylinder
head to the dimensions shown in “Dimensions of
recesses for valve seat inserts”, or machine out the
old insert. Remove all debris and clean the insert
recess.
4. If the bottom face of the cylinder head has been

machined, the insert will have to be surface ground on
the back face to ensure that there is no protrusion of
the insert above the bottom face of the cylinder head.

After the back of the insert has been ground, ensure
that the outer edge of the back face has a 0,9 - 1,3 mm
(0.035 - 0.051 in) chamfer at 30° to the vertical.
5. With the bore of the new, partially finished, valve

guide used as a pilot, and with the rear face of the
insert towards the cylinder head, press in the insert
with the valve seat insert tool, see “Valve seat insert
tool”.
Caution: Do not use a hammer on the insert and do not

use lubrication.
Use a hydraulic press or a hand press in one continuous

movement. Ensure that the bottom of the insert is in
contact with the bottom of the recess.
6. Ream the valve guide and cut the valve seat at an

included angle of 120° for 30° valve seats. (See
Inspection And To Correct on Page 70-30-20.)
Ensure that the depth of the valve head below the face of
the cylinder head is within the production limits, refer to
the relevant Data and dimensions for the “Intake and
exhaust valves”.
NOTE: Work as near as possible to the minimum

value to allow for future wear on the valve
seal.

PISTON AND CONNECTING ROD ASSEMBLIES Piston cooling jets are fitted in the cylinder block to spray
lubricating oil onto the inner surface of the pistons. The
General Description correct piston height is important to ensure that the
piston does not contact the cylinder head and to ensure
The pistons used in the 1100 Series 4 cylinder engines the efficient combustion of fuel.
have a combustion chamber in the top of the piston.
Piston (A) is for models RE. RF. and piston (B) is for The piston height is controlled by the length of the
models RG, RH, RJ, and RK. The combustion chamber is connecting rod. There are six length grades of
designed to give an efficient mix of fuel and air. connecting rods used to obtain the correct piston height.
Figure 70-40-1 To obtain the different grades, the small-end bush is

machined oft-center. The amount that the bush is off
center gives the different length grades.
In service, a partially finished small-end bush is available,

which can be fitted to the original connecting rod and
machined to obtain the correct length grade, (See
Partially Finished Small End Bush on Page 70-40-12.)
Specialist equipment and personnel with the correct
training are needed to machine the partially finished
small-end bush. Connecting rod kits are also available
with the small end bush fitted and machined to obtain the
correct connecting rod grade.
NOTE: If the crankshaft or the cylinder block is to be

renewed, it may be necessary to change the
S45053
grade of the connecting rods. (See Piston And
Connecting Rod Assembly on Page 70-40-8.)
Figure 70-40-2 This will occur if the correct piston height
above the cylinder block face cannot be
maintained with the original connecting rod
assemblies. (See Piston And Connecting Rod
Assembly on Page 70-40-8.)
NOTE: Always use the engine identification number

to order new parts.
Figure 70-40-3
S45054
The pistons and connecting rods are matched to the

relevant cylinder.
The pistons have two compression rings and an oil

control ring. 'The groove for the top ring has a hard metal
insert to reduce wear of the groove. The piston skirt has a
S45055
layer of graphite to improve the wear characteristics.
Axial location of the fully floating gudgeon pin is by The connecting rod is a one-piece forging that is
circlips, The gudgeon pin is off-center to reduce the noise fractured hydraulically to split the big end cap from the
level. connecting rod. This process produces rough but
accurately matched surfaces (C1).

PISTON AND CONNECTING ROD ASSEMBLIES 8. Carefully push the connecting rod up the cylinder bore
(CONT’D) just enough to allow access to the upper half of the
shell bearing. Remove the shell bearing (A6) from the
Big End Bearing connecting rod (A1). Keep the bearing with the
connecting rod.
Removal
1. Drain the engine lubricating on.
2. Remove the lubricating oil sump. (See Sump on Page

70-100-6.)
3. Remove the lubricating oil pump, (See Lubricating Oil

Pump Assembly on Page 70-100-10.) or remove the
balancer unit. (See Balancer Unit on Page 70-50-17.)
Figure 70-40-4

S45056
4. Release the fasteners (A4) and remove the bearing

cap (A3).
Caution: Do not stamp or punch the connecting rod

assembly, as this could cause a fracture.
5. Mark the bearing cap and the connecting rod with the
cylinder number to ensure correct assembly.
Caution: Engine models RG, RH, RJ and RK have a

different shell bearing fitted to the cap and
connecting rod. Ensure that the relevant shell
bearing is kept with the correct cap or connecting
rod.
6. Rotate the crankshaft until the relevant connecting rod

is at its lowest position.
7. Remove the shell bearing (A5) from the cap (A3).

Keep the bearing with the cap.

PISTON AND CONNECTING ROD ASSEMBLIES Figure 70-40-6
(CONT’D)
Big End Bearing (Cont’d)
Installation
1. Clean the bearing faces of the connecting rod and the

crank pin.
Caution: Engine models RG, RH, RJ and RK have a

different shell bearing fitted to the cap and connecting
rod. Ensure that the relevant shell bearing is kept with the
correct cap or connecting rod.

S45058
assembly, as this could cause a fracture.
2. Clean the complete bearing and lubricate the bearing 4. Clean, lubricate and fit the lower half of the shell
surface and the crank pin with clean engine bearing into the cap; ensure that the bearing shell is
lubricating oil. fitted centrally (A1). Fit the connecting rod fasteners.
Fit the cap to the connecting rod. Ensure that the
3. Fit the upper half of the shell bearing to the assembly has both of the forged marks on the same
connecting rod; ensure that the bearing shell is fitted side (B1).

centrally (A1). Fit the connecting rod to the crank pin.
Ensure that the forged marks (B1) face to the front of 5. Tighten the new fasteners to an initial torque of 18
the engine. N•m (13 Ibf ft) 1,9 kgf m.
NOTE: The fasteners used with these connecting 6. Tighten the new fasteners to 70 N•m (52 Ibf It) 7,1 kgf
rods must only be used once. m. The fasteners must then be tightened a further
1200
Figure 70-40-5
7. Ensure that the crankshaft rotates freely.
8. Fit the lubricating oil pump, (See Lubricating Oil Pump

Assembly on Page 70-100-10.) or fit the balancer unit.
(See Balancer Unit on Page 70-50-17.)
9. Fit the lubricating oil sump (See Sump on Page 70-

100-6.) and fill the sump to the correct level with
lubricating oil of an approved grade.
Inspecting
1. Check the bearings and the crank pin for wear or

other damage.
S45057

PISTON AND CONNECTING ROD ASSEMBLIES
(CONT’D)
Piston And Connecting Rod
Removal
1. Drain the lubricating all and the cooling system.
2. Remove the cylinder head assembly. (See Removal

on Page 70-30-9.)
3. Remove all carbon from the top of the bores of the

cylinders.

70-100-6.)
5. Remove the lubricating oil pump, (See Lubricating Oil

Pump Assembly on Page 70-100-10.) or remove the
balancer unit. (See Balancer Unit on Page 70-50-17.)

assembly, as this could cause a fracture. The

pistons and connecting rods are matched to the
relevant cylinder. Mark each connecting rod and
piston with the cylinder number to ensure correct
assembly.
6. Remove the big end caps and the big end bearings
from the connecting rods. (See Big End Bearing on
Page 70-40-2.)
Caution: Do not allow the connecting rods to hit the piston

cooling jets. If a cooling jet is hit, renew it if
necessary.
7. Rotate the connecting rods 90° to prevent contact

with the piston cooling jets. Push the pistons and the
connecting rods out through the top of the cylinder
liners. Keep the bearings and caps together to ensure
that they can be fitted in their original positions.
8. Inspect the crank pins for damage.

PISTON AND CONNECTING ROD ASSEMBLIES Caution: Ensure that the connecting rod will not hit the
(CONT’D) piston cooling jet (if fitted) as the connecting rod
assembly is fitted.
Piston And Connecting Rod (Cont’d)
Figure 70-40-8
Installation
Special Tools
Piston Replacer Tool 21825491
1. Ensure that the piston, the cylinder bore, the crank pin
and the big end of the connecting rod are clean.
Lubricate the piston and the cylinder bore with clean
engine lubricating oil.
2. Rotate the crankshaft until the relevant crank pin is at S45059

its lowest position. Lubricate the crank pin with clean
6. Push the piston and connecting rod assembly through
3. Fit the upper half of the shell bearings to the the piston replacer tool (A) and onto the crank pin.

connecting rod. Ensure that the bearing shell is fitted The piston and connecting rod assembly must be
correctly. (See Big End Bearing on Page 70-40-2.) rotated to ensure that the connecting rod will not hit
Lubricate the bearing with clean engine lubricating oil. the piston cooling jet as the assembly is fitted. When
the connecting rod has passed the piston cooling jet,
4. Put the piston replacer tool in position at the top of the rotate the connecting rod until the arrow mark on top
relevant cylinder. The tool has a tapered bore to of the piston is towards the front of the engine.
compress the piston rings when the piston and
connecting rod assembly is fitted. Ensure that the 7. Clean the connecting rod cap and the lower half of the
smaller end of the tapered bore is towards the face of bearing. Fit the bearing to the cap; ensure that the
the cylinder block. bearing is fitted correctly. (See Big End Bearing on
Page 70-40-2.) Lubricate the bearing with clean
Figure 70-40-7 engine lubricating oil. Fit the cap and ensure that the
assembly number is the same as that on the
connecting rod and that the numbers are on the same
side. Tighten the fasteners gradually and evenly. (See
Big End Bearing on Page 70-40-2.)
8. Check that the crankshaft will rotate freely.
9. Check the piston height above the top face of the

cylinder block.(See Piston And Connecting Rod
10. Fit the lubricating oil pump (See Lubricating Oil Pump
11. Fit the lubricating oil sump. (See Sump on Page 70-
S45060
100-6.)
5. Put the piston ring gaps 1208 apart. Pass the 12. Fit the cylinder head assembly. (See Installation on
connecting rod through the piston replacer tool and Page 70-30-11.)
allow the piston to enter the tool. The arrow mark on 13. Fill the sump to the correct level with lubricating oil of
the top of the piston (B) must be towards the front of an approved grade.
the engine.
14. Fill the cooling system.

PISTON AND CONNECTING ROD ASSEMBLIES If any of the components listed below are renewed. refer
(CONT’D) to the relevant operation:
Piston And Connecting Rod (Cont’d) • The connecting rod. (See Piston And Connecting Rod
To Check The Piston Height Above The Cylinder Block
• The small end bush. (See Partially Finished Small
Special requirements End Bush on Page 70-40-12.)
Special Tools
Piston Height Tool 21825496
Dial Gauge for use with 21825496 21825617
Caution: If the correct piston height above the cylinder

block is not obtained, damage to the engine can
occur and the engine may not be emissions
compliant.
Figure 70-40-9

S45061
Put the piston height tool (A) on the face of the cylinder
block and rotate the gauge dial to the zero position.
Rotate the crankshaft until the piston crown is
approximately at top dead center (TOG). Carefully put
the tool over the top of the piston with the plunger of the
gauge in contact with the piston above the axis of the
gudgeon pin. Rotate the crankshaft to ensure that the
piston is at the highest position and make a note of the
gauge indication.
The piston height above the top face of the cylinder block
should be 0,21 - 0,35 mm (0.008 - 0.014 in).
NOTE: The top of the piston should not be machined.
NOTE: If the original piston is used, ensure that it is

assembled to the correct connecting rod and
is used in the original cylinder.

(CONT’D)
Piston Rings
Removal
NOTE: The pistons have two compression rings and

an oil control ring. All the piston rings are
above the gudgeon pin. To ensure that the
correct type is obtained always use the engine
identification number to order new parts.
Caution: Only expand the ring gaps enough to ensure

that the ends of the rings do not damage the
piston when the ring is removed or put into
S45062
position.
1. Remove the piston rings with a suitable ring expander. 1. Fit the spring of the oil control ring in the bottom
Keep the rings with their relevant piston. groove with the latch pin (A1) inside both ends of the
spring (A). Fit the oil control ring over the spring.
Installation Ensure that the ring gap is at 180° to the latch pin.
Use a suitable piston ring expander to fit the piston rings. 2. Fit the cast iron ring with the taper face into the

second groove.
Caution: Only expand the ring gaps enough to ensure
that the ends of the rings do not damage the 3. The second ring has a green identification mark which
piston when the ring is removed or put into must be on the left of the ring gap when the ring is
position. fitted and the piston is upright. with the word ''TOP''
towards the top of the piston.
4. The first ring has a red identification mark which must

be on the left of the ring gap when the ring is fitted and
the piston is upright.
5. Ensure that the ring gaps are 120° apart.

PISTON AND CONNECTING ROD ASSEMBLIES Assembly
(CONT’D)
1. Clean the bore of the small end bush and lubricate it
Piston And Connecting Rod Assembly with clean engine lubricating oil.
Disassembly 2. Fit a new circlip in the circlip groove of one of the

gudgeon pin bosses. Ensure that it fits correctly in the
1. Remove the piston rings. (See Piston Rings on Page groove.
70-40-7.)
Figure 70-40-12
2. Remove the circlips which retain the gudgeon pin.
Caution: The pistons and connecting rods are matched to

the relevant cylinder. Note the position of each
connecting rod and piston for correct assembly.
Figure 70-40-11

S45064
3. With the piston upside down, put the connecting rod

in position with the forged mark (A1) on the same side
as the recess in the gudgeon pin boss (A2). If the
original piston is used, ensure that it is assembled to
S45063 the correct connecting rod and is used in the original
cylinder.
3. Put a temporary mark on the piston to indicate the NOTE: 1100 Series 4 cylinder engines have six
cylinder number as shown on the connecting rod. Put connecting rod length grades controlled by
the temporary mark on the piston on the same side as the small end bush machining. If a new
the mark on the big end to ensure that they are connecting rod is fitted, ensure that it is of the
assembled correctly (A). correct length grade. (See Piston And
Connecting Rod Assembly on Page 70-40-8.)
4. Push the gudgeon pin out by hand. If the gudgeon pin
is tight, heat the piston to 40° - 50°C (100° - 120°F) for 4. Lubricate the gudgeon pin bosses with clean engine
easy removal of the gudgeon pin. lubricating oil and push in the gudgeon pin towards
the circlip. If the gudgeon pin is a tight fit in the piston,
5. Inspect the piston and connecting rod assembly. (See heat the piston to 40° - 50°C (100° - 120°F) before the
Piston And Piston Rings on Page 70-40-10.) and (See gudgeon pin is fitted.
Connecting Rod on Page 70-40-11.)
5. Fit a new circlip in the groove in the other gudgeon pin
boss. Ensure that it fits correctly in the groove.
6. Fit the piston rings. (See Piston Rings on Page 70-40-

7.)

(CONT’D)
Piston And Connecting Rod Assembly (Cont’d)
To Check The Length Of A Connecting Rod
A partially finished small end bush, which can be fitted to

the original connecting rod and machined to obtain the
correct length grade is available. (See Partially Finished
Small End Bush on Page 70-40-12.) Specialist
equipment and personnel with the correct training are
needed to machine the partially finished small end bush.
Connecting rod kits are also available with the small end
bush fitted and machined to obtain the correct connecting
S45065
rod grade.
Caution: It is important that the piston does not contact Identification of the length grade is by a letter or color
the cylinder head. Ensure that the piston height which is marked on the side of each connecting rod (A1).
above the cylinder block is correct. The letter F is the longest grade of connecting rod and
letter L is the shortest grade. The difference between
Caution: Ensure that the connecting rods are fitted in the grades is 0,046 mm (0.0018 in).
correct cylinder. Record the position of the

connecting rod and its relevant cylinder when it is If the grade letter or color on the side of the connecting
removed from the engine. rod cannot be seen, the length can be checked by the
measurement of the dimension (X) shown in (A). Before
To ensure that the piston height above the cylinder block the length of the connecting rod is measured, ensure that
is correct, the engine may have up to six length grades (F the bores of the big end and the small end are square
to L) of connecting rods fitted. and parallel. (See Connecting Rod on Page 70-40-11.)
The length is checked with the big end bearing removed
and the original small end bush fitted. The dimensions for
each grade are listed in the table below:
Grade Letter Color Code Length (mm)

F Red 165,728 - 165,761
G Orange 165,682 - 165,715
H White 165,637 - 165,670
J Green 165,591 - 165,624
K Purple 165,545 - 165,578
L Blue 165,499 - 165,532

(CONT’D)
Piston And Piston Rings
Inspection
1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in their

grooves and that the rings are not broken.
3. Remove the piston rings, see Operation 4 - 7, and

dean the piston ring grooves and the piston rings.
NOTE: Engine models RG, RH, RJ, and RK, have

S45066
pistons that have a tapered top groove and
the piston ring is wedge shaped. The top
piston ring clearance cannot be checked by 5. Clean all carbon from the top of the cylinder bore. Fit
this method. each piston ring in the top part of the cylinder bore
and measure the ring gap with feeler gauges (B). The
Figure 70-40-14 coil spring must be removed from the oil control ring
when the gap of this piston ring is measured.

The piston ring gaps for new components are given in the
relevant Data and dimensions for the “Piston rings”.
S45067
4. Fit new piston rings in the grooves and check for wear
of the grooves with feeler gauges (A). Compare the
piston ring clearance in the groove to that given for
new components in the relevant Data and dimensions
for the “Pistons and piston cooling jets”, and renew
the piston if necessary.

(CONT’D)
Connecting Rod
Inspection
1. Check the small end bush for wear or for other

damage and renew it, if necessary.
NOTE: Connecting rod kits are available with a new

small-end bush fitted and finished to the
correct grade. (See Piston And Connecting
Rod Assembly on Page 70-40-8.) to identify
the correct connecting rod grade.
A partially finished small end bush, which can be fitted to

the original connecting rod and machined to obtain the
correct length grade is also available. (See Partially
Finished Small End Bush on Page 70-40-12.)
2. Check the connecting rod for distortion. Refer to the

relevant Data and dimensions for the “Connecting
rods and big end bearings” to identify the correct

mandrel size.
NOTE: The large and small end bores must be square

and parallel with each other within the limits
of +/- 0,25 mm (0.010 in) measured 127 mm
(5.0 in) each side of the connecting rod axis
on a test mandrel. With the small end bush
fitted, the limits are reduced to +/- 0,06 mm
(0.0025 in).
3. Check the fit of the gudgeon pin in the small end bush
and check the gudgeon pin for wear, refer to the
relevant Data and dimensions for the “Gudgeon pins
and small end bushes”.

(CONT’D)
Partially Finished Small End Bush
NOTE: For details on how to change the partially

finished small end bush, contact your nearest
Perkins Dealer Distributor for advice.

PISTON AND CONNECTING ROD ASSEMBLIES Inspection Of The Jet Alignment
(CONT’D)
NOTE: Ensure that the end of a 1,70 mm (0.067 in)
Piston Cooling Jets diameter rod is round, to prevent damage to
the piston cooling jet bore.
Removal
Carefully insert a 1,70 mm (0.067 in) diameter tad. of 300
Release the set screw (A1) and remove the piston mm (11.8 in) in length, into the jet. If a suitable rod is not
cooling jet assembly. available, reduce the end of a thicker rod to 1,70 mm
(0.067 in) diameter for a length of 16,00 mm (0.630 in).
NOTE: The crankshaft is removed in (A) to show
clearly the piston cooling jet. Figure 70-40-17
Installation
1. Check that the spring loaded valve moves freely

against spring pressure in the valve assembly and
that the jet tube is not damaged. Renew piston
cooling jets as necessary.
2. Fit the piston cooling jet; ensure that the valve is fitted
correctly in the locating hole in the cylinder block.
Figure 70-40-16

S45069
When the rod is inserted into the jet it must extend out of
the top of the cylinder within the area shown in (A).
Replace the piston cooling jet, as necessary.
S45068
3. Fit the set screw (A1) and tighten to 9 N•m (7 Ibf ft.)
0,9 kgf m.


CRANKSHAFT ASSEMBLY The timing ring is an interference fit onto the machined
surface of the web, The timing ring is fitted behind the
General Description crankshaft palm and is located by a dowel.
The crankshaft is forged from chromium molybdenum The rear end oil seal is made from a PTFE material and
steel and has five main journals, There is a large flange is an integral part of the pressed steel housing, which is
at the rear of the crankshaft to which the flywheel is fitted. fitted to the cylinder block.
End-float and thrust movements are controlled by two The crankshaft pulley (A2) is held in position by a plain
split 3608 thrust washers on both sides of the center thrust block (A3) and three set screws (A4). The nose
main bearing. (A1) of the crankshaft and the pulley is serrated for
location.
The main bearings have steel backs with an aluminum -
tin bearing material, and main bearing caps are made of
cast iron or spheroidal graphite iron.
Figure 70-50-1

S45070

CRANKSHAFT ASSEMBLY (CONT’D)
Crankshaft Pulley Installation
Removal 1. Put the pulley (A2) in position on the crankshaft nose

(A1). Lubricate lightly the threads of the set screws
1. Remove the fan drive belt(s). (See Alternator on (A4) with clean engine lubricating oil. Fit the thrust
Page 70-140-1.) block (A3) and the set screws (A4) and tighten the
screws to 115 N•m (85 Ibf ft) 11,8 kgf m.
2. Remove the three set screws (A4) which hold the
pulley and remove the set screws, the thrust block 2. Check each set screw again to ensure that they are
(A3) and the pulley (A2). still to the correct torque.
3. Clean the components and check for damage. Renew 3. Fit the drive belt(s). (See Alternator on Page 70-140-
damaged components as required. 1.)
4. Check the area of the seal contact on the pulley for

wear. If there is excessive wear a wear sleeve can be
fitted. (See To Remove And To Fit A Wear Sleeve on
Page 70-50-7.)
Figure 70-50-2

S45070

CRANKSHAFT ASSEMBLY (CONT’D) NOTE: If the crankshaft palm has a wear groove
caused by the old oil seal assembly, a wear
Rear End Oil Seal Assembly sleeve must be fitted to the crankshaft palm
before the new assembly is fitted. (See To
Caution: The new rear end oil seal assembly includes a Remove And To Fit A Wear Sleeve on Page 70-
plastic protection sleeve (A2) that is fitted to the 50-7.)
inside of the seal. This sleeve is to protect the oil
seal from damage when it is fitted to the NOTE: An alignment tool is needed to fit the rear end
crankshaft palm (A1). The plastic sleeve must oil seal assembly.
remain inside the seal until the assembly is fitted.
When the assembly is fitted, the plastic sleeve will NOTE: The rear end oil seal cannot be used again and
be pushed out of the oil seal and the assembly. must be replaced if removed.
The plastic sleeve must be discarded after the
assembly is fitted. The seal of the new rear end oil Removal
seal assembly is pre-wexed, there is no need to
lubricate the palm or the seal before it is fitted. 1. Remove the drive components from the rear end of
the engine.
NOTE: The oil seal for the rear end oil seal assembly
cannot be renewed, if the seal is faulty, the 2. Remove the flywheel, (See Flywheel on Page 70-130-
complete assembly must be renewed. 1.) and the flywheel housing. (See Flywheel Housing
on Page 70-130-3.)
3. Remove the Torx screws from the rear end oil seal
housing and remove the assembly.

Figure 70-50-3
S45072

CRANKSHAFT ASSEMBLY (CONT’D) 2. Remove the new rear end oil seal assembly (A3) from
its pack. Ensure that the plastic sleeve (A2) supplied
Rear End Oil Seal Assembly (Cont’d) with the rear end oil seal is square within the rear end
oil seal. The plastic protection sleeve must be in place
Installation when the seal is fitted to the crankshaft palm, this will
prevent the seal being damaged when fitted.
Caution: To prevent contamination of the oil seal surface,
keep the new assembly packed until required for 3. Place the rear end oil seal over the crankshaft palm
use. and engage the plastic protection sleeve (B1) onto the
crankshaft palm (A1).
NOTE: The rear end oil seal cannot be used again
and must be replaced if removed. 4. With the plastic protection sleeve engaged on the
crankshaft palm, push the rear end oil seal assembly
1. Ensure that the crankshaft pal m (A1), the rear face of evenly and smoothly onto the crankshaft palm until it
the cylinder block and the bridge piece are dry, free is against the cylinder block. The plastic protection
from dirt, and that there are no rough metal edges. Do sleeve will be pushed out of the assembly (C).
not use a lubricant on either the crankshaft palm. or
on the rear end oil seal. as the seal is pre-waxed.
Figure 70-50-4

S45072
S45074 S45075

CRANKSHAFT ASSEMBLY (CONT’D) NOTE: Ensure that the two rubber locating pins are
correctly located into the cylinder block.
Rear End Oil Seal Assembly (Cont’d)
NOTE: Ensure that there is no distortion of the
Installation (Cont’d) rubber dust lip and that is in full contact with
crankshaft palm. If there is distortion, discard
5. Discard the plastic sleeve. the seal and replace with a new seal.
6. Rotate the rear end oil seal (D3) to align the holes in 9. Tighten set screws 1, 2, 3, 4, 5, 6, 7, and 10 in the
the rear end oil seal assembly with the holes in the sequence shown in (E) to 22 N•m (16 Ibf ft) 2,2 kgf m.
cylinder block rear face and the cylinder block bridge
piece. 10. Remove the alignment tool and tighten the remaining
Torx screws 8 and 9 in sequence (E) to 22 N•m (16 lbf
7. Loosely fit the Torx screws (D5). It) 2,2 kgf m.
8. Place the seal alignment tool (D4), onto the 11. Fit the flywheel, (See Flywheel on Page 70-130-1.)
crankshaft palm and over the rear end oil seal housing and the flywheel housing. (See Flywheel Housing on
to align the rear end oil seal to the crankshaft palm. Page 70-130-3.)
12. Fit the drive components to the rear end of the engine.
Figure 70-50-7

S45072
Figure 70-50-8
S45077

CRANKSHAFT ASSEMBLY (CONT’D) 1. Outer surface (F1) to be knurled
Rear End Oil Seal Assembly (Cont’d) 2. Remove all sharp edges
Alignment Tool 3. To be made from material EN 32, harden 0,5 mm

deep
The alignment tool (F) must be manufactured locally to
the following specifications NOTE: All dimensions are in millimeters.
Figure 70-50-9

S45078

CRANKSHAFT ASSEMBLY (CONT’D) Caution: The wear sleeve must be fitted within five
minutes of applying the sealant.
To Remove And To Fit A Wear Sleeve
4. Ensure that the crankshaft is fully forward in the
Special Requirements engine.
Special Tools Figure 70-50-11

POWERPART Liquid 21820518
Gasket
Removal
1. Remove the rear end oil seal. (See Rear End Oil Seal
2. With a sharp tool mark a deep line along the length of

the sleeve.
3. Insert a suitable thin blade between the crankshaft

palm and the sleeve next to the marked line. The wear S45080
sleeve will separate along the marked line.

4. Remove the wear sleeve. Use a suitable cleaner to 5. Place the wear sleeve onto the crankshaft palm (B3),
remove any sealant from the crankshaft palm. use the tool (B1) that is supplied with the new wear
sleeve and a suitable hammer, to force the wear
Installation sleeve (B2) over the crankshaft palm leaving a gap
(B5) of 0,4 - 0,6 mm (0.016 - 0.024 in).
1. Ensure that the crankshaft palm is dry and free from
oil, dirt and sealant. 6. Remove the tool and measure the gap (B5) between
the wear sleeve flange and the cylinder block in two
2. Remove any rough areas from the crankshaft palm places 180 apart. The correct gap is 0,4 - 0,6 mm
surface. (0.016 - 0.024 in).
Figure 70-50-10 7. After the wear sleeve has been fitted, check and
remove any rough metal edges from the crankshaft
palm and the wear sleeve.
8. Fit a new rear end oil seal. (See Rear End Oil Seal
S45079
3. Apply a small continuous bead of sealant (Al), that

does not harden, to the inner surface of the wear
sleeve 5,0 mm (0.197 in) from the flange end of 'the
sleeve (A1).

CRANKSHAFT ASSEMBLY (CONT’D) Figure 70-50-14
Thrust Washers
Inspection Of Crankshaft End-Float
Figure 70-50-12
S45083
The end-float can be checked with a feeler gauge

between a thrust washer and the crankshaft (B), or with a
dial test indicator on one end of the crankshaft to check
S45081 the movement (C).
If the end-float is more than the tolerance given in the

The axial movement of the crankshaft is controlled by relevant Data and dimensions for the “Crankshaft”, thrust
thrust washers fitted both sides of the center main washers which are 0,019 mm (0.0075 in) oversize can be
bearing (A). fitted.
Figure 70-50-13 The oversize thrust washers can be fitted to one or to

both sides of the main bearing. They are fitted instead of
the standard size washer, to reduce the end-float to the
factory tolerances.
S45082

Thrust Washers (Cont’d)
Removal
1. Drain the lubricating oil and remove the lubricating oil

sump. (See Sump on Page 70-100-6.)
2. If necessary, remove the lubricating oil pump. see

(See Lubricating Oil Pump Assembly on Page 70-
100-10.), or remove the balancer unit. (See Balancer
Unit on Page 70-50-17.)
3. Release the set screws of the center main bearing

and remove the main bearing cap complete with the
lower halves of the thrust washers.
Figure 70-50-15

S45084
4. Use a suitable tool (A1) made of a soft material to

push each of the upper halves of the thrust washers
from their recesses. Where necessary, move the
crankshaft to the front or to the rear to loosen a tight
washer.

CRANKSHAFT ASSEMBLY (CONT’D) 4. Ensure that the location thimbles (B2) are fitted
correctly in the main bearing cap or in the cylinder
Thrust Washers (Cont’d) block.
Installation 5. Ensure that the bearing is fitted correctly in the cap

and that the bearing and the crankshaft journal are
1. Lubricate the thrust washers with clean engine clean. Lubricate the bearing with clean engine
lubricating oil. lubricating oil.
Caution: Factory built engines have an upper shell 6. Fit the cap with the location tags of both halves of the
bearing that has an lubricating oil slot (C1) that is shell bearings to the same side (B1), ensure that the
fitted to the number one crankshaft journal. The plain bearing shell is fitted to the lower bearing cap
remaining upper shell bearings have a lubricating (B).
oil holes (C2). For service all upper shell bearings
will be replaced with bearings that have the 7. Tighten the main bearing set screws to 245 N•m (181
lubricating oil slot (C1). Ibf ft) 25,0 kgf m.
Figure 70-50-16
8. Ensure that the crankshaft turns freely. If the thrust
washers have been removed and fitted, check the
crankshaft end-float. (See Thrust Washers on Page
70-50-8.)
9. If necessary, fit the lubricating oil pump, (See
Lubricating Oil Pump Assembly on Page 70-100-10.)

or fit the balancer unit. (See Balancer Unit on Page
70-50-17.)
10. Fit the lubricating oil sump, (See Sump on Page 70-
Figure 70-50-18
S45085
2. Slide each of the upper halves of the thrust washers

into their recesses in the cylinder block. Ensure that
the sides of the thrust washers that have the grooves
(A1) are against the crankshaft.
3. Fit the lower half thrust washers to the main bearing

cap with the location tags in their recesses.
Figure 70-50-17
S45087
S45086

Main Bearings
Removal (With The Crankshaft In Position)
Caution: Ensure that the tops of the main bearing caps

are stamped with their relevant position number. Keep
the bearings with their relevant caps.
NOTE: If more than one set of main bearings are to

removed then identify, and keep each pair as
a set.
NOTE: If the rear main bearing cap is to be removed

with the crankshaft in position, the flywheel,
the flywheel housing, the rear end oil seal
assembly and the bridge piece will have to be
removed.
1. Drain the lubricating oil and remove the sump. (See

Sump on Page 70-100-6.)
2. Remove all necessary components to get access to

the specific bearing cap.
3. Release the set screws of the bearing cap and

remove the bearing cap. Remove the lower half of the
shell bearing from the cap.
Figure 70-50-19
S45088
4. With a suitable tool (A1), push the upper half of the

shell bearing from the side opposite to the location tag
(A2) to remove the bearing tag from its recess (A3) in
the bearing housing. Carefully rotate the crankshaft to
release the bearing from its housing.

CRANKSHAFT ASSEMBLY (CONT’D) 8. Fit all the components which were removed for
access to the main bearing cap.
Main Bearings (Cont’d)
9. Fit the lubricating oil sump, see Operation 10 - 5 J and
Installation (With The Crankshaft In Position) fill the sump to the correct level with lubricating oil of
an approved grade.
1. Clean the upper half of the shell bearing and lubricate
the bearing surface with clean engine lubricating oil. Inspection
Caution: Only the upper half of the bearing has 1. Inspect the bearings for wear and for other damage. If
lubrication holes and must be fitted to the cylinder block. a bearing is worn or damaged, renew both halves of
the shell bearings and check the condition of the other
2. Fit the plain end of the upper half of the bearing bearings.
between the crankshaft journal and the side of the
bearing housing which has the recess for the location
tag. Slide the bearing into its housing until the tag on
the bearing is fitted correctly in its recess in the
housing.
3. Clean the lower half of the bearing and the cap,

lubricate the bearing surface with clean engine
lubricating oil.
4. Fit the bearing into the cap with the tag of the bearing

fitted correctly in the recess in the cap.
Figure 70-50-20
S45089
5. Ensure that the location thimbles (A2) are fitted

correctly to the cap or to the cylinder block. Fit the
bearing cap with the location tags of both bearings on
the same side (A1).
6. Inspect the set screws for damage and for distortion

and renew them if necessary. Lightly lubricate the set
screw threads with clean engine lubricating oil. Fit the
set screws and tighten the set screws to 245 N•m
(181Ibf ft) 25,0 kgf m.
7. Ensure that the crankshaft turns freely. If the thrust

washers have been removed and fitted, check the
crankshaft end-float. See Operation 5 - 4.

CRANKSHAFT ASSEMBLY (CONT’D) 10. Remove the timing gears and the timing case. Timing
case and drive assembly.
Crankshaft
11. Remove the flywheel, (See Flywheel on Page 70-130-
Removal 1.) and the flywheel housing. (See Flywheel Housing
on Page 70-130-3.)
NOTE: If the crankshaft is to be renewed, it may be
necessary to change the grade of the 12. Remove the rear end oil seal housing. (See Rear End
connecting rods. (See Piston And Connecting Oil Seal Assembly on Page 70-50-3.)
Rod on Page 70-40-4.) This will occur if the
correct piston height above the block face 13. Remove the bridge piece.
cannot be maintained with the original piston
and connecting rod assemblies. (See Piston WARNING: The engine should be upside down
And Connecting Rod on Page 70-40-4.) before the fasteners for the crankshaft are
removed. If the engine cannot be turned upside
WARNING: Use lift equipment or obtain down support the crankshaft before the
assistance to life heavy engine components fasteners are removed.
such as the housing and the crankshaft.
14. Remove the caps of the connecting rods. Keep the
1. Before the engine is removed from the vehicle or from bearings and caps together. Remove the bolts of the
the machine, drain the lubricating oil and the coolant. connecting rods and carefully push the pistons
towards the top their bores. (See Piston And
2. Remove the lubricating oil sump. (See Sump on Page Connecting Rod Assembly on Page 70-40-8.)
70-100-6.)

15. Ensure that the tops of the main bearing caps are
3. Remove the fan, (See Fan on Page 70-120-10.), the stamped with their relevant position number. Remove
drive belts, (See Alternator on Page 70-140-1.), the the main bearing caps- the lower half of the shell
fan drive pulley and housing, (See Fan Drive on Page bearings and the upper and lower thrust washers.
70-120-10.)and the coolant pump. (See Coolant Keep the bearings with their relevant caps. (See
Pump on Page 70-120-6.) Thrust Washers on Page 70-50-8.) and (See Main
Bearings on Page 70-50-11.)
4. Remove the fuel injection pump:
16. Lift out the crankshaft. Remove the upper half of the
5. Remove the lubricating oil pump, see Operation 10 - bearings and keep each, bearing with its relevant
9, or remove the balancer unit, see Operation 5 - 15. lower half and cap.
- For Bosch VP30 fuel injection pumps. (See Bosch Caution: The engine should be upside down before the
VP30 Fuel Injection Pump on Page 70-110-12.) fasteners for the crankshaft are removed. If the engine
cannot be turned upside down support the crankshaft
- For Bosch EPVE fuel injection pumps. (See Bosch before the fasteners are removed.
EVPE Fuel Injection Pump on Page 70-110-17.),
- For Delphi DP210 fuel injection pumps. (See Delphi

DP210 Fuel Injection Pump on Page 70-110-20.)
6. Remove the crankshaft pulley. (See Crankshaft Pulley

on Page 70-50-2.)
7. Remove the alternator and its mounting bracket. (See

Alternator on Page 70-140-1.)
8. Remove the exhauster if fitted. (See Exhauster on

Page 70-150-4.)
9. Remove the timing case cover. (See Timing Cover on

Page 70-60-2.).

Crankshaft (Cont’d)
Installation
Special Tools
POWERPART Silicone 21826038
Adhesive
1. Ensure that all lubricating oil passages are clean and

free from restriction.
2. Clean the main bearing housings and the upper half S45090
of the bearings. Fit the shell bearings with the location
tags fitted correctly in their recesses. Lubricate the
Figure 70-50-22
bearings with dean engine lubricating oil.
3. Ensure that the main journals of the crankshaft are
clean. Put the crankshaft in position on the upper
bearings.
4. Clean and lubricate the upper halves of the thrust

washers and slide them into their recesses on both
sides of the bearing housing. Ensure that the slotted
sides of the thrust washers are towards the
crankshaft. (See Thrust Washers on Page 70-50-8.)
5. Clean the bearing caps and the lower half of the
bearings. Fit the bearings to the caps with the location
tags fitted correctly in their recesses. Lubricate the
bearings with clean engine lubricating oil.
S45091
6. Clean the lower halves of the thrust washers and
lubricate them with clean engine lubricating oil. Fit the
thrust washers on both sides of the bearing cap for 10. When the bridge piece is in position, inject POWER
the center main bearing. PART Silicone adhesive into the groove (B2) at each
end of the bridge piece. Continue to inject adhesive
7. Check that the location thimbles for the main bearing until the groove is completely full and the adhesive
caps are fitted correctly in the caps or in the cylinder leaves the lower groove (B1) at the front and rear of
block. Fit the bearing caps in their correct positions the bridge piece.
with the location tags of the bearings on the same
side. Figure 70-50-23
8. Fit the set screws to the main bearing caps and
tighten them to 265 N•m (196 Ibf ft) 27,0 kgf m.
9. Clean the bridge piece and the location areas for the
bridge piece in the cylinder block. Use a straight edge
(A2) to ensure that the bridge piece is in line with the
rear face of the cylinder block. Tighten the bridge
piece cap screws (A1) to 16 N•m (12 Ibf ft) 1,6 kgf m.
NOTE: The maximum protrusion for the bridge piece
(C2) to the cylinder block (C1) is 0 - 0,075 mm
(0 - 0.0029 in) (C3).
S45092

CRANKSHAFT ASSEMBLY (CONT’D) Inspection
Crankshaft (Cont’d) Check the crankshaft for wear and other damage. The
maximum permissible wear and ovality on the crankshaft
Installation (Cont’d) journals and crank pins is 0,04 mm (0.0016 in).
11. Fit the connecting rod caps. (See Piston And The main journals and the crank pins of standard size
Connecting Rod on Page 70-40-4.) Rotate the crankshafts can be machined to 0,25 mm (0.010 in), 0,50
crankshaft two turns to ensure free movement. mm (0.020 in) or 0,75 mm (0.030 in) undersize on
diameter, see “Crankshaft overhaul”. Special undersize
12. At the lubricating oil pump, (See Lubricating Oil Pump bearings are available.
13. Fit the rear end oil seal housing. (See Rear End Oil
Seal Assembly on Page 70-50-3.)
14. Fit the flywheel housing, (See Flywheel on Page 70-

130-1.) and the flywheel. (See Flywheel Housing on
Page 70-130-3.)
15. Fit the timing case and the timing gears. Timing case
and drive assembly.
16. Fit the timing case cover. (See Timing Cover on Page

70-60-2.)
17. Fit the exhauster if removed. (See Exhauster on Page

70-150-4.)
18. Fit the alternator and its mounting bracket. (See

Alternator on Page 70-140-1.)
19. Fit the crankshaft pulley. (See Crankshaft Pulley on

Page 70-50-2.)
20. Fit the fuel injection pump:
• For Bosch VP30 fuel injection pumps. (See Bosch

VP30 Fuel Injection Pump on Page 70-110-12.)
• For Bosch EPVE fuel injection pumps. (See Bosch

EVPE Fuel Injection Pump on Page 70-110-17.)
• For Delphi DP210 fuel injection pumps. (See Delphi

21. Fit the coolant pump, (See Coolant Pump on Page 70-
120-6.) the fan drive pulley and housing, (See Fan
Drive on Page 70-120-10.) the drive belts, (See
Alternator on Page 70-140-1.) and the fan. (See Fan
on Page 70-120-10.)
100-6.)
23. After the engine has been installed, fill the lubricating
oil sump to the correct level with an approved oil.

Crankshaft (Cont’d) Installation
Removal WARNING: Ensure that suitable protective

clothing is worn.
WARNING: Ensure that suitable protective
clothing is worn.
Caution: Apply heat to the timing ring evenly to reduce
the risk of damage and distortion to the timing ring (A1).
Caution: Apply heat to the timing ring only to reduce the Caution: Carefully fit the timing ring, do not damage the
risk of damage to the crankshaft.
crankshaft palm oil seal face.
Caution: Carefully remove the timing ring, do not
1. Ensure that the timing ring bore, and the crankshaft
damage the crankshaft palm oil seal face.
timing ring location shoulder, are both clean and free
from any rough metal edges.
1. Remove the crankshaft from the cylinder block. (See
Crankshaft on Page 70-50-13.)
2. If the locating dowel (A2) was removed press a new
locating dowel into the hole in the crankshaft web.
NOTE: If a “speed sleeve” (wear sleeve) has been
Ensure that the locating dowel is at the bottom of the
fitted to service the crankshaft palm seal
hole.
diameter, the shoulder of this sleeve must be
removed to give clearance for the timing ring.
3. Support the crankshaft in a vertical position with the

crankshaft palm at the top.
2. Support the crankshaft in a vertical position with the
crankshaft palm at the bottom.
4. Heat the timing ring (A1) in an oven to a temperature
of between 207° - 250°C (405° - 482°F). With the
Figure 70-50-24
timing ring bore chamfer and relief groove towards the
crankshaft web, and the dowel hole aligned with the
dowel, immediately fit the timing ring. Ensure that the
timing ring is fitted fully against the crankshaft web
shoulder.
5. Allow the timing ring to cool safely.
6. Fit the crankshaft to the cylinder block. (See

Crankshaft on Page 70-50-13.)
S45093
3. Apply heat to the timing ring (A1) with a flame. The

temperature of the timing ring must not exceed 270°C
(518°F). When heat is applied to the timing ring, the
ring will fall off the crankshaft web.
4. Discard the old timing ring after it has been allowed to

cool safely.
5. Do not remove the timing ring locating dowel (A2)

from the crankshaft web unless the locating dowel is
damaged.

Balancer Unit
Special Tools
Timing Pin 27610225
Removal
1. Drain the lubricating oil from the sump and remove the
sump, see Operation 10 - 4.
2. Set the piston of the number 1 cylinder to TOG, see S45096
Operation 8 - 1.
3. Insert the timing pin (C1) into the balancer, ensure
3. Fit two suitable M10 guide studs into positions (B1).
that the timing pin is fully located in the drive shaft.
WARNING: The weight of the unit is 4. Insert the timing pin (D1) into balancer, ensure that
approximately 25 kg (55 lb). the timing pin is fully located in the drive shaft and that
the balancer weights are pointing away from the
cylinder block.

4. Provide a support for the balancer unit before release
5. Carefully fit the balancer unit onto the two M10 guide
of the set screws from the engine.
studs in the cylinder block, check that the balancer
5. Release the set screws and carefully remove the unit is fitted correctly on the thimble and the dowel.
balancer unit. Ensure that the idler and crankshaft gears are in
mesh. Fit two set screws in the center positions of the
Installation
balancer frame, then tighten the set screws to 54 N•m
Figure 70-50-25 (40 lbf ft) 5,5 kgf m.
6. Remove the two M10 guide studs and fit the four
remaining set screws in their correct position. Tighten
the set screws to 54 N•m (40 Ibf ft) 5,5 kgf m.
7. Rotate the crankshaft through two turns to ensure that
it is free to rotate.
8. Fit the lubricating oil sump, (See Sump on Page 70-
Figure 70-50-27
S45095
1. Ensure that the contact faces of the cylinder block and

of the balancer unit are clean and that the thimble (A1)
and the dowel (A2) are fitted correctly to the cylinder
block or to the balancer unit.
2. Set the piston of the number 1 cylinder to TOG, see

Operation 8 - 1.
S45097

CRANKSHAFT ASSEMBLY (CONT’D) 4. Release the nut of the lubricating oil pump gear and
remove the nut. Using a suitable 2 legged puller
Oil Pump locate the puller arms on the back of the gear (B1)
and remove the lubricating oil pump gear from the
Disassembly shaft.
1. Remove the balancer from the engine. (See Balancer Figure 70-50-30
Unit on Page 70-50-17.)
2. To prevent movement of the drive shaft. Put a suitable

flat distance piece in position between the balancer
weights.
Figure 70-50-28
S45100

5. Release the four set screws (C1) from the lubricating
oil pump cover plate and remove the cover.
6. Inspect the lubricating oil pump. (See Lubricating Oil

S45098 Pump Assembly on Page 70-100-10.)
7. Dismantle the lubricating oil relief valve. (See Relief

3. Release the set screw and remove the idler gear Valve on Page 70-100-12.)
assembly (A).
NOTE: Keep the components together as an

assembly.
Figure 70-50-29
S45099

Oil Pump (Cont’d)
Assembly
Special Tools
POWERPART Threadlock and 21820117
nutlock
1. Assemble the lubricating oil relief valve. (See Relief

Valve on Page 70-100-12.) S45102
Figure 70-50-31
NOTE: Ensure that the flats on the thrust washer (B2)
are aligned.
4. If necessary, renew the idler gear. Lubricate the bush

with clean engine lubricating oil. Fit the hub into the
bush and fit the thrust washer onto the rear of the hub.

Ensure that the threads of the set screw are clean and
dry. Fit the set screw through the assembly and apply
a small amount of POWER PART Threadlock and
nutlock to the thread. Fit the assembly to the front of
the balancer unit. Tighten the set screw to 26 N•m (19
Ibf ft) 2,6 kgf m.
5. Check the end-float of the idler gear with a feeler

S45101 gauge between the front face of the idler gear and the
hub. Check the backlash between the idler gear and
the drive shaft gear. Refer to the Data and dimensions
2. Fit the four set screws (A1) to the lubricating oil pump for “Balancer unit”.
cover plate and tighten to 26 N•m (19 Ibf ft) 2,6 kgf m.
6. Fit the suction tube and the joint and tighten the set
3. Fit the lubricating oil pump gear and nut, gradually screws, if removed.
tighten to 95 N•m (70 Ibf ft) 9,7 kgf m.
7. Remove the distance piece from the balancer
weights.
8. Fit the balancer to the engine. (See Balancer Unit on

Page 70-50-17.)

CRANKSHAFT ASSEMBLY (CONT’D) 5. Check the rotor end-float with a straight edge and a
feeler gauge. For all the above clearances, refer to the
Oil Pump (Cont’d) Data and dimensions for the “Lubricating oil pump”.
Inspection 6. Lubricate the inner and outer rotor with clean engine
lubricating oil. Clean the top face of the oil pump and
NOTE: If any part is worn enough to have an effect on the inner face of the cover. Fit the cover. Tighten the
the performance of the oil pump, the complete set screws to 28 N•m (21 Ibf ft) 2,9 kgf m.
oil pump must be renewed.
1. Remove the set screws and remove the cover of the

oil pump.
2. Remove the outer rotor and clean thoroughly all the

parts. Check for cracks and any other damage.
Figure 70-50-33

S45104
3. Fit the outer rotor and check the outer rotor to body
clearance (A), refer to the Data and dimensions for
the “Lubricating oil pump”.
Figure 70-50-34
S45103
4. Check the inner rotor to outer rotor clearance (B),

refer to the Data and dimensions for the “Lubricating
oil pump”.

TIMING CASE AND DRIVE ASSEMBLY Figure 70-60-2
General Description
The timing case is made of either aluminum or cast iron.
The cast iron timing case is used to mount two power

take-off units.
The timing gears are made of steel. There are two

different types of steel camshaft gear and upper idler
gear. One for heavy duty and one for light duty. A power
take-off is available on either the left hand side. or the
right hand side or on both sides of the timing case. Some
engines have an idler gear with a roller bearing.
The drive from the crankshaft gear passes through an

idler gear to the camshaft gear and to the gear of the fuel S45106
injection pump. The drive from the crankshaft gear also
passes through a lower idler gear to the gear of the
lubricating oil pump. The coolant pump is driven by the
gear of the fuel injection pump. The camshaft and the fuel
injection pump run at half the speed of the crankshaft.

Figure 70-60-1
S45105
In (A) the electronic fuel pump gear is fitted. In (B) the

mechanical fuel pump gear is fitted.
The timing case contains the front oil seal.

TIMING CASE AND DRIVE ASSEMBLY (CONT’D)
Timing Cover
Removal
NOTE: To assist with access to the timing case cover,

the fan drive can be removed. (See Fan Drive
on Page 70-120-10.)
NOTE: The timing case cover can be removed with

the crankshaft pulley fitted.
1. Remove the coolant pump. (See Coolant Pump on

Page 70-120-6.)
Figure 70-60-3

S45107
2. Remove the set screws and the cover (A1), together

with the joint. 3 Remove the joint from the cover and 
discard the joint.

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) Figure 70-60-6
Timing Cover (Cont’d)
Installation
1. Clean the joint faces of the timing case and cover.
Figure 70-60-4
S45110
7. Tighten the cover set screws (C2) and coolant pump

fasteners (C1) together to 22 N•m (16 Ibf ft) 2,2 kgf m.
S45108 9. If removed fit the crankshaft pulley. (See Crankshaft

Pulley on Page 70-50-2.)
2. The new joint must be aligned by the three joint 10. Fit the fan drive. (See Fan Drive on Page 70-120-10.)
dowels (A1). The joint dowels are a push fit into the
cover (A2).
Figure 70-60-5
S45109
3. Fit two temporary studs (B1) through the timing case

and into the cylinder block.
4. Remove the timing pins, if fitted.
5. Fit the cover to timing case and loosely fit the set
screws.
6. Loosely fit the coolant pump. (See Coolant Pump on

Page 70-120-6.)

Mechanical Fuel Pump Gear
Removal
Special tools
Description Part number
Crankshaft timing pin 27610211
rocker arm tools 27610227
Camshaft timing pin 27610212
S45111
Caution: These procedures must only be carried out by
a person with the correct training.
Figure 70-60-8
Caution: If the Delphi DP210 fuel injection pump nut (A1)
is loosened before the fuel pump timing is set and the
pump locked, the fuel injection pump timing will be lost
and the fuel injection pump will have to be removed and
sent to your nearest Perkins Dealer / Distributor to be

reset.
Caution: The Delphi DP21 0 fuel injection pump must
remain locked if the fuel pump gear is removed. The fuel
injection pump timing will be lost and the fuel injection
pump will have to be removed and sent to your nearest
Perkins Dealer Distributor to be reset.
Caution: If the Bosch EPVE fuel injection pump timing is
lost, the pump timing can be reset on the engine. (See To
Check The Timing Of The Bosch EPVE Fuel Injection
S45112
Pump on Page 70-80-4.)
Caution: The timing pins are a push fit. Do not use
3. Apply pressure counter clockwise by hand to the fuel
excessive force to fit the pins.
pump gear (A2), to remove back lash from the gears
Caution: The engine is pin timed at TDC, do not use the
(B1), then lock the fuel injection pump.
pins as a locking device when repairs are carried out on
the engine. 4. There are two types of mechanical injection pump the
Bosch EPVE and Delphi DP210. Both have different
NOTE: The fuel pump gear can be removed with the locking screws and require a different method to lock
crankshaft pulley fitted. the pump.
NOTE: It is recommend to help rotate the crankshaft, • To lock the Bosch EPVE pump shaft, ensure the
that the glow plugs are removed. (See Starting backlash is removed. Loosen the locking screw (C2)
Aid (Glow Plug) on Page 70-140-7.) and remove the washer (C1). Tighten the locking
screw (C2) to 31 N•m (23 Ibf ft) 3,1 kgf m.
1. Rotate the crankshaft to TDG. (See To Set Number 1 • To lock the Delphi DP21 0 pump shaft, ensure the
Piston To TDC On The Compression Stroke on Page backlash is removed. Loosen the locking screw (D1)
70-80-2.) and move the washer (D2). Tighten the locking screw
(D1) to 17 N•m (12 Ibf ft) 1,7 kgf m. The washer (D2)
2. Remove the rocker arm. (See Rocker Arm on Page can now rotate around the locking screw (D1) with the
70-30-4.) pump shaft locked.
5. Release the nut (E2) and fit a suitable two legged
Caution: The backlash must be removed from all the
puller (E3). Tighten the puller until the gear is
gears before the fuel injection pump is locked. Failure to
released.
do so will make the fuel pump timing incorrect.
6. Remove the puller (E3) and the nut (E2). Remove the
gear (E1).

Mechanical Fuel Pump Gear (Cont’d)
Installation
Special tools
Caution: These procedures must only be carried out my

S45114
Caution: The drive shaft of the pump must not be turned
without the locking screw released, as this will damage
be the drive shaft. 4. Fit the washer and nut (B1) and tighten by hand.

Caution: The engine is pin timed at TOG, do not use the Caution: The backlash must be removed before the fuel
pins as a locking device when repairs are carried out on injection pump is released. Failure to do so will make the
the engine. fuel pump timing incorrect.

1. Clean and check the fuel pump gear and renew if Figure 70-60-11
damaged. Clean the fuel injection pump tapered shaft
(A1).
2. Check the engine is set to TDC. (See To Set Number

1 Piston To TDC On The Compression Stroke on
Page 70-80-2.)
Figure 70-60-9
S45115
5. Apply pressure counter clockwise by hand (B2) to the

fuel pump gear to remove the backlash from all the
gears (C1). Tighten the nut (B1) to 24 N•m (18 Ibf ft)
2,4 kgf m.
S45113
3. Fit the gear (A2) onto the tapered shaft (A1). Check
that the fuel pump gear is correctly in mesh with the 
idler gear.

Mechanical Fuel Pump Gear (Cont’d)
Figure 70-60-12
S45118
Figure 70-60-15
S45116

6. Release the locked fuel pump shaft.
• To release the Bosch EPVE pump shaft, ensure the

backlash is removed. Loosen the locking screw (D2)
and fit the washer (D1). Tighten the locking screw
(D2) to 12 N•m (9 Ibf ft) 1,2 kgf m.
• To release the Bosch EPVE pump shaft, ensure the

backlash is removed. Loosen the locking screw (D2)
and fit the washer (D1). Tighten the locking screw S45119
(D2) to 12 N•m (9 Ibf ft) 1,2 kgf m.
Figure 70-60-13 9. Check the fuel injection pump gear end-float (F1) and
the backlash (G1), see ''Timing case and drive
assembly.”
10. Lightly lubricate each gear with clean engine

lubricating oil.
70-60-2.)
12. Fit the glow plugs. (See Starting Aid (Glow Plug) on
Page 70-140-7.)
4.)
S45117
30-2.)
7. Tighten the nut (B1) to 88 N•m (65 Ibf ft) 9,0 kgf m.
8. Remove the two timing pins.

Electronic Fuel Pump Gear
Removal
Special tools
Fuel pump timing pin 27610032
S45120
3. With all three timing pins fitted (A1), remove the set
Caution: If the hub nut (A3) is loosened the fuel injection screws (A2) and the hardened washers from the gear.
pump timing will be lost and the fuel injection pump will
have to be removed and sent to your nearest Perkins Figure 70-60-17
Dealer / Distributor to be reset.

Caution: The timing pins are a push fit and must not be
forced into place.
Caution: The engine is pin timed at TOC, do not use the

the engine
NOTE: The fuel pump gear can be removed with the

crankshaft pulley fitted.
1. Rotate the crankshaft to obtain TDC. (See To Set

Number 1 Piston To TDC On The Compression
Stroke on Page 70-80-2.) S45121
2. Set the Bosch VP30 fuel injection pump timing. (See

To Check The Timing Of The Bosch VP30 Fuel 4. Remove the gear (B 1) from the hub (B2).
Injection Pump on Page 70-80-3.)

Electronic Fuel Pump Gear (Cont’d)
Installation

Caution: The engine is pin timed at TDC, do not use the

the engine.
NOTE: The fuel pump gear will only fit correctly in

one position.
Figure 70-60-18
S45123
Caution: To ensure that the engine is correctly timed,

backlash must be removed from all the gears.
5. Apply pressure counterclockwise by hand (B1) to the

fuel pump gear (B2), to remove the backlash.

6. Tighten the set screws (B3) to 22 N•m (161bf ft) 2,2
kgf m.
7. Remove the timing pins.
8. Check the fuel pump gear end-float and backlash, see

''Timing case and drive assembly”.
S45122
9. Lightly lubricate each gear with clean engine

1. Clean and check the fuel pump gear (A1) for damage lubricating oil.
and renew if necessary. Clean the fuel injection pump
hub (A3). 10. Fit the timing case cover. (See Timing Cover on Page
70-60-2.)
2. If the timing pin (A2) has been removed. rotate the
hub (A3) until the slot in the hub is aligned with the 11. Fit the glow plugs. (See Starting Aid (Glow Plug) on
hole in the pump body. Insert the timing pin through Page 70-140-7.)
the slot into the hub (A3) and fully into the body of the
fuel injection pump. 12. Fit the rocker cover. (See Rocker Cover on Page 70-
30-2.)
3. With all three timing pins fitted. fit the fuel pump gear
(A1) over the timing pin (A2) and onto the hub (A3).
4. Loosely fit the flat hardened washers and set screws

(B3).

Idler Gear and Hub
Removal
Figure 70-60-20
S45125
Figure 70-60-22
S45124

NOTE: There are two types of idler gear and hub. One
gear is bushed and the other is fitted with
roller bearings. This gear is the heavy duty
idler gear. To remove the heavy duty idler gear
assembly, the plate (A2) is removed and fitted
as part of the gear assembly. To dismantle the
assembly. (See Heavy Duty Idler Gear on Page
70-60-12.)
NOTE: When the idler gear is to be removed, it is S45126

good practice to mark the plate (A2) and the
idler gear, to help align the parts when they
are to be assembled. Figure 70-60-23
1. Remove the fuel pump gear; for the mechanical fuel

pump gear, (See Mechanical Fuel Pump Gear on
Page 70-60-4.) and for the electronic fuel pump gear.
(See Electronic Fuel Pump Gear on Page 70-60-7.)
2. Remove the rocker arm. (See Rocker Arm on Page

70-30-4.)
3. Remove the three set screws (A1) and the plate (A2)
from the idler gear. Remove the gear and the hub
assembly (B1) from the recess (D1) in the cylinder
block. The hub assembly (B1) must be moved forward
and lifted over the front oil seal housing (B2).
S45127
4. Slide the hub (C2) out of the gear (C1).

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) Caution: - The marked teeth (A2) on the idler gear must
not be used as timing marks
Idler Gear and Hub (Cont’d)
Caution: The engine is pin timed at TOG, do not use the
Installation pins as a locking device when repairs are carried out on
the engine.
Special Requirements NOTE: To fit the heavy duty idler gear assembly the
plate (B2) is fitted as part of the gear
Special tools assembly. The plate will be marked with the
Description Part number word TOP, ensure this is facing the front of the
engine this is to allow the gear assembly to be
Crankshaft timing pin 27610211 fitted correctly. To assemble the heavy duty
Camshaft timing pin 27610212 idler gear. (See Heavy Duty Idler Gear on Page
Fuel pump timing pin 27610032 70-60-12.)
1. Clean and check the hub and gear for damage, renew
Figure 70-60-24
if necessary.
2. Check the engine timing. (See To Set Number 1
Piston To TDC On The Compression Stroke on Page
70-80-2.)
3. Lubricate the hub with clean lubricating engine oil and
fit the gear to the hub. Rotate the hub in the gear to
align the oil way to the top.

Figure 70-60-26
S45128
Figure 70-60-25
S45130
4. Fit the hub assembly (C1) over the front oil seal
housing (C2) and into mesh with crankshaft gear and
camshaft gear. Check that the hole (D1) is towards
the cylinder head.
S45129
Caution: The hub assembly must be aligned correctly to

the plate (B2) and the cylinder block to allow the gear to
be lubricated.
Caution: The marked teeth (A2) on the idler gear must

be assembled to the hub so that they face to the front.

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) Removal And Installation Of Idler Gear Brushes
Idler Gear and Hub (Cont’d) Caution: If the bushes in the idler gear are to be
renewed, the backlash between the camshaft gear and
Installation (Cont’d) the idler gear, and between the idler gear and the fuel
pump gear must be accurate.
Figure 70-60-27
If the bushes are to be changed, remove them with a
suitable puller. If a puller is not available, machine off the
face of one of the bushes and press them out Press in
new bushes and machine the bores to get the correct
clearance on the hub. The gear must have the correct
backlash. Machine the faces to get the correct end
clearance.
When assembled, the idler gear backlash between the

crank gear and idler gear must be checked in four
positions. Rotate the crankshaft clockwise viewed from
the front, and check the backlash between the two gears
every 90°, see “Timing case and drive assembly”.
S45131

Figure 70-60-28
S45132
5. Align the plate (E2) to the three holes in the hub. Fit
the set screw (E3).
6. With the hub assembly fitted, tighten evenly the three

set screws (E3) to 44 N•m (32 lbf) 4,5 kgf m.
7. Check the end float (E1) and back lash. (See TIMING
CASE AND DRIVE ASSEMBLY on Page 70-60-1.)
8. Fit the mechanical fuel pump gear, (See Mechanical

Fuel Pump Gear on Page 70-60-4.) or the electronic
fuel pump gear. (See Electronic Fuel Pump Gear on
Page 70-60-7.).

4.)

Heavy Duty Idler Gear
Disassembly
Figure 70-60-29
S45133

1. Remove the set screw (A2), and the plate (A3) from
the assembly.
2. Press the hub (All) out of the bearing housing (A8).
3. Remove the circlip (A4) and the thrust washer (A5)

from the gear (A6). Slide the bearing housing (A8)
with the rollers (A7) out of the gear (A6).
NOTE: With the removal of the bearing from the gear,

the rollers (A7) will become loose.
4. Remove the circlip (A10) and the thrust washer (A9).

Heavy Duty Idler Gear (Cont’d)
Assembly
Figure 70-60-30
S45133

Special Requirements 4. Fit the thrust washer (A5) and the circlip (A4). Lightly
lubricate the bearing with clean engine lubricating oil.
Special tools
5. Press the gear assembly onto the hub (A 11).
POWERPART Threadlock 21820117 NOTE: If the old set screw (A2) is to be used. apply
and nutlock POWERPART Threadlock and nutlock.
Caution: The bearing and the hub must be fitted so that 6. Fit the plate (A3) and the set screw (A2) to the gear
the marked teeth of the heavy duty idler gear are to the assembly. Rotate the plate (A3) until the three holes
front. in the plate are aligned correctly to the three holes in
the hub (A 11). The plate (A3) will be marked with the
Caution: The new bearing assembly has a sleeve fitted,
word TOP, ensure this is facing the front of the
to hold the needle roller bearing securely. The sleeve
engine. Tighten the set screw (A2) to 9 N•m (7 Ibf ft)
must not be removed before the bearing assembly is
0,9 kgfm.
fitted into the gear. If the sleeve is removed from the
bearing assembly before the bearing is fitted, the bearing
rollers will become loose.
Caution: The hub assembly must be aligned correctly to
the plate (A3) and the cylinder block to allow the gear to
be lubricated.
Caution: If a used bearing assembly is dismantled and
the rollers become loose, a new bearing assembly must
be fitted.
1. Clean all parts and check for wear and damage,
renew as necessary.
2. Fit the circlip (A 10) into the back face of the gear (A6).
slide the thrust washer (A9) into the front face of the
gear bore (A1).
3. Align the new bearing assembly with the sleeve to the

front face (A1) of the gear bore. push the bearing
assembly out of the sleeve and into the gear bore.

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) Installation
Camshaft Gear NOTE: The camshaft timing pin is a push fit into the
timing case. The camshaft-gear will rotate a
Removal small amount when the pin is fitted. This is to
allow the assembly of the gears and removal
Caution: The engine is pin timed at TOC, do not use the of the backlash from the gears when needed,
pins as a locking device when repairs are carried out on with the timing pin fitted.
the engine.
1. Clean and check the camshaft gear and camshaft key
1. Remove the idler gear. (See Idler Gear and Hub on for wear and damage, renew if necessary.
Page 70-60-9.)
2. Ensure that the camshaft key is fitted correctly.
2. Remove the camshaft timing pin.
3. Fit the camshaft gear to the camshaft with the marked
Figure 70-60-31 teeth towards the front and the keyway correctly
aligned with the key. If necessary, lightly hit the gear
with a soft-face hammer to engage the key into the
keyway. Fit the camshaft timing pin. If the camshaft
needs to be rotated, remove the rocker arm.(See
Rocker Arm on Page 70-30-4.)
4. Fit the washer and set screw (A1) to the gear and
tighten the set screw to 95 N•m (70 Ibf ft) 9,7 kgf m.

5. Fit the idler gear. (See Idler Gear and Hub on Page
70-60-9.)
S45135
3. Remove the set screw (A1), with its washer, and

remove the gear from the camshaft. Ensure that the
key in the camshaft is not lost.

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) NOTE: If the timing case is removed from the engine.
the seal can be removed from the timing case.
Front Oil Seal Use a suitable adaptor to press the seal out of
the timing case. Ensure that the timing case is
Removal supported correctly, and that excessive
pressure is not used to remove the seal, this
Special Requirements can damage or distort the case.
Special tools
Three legged puller 27610230
To remove the oil seal from the timing case fitted to

the engine
WARNING: The oil seal is made of “Viton”, see

the safety precautions for “Viton Seals”.
Caution: The oil seal housing must not be damaged

when the oil seal is removed.
1. Remove the crankshaft pulley. (See Crankshaft

2. Thoroughly clean the area around the oil seal

housing.
Figure 70-60-32
S45136
3. Fit the legs (A2) of the puller under the oil seal and
lock into position.
4. Fit a suitable distance piece (A1) between the

crankshaft and the puller.
5. Remove the oil seal from the housing.
6. Discard the oil seal.

Front Oil Seal (Cont’d)
Installation
Figure 70-60-33
S45137

Special Requirements 1. Clean the oil seal housing and check for damage,
renew if necessary.
Special tools
Description Part number 2. Check the crankshaft pulley seal face for wear. To
repair the pulley. (See Front Oil Seal on Page 70-60-
Crankshaft front oil seal 21825577 15.)
replacer
Pressure plate for use with 21825578 3. Assemble the oil seal tool. Fit the fastener plate (A7)
21825577 to the front of the crankshaft.
Fastener plate for use with 21825580 4. Assemble the nut (A1) and the pressure plate (A2)
Adaptor for use with 27610217 onto the threaded bar (A3).
21825577
5. Align the seal (A6) and the sleeve (A5) to the front of
To Install The Oil Seal With The Timing Case Installed the oil seal housing (A8).
WARNING: The oil seal is made of “Viton”, see 6. Fit the adaptor (A4) onto the sleeve (A5).
the safety precautions for “Viton Seals.”
7. Put the pressure plate assembly onto the adaptor
(A4) and tighten the threaded bar (A3) onto the
Caution: New timing case oil seals have a sleeve (A5) fastener plate (A7). Check the alignment of the
fitted to protect the oil seal. Do not remove the sleeve assembly and the oil seal to the oil seal housing.
until the crankshaft pulley is to be fitted. Discard the new
oil seal if the sleeve (A5) is not fitted. 8. Fit a rod through the hole in the end of the threaded
bar to prevent movement of the bar when the nut is
Caution: Damage may be done to the seal if the correct tightened. Tighten the nut (A1) to push the seal into
tool is not used. the housing. Tighten until contact is made with the
bottom face of the oil seal housing.
Caution: It is important that only genuine Perkins parts
9. Remove the replacer tool.
are used. The use of a seal that is not a genuine Perkins
part may damage the engine and will affect the warranty. 10. Turn and pull the sleeve (A5) counterclockwise. to
remove the sleeve from the oil seal.
Caution: Do not lubricate the oil seal or the oil seal
housing. 11. Fit the crankshaft pulley immediately. (See Crankshaft

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) Installation Of A Wear Sleeve
Front Oil Seal (Cont’d) Figure 70-60-34
To Install the Oil Seal with the Timing Case Removed
1. Clean the oil seal housing and check for damage,

renew if necessary.
2. Check the crankshaft pulley for damaged. To repair

the pulley. (See Front Oil Seal on Page 70-60-15.)
3. Check that the new oil seal has the sleeve protector
fitted.
4. Align the oil seal to the oil seal housing. Do not S45138
lubricate the oil seal or the housing.
5. With a suitable tool, press the oil seal into the housing To renew a worn or damaged crankshaft pulley. a wear
until contact is made with the bottom face of the  sleeve (A2) is fitted over the spigot (A1).
housing.
1. Remove the crankshaft pulley. (See Crankshaft

6. Fit the timing case. (See Timing Case on Page 70-60- Pulley on Page 70-50-2.)
18.)
NOTE: Full instructions and a special tool to fit the
7. When the front timing case cover is fitted, turn and pull wear sleeve are in each service kit.
the sleeve protector counterclockwise, to remove the
sleeve from the seal. 2. Fit the wear sleeve, in accordance with the
manufacturer's instructions. It is not necessary to
8. Fit the crankshaft pulley immediately. (See Crankshaft remove the flange (A3) of the wear sleeve after it has
Pulley on Page 70-50-2.) been fitted. A new front oil seal (A4) must be used
when a wear sleeve is fitted.

Page 70-50-2.)

Timing Case
Removal
Special tools
S45139
NOTE: It is not necessary to remove the alternator, if
the belts and the link set screw are removed.
The alternator can be rotated away from the 12. Remove the internal set screws (A1) and the outer set
timing case. screws (A2) of the timing case.
1. Drain the lubricating oil and coolant. Figure 70-60-36
2. Remove the fan drive. (See Fan Drive on Page 70-

120-10.)
3. If not previously removed. remove the crankshaft

pulley. (See Crankshaft Pulley on Page 70-50-2.)
4. If required remove the alternator. (See Alternator on

Page 70-140-1.)

70-100-6.)
6. Remove the fuel injection pump:

• For Bosch fuel injection pumps. (See Bosch VP30 S45140
Fuel Injection Pump on Page 70-110-12.) or (See
Bosch EVPE Fuel Injection Pump on Page 70-110-
17.) 13. Remove the timing case from the cylinder block.
Remove the upper joint (B1) from the timing case, and 
• For the Delphi DP210 fuel injection pump. (See Delphi
the lower joint from the cylinder block.
14. Discard all old joints.
7. Remove the coolant bypass. (See Lubricating Oil
Cooler on Page 70-120-11.)
8. Remove the PTO, if fitted.
9. Remove the crankshaft timing pin and the camshaft

timing pin.
10. Remove the camshaft gear. (See Camshaft Gear on

Page 70-60-14.)
11. Remove the timing case oil seal if a new oil seal is to
be fitted. (See Front Oil Seal on Page 70-60-15.)

Timing Case (Cont’d)
Installation
Special tools
Alignment tool 27610216 S45142
POWERPART Retainer 21820608

4. Fit the upper timing case joint (B1) to the timing case
NOTE: If a new timing case is to be fitted, it may be (B2).
necessary to fit blanking plugs. Apply
POWERPART retainer, part number 21820608, Figure 70-60-39
to the blanking plug bore. This plug must be
fitted into the timing case before the case is

fitted to the engine.
1. Clean and check the timing case for damage, renew

if necessary.
Figure 70-60-37
S45143
5. Fit the alignment tool (C2) into the block, and secure
in place.
6. Fit the timing case (C1) over the alignment tool (C2)
and onto the cylinder block. Fit the set screws into the
S45141
timing case and tighten by hand.
2. Check that the camshaft thrust washer is fitted

correctly. Fit the lower timing case joint (A1) onto the
cylinder block.
3. Fit two temporary studs (A2) to the cylinder block.

TIMING CASE AND DRIVE ASSEMBLY (CONT’D) 14. Fit the timing case cover. (See Timing Cover on Page
70-60-2.)
Timing Case (Cont’d)
15. Fit the coolant pump. (See Coolant Pump on Page 70-
Installation (Cont’d) 120-6.)
Figure 70-60-40 NOTE: The coolant pump set screws should be

tightened together with the timing case cover
set screws.
16. Fit a new oil seal to the timing case. (See Front Oil
Seal on Page 70-60-15.)

Page 70-50-2.)
18. If removed fit the alternator. (See Alternator on Page

70-140-1.)
19. Fit the fan drive. (See Fan Drive on Page 70-120-10.)
S45144 20. When the engine is fitted into the application, fill the
lubricating oil sump to the correct level and with the
correct grade of engine lubricating oil. (See Sump on

7. Align the timing case (D2) to the cylinder block (D1). Page 70-100-6.) Fill the cooling system to the correct
level, and with the recommended POWERPART
NOTE: To seal the lubricating oil sump joint. ensure Antifreeze.
that the bottom of the timing case is correctly
aligned with the bottom of the cylinder block
before the set screws are tightened. The
alignment of the bottom face of the timing
case (D2) and the cylinder block (D1) must not
exceed ± 0,05 mm (0,002 in).
8. Tighten the set screws to 22 N•m (16 Ibf ft) 2,2 kgf m,
and check the alignment (C3) of the timing case face
to the cylinder block face, adjust if necessary.
9. Fit the coolant bypass. (See Lubricating Oil Cooler on

Page 70-120-11.)
100-6.)
11. Fit the camshaft gear. (See Crankshaft Gear on Page

70-60-21.)
12. Fit the idler gear. (See Idler Gear and Hub on Page
70-60-9.)
13. Fit the fuel injection pump:

• For Bosch fuel injection pumps. (See Bosch VP30
Fuel Injection Pump on Page 70-110-12.) or(See
Bosch EVPE Fuel Injection Pump on Page 70-110-
17.)
• For the Delphi DP210 fuel injection pump. (See Delphi

Crankshaft Gear Caution: Do not use a flame to heat the gear, as this can
cause local damage.
Removal
Figure 70-60-41
1. Remove the timing case. (See Timing Case on Page
70-60-18.)
2. The crankshaft gear is a transition fit on the

crankshaft. It may slide off easily or, if it is a tight fit
and the gear is to be renewed, it may be necessary to
remove the crankshaft, to remove the gear safely.
(See Crankshaft on Page 70-50-13.)
S45145
1. The gear (A1) can fit easily, or it may be necessary to

heat the gear before it will fit onto the crankshaft. If the
gear is to be heated, heat the gear in an oven to not
more than 200ºC (392ºF). If an oven is not available,
heat the gear in coolant which is at its boiling point.
2. Align the keyway in the gear to the key in the

crankshaft.
3. Fit the gear (A1) with the shoulder (A2) facing

outwards.
4. Fit the timing case. (See Timing Case on Page 70-60-

18.)

Camshaft and Tappets 1. Ensure that an components are clean and are
lubricated with clean engine lubricating oil.
Removal 2. With the engine upside down, fit the tappets into
position.
1. Remove the timing case. (See Timing Case on Page
70-60-18.) 3. Carefully fit the camshaft.
2. Remove the rocker cover. (See Rocker Cover on Figure 70-60-44

Page 70-30-2.)
3. Remove the rocker arm and the push rods. (See

Rocker Arm on Page 70-30-4.)
Figure 70-60-42

S45148
4. Fit the camshaft thrust washer (A2). Ensure that it is

fitted correctly onto the hollow dowel (A1).
5. Turn the engine the right way up.

S45146
6. Fit the timing case. (See Timing Case on Page 70-60-
18.)
Figure 70-60-43
7. Check that the camshaft end-float is within the limits.
see “Camshaft”.
8. Fit the push rods.

4.)
10. Adjust the valve tip clearance. (See Valve Tip

Clearances on Page 70-30-6.)
30-2.)
S45147
4. With the engine upside down, remove the camshaft

thrust washer (A1) and carefully remove the camshaft
(B).
5. Remove the tappets.

6. Inspect the camshaft and the tappets for wear and
other damage, also inspect the camshaft bush.
Renew the components as necessary.

CYLINDER BLOCK ASSEMBLY Cylinder Block
General Description Disassembly
The cylinder block is made of high duty cast iron with an The cylinder block is made of high duty cast iron with an
integral crankcase. The sides of the cylinder block extend integral crankcase. The sides of the cylinder block extend
below the crankshaft center line to give added strength. below the crankshaft center line to give added strength.
The cylinder block provides full length support for the The cylinder block provides full length support for the
cylinder bores. cylinder bores.
All bores are honed with silicon carbide tools to a NOTE: If the cylinder block is to be renewed, it may
controlled finish to ensure long life and low oil be necessary to change the grade of the
consumption. A bush is fitted in the cylinder block for the connecting rods. (See Connecting Rod on
front camshaft journal and the other camshaft journals Page 70-40-11.) This will occur if the correct
run directly in the block. piston height above the block face cannot be
maintained with the original piston and
NOTE: Your Perkins Dealer / Distributor has connecting rod assemblies. (See Piston And
specialist equipment and personnel with the Connecting Rod Assembly on Page 70-40-8.)
correct training to repair worn cylinder bores.
NOTE: All of the components that need to be
removed for access to the cylinder block are
referred to in the procedure below. As a result
some of the stages within operations may be
repeated.

1. Ensure that all engine fluids are drained.
2. Remove the ECM, if fitted, (See Engine Control

Module (ECM) on Page 70-140-11.) the wiring
harness, and the speed and timing sensor, if fitted.
(See Speed And Timing Sensor on Page 70-140-15.)
3. Remove the VLPM, if fitted, “Voltage Load Protection

Module” on page 13.
4. Remove the lubricating oil cooler. (See Lubricating Oil

5. Remove the lubricating oil filter head. (See Filter

Head on Page 70-100-5.)
6. Remove the cylinder head. (See Removal on Page

70-30-9.)
7. Remove the crankshaft. (See Crankshaft on Page 70-

50-13.)
8. Remove the piston and the connecting rod

assemblies. (See Piston And Connecting Rod on
Page 70-40-4.)
9. Remove the camshaft. (See Camshaft and Tappets

on Page 70-60-22.)
10. Remove the piston coating jets, if fitted. (See Piston

Cooling Jets on Page 70-40-13.)

CYLINDER BLOCK ASSEMBLY (CONT’D) 13. Fill the lubricating oil sump to the correct level with an
approved lubricating oil.
Cylinder Block (Cont’d)
14. Eliminate air from the fuel system. (See Removing Air
Assembly From The Fuel System on Page 70-110-11.)
Special Requirements Inspection
Consumable products 1. Clean the internal passages for the coolant and the
Description Part number oil.
POWERPART Threadlock 21820117 2. Check the cylinder block for cracks and for other
and nutlock damage.
The cylinder block is made of high duty cast iron with an Figure 70-70-1
integral crankcase. The sides of the cylinder block extend
below the crankshaft center line to give added strength.
The cylinder block provides full length support for the
cylinder bores.
1. Clean thoroughly the new cylinder block. Ensure that

all the oil passages are clean and free from debris.
2. Remove the threaded plugs from the old cylinder

block and clean the threads. Seal the threads with
POWER PART Threadlock and nutlock, and fit the
threaded plugs into the new cylinder block.
3. Fit the piston cooling jets. (See Piston Cooling Jets on

Page 70-40-13.) S45149
4. Fit the crankshaft. (See Crankshaft on Page 70-50-

13.) Do not fit the lubrication oil sump at this time. 3. Check the camshaft bush for wear. If the bush is to be
renewed, use a suitable adaptor to press it out of the
5. Fit the piston and connecting rod assemblies. (See bore. Ensure that the lubricating oil hole in the new
Piston And Connecting Rod on Page 70-40-4.) bush (A1) will be towards the front of the engine when
fitted. Press in the new bush with the oil hole on the
6. Fit the camshaft. (See Camshaft and Tappets on same side and aligned with the oil hole in the block
Page 70-60-22.) until the front end of the bush is aligned with the face
of the recess.
7. Fit the lubricating oil filter housing. (See Filter Head
on Page 70-100-5.)
8. Fit the lubricating oil cooler. (See Lubricating Oil

9. Fit the ECM, if removed, (See Engine Control Module

(ECM) on Page 70-140-11.) the wiring harness, and
the speed and timing sensor, if removed. (See Speed
And Timing Sensor on Page 70-140-15.)
10. Fit the VLPM, if removed. (See Voltage Load

Protection Module on Page 70-140-13.)
11. Install the engine into the vehicle or machine.

CYLINDER BLOCK ASSEMBLY (CONT’D)
Cylinder Bore
Inspection
To ensure the best performance during the life of the

engine it is important that worn or damaged cylinder
bores are re-bored and re-honed.
The condition of a cylinder bore is decided by:
• The amount and location of any polished areas.
• Wear 4.
• Damage to the bore wall.
NOTE: It will not be necessary to re-bore / re-hone if:
• The honed finish can still be clearly seen.
• The engine performance and oil consumption are

acceptable.

To Check The Condition Of A Cylinder Bore
1. Inspect the bore surface for cracks and deep

scratches.
2. Check the bore wall for areas where the honed finish
has been polished away. Check especially the area
around the top of the bore just below the carbon ring.
In this area, thrust from the top piston ring is at its
maximum.
Caution: Do not use “Flex-hone” to repair cylinder bores.
Caution: New oversized piston and rings must be fitted

when the cylinder bore is re-bored / re-honed.
Caution: An engine can have high oil consumption with

very little wear of the bores, if the surfaces of the bores
are glazed.
Caution: Specialist training and equipment are needed

to machine the finish of a cylinder bore.


ENGINE TIMING Figure 70-80-2
General Description
To ensure that the 1100 Series 4 cylinder engines have

an accurate system of timing, the engines are pin timed.
This system will set the engine so that number one piston
is at top dead center (TOG) on the compression stroke.
To reach the accurate fuel injection needed for engines to

conform to emissions legislation, the latest fuel injection
pumps operate at a static timing of TDC.
It is important that fuel injection timing is accurate to

conform to emissions legislation. Always use Operation S45465
8-1 to obtain TOG on the compression stroke of number
one cylinder.
Caution: The Delphi DP210 nut (B1) must not be
Figure 70-80-1 released until TOG on the compression stroke is set, the
backlash is removed from the fuel injection pump gear
and the fuel pump shaft is locked. If the nut (B1) is
loosened before TDG on the compression stroke is set
and the fuel pump shaft is locked the fuel pump timing

will be lost. The pump will have to be removed and sent
to your nearest Perkins Dealer / Distributor to be reset.
Caution: The Bosch EPVE nut (B1) must not be

released until TDC on the compression stroke is set, the
backlash is removed from the fuel injection pump gear
and the fuel pump shaft is locked. If the nut (B1) is
loosened before TOG on the compression stroke is set
and the fuel pump shaft is locked, the fuel pump timing
will be lost. To adjust the fuel pump timing. (See To
S45150 Check The Timing Of The Bosch EPVE Fuel Injection
Pump on Page 70-80-4.)
Caution: If the hub nut (A1) is loosened the Bosch VP30

fuel injection pump timing will be lost and the fuel
injection pump will have to be removed and sent to your
nearest Perkins Dealer / Distributor to be reset.

ENGINE TIMING (CONT’D) 4. To set the No 1 piston to TOC on the correct stroke.
Rotate the crankshaft in the normal direction of
To Set Number 1 Piston To TDC On The Compression rotation until the intake valve (A7) of number 4
Stroke cylinder has just opened and the exhaust valve (A8)
of the same cylinder has not closed completely.
Figure 70-80-4
SPECIAL TOOLS
Fuel Pump Timing Pin 27610212
Caution: This procedure must only be carried out by a

person with the correct training.
Caution: The timing pins are a push fit. Do not use

excessive force to fit the pins
Caution: Do not use the pins as a locking device when

repairs are carried out on the engine.
S45464
Caution: The timing pins must be removed before the

timing case cover is fitted. Failure to do so will damage
5. Carefully rotate the crankshaft in the normal direction
the engine.
of rotation. Align the hole in the crankshaft with the
hole in the cylinder block and the timing case (B1).
Caution: The marks on the timing gears are not to be
Insert the crankshaft timing pin through the timing
used as timing marks. The marks indicate the front of the
case and the cylinder block. Push the pin fully into the
gear only
hole in the crankshaft web.
1. Remove the rocker cover. (See Rocker Cover on
6. Insert the camshaft timing pin, through the hole in the
Page 70-30-2.)
camshaft gear (B2) and into the body of the timing
2. Remove the glow plugs. (See Starting Aid (Glow case. With the two timing pins fitted the engine is set
Plug) on Page 70-140-7.) at TOC number one on the compression stroke.
3. Remove the timing case cover. (See Timing Cover on NOTE: The camshaft timing pin is a push fit into the
Page 70-60-2.) timing case. The camshaft-gear can rotate a
small amount when the pin is fitted. This is to
NOTE: The crankshaft timing pin can be inserted with allow the assembly of the gears and removal
the crankshaft pulley still fitted. of the backlash from the gears, with the timing
pins fitted.
Figure 70-80-3
7. Remove the timing pin from each gear.

70-60-2.)

Page 70-140-7.)
30-2.)
S45151

ENGINE TIMING (CONT’D) Figure 70-80-6
To Check The Timing Of The Bosch VP30 Fuel

Injection Pump
SPECIAL TOOLS
Camshaft Timing Pin 27610212
Fuel Pump Timing Pin 27610032
Caution: This procedure must only be carried out by a

person with the correct training
S45466
Caution: If the hub nut (C1) is loosened the fuel injection
pump timing will be lost and the fuel injection pump will
have to be removed and sent to your nearest Perkins 2. Insert the fuel pump timing pin through the gear (A1)
Dealer / Distributor to be reset. and through the slot in the hub (B1). Push the pin fully
into the hole (B2) in the body of the fuel injection
Caution: Do not use the pins as a locking device when pump.
repairs are carried out on the engine.
3. With all three timing pins fitted, the engine is set at

Caution: The fuel pump timing pin is a push fit. Do not TDC No 1 piston and the fuel injection pump timing is
use excessive force to fit the pin. correct
1. Rotate the crankshaft to obtain TDC. (See To Set 4. If the timing pin cannot be pushed into the fuel
Number 1 Piston To TDC On The Compression injection pump body, and the engine is correctly set at
Stroke on Page 70-80-2.) TDC. (See To Set Number 1 Piston To TDC On The
Compression Stroke on Page 70-80-2.) The fuel
NOTE: Do not remove the timing pins from the engine injection pump must be removed, (See Bosch VP30
after TDC is set. Fuel Injection Pump on Page 70-110-12.) and sent to
your nearest Perkins Dealer / Distributor to be reset.
Figure 70-80-5
5. Remove all timing pins from the engine.
Figure 70-80-7
S45152
S45467

ENGINE TIMING (CONT’D) 3. Remove the plug (A1) and washer from the rear of the
fuel pump and fit the Bosch EPVE fuel pump timing 
To Check The Timing Of The Bosch EPVE Fuel adaptor (B1), and a suitable dial gauge (B2). Set the
Injection Pump dial gauge to indicate approximately 3,0 mm (0.12 in).
Special Requirements 4. Slowly rotate the crankshaft, counterclockwise from

the front of the engine, until the dial gauge indicates
SPECIAL TOOLS that the plunger of the fuel injection pump is at the
bottom of its stroke. Set the dial to zero.
Bosch EPVE fuel pump 27610248 5. Slowly rotate the crankshaft clockwise, until the
timing adaptor crankshaft timing pin can be pushed into the
crankshaft web. With the engine set at TDC, check
Caution: This procedure must only be carried out by a the reading on the dial gauge. Fuel injection pump
person with the correct training. with the code ER has a plunger lift of 1,55 mm
(0.061in).
Number 1 Piston To TDC On The Compression 6. If the fuel pump timing is correct, remove the dial
Stroke on Page 70-80-2.) gauge and the Bosch EPVE fuel pump timing adaptor.
Fit a new washer and the plug. Tighten the plug to 29
2. Remove the high pressure fuel pipes from the fuel N•m (21 Lbf ft) 2,9 kgf m.
injection pump.
7. If the fuel injection pump timing is to be adjusted. (See
Figure 70-80-8 To Check The Timing Of The Bosch EPVE Fuel

Injection Pump on Page 70-80-4.)
8. Fit the high pressure fuel pipes to the fuel injection

pump.
9. Eliminate the air from the fuel system. (See Removing

Air From The Fuel System on Page 70-110-11.)
S45153
Figure 70-80-9
S45468

ENGINE TIMING (CONT’D) 7. Rotate the crankshaft slowly clockwise, until the
needle of the dial gauge indicates the required
To Adjust The Timing Of The Bosch EPVE Fuel plunger lift. (See To Check The Timing Of The Bosch
Injection Pump EPVE Fuel Injection Pump on Page 70-80-4.)
Special Requirements Figure 70-80-11
SPECIAL TOOLS
Bosch EPVE fuel pump 27610248
timing adaptor
Caution
• This procedure must only be carried out by a person

with the correct training.
• Do not turn the fuel injection pump with the pump

shaft locked.
S45469
1. Rotate the crankshaft to obtain TDC, see Operation

8 - 1.
8. To lock the Bosch EPVE pump shaft, loosen the

locking screw (B2) and remove the washer (B1).
2. Remove the rocker arm, see Operation 3 - 4.
Tighten the locking screw (B2) to 31 N•m (23 ft-lb) 3,1
kgf m. Ensure that the needle of the dial gauge has
3. Remove the high-pressure fuel pipes from the fuel
not moved.
injection pump.
Figure 70-80-10 9. Remove the Bosch Mechanical fuel pump gear. (See
Mechanical Fuel Pump Gear on Page 70-60-4.)
Figure 70-80-12
S45154
4. Remove the plug and washer from the rear of the fuel S45155
pump and fit the Bosch EPVE fuel pump timing

adapter (a!) and a suitable dial gauge (A2). Set the
dial gauge to indicate approximately 3,0 mm (0.12 in). NOTE: There is no key fitted into the keyway (C1).
5. Remove the timing pins.
6. Rotate the crankshaft slowly counter-clockwise and

then clockwise, until the needle of the dial gauge
indicates that the plunger of the fuel injection pump is
at the bottom of its stroke. Set the dial to zero.

ENGINE TIMING (CONT’D) 13. Fit the glow plugs. (See Starting Aid (Glow Plug) on
Page 70-140-7.)
To Adjust The Timing Of The Bosch EPVE Fuel
Injection Pump (Cont’d) 14. Fit the high pressure fuel pipes.
Figure 70-80-13 15. Fit the timing case cover. (See Timing Cover on Page
70-60-2.)
4.)
30-2.)
S45471
NOTE: If the fuel injection pump is on the correct

stroke, the keyway (C1) is towards the outlet
(D1).

Stroke on Page 70-80-2.)
11. Fit the fuel pump gear. (See Mechanical Fuel Pump
Gear on Page 70-60-4.)
Figure 70-80-14
S45470
12. Ensure that the needle of the dial gauge has not
moved. Remove the dial gauge and the Bosch EPVE
fuel pump timing adaptor (A1). Fit a new washer and
tighten the plug (E1) to 29 N•m (21 Ibf ft) 2,9 kgf m.

ENGINE TIMING (CONT’D)
To Check The Timing Of The Delphi DP210 Fuel

Injection Pump
Caution: The fuel pump timing of the Delphi DP210 fuel

injection pump most not be checked or adjusted. If
the fuel pump timing is lost, the pump must be removed
and sent to your nearest Perkins Dealer / Distributor to
be reset.
NOTE: To remove the Delphi DP210 fuel injection

pump, see Operation 11 - 13.

ENGINE TIMING (CONT’D) 7. Rotate the crankshaft, clockwise from the front, until
the intake valve of the rear cylinder has just opened,
To Check The Valve Timing and the exhaust valve has just closed. Set the valve
tip clearance of the intake valve of No 1 cylinder to
NOTE: Do not fit the timing case cover, the glow 0,20 mm (0.008 in). Set the valve tip clearance of the
plugs or the rocker cover at this stage exhaust valve of No 1 cylinder to 0,45 mm (0.018 in).
1. Set the piston of number 1 cylinder to TDC on the 8. Fit the timing case front cover. (See Timing Cover on
compression stroke. (See To Set Number 1 Piston To Page 70-60-2.)
TDC On The Compression Stroke on Page 70-80-2.)
2. Mark the pulley at TDC. Set a temporary pointer to the Page 70-140-7.)
mark.
3. For naturally aspirated engines: 30-2.)
• Set the valve tip clearance of number 1 cylinder intake 11. Remove the temporary pointer from the timing case
valve to 0,589 mm (0,023 in) and No 1 exhaust valve and the timing mark from the pulley.
to 0,698 mm (0.027 in).
4. For turbocharged engines:
• Set the valve tip clearance of number 1 cylinder intake

valve to 1,220 mm (0.048 in) and No 1 exhaust valve

to 1,302 mm (0.051 in).
5. Rotate the crankshaft, clockwise from the front, until

the push rod of number 1 cylinder intake valve is just
loose and the push rod for number 1 exhaust valve is
equally loose. In this position, check if the mark on the
crankshaft pulley or damper is within +/- 2.5° of the
temporary pointer. Use the formula below to find the
measurement which is equal to 2.5° on the pulley or
damper.
CxP
360
C = circumference of pulley or damper
P = 2.5 degrees
NOTE: One tooth on the camshaft gear is equivalent

to 18 mm (0.62in) at the circumference of a
pulley of 200 mm (7.87 in) diameter.
NOTE: One tooth on the camshaft gear is equivalent

to 16 mm (0.70 in) at the circumference of a
pulley of 170 mm (6.69 in) diameter.
6. If the timing is more than 2.5° out of position, the

timing gears are likely not to be in correct mesh.

ASPERATION SYSTEM
General Description
Air Circuit of Turbocharger
Compressed Air Flow
Engine
Cylinder
Turbocharger Oil Inlet
Charged Air Cooler
Compressor Turbine Wheel
Ambient Exhaust
Air Inlet Gas
Discharge
Compressor Wheel
Wastegate
Oil Outlet

S47106
WARNING: Turbochargers operate at high Figure 70-90-2

speed and at high temperatures. Keep fingers,
tools and debris away from the inlet and outlet
ports of the turbocharger and prevent contact
with hot surfaces.
Figure 70-90-1
S45156
All turbochargers that are fitted with a waste-gate unit

(B1). The waste-gate, which is controlled by boost
pressure from the inlet manifold, will allow some of the
exhaust gases to bypass the turbine rotor at higher
S45157 engine speeds. With this arrangement the turbocharger
can be designed to be more effective at lower engine
The turbocharger is fitted between the exhaust and speeds.
intake manifold and is driven by exhaust gas. The
turbocharger passes air to the engine at more than
atmospheric pressure. It is lubricated by oil from the main
gallery. The oil enters through the bearing housing of the
turbocharger and returns to the cylinder block. From
there it is returned to the lubricating oil sump.

ASPERATION SYSTEM (CONT’D) 4. Fit the set screws (A3) and tighten to 44 N•m (33 Ibf
ft) 4,5 kgf m.
Exhaust Elbow
NOTE: If the support bracket (B1) is to be removed
Removal and fitted, remove the exhaust elbow, and
remove the three set screws that hold the
Figure 70-90-3 support bracket. To fit the bracket, align the
support bracket to the cylinder block. Fit the
top set screw (A2) to align the bracket, then fit
the two remaining set screws. Tighten to 44
N•m (33 Ibf ft) 4,5 kgf m.
5. Connect the exhaust elbow to the application.
S45158

1. Remove the two set screws (A3) from the exhaust
elbow (A1).
2. Pull the exhaust elbow (A1) away from the adaptor

(A4).
Installation
1. Ensure that all the component faces are clean and

free from damage, renew if necessary.
2. Push the exhaust elbow (A1) onto the adaptor (A4).
Figure 70-90-4
S45334
3. Align the exhaust elbow (A1) to the support bracket (B

1) and the exhaust pipe of the application.

ASPERATION SYSTEM (CONT’D) 8. Remove the set screws (A4) from the bottom flange of
the oil drain pipe.
Turbocharger Side Mount
9. Remove the nuts (A1) at the turbocharger to exhaust
WARNING: The sealing washers used on the manifold flange. Remove the turbocharger and the
lubricating oil pipe (B1) contain Viton. Read the gasket with the drain pipe. Remove the bottom joint of
safety precautions. the drain pipe.
WARNING: Discard old lubricating oil in a safe 10. Remove the set screws from the top of the oil drain
place and in accordance with local regulations. pipe and remove the pipe and joint from the
turbocharger. Discard all old joints and gaskets.
Cover the open ports in the manifold, the
Caution: Ensure that the turbocharger waste-gate and turbocharger and the pipes to ensure that dirt will not
the actuator rod of the waste-gate are not used to lift or enter.
move the turbocharger. This could damage the waste-
gate and affect the calibration. 11. Check the air hoses and the oil drain pipe for damage,
renew if necessary.
Remove
Figure 70-90-6
1. Thoroughly clean the turbocharger.
2. Remove the air cleaner hose at the compressor inlet.
3. Put a suitable container under the oil drain pipe.

4. Disconnect the exhaust pipe for the application and
remove the exhaust elbow from the turbocharger.
(See Exhaust Elbow on Page 70-90-2.)
Figure 70-90-5
S45335
S45159
5. Remove the three nuts (A2) of the adaptor plate and

remove the adaptor plate (A3).
6. Release the hose clip of the compressor outlet.

Remove the set screws of the crossover pipe.
Remove the crossover pipe complete with the old
gasket and hose. Discard the gasket.
7. Remove the banjo bolts (A5) and the sealing

washers. Remove the pipe and discard the old
sealing washers.

ASPERATION SYSTEM (CONT’D) 4. Fit a new gasket (A4) to the exhaust manifold flange.
If the original nuts are to be used, ensure that the
Turbocharger Side Mount (Cont’d) threads of the studs are clean. Apply a suitable
compound to the studs to prevent seizure.
Installation
NOTE: The threads of new nuts are phosphated to
WARNING: The sealing washers used on the prevent seizure.
lubricating oil pipe (B1) contain Viton. Read the
safety precautions. Figure 70-90-8
Caution: The compressor inlet hose has a heat shield

material that partly covers the hose. When a new hose is
fitted, the hose must be correctly aligned to the exhaust
to protect the hose from the heat.
Caution: When a new compressor inlet hose is to be
fitted, use a water and 5% soap solution to fit the hose
into position. Do not use oil or grease.
Caution: The reflective heat shield of the inlet hose must
be kept clean and free from dust, oil or paint. If the
surface of the heat shield is not shiny, the part that is
protected by the heat shield could be damaged.
1. Remove the covers from the pipes, manifold and

S45336

turbocharger.
2. Check that the turbocharger inlet and outlet ports are 5. Fit the turbocharger (A1). Fit the nuts (B1) and tighten
clean and free from restriction and that the them to 47 N•m (34 Ibf ft) 4,8 kgf m.
turbocharger shaft rotates freely. Also check that the
open ports in the intake crossover pipe and the 6. Fit the bottom flange of the pipe (A2) together with a
exhaust pipe are clean and free from restriction. new joint and tighten the flange set screws to 22 N•m
(161bf ft) 2,2 kgf m. Tighten the top flange set screws
Figure 70-90-7 to 9 N•m (7 Ibf ft) 0,9 kgf m.
7. Lubricate the bearing housing of the turbocharger

with clean engine lubricating oil. Fit loosely the pipe
(A3) and new sealing washers. Tighten both banjo
bolts to 22 N•m (16 Ibf ft) 2,2 kgf m.
NOTE: Ensure that the lubricating oil pipe (A3) does

not come in contact with other components.
S45160
3. Fit loosely the drain pipe (A2) and its new joint to the
turbocharger (A1).
NOTE: The turbocharger drain pipe has different size

set screws. The top flange has 6 mm set
screws and the bottom flange has 8 mm set
screws.

ASPERATION SYSTEM (CONT’D) Check The Operation Of The Waste-gate
Turbocharger Side Mount (Cont’d) If the waste-gate valve does not operate at the correct
pressure, it can affect the engine performance.
If the valve opens at a low pressure, this can cause black
Figure 70-90-9 exhaust smoke and loss of power at lower engine
speeds.
Figure 70-90-10
S45161

8. Fit the adaptor plate (C4) to the turbocharger and fit
S45162
loosely the three nuts.
9. Fit the exhaust elbow to the adaptor. (See Exhaust 1. Disconnect the actuator hose (A2) at the actuator.
Elbow on Page 70-90-2.) Connect to the actuator an air supply which can be
adjusted accurately and is fitted with an accurate
10. With the elbow secure, tighten the nut (C1) by hand, gauge.
then (C2) and (C3). Tighten the nuts in the same
sequence to 25 N•m (18 Ibf ft) 2,5 kgf m. 2. Fasten a dial test indicator (A1) to the turbocharger
with its plunger in contact with the end of the actuator
11. Connect the exhaust pipe for the application to the rod (A3) to measure the axial movement of the rod.
exhaust elbow.
Caution: Do not apply an air pressure of more than 205
12. Fit the crossover pipe and hose to the turbocharger. kPa (30 Ibflin²) 2,1 kgUcm2 to the actuator. Higher
Tighten the set screws to 22 N•m (16 Ibf ft) 2,2 kgf m. pressures may damage the actuator.
Tighten the hose clip to 5 N•m (4lbf ft) 0,5 kgf m.
3. Slowly apply air pressure. Check that the pressure
13. Check that there is no restriction in the hose from the necessary to move the rod 1,00 mm (0.039 in), is
air filter to the turbocharger. Fit the hose and tighten within limits, refer to the Data and dimensions for
the clip to 5 N•m (4 Ibf ft) 0,5 kgf m. “Turbocharger”. Ensure that the pointer returns to
zero when the pressure is released. Repeat the test
several times to ensure that an accurate reading is
obtained. It may be necessary to lightly hit the turbine
housing with a soft hammer during the test operation.
4. Consult your nearest Perkins Dealer / Distributor if the

operation of the waste-gate is not correct.
5. If the air pressure is correct, release the air pressure,

remove the test equipment and connect the actuator.

ASPERATION SYSTEM (CONT’D)
Turbocharger Faults
Caution: If the turbocharger or waste-gate is found to be

damaged or faulty, a new turbocharger must be fitted.
The chart below is given to assist in the correct diagnosis
of turbocharger faults.
Problems Possible causes code numbers

Not enough power 1,4,5,6,7,8,9,10,11,18,20,21,22,25,26,27,28,34,35,36
Black smoke 1,4.5,6,7,8.9,10,11,18,20,21,22,25,26,27,28,34,35,36
Blue smoke 1,2,4,6,8,9,17,19,20,21,22,30,31,32,34
High lubricating oil consumption 2,8,15,17,19,20,28,29,31,32,34
Too much lubricating oil at turbine end 2,7,8,17,19,20,22,28,30,31,32
Too much lubricating oil at compressor end 1,2,4,5,6,8,19,20,21,28,31,32
Not enough lubrication 8,12,14,15,16,23,24,29,32,33,37,38
Lubricating oil in the exhaust manifold 2,7,17,18,19,20,2~28,31,32
Inside of the intake manifold wet 1,2,3,4,5,6,8,10,11,17,18,19,20,21,28,32,34
Damaged compressor impeller 3,4,6,8,12,15,16,20,21,23,24,29,32,33,37,38

Damaged turbine rotor 7,8,12,13,14,15,16,18,20,22,23,24,25,27,29,32,33,37,38
Rotating assembly does not turn freely 3,6,7,8,12,13,14,15,16,18,20.21,22,23,24,29,32,33,37,38
Worn bearings, bearing bores, journals 6,7,8,12,13,14,15,16.23,24,29,33,37,38
Noise from turbocharger 1,3,4,5,6,7,8,9,10,11,12,13,14,15,16,18,20,21,22,23,24,
29,32,33,34,37,38
Sludge or carbon deposit in bearing housing 2,11,13,14,15,17,18,24,29,33,37,38

ASPERATION SYSTEM (CONT’D) 25. Faulty fuel injection pump.
Turbocharger Faults (Cont’d) 26. Worn or damaged atomizers.
List of Possible Causes 27. Valves burned.
1. Element of the air filter dirty. 28. Worn piston rings.
2. Restricted crankcase breather. 29. Lubricating oil leakage from supply pipe.
3. Element of the air filter not fitted, or not sealing 30. Excessive preservation fluid (on initial engine start).
correctly. Loose connection to turbocharger.
31. Excessive engine idle period.
4. Internal distortion or restriction in pipe from air filter to
turbocharger. 32. Restriction in turbocharger bearing housing.
5. Damaged / restricted crossover pipe, turbocharger to 33. Restriction in lubricating oil filter.
intake manifold.
34. Wet type air cleaner: Restricted, dirty element,
6. Restriction between air filter and turbocharger. viscosity of oil too low / high.
7. Restriction in exhaust system. 35. Waste-gate actuator faulty or damaged.
8. Turbocharger loose or clamps / set screws loose. 36. Waste-gate valve not free.

9. Intake manifold crossover pipe has cracks, is loose, or 37. Engine stopped too soon from high load.
has flange distortion.
38. Insufficient lubricating oil.
10. Exhaust manifold has cracks, is loose, or has flange
distortion.
11. Restricted exhaust system.
12. Delay of lubricating oil to turbocharger at engine start.
13. Insufficient lubrication.
14. Dirty lubricating oil.
15. Incorrect lubricating oil.
16. Restricted lubricating oil supply pipe.
17. Restricted lubricating oil drain pipe.
18. Turbine housing damaged or restricted.
19. Leakage from turbocharger seals.
20. Worn turbocharger bearings.
21. Excessive dirt in compressor housing.
22. Excessive carbon behind turbine rotor.
23. Engine speed raised too rapidly at initial start.
24. Insufficient engine idle period.

ASPERATION SYSTEM (CONT’D) Installation
Open Engine Breather Figure 70-90-12
Removal
1. Release the hose clip and remove the hose from the
breather pipe assembly.
Figure 70-90-11
S45164
1. Fit the new joint (B4) into the breather pipe housing.
2. Push the two fasteners (B2) into the breather pipe

assembly.

S45163
3. Fit a new O-ring (B3) to the breather pipe assembly
and lubricate the O-ring with clean lubricating engine
2. Release the two fasteners (A2) and pull the breather oil.
pipe assembly (A1) out of the rocker cover.
4. Push the breather pipe assembly into the rocker cover
3. Remove the O-ring (A3). and tighten the fasteners to 9 N•m (7 Ibf ft) 0,9 kgf m.
4. Remove the joint (A4) and the two fasteners (A2) from 5. Fit the breather hose and tighten the clip to 5 N•m
the breather pipe assembly. (4 Ibf ft) 0,5 kgf m.
5. Clean all the components and discard all joints and O-

rings.

ASPERATION SYSTEM (CONT’D) Installation
Natural Aspirated Engine Breather Figure 70-90-14
Removal
Figure 70-90-13
S45166
1. Fit the new joint (B4) into the breather pipe housing.
S45165
2. Push the two fasteners (B2) into the breather pipe
assembly.

1. Release the two fasteners (A2) and pull the breather
pipe assembly (A1) out of the rocker cover. 3. Fit a new O-ring (B3) to the breather pipe assembly
and lubricate the O-ring with clean lubricating engine
2. Remove the O-ring (A3). oil.
3. Remove the joint (A4) and the two fasteners (A2) from 4. Push the breather pipe assembly into the rocker cover
the breather pipe assembly. and tighten the fasteners to 9 N•m (7 Ibf ft) 0,9 kgf m.
4. Clean all the components and discard all joints and O- 5. Fit the breather hose and tighten the clip to 5 N•m (4
rings. Ibf ft) 0.5 kgf m.

ASPERATION SYSTEM (CONT’D)
Closed Engine Breather
NOTE: For details on how to change the closed

crankcase breather and element, contact your
nearest Perkins Dealer / Distributor for advice.

LUBRICATION SYSTEM These engines are fitted with piston cooling jets that are
connected-to the oil pressure rail and spray lubricating oil
General Description inside the pistons to keep them cool.
Pressure lubrication is supplied by a rotor type pump Key to the oil flow diagram.
which is driven through an idler gear from the crankshaft
gear. The pump has an inner rotor and an outer rotor 1. Suction pressure to the lubrication oil pump.
which are off-set to each other. There is an interference
fit between the inner rotor and the drive shaft. When the 2. Main engine lubrication oil pressure.
pump rotates, the space between the lobes which are in
mesh increases to cause a suction to fill the space and 3. Reduced engine lubrication oil pressure.
the decrease to create a pressure increase.
Lubricating oil from the sump passes through a strainer

and pipe into the suction side of the pump. The pump
delivers the oil to the cylinder block. If an oil cooler is
fitted the oil is transferred to and from the oil cooler by a
internal passage in the cylinder block. The oil is
transferred by the oil pump frame to the oil filter passage
in the cylinder block. If an oil cooler is not fitted the oil is
transferred directly to the oil filter passage.
Then relief valve is integral with the pump and re-

circulates the excess oil directly back to oil pump inlet.

The lubricating oil passes through the oil filter and
directly back to the main pressure rail which drilled the
full length of the left side of the cylinder block.
From the pressure rail, lubricating oil passes to the main

bearings of the crankshaft and through passages in the
crankshaft to the big end bearings. The pistons and the
cylinder bores by the oil jets which are attached the main
pressure rail.
Lubricating oil passes from the main bearings through

passages in the cylinder block to the journals of the
camshaft. The front camshaft bearings feed oil through a
drilling in the cylinder block and cylinder head to the
rocker shaft. The oil passes through the center of the
rocker shaft to the rocker levers. The rocker pads, valve
stems, cam lobes and the tappets are splash lubricated.
The hub of the idler gear is lubricated by oil from the end
pressure rail and the timing gears are splash lubricated.
The lubricating oil for turbochargers is delivered by an

external pipe from a tapping on the side of the cylinder
block above the right hand side of filter face. The oil
returns from the turbocharger down another extended
drain pipe into the side of the cylinder block from a
connection on the right side of the cylinder block. or filter
head, through an external pipe to the turbocharger, The
oil passes through the turbocharger and returns through
a pipe to the sump.
Top mounted turbochargers are fed from the filter head,

or from a connection on the right hand side of the engine.

LUBRICATION SYSTEM (CONT’D)
Lubrication System Flow Diagram
S45167

LUBRICATION SYSTEM (CONT’D) 8. Operate the engine and check for leakage from the
filter. When the engine has cooled, check the oil level
Canister Type Oil Filter on the dipstick and add more oil into the sump, as
necessary.
WARNING: Discard the used canister, and

lubricating oil in a safe place and in accordance
with local regulations.
Caution: The canister contains a valve and a special

tube to ensure that lubricating oil does not drain from the
filter, when the lubricating oil is changed. Ensure that the
correct Perkins POWERPART canister is used.
Caution: Ensure that the application is on a level surface

to ensure an accurate reading on the dipstick.
1. Put a suitable container below the lubricating oil filter.
2. Remove the filter canister with a strap wrench.

Ensure that the adaptor is secure in the filter head.
Discard the canister.

3. Clean the filter head.
Figure 70-100-1
S45168
4. If the filter canister is mounted vertically position (A)

add clean engine lubricating oil to the new canister.
Allow the oil enough time to pass through the filter
element.
5. Lubricate the top of the canister seal (A1) with clean

6. Fit the new canister and tighten by hand only. Do not

use a strap wrench.
7. Remove the container and discard the old lubricating

oil.

LUBRICATION SYSTEM (CONT’D) Figure 70-100-3
Element Type Oil Filter
WARNING: Discard the used canister, and

lubricating oil in a safe place and in accordance
with local regulations.
Caution: Ensure that the application is on a level surface

to ensure an accurate reading on the dipstick.
1. Put a suitable container below the lubricating oil filter.
Figure 70-100-2 S45337
4. Clean the filter casing and replace the seal (B2). Fit
a new seal to the drain plug and fit the plug finger
tight.
5. Fit the new filter element (B1) into the casing and
rotate the element to locate it into position.

6. If the filter casing is in vertically mounted position (A),
add clean engine lubricating oil to the filter casing.
Allow the oil enough time to pass through the filter
element.
7. Lubricate the seal (B2) with clean engine lubricating

oil. Fit the casing (A3) into the filter head (A4).
S45169 8. Tighten the casing (A3) to 25 N•m (18 Ibf ft) 2,5 kgf m.
9. Tighten the drain plug to 12 N•m (9 Ibf ft) 1,2 kgf m.

NOTE: On the horizontal filter assembly the drain
plug (A2) is in the filter head and should not 10. Remove the container and discard the old lubricating
be removed. oil.
2. Remove the drain plug (A2) together with the seal 11. Operate the engine and check for leakage from the
and drain the lubricating oil. filter. When the engine has cooled, check the oil level
on the dipstick and add more oil into the sump, as
3. Fit a 1/2” square drive ratchet into the recess (A1) necessary.
and remove the filter casing (A3). Discard the old filter
element.

LUBRICATION SYSTEM (CONT’D) 3. Remove the set screws and remove the filter head
(A2) (B2) from the cylinder block. Discard the joint
Filter Head (A1) (B1).
Special Requirements 4. Clean the joint face (A1) (B1) of the filter head and the
cylinder block.
Consumable products
Description Part number Installation
POWERPART Threadlock 21820117 1. Ensure that all joint surfaces are clean and free from
and nutlock damage.
Removal 2. Fit a new joint to the filter head the joint is fitted dry.
Caution: If a balancer is fitted, the oil filter head must NOTE: The set screws for securing the filter head
only be mounted on the left hand of the engine. have a sealant (MEAS) applied by the
manufacturer to the first 13,0 mm (0.50 in) of
1. Put a tray under the filter head to contain spilt the threads. If the set screws are used again,
lubricating oil. the sealant must be removed from the male
and female threads and POWERPART
2. Remove the filter canister. (See Canister Type Oil Threadlock and nutlock applied to the first
Filter on Page 70-100-3.) or (See Element Type Oil 13,0mm (0.50 in) of the set screw threads.
Filter on Page 70-100-4.)
3. Fit the filter head to the cylinder block. Gradually and

Figure 70-100-4 evenly tighten the set screws.
4. Fit the new filter canisters. (See Canister Type Oil

Filter on Page 70-100-3.) or (See Element Type Oil
Filter on Page 70-100-4.)
S45170
Figure 70-100-5
S45338

Sump
Removal
WARNING: Discard the used lubricating oil in a

safe place and in accordance with local
regulations.
WARNING: Before the sump is removed,

especially with the cast iron version, ensure that
the sump is fully supported before the set
screws are removed.
1. Operate the engine until it is warm.
Figure 70-100-6

S45171
2. Stop the engine, remove the sump drain plug (A1) and
its O-ring, and drain the oil. Where necessary, remove
the dipstick and the dipstick tube. (See Dipstick Tube
on Page 70-100-8.)
3. Provide a support for the sump and remove the set

screws and, if relevant, the two nuts which fasten the
sump to the timing case. Lower the sump and remove
and discard the joint.
4. Wash the sump with an approved cleaning fluid,

ensure all the cleaning fluid is removed. Clean the
flange face of the sump and of the cylinder block.

LUBRICATION SYSTEM (CONT’D) Figure 70-100-8
Sump (Cont’d)
Installation
Consumable products
POWERPART Threadlock 21820117
and nutlock
POWERPART Silicone 1861108
rubber sealant
S45339
NOTE: If either the cylinder block bridge piece, and I
or the timing case, have just been fitted then
fit the sump before any bridge piece / timing Figure 70-100-9
case sealant has been allowed to cure.
NOTE: If the sump only is to be fitted, then any old

surface sealant from either the cylinder block
bridge piece, and/or the timing case, should

be removed and renewed
1. Remove any old sealant from the cylinder block

bridge piece, timing case, and cylinder block joint
surfaces.
2. Ensure that the joint faces of the cylinder block and

the sump are both free from dirt and damage.
Figure 70-100-7 S45340
4. Apply a bead of POWERPART Silicone rubber

sealant to the joints between the cylinder block and
the timing case (C1), and the cylinder block and the
bridge piece (B2).
NOTE: Handle the sump joint with care as rubber-

sealing bead can be easily damaged.
5. Place the joint onto the cylinder block over the

alignment studs and ensure that all of the fixing holes
align correctly.
6. Place the sump onto the cylinder block over the

S45172
alignment studs.
3. Insert four alignment studs into holes (A1). NOTE: The set screws for securing the sump have a
sealant (MEAS) applied by the manufacturer
to the first 13,0 mm (0.50 in) of the threads. If
the set screws are used again, the sealant
must be removed from the male and female
threads and POWERPART Threadlock and
nutlock applied to the first 13,0 mm (0.50 in) of
the set screw threads.

LUBRICATION SYSTEM (CONT’D) Dipstick Tube
Sump (Cont’d) Removal And Installation
Installation (Cont’d) Special Requirements
7. Loosely fit the set screws into all of the available holes Consumable products
by hand.
8. Remove the alignment studs and fit the remainder of POWERPART Threadlock 21820117
the set screws. and Nutlock
Figure 70-100-10 1. Remove the dipstick tube M16 gland nut and remove
the tube from the sump.
2. Clean the gland nut and the thread in the sump of all
old sealant.
3. Ensure that the rubber seal is fitted to the dipstick

tube assembly.
4. Apply POWERPART Threadlock and Nutlock to the

threads of the gland nut.

5. Fit the dipstick tube to the sump in the correct
position, tighten the gland nut to 18 N•m (14 Ibf ft) 1,8
kgf m.
S45341
9. Tighten the four set screws (D1) to 22 N•m (16Ibfft)

2,2 kgf m.
10. Tighten the remaining set screws to 22 N•m (161bf ft)

2,2 kgf m.
11. Fit the drain plug, if necessary fit a new O-ring, and
tighten to 34 N•m (25 Ibf ft) 3,5 kgf m.
Figure 70-100-11
S45173
12. Fill the sump to the mark (E2) on the dipstick with new
engine lubricating oil of an approved grade.

LUBRICATION SYSTEM (CONT’D) Inspection
Oil Strainer And Suction Pipe 1. Wash the assembly in an approved cleaning fluid and
dry it thoroughly.
The oil strainer is an integral part of the suction pipe. No
regular service is necessary but wash the strainer when it 2. Check the pipe. the strainer and the welded joints for
is removed. cracks and other damage.
Removal 3. If a component is damaged, renew as necessary.
1. If not already removed; remove the lubricating oil

2. Remove the set screws from the flange of the suction

pipe. Remove the suction pipe and strainer. Remove
the old joint. Clean the flange face of the oil pump and
the suction pipe.
Installation
Figure 70-100-12

S45174
1. Fit the suction pipe to the oil pump together with a

new joint. Tighten the set screws (A1).
2. Fit the lubricating oil sump, see Operation 10 - 5.

LUBRICATION SYSTEM (CONT’D) Installation
Lubricating Oil Pump Assembly Figure 70-100-14
Removal
WARNING: Discard the used lubricating oil in a

safe place and in accordance with local
regulations.
1. If not already removed: remove the lubricating oil

Figure 70-100-13
S45176
1. Fill the oil pump assembly with clean engine

lubricating oil. Fit the oil pump assembly to the

cylinder block. Ensure that the dowel (A1) and the
thimble (A2) are correctly located, then tighten the set
screws to 22 N•m (16 Ibf ft) 2,2 kgf m.
S45175
2. Check the idler gear for wear and other damage. If the
gear is damaged, it must only be renewed as an
assembly. The assembly consists of an idler gear, an
2. Remove the set screws (A1) and remove the oil pump idler shaft and a front plate.
assembly.
Figure 70-100-15
S45342
3. Check that there is backlash between the oil pump

idler gear and the crankshaft gear (B).

LUBRICATION SYSTEM (CONT’D) 6. Lubricate the inner and outer rotor with clean engine
lubricating oil. Clean the top face of the oil pump and
Lubricating Oil Pump Assembly (Cont’d) the inner face of the cover. Fit the cover. Tighten the
set screws to 28 N•m (21 Ibf ft) 2,9 kgf m.
Inspection
NOTE: For all the clearances, refer to the Data and

dimensions for the “Lubrication system”.
1. Remove the set screws and remove the cover of the

oil pump.
2. Remove the outer rotor and clean all the parts. Check
for cracks and any other damage.
Figure 70-100-16

S45177
3. Fit the outer rotor, and check the outer rotor to body
clearance (A).
Figure 70-100-17
S45343
4. Check the inner rotor to outer rotor clearance (B).
5. Check the rotor end-float with a straight edge and a

feeler gauge.

LUBRICATION SYSTEM (CONT’D) Removing and Installing the Relief Valve in the
Lubricating Oil Pump
Relief Valve
Caution: Do not change the operation pressure of the
Removing and Installing the Relief Valve in the Balancer relief valve by a method other than the installation of new
components.
Removal
Removal
Figure 70-100-18
Figure 70-100-20
S45178

S45179
Figure 70-100-19
Figure 70-100-21
S45344
S45345
1. Remove the plug that retains the relief valve (A1).

Remove the spring and valve (B). 1. Remove the plug which fastens the relief valve (A1).
and remove the spring and valve (B).
Installation
Installation
1. Ensure the relief valve is clean.
1. Ensure the relief valve is clean.
2. Place the relief valve and spring into the balancer.
2. Place the valve spring and relief valve into the
3. Tighten the plug for the relief valve (A1) to 22 N•m (16 lubricating oil pump.
lbf ft) 2,2 kgf m.
3. Tighten the plug for the relief valve (A1) to 22 N•m (16
Ibf ft) 2,2 kgf m.

Relief Valve (Cont’d)
Inspecting the Relief Valve in the Lubricating Oil Pump /

Balancer
Caution: Do not change the operation pressure of the

relief valve by a method other than the installation of new
components.
1. Check the spring for wear and other damage and. if

possible, check the load necessary to compress the
spring to its fitted length, refer to the Data and
dimensions for “Oil pressure relief valve (oil pump)” or
“Oil pressure relief valve (balancer)”.
2. Check the plunger for wear and other damage and

ensure that it slides easily in the bore of the relief
valve.
3. Check the body and the end plug for wear and other
damage.

4. Renew worn or damaged components.


FUEL SYSTEM Figure 70-110-2
General Description
Cautions:
• There are no adjustments that can be carried out on

the Bosch VP30 and Delphi DP210 fuel pumps. The
fuel injection equipment must only be checked by
personnel who have had the correct training.
• If a fuel injection pump is returned for repair, or under

warranty, then all of the fuel ports must be closed with
a plastic blanking cap to prevent the entry of water
and dirt into the pump. If these blanking caps are not
fitted then the warranty will be affected. S45346
• A new fuel injection pump will be supplied with the

pump shaft in the locked position. The drive shaft of • Bosch EPVE (B).
the pump must not be turned without the spacer (B2)
in position under the locking screw (B1). Figure 70-110-3
• The 1100 Series four cylinder engines are used for

industrial, construction and agricultural applications

and use three different types of fuel injection pump:
Figure 70-110-1
S45347
• Delphi DP210 (C).
These fuel injection pumps conform to emissions

S45180
legislation.
• Bosch VP30 (A).

FUEL SYSTEM (CONT’D) Figure 70-110-6
General Description (Cont’d)
Figure 70-110-4
S45349
Bosch EPVE (E) and Delphi DP210 (F) fuel injection

S45181 pumps have locking screws which lock the shaft. It is
important that the locking screw is released and the
pump shaft is free to turn when the pump is fitted to the
On the Bosch VP30 the pump timing, the speed engine.
adjustment and amount of fuel supplied are all controlled

electronically by the ECM. The fuel injection pump timing The electronic fuel lift pump and fuel filter are a single
is by a pin (D1) that is fitted through the fuel pump gear, assembly.
the pump flange and into the pump body,
The maximum no-load speed is shown on the emissions
Figure 70-110-5 data plate fitted to various positions on the side of the
cylinder block, see “Engine identification”.
The atomizers, which are of the valve covered orifice

(VCO) type, have nozzles with five-boles. The atomizers
inject fuel in a very fine spray into the combustion
chamber in the top of each piston.
The atomizers are set in the factory and are not

serviceable; they must be checked in accordance with
the preventive maintenance schedules.
S45348

Cold Start Advance Unit (KSB)
Figure 70-110-7
S45183
Figure 70-110-9
S45182
Delphi DP210 and Bosch EPVE (A) fuel injection pumps

have a cold start advance unit that holds the timing of the

pump in an advanced position when the engine is cold.
Caution: It is important that the electrical connections to

the sender unit are connected correctly. Failure of the
KSB to operate correctly could result in damage to the
engine as the timing will be fully advanced for normal
operation. The sender unit, is on the rear of the timing
case on the left side of the engine with the engine cold,
the sender unit energizes to advance the pump timing for
the cold start operation of the Delphi and Bosch fuel S45350
injection pumps.
NOTE: The wiring diagrams on the following page Wiring diagrams for the cold start advance unit fitted to
show the sender unit position when the some Delphi DP210 Series and Bosch EPVE injection
engine is cold. pumps are shown in the illustrations (A), and (B)
respectively. For easy identification the cables are shown
To ensure that the engine conforms to emissions in circles on the illustrations.
legislation, it is important that the electrical connections
of the engine cold start advance unit are fitted correctly The amperage of each of the cables is listed in the cable
before the engine is operated. identification table below. The identification numbers for
the electrical components are shown in triangles. Refer
to the component identification list to find a component.
Cable identification (1) Component identification (2)

Cable (Number) Current (Amperes) Current (Amperes) Description
1 3 1 Fuel injection pump
2 3 2 Engine stop solenoid
3 6 3 Sender unit
4 3 4 Start switch
5 3 5 Cold start advance unit
(1) For numbers shown in circles
(2) For numbers shown in triangles

FUEL SYSTEM (CONT’D)
Typical Fuel System
Fuel Circuitry
Injection Nozzles
Combustion
Chamber
Fuel Tank
Injection
Pump

High Pressure
Low Pressure
Tank Pressure Fuel Transfer Pump
Fuel Filters S47108
Figure 70-110-10 The fuel injection pump has a self-vent pipe to remove air
from the fuel system back into the fuel tank through a
connection on the connector block. The fuel in the
injection pump also lubricates and cools the pump. The
amount of fuel and the fuel injection timing is controlled
by the Engine Control Module (ECM).
The fuel injection pump increases the fuel pressure and

injects high-pressure fuel at the correct time and
sequence through pipes to the atomizers (A1).
S45184
The position of the fuel system components may vary

from application to application; this information is
provided for training purposes only.
Fuel from the tank passes to the electric lift pump filter
(A4). Fuel leaves the lift pump (A3) under pressure to the
fuel injection pump (A6).

FUEL SYSTEM (CONT’D) 2. Thoroughly clean the outside surfaces of the fuel filter
assembly. Open the drain tap (A1) at the bottom of 
Fuel Filter Assembly the filter casing to drain the fuel from the filter.
Replacing 3. Use a strap wrench to loosen the filter casing.

Remove the casing and element from the fuel filter
WARNING: The combustible material of some head.
components of the engine (for example certain
seals) can become extremely dangerous if it is Figure 70-110-12
burned. Never allow this burnt material to come
into contact with the skin or with the eyes, see “Viton
seals” for safety precautions.
WARNING: Discard the used element and fuel
oil in a safe place in accordance with local
regulations.
WARNING: If the fuel level in the tank is higher
than the fuel lift pump, the supply and return
fuel line valves must be turned off before
servicing or repairs are made. If the fuel line
valves are not turned off, fuel will flow through the
system.
WARNING: Ensure that the starter switch is in
the OFF position before any service or repairs
are made to the fuel system. If the lift pump has S45351

power, fuel will be released.
4. To remove the filter element from the casing; Press
Caution: It is important that only genuine Perkins parts
down on the filter element (B1), against the spring, 
are used. The use of an element that is not a genuine
pressure, and rotate the element to the left to
Perkins part may damage the fuel injection pump.
release it from the filter casing (B4).
Caution: The pre-filter canister and main filter elements
5. Put the new filter element inside the casing and press
must be renewed at the same time.
the element down against the spring pressure. 
Rotate the element to the right to lock the element
Caution: Do not allow dirt to enter the fuel system.
into the casing.
Before a connection is disconnected, clean the area
around the connection. After a component has been
6. Fit a new seal (B3) to the casing and lightly lubricate
disconnected, fit a suitable cover to all open connections.
the seal face with clean fuel oil.
1. Place a suitable container below the fuel filter
7. Check that the thread (B2) on the inside of the
assembly to retain spilled fuel oil.
element is not damaged.
Figure 70-110-11
8. Fit the filter assembly to the fuel filter head and tighten
by hand until the filter assembly contacts the filter
head. Tighten the assembly a further 1/8 of a turn by
hand. Do not use strap wrench.
9. Close the drain tap (A) and remove the container.
S45185

Atomizers
Identifying A Faulty Atomizer
Regular maintenance of the atomizers is not necessary.

The atomizer should be renewed and not cleaned, and
renewed only if an atomizer fault occurs. The major
problems that may indicate that new atomizers are
needed are listed below:
• Engine will not start or is difficult to start.
• Not enough power.

S45352
• Engine misfires or runs erratically
• High fuel consumption. Release and tighten the union nuts (B1) of the high-
pressure fuel pipe at each atomizer, one at a time. Do not
• Black exhaust smoke. loosen the union nut more than half a turn. When the
union nut of the defective atomizer is released. It has little
• Engine knocks or vibration. or no effect on the engine speed.

• Excessive engine temperature.
WARNING: If your skin comes into contact with

high-pressure fuel, obtain medical assistance
immediately.
WARNING: Keep away from moving parts

during engine operation. Some moving parts
cannot be seen clearly while the engine runs.
Figure 70-110-13
S45186
To find the defective atomizer, release the atomizer cover

set screws (A1) and remove the atomizer cover (A2), run
the engine at fast idle.

Atomizers (Cont’d)
Removal
Caution: Atomizers must be removed and fitted by a

person with the correct training.
Caution: Do not allow dirt to enter the fuel system.

Before a connection is disconnected, clean thoroughly
the area around the connection. After a component has
been disconnected, fit a suitable cover to all open
connections.
Figure 70-110-15 S45354
2. Remove the fuel leak-off pipe from the connection

(C2).
3. Remove the union nuts of the high-pressure pipe from

the atomizer (C1) and from the fuel injection pump. Do
not bend the pipe. If necessary, remove the pipe

clamps. Fit a plastic cap to cover the fuel inlet
connection.
4. Remove the set screw (C3) from the clamp (C4) and
remove the atomizer and its seat washer from the
recess in the cylinder head.
S45187
Cautions: Remove and discard the seat washer (B1). If
the original seat washer remains in the recess for the
1. Release the atomizer cover set screws (A1) and atomizer, the nozzle protrusion will be incorrect when a
remove the atomizer cover (A2). new seat washer is added.
Figure 70-110-16
S45353

FUEL SYSTEM (CONT’D) Caution: Do not tighten the union nuts of the high-
pressure pipes to more than the recommended torque
Atomizers (Cont’d) value. If there is a leakage from the union nut, ensure
that the pipe is correctly aligned with the atomizer inlet
Installation
Caution: Do not tighten the atomizer union nut more, as
Figure 70-110-18 this can cause a restriction at the end of the pipe. This
can affect the fuel delivery.
5. Remove the plastic cap and fit the high-pressure fuel

pipe. Tighten the union nuts to 27 N•m (20 Ibf ft) 2,8
kgf m.
6. If removed earlier, fit the high pressure fuel pipe

clamps.
7. Fit the fuel leak-off pipes to the connectors (B2).
8. Operate the engine and check for leakage of fuel and

that there is no air in the system.
9. Stop the engine. Refit the atomizer cover and tighten

the set screws. (See Atomiser Cover on Page 70-30-
S45188 1.)

1. Put the new seat washer (A2) into the seat recess in
the cylinder head.
2. Ensure that the atomizer seal (A1) is not damaged.

Apply a small amount of clean engine oil to the seal.
Figure 70-110-19
S45355
Caution: The atomizer must be fitted so that the two

leak-off connections (B2) point away from the cylinder
head towards the intake manifold.
3. Place the atomizer (B1) into the recess in the cylinder

head.
4. Fit the clamp (B4), tighten the set screw (B3) for the
clamp to 27 N•m (20 Ibf ft) 2,8 kgf m.

FUEL SYSTEM (CONT’D) Installation
Fuel Lift Pump And Filter Assembly NOTE: Ensure that new rubber washers are fitted to
the set screws and the cylinder block before
Caution: Do not allow dirt to enter the fuel system. the electric fuel lift pump and filter assembly
Before a connection is disconnected, clean thoroughly is fitted.
the area around the connection. After a component has
been disconnected, fit a suitable cover to all open 1. Fit the set screws (A1) and new rubber washers to the
connections. fuel lift pump and filter assembly.
Removal 2. Fit the spacer and the set screw (A2) to the support
bracket (A3) for the fuel pipe.
1. Disconnect the fuel pipes from the electric fuel lift
pump and filter assembly. 3. Fit the fuel pipes to the fuel lift pump and filter
assembly.
2. Drain the electric fuel lift pump and filter assembly,
see Operation 11 - 1. 4. Eliminate any trapped air from the fuel system. (See
Removing Air From The Fuel System on Page 70-
Figure 70-110-20 110-11.)


S45189
3. Remove the set screw (A2) and the spacer from the
support bracket (A3) for the fuel pipes.
4. Remove the set screws (A1) and rubber washers.

Remove the electric fuel lift pump and filter assembly.

FUEL SYSTEM (CONT’D) Pressure Regulator Test
Fuel Lift Pump and Filter Assembly (Cont’d) 1. Remove the fuel lift pipe from the fuel injection pump,
fit a suitable pipe with a pressure test point and
Testing connect a 0 - 80 kPa (0 - 12 Ibf/in²) 0 - 0,8 kgf/cm²
pressure gauge.
1. Remove the two outlet fuel pipes from the electric fuel
lift pump and filter assembly, make note of the 2. Operate the engine at idle for two minutes to allow
location of the pipes to ensure that the pipes are fitted any trapped air to be removed.
correctly.
3. The reading on the pressure gauge should be as
2. Connect two suitable rubber hoses to the outlet pipes below:
(feed to fuel infection pump and return to the fuel
tank), and place into a three liter measuring cylinder. • Bosch EPVE = 31 kPa (4.49 Ibf/lin²) 0,31 kgf/cm² at
idle. and rated speed 31 kPa (4.49 Ibf/lin²) 0.31 kgf/
3. Operate the engine until a consistent flow of fuel is cm²
running from the outlet pipe of the fuel injection pump. • Bosch VP40 = 27,5 kPa (3.98 Ibf/lin²) 0,28 kgf/cm² at
idle, and rated speed 24kPa (3.48 Ibf/lin²) 0,24 kgf/
NOTE: The return pipe to the fuel tank will have a cm²
slower flow than the feed pipe from the fuel
• Delphi DP210 = 27,5 kPa (3.98 Ibf/lin²) 0,28 kgf/cm²
injection pump.
at idle, and rated speed 28kPa (4.06 Ibf/lin²) 0,28 kgf/
cm²
4. The combined flow of both pipes should be at a rate
of 2 L/min as a minimum.
4. The combined flow of both pipes should be at a rate

of 2 L/min as a minimum.
5. If the flow is less than 2 L/min, replace the electric fuel
lift pump and filter assembly.
5. Connect the fuel lift pipe to the fuel injection pump.
Operate the engine at idle for two minutes.
6. Connect the electric fuel lift pump outlet pipes in the
correct position.
NOTE: If the fuel lift pump and filter assembly does
not meet the above specifications check for
the following; that all the electrical,
connections are fitted, there are no leaks in
the pipes and connections, that the seal on
the drain tap does not leak and that the O-ring
for the canister to the lift pump does not leak.

Removing Air From The Fuel System
If air enters the fuel system, it must be removed before

the engine can be started.
Air can enter the system if:
• The fuel tank is drained during normal operation.
• The low-pressure fuel pipes are disconnected.
• A part of the low-pressure fuel system leaks during

engine operation.
S45190
• A fuel system component such as a filter element, or
a fuel pump, has been installed during a service.
3. Loosen the high pressure pipes (A1) at the atomizers.
• The high pressure fuel pipes have been
disconnected. 4. Operate the starter motor until fuel free from air
comes from the connections.
Caution: Do not operate the engine until the air is
eliminated from the fuel injection pump. 5. Tighten the connections to 30 N•m (22 Ibf ft) 3,0 kgf

m.
Caution: After the air is eliminated, operate the engine at
low idle for two minutes. 6. Start the engine and check for leaks.
The Delphi DP210 fuel Injection pump will eliminate air 7. Fit the atomizer cover and tighten its set screws, see
automatically when the start key is turned to the RUN Operation 3 - 1.
position for three minutes.
The Bosch VE and the VP30 fuel injection pumps will not
eliminate air automatically.
1. Release the atomizer cover set screws and remove

the atomizer cover. (See Atomiser Cover on Page 70-
30-1.)
2. Turn the start key to the RUN position for three

minutes, then return the key to the OFF position.

Bosch VP30 Fuel Injection Pump
General Descriptions
Figure 70-110-22
S45356
Caution: A new fuel injection pump will be supplied with

the pump shaft in the locked position. The drive shaft of
S45191 the pump must not be turned without the spacer (B2) in
position under the locking screw (B1). Before the

crankshaft is turned, or the pump is fitted, put the spacer
Caution: Do not loosen the nut (A2) from the fuel into position under the locking screw to ensure that the
injection pump. The fuel pump hub is fitted to the shaft in pump drive shaft is released
the factory to ensure that the fuel pump is in the correct
position for timing. If the nut is loosened and the hub The manufacturer fits the hub (A2) to the pump to ensure
moves, the hub will need to be accurately fitted to the very accurate timing. These engines have the drive gear
pump by use of specialist equipment before the pump fastened to the hub instead of to the shaft of the pump.
can be fitted to the engine.
The mounting flange has holes instead of slots to prevent
incorrect adjustments to the engine timing by rotation of
the fuel pump.
Accurate timing of the pump to the engine is by a pin (A1)

used to align the fuel pump gear and the hub with a hole
in the body of the fuel pump. The gear is passed over the
pin and fastened to the hub with four flanged set screws
and hardened washers.
An O-ring (B3) is fitted into a groove in the pump flange.

This O-ring is fitted instead of a joint between the pump
flange and the timing case.

Bosch VP30 Fuel Injection Pump (Cont’d)
Removal
Special tools
Spanner for flange nut of 21825964
the Bosch fuel injection
pump
Timing pin 27610032
Figure 70-110-24
S45357
3. 3 Insert the timing pin (B5) through the hole (B3) in the
fuel pump gear and the slot of the hub (B2). Push the
pin fully into the hole (B1) ill the body of the fuel pump.

If the pin can be fully inserted then the pump timing is
correct.
There should be no resistance when the pin is inserted.
Caution: Use a second spanner to prevent movement of

the high pressure outlet on the pump when the union nut
for each high pressure pipe is released.
S45192
4. Remove the low pressure and the high pressure fuel
pipes from the pump.
Caution: Do not loosen the nut (A2) from the fuel 5. Remove the low pressure and the high pressure fuel
injection pump. The fuel pump hub is fitted to the shaft in pipes from the pump.
the factory to ensure that the fuel pump is in the correct
position for timing. If the hub is moved, the hub will need Caution: Do not rotate the crankshaft when the pump is
to be accurately fitted to the pump by use of special not on the engine.
equipment.
1. Disconnect the battery.
2. Set the engine to TDC number 1 cylinder

compression stroke, see Operation 8 - 1.

Removal (Cont’d)
6. Disconnect the electrical connection by pulling the

locking mechanism as shown (E) from the connector.
Carefully remove the connector from the fuel pump.
Do not damage the pins of the connector.
Figure 70-110-26
S45359
Figure 70-110-29

S45193
Figure 70-110-27
S45360
8. Remove the set screw from the fuel pump support

bracket (F1).
9. Remove the set screws and washers from the timing

case that secure the fuel pump and remove the pump.
10. Discard the fuel pump O-ring (C3).
S45358
7. Remove the four set screws and the hardened

washers (D4), remove the fuel pump gear from the
hub of the fuel injection pump.

Installation
Special tools
Spanner for flange nut of 21825964
the Bosch fuel injection
pump
Timing pin 27610032
Cautions:
The engine must be set to TDC number 1 cylinder

compression stroke before the pump is fitted. (See To Set S45195
Number 1 Piston To TDC On The Compression Stroke on
Page 70-80-2.)
4. Put the fuel pump gear onto the hub of the fuel pump.
Figure 70-110-30 The set screws (B4) for the fuel pump gear should be

in the center of the slots to allow for the removal of
backlash. Loosely fit the set screws.
5. Insert the timing pin (B5) through the hole (B3) of the
fuel pump gear and the slot of the hub (B2) until it can
be pushed fully into the hole (B1) in the body of the
fuel injection pump. If the timing pin cannot be pushed
into the pump body, check that the engine is correctly
set at TDC on the number 1 cylinder. (See To Set
Stroke on Page 70-80-2.)
6. 6 Carefully turn the gear counterclockwise by hand to

remove the backlash between the idler gear and the
fuel pump gear. Do not rotate the crankshaft or the
S45194
fuel injection pump shaft. Tighten the set screws for
the fuel injection pump gear to 28 N•m (20 Ibf ft) 2,8
A new fuel injection pump will be supplied with the pump kgf m.
shaft in the locked position. The drive shaft of the pump
must not be turned without the spacer (A2) in position 7. Remove the timing pin.
under the locking screw (A1). Before the crankshaft is
turned, or the pump Is fitted, put the spacer into position 8. Fit the timing case cover. (See Timing Cover on Page
under the locking screw to ensure that the pump drive 70-60-2.)
'shaft is released.
1. Fit a new O-ring (A3) to the pump flange.
2. Lightly lubricate the O-ring with clean engine

lubricating oil. Fit the pump into position in the timing
case and fit the three washers and set screws.
3. Loosely fit the set screw (C1) of the support bracket

Ensure that force is not applied to the fuel injection
pump.

Figure 70-110-32
S45196
11. Fit the electrical connector to the fuel pump; to fit the
electrical connector, push the connector fully into the
socket on the fuel pump, to lock the connector to the
S45361 fuel pump push in the locking clamp (D). Ensure that
the connector pins are not damaged.

9. 9 Tighten the set screw (C1) of the support bracket to 12. Connect the battery.
44 N•m (32 Ibf ft) 4,4 kgf m. Ensure that force is not
applied to the fuel injection pump. 13. Eliminate air from the fuel system. (See Removing Air
From The Fuel System on Page 70-110-11.)
Caution: Do not tighten the union nuts of the high-
pressure pipes more than the recommended torque 14. Operate the engine and check for leakage of fuel and
tension. If there is a leakage from the union nut, ensure that there is no air in the system.
that the pipe is correctly aligned with the pump outlet. Do
not tighten the pump union nut more, as this can cause a
restriction at the end of the pipe. This can affect the fuel
delivery.

for each high pressure pipe is tightened.
10. Fit the low pressure and the high pressure fuel pipes
to the pump. Tighten the high pressure pipe union
nuts to 27,5 N•m (21Ibf ft) 2,8 kgf m.

Bosch EVPE Fuel Injection Pump
Figure 70-110-34
S45197

Figure 70-110-35
S45362

the pump must not be turned without the spacer (B2) in
position under the locking screw (B1).
Bosch EPVE fuel injection pumps have a drive gear

fastened to the shaft of the pump.
An O-ring (A3) is fitted into a groove in the pump flange.


Bosch EVPE Fuel Injection Pump (Cont’d)
Removal
1. Disconnect battery.

compression stroke, see Operation 8 - 1.
Figure 70-110-36
S45198

bracket (B1).
7. Remove the set screws and washers that secure the

fuel pump and remove the pump.

Figure 70-110-38
S45199
3. Lock the pump shaft; to lock the fuel injection pump

shaft loosen the locking screw (A2) and remove the
spacer (A1). Tighten the locking screw (A2) to 31 N•m
(23 Ibf ft) 3,1 kgf m.

4. Remove the low pressure and the high pressure fuel

pipes from the pump. S45363
Caution: Do not rotate the crankshaft when the pump is

not on the engine. 8. Discard the fuel pump O-ring (C3).
5. Remove the fuel pump gear, see Operation 6 - 3.
NOTE: Remove the KSB electrical connections.

Bosch EVPE Fuel Injection Pump (Cont’d)
Installation
Caution: The engine must be set to TDC number 1

cylinder compression stroke before the pump is fitted,
see Operation 8 - 1.
Figure 70-110-39
S45201
5. Tighten the set screw (B1) of the support bracket to

44 N•m (32Ibf ft) 4,4 kgf m. Ensure that farce is not
applied to the fuel injection pump.

pressure pipes more than the recommended torque

tension. If there is a leakage from the union nut, ensure
S45200 that the pipe is correctly aligned with the pump outlet. Do
Caution: A new fuel injection pump is supplied with the delivery.
pump shaft in the locked position. The drive shaft of the
pump must not be turned without the spacer (A2) in Caution: Use a second spanner to prevent movement of
position under the locking screw (A1). the high pressure outlet on the, pump when the union nut
for each high pressure pipe is tightened
Caution: Do not rotate the crankshaft when the pump is
not on the engine. 6. Fit the low pressure and the high pressure fuel pipes
to the pump. Tighten the high pressure pipe union
1. Fit a new O-ring (A3) to the pump flange. Lightly nuts to 27,5 N•m (21 Ibf ft) 2,8 kgf m.
lubricate the O-ring with clean engine lubricating oil.
Put the pump into position in the timing case and fit 7. Connect the battery.
the three washers and set screws, then tighten the set
screws to 25 N•m (18Ibfft) 2,5 kgf m. 8. Fit the KSB electrical connection.
2. Loosely fit the set screw (B1) of the support bracket. 9. Eliminate air from the fuel system. (See Removing Air
Ensure that force is not applied to the fuel injection From The Fuel System on Page 70-110-11.)
pump.
3. Fit the fuel pump gear. (See Mechanical Fuel Pump that there is no air in the system.
Caution: The fuel pump gear must be fitted to the engine

before the crankshaft is rotated.

70-60-2.)

Delphi DP210 Fuel Injection Pump
Cautions:
Caution: If the fuel injection pump is removed from the

engine, it will need to be returned to your nearest Perkins
Dealer / Distributor for the pump timing to be checked or
reset.
Caution: Do not unlock the shaft of the fuel injection

pump until the fuel pump gear is fitted.
S45364
Figure 70-110-41
An O-ring (B1) is fitted into a groove in the pump flange.


S45202

the pump must not be turned without the spacer (A2) in
position under the locking screw (A1).
Delphi DP210 fuel injection pumps have a drive gear

fastened to the shaft of the pump.

Delphi DP210 Fuel Injection Pump (Cont’d)
Removal
1. Disconnect the battery.

compression stroke. (See To Set Number 1 Piston To
TDC On The Compression Stroke on Page 70-80-2.)
Figure 70-110-43
S45204

bracket (B1).
7. Remove the set screws and washers that secure the

fuel pump arid remove the pump.

Figure 70-110-45
S45203
3. Lock the pump shaft: To lock the fuel injection pump

shaft loosen the locking screw (A2) and rotate the
washer (A1). Tighten the locking screw (A2) to 17
N•m (12 Ibf ft) 1,7 kgf m.

4. Remove the low pressure and the high pressure fuel S45365
pipes from the pump.
5. Remove the fuel pump gear, see Operation 6 - 3. 8. Discard the fuel pump O-ring (C1).

FUEL SYSTEM (CONT’D) 2. Fit the pump into position in the timing case, fit the
three washers and set screws, then tighten the set
Delphi DP210 Fuel Injection Pump (Cont’d) screws to 25 N•m (18 Ibf ft) 2,5 kgf m.
Installation Figure 70-110-48
Cautions:
Caution: The engine must be set to TOG number 1

cylinder, compression stroke before the pump is fitted.
(See To Set Number 1 Piston To TDC On The
Compression Stroke on Page 70-80-2.)
Caution: Do not unlock the shaft of the fuel injection

pump until the fuel pump gear is fitted.
Figure 70-110-46
S45206
3. Loosely fit the set screw (C1) of the support bracket

Ensure that force is not applied to the fuel pump.

4. Fit the fuel pump gear. (See Mechanical Fuel Pump
Caution: The fuel pump gear must be fitted to the engine

before the crankshaft is rotated.
S45205 5. Fit the timing case cover. (See Timing Cover on Page
70-60-2.).
Caution: A new fuel injection pump will be supplied with 6. Tighten the set screw (C1) of the support bracket to
the pump shaft in the locked position. The drive shaft of 44 N•m (32 Ibf ft) 4,4 kgf m. Ensure that force is not
the pump must not be turned without the spacer (A2) in applied to the fuel pump.
position under the locking screw (A1).
Figure 70-110-47
S45366
1. Fit a new O-ring (B1) to the pump flange. Lightly

lubricate the O-ring with clean engine lubricating oil.

Delphi DP210 Fuel Injection Pump (Cont’d)
Cautions:

pressure pipes more than the recommended torque
tension. If there is a leakage from the union nut, ensure
that the pipe is correctly aligned with the pump outlet. Do
delivery.

for each high pressure pipe is tightened.
Fit the low pressure and the high pressure fuel pipes to
the pump. Tighten the high pressure pipe union nuts to
27.5 N•m (21 Ibf ft) 2,8 kgf m.

8. Eliminate air from the fuel system, see Operation 11 -

8.



COOLING SYSTEM
General Description
Coolant from the bottom of the radiator passes through

the centrifugal coolant pump that is fitted onto the front of
the timing case, to assist the flow of the coolant through
the system.
The coolant pump is gear driven by the fuel injection

pump gear.
An integral oil cooler, if fitted, has an aluminum cover with

a five or seven plate element. The oil cooler has no
external pipes and is fitted to the left side of the cylinder
block.
From the pump, the coolant passes through a passage in

the timing case to the coolant jacket in the top left side of
the cylinder block. The coolant continues to the rear of
the cylinder block where some of the coolant passes into
the lubricating oil cooler. If one is fitted. Some of the
coolant passes around the element of the integral cooler
and then to the rear of the cylinder block.

The coolant then passes from the rear of the cylinder
block and into the cylinder head. The coolant leaves the
cylinder head at the front and passes into the thermostat
housing.
If the thermostat is closed, the coolant goes directly

through a bypass to the inlet side of the coolant pump. If
the thermostat is open, the thermostat closes the bypass
and the coolant passes to the top of the radiator.

COOLING SYSTEM (CONT’D)
Coolant Flow Diagram
S45207

COOLING SYSTEM (CONT’D) Figure 70-120-2
Thermostat
Removal
Consumable products
POWERPART Red rubber 27610226
grease
Figure 70-120-1
S45367
4. Press down on the thermostat using the thermostat

tool (B1) and rotate the thermostat to release it from
the housing (B2).
5. Remove the thermostat from the housing.

S45208
NOTE: Engines are fitted with a single thermostat (A).

Identification of the thermostat is by the
nominal temperature which is stamped on the
bypass valve.
1. Drain the coolant in the cooling system to a level

below the thermostat position and disconnect the top
hose from the coolant outlet connection.
2. Release the two set screws (A1) and remove the

thermostat housing from the cylinder head.
3. Remove the O-ring and discard.

Thermostat (Cont’d)
Installation
Consumable products
grease
Special tools
Thermostat tool 27610226 S45369
1. Clean the thermostat housing. Ensure that the

3. Lubricate a new O-ring (B1) with POWERPART Red
grooves for the spring retainers and the seat for the
rubber grease before it is fitted. Fit O-ring. Place the
O-ring are free of debris.
thermostat (C1) in position in the housing (C3).
Figure 70-120-3
Figure 70-120-6

S45209
S45370
2. Ensure that the jiggle pins (A1) in the thermostat are

both free to move.
4. Use the thermostat tool (D1) to push and rotate the
thermostat to engage the spring retainers into the
Figure 70-120-4
grooves in the housing (C2) and (C4).
5. Fit the thermostat assembly to the cylinder head and

tighten the set screws.
6. Connect the top hose and fill the cooling system.
S45368

Thermostat (Cont’d)
Testing
Figure 70-120-7
S47109
Thermal opening temperature: 77 - 82°C (171 - 180°F)

The temp when thermostat is fully open: 93°C (199°F)
Opening distance: 10 mm (0.4 in)
NOTE: Radiator Cap pressure is 0,8 bar (12 psi).
NOTE: Do not remove the thermostat from the

housing to test.
1. Place the thermostat and the housing in a suitable

container filled with coolant.
2. Heat the coolant gradually. Use a thermometer to

check the temperature at which the valve starts to
open and at which it is fully open. For the correct
operating temperatures, refer to the Data and
dimensions for “Thermostat”.
Caution: If the thermostat does not operate correctly, it

must be renewed. Do not try to adjust the settings.

Coolant Pump
NOTE: Identification of the coolant pump is by the

part number that is cast onto the coolant
pump body.
Removal
Figure 70-120-8

S45210
1. Drain the cooling system and disconnect the hose at

the inlet connection of the coolant pump.
2. Remove the nine set screws in (A) which retain the

coolant pump and remove the coolant pump.
3. Remove and discard the joint.

COOLING SYSTEM (CONT’D) 4. Fit the pump (B1) onto the guides and into the timing
case cover with its gear in mesh with the gear of the
Coolant Pump (Cont’d) fuel injection pump.
Installation NOTE: The set screws that retain the coolant pump
have a sealant (MEAS) applied by the
Special Requirements manufacturer to the first 13,0 mm (0.50 in) of
the threads. If the set screws are used again,
Consumable products the sealant must be removed from the male
Description Part number and female threads and POWERPART
Threadlock and nutlock applied to the first
POWERPART Red rubber 21820117 13,0 mm (0.50 in) of the set screw threads.
grease
5. Fit and lightly tighten the seven set screws which
1. Ensure that all joint faces are clean. retain the pump to the cover of the timing case. The
pump is a tight fit in the cover, but can be pulled into
2. Check the drive gear of the coolant pump for wear or position if the set screws for the pump are gradually
other damage. If the gear is damaged, the pump must and evenly lightened.
be renewed.
6. Remove the guides and fit the remaining set screws.
Figure 70-120-9
Figure 70-120-11

S45211
S45372
3. Fit two suitable guides (A1), fit a new joint (A2).

7. Tighten all the set screws (C) on the coolant pump to
Figure 70-120-10 22 N•m (16 Ibf ft) 2,2 kgf m.
8. Connect the hose to the inlet connection of the

coolant pump and fill the cooling system.
9. Operate the engine and check for leakage.
S45371

Coolant Pump (Cont’d)
Disassembly
Figure 70-120-12
S45213
S45212
4. To remove the coolant seal (C4), it will be necessary

to break the seal and use an extractor to remove the

1. Remove the set screws, (A1) the cover and the joint
Discard the joint. center sleeve of the seal from the body of the shaft.
This will loosen the grip of the seal on the shaft. To
Figure 70-120-13 remove the body of the seal, drill three 3,175 mm
(0.125 in) holes through the top of the coolant seal
1200 apart. Fit three 25,4 mm (1.00 in) self-tapping
screws. Insert a suitable lever through the coolant
inlet of the pump body and gradually and evenly apply
the lever under the head of each self-tapping screw to
remove the seal. Discard the seal.
NOTE: Do not damage the sealing face of the oil seal

housing during removal of the seal.
5. Remove and discard the circlips (C6) (C7).
6. Put the impeller end of the pump body face down on

a suitable press. Press the drive gear end of the shaft
through the gear (C10) and the pump body until the
S45373 shaft (C3) and ball bearing assembly (C8) are
released from the pump. Discard the bearing and the
shaft. The gear will also be released through the side
2. To remove the impeller (B3) from the pump shaft; drill of the housing.
twelve 6,35 mm (0.25 in) holes between the existing
holes at equal distance around the impeller. Drilling 7. Inspect the gear for wear or other damage and renew
these holes will break pieces off the impeller (B3) to it, if necessary.
allow the 2 legged puller to be correctly fitted. 8. Put the impeller end of the pump body face down on
a press and use a suitable mandrel to engage the
3. The impeller can be removed by using a suitable two outer face of the oil seal (C11). Press out the oil seal
legged puller attached to the back of the impeller (B1). and discard it.
Tighten the center set screw (B2) of the puller until the
impeller is removed. Discard the impeller. 9. With the impeller end of the pump body face down on
a press, use a suitable mandrel to engage the outer
Caution: Do not damage the sealing face of the coolant race of the needle roller bearing (C9). Press out the
seal housing during removal of the seal. bearing and discard it.

COOLING SYSTEM (CONT’D) 6. Turn the pump over and press the needle roller
bearing (A9) into the bearing housing until the end of
Coolant Pump (Cont’d) the bearing is level with or 0,5 mm (0.020 in) below the
top of the housing.
Assembly
Caution: Do not lubricate the coolant seal (A4). The
Caution: It is important that all of the components in the coolant seal must not be contaminated with oil or grease.
kit for the coolant pump are used. If the coolant seal is held by hand, it should be held by
the edge of the outside flange.
1. Clean thoroughly the inside of the pump body, the
bearing bores and the counterbore for the coolant Figure 70-120-16
seal. These bores and their chamfers must be clean
and free of corrosion.
2. Put the gear end of the pump body face down on a

press. Use a suitable mandrel to engage the outer
face of the oil seal and press in until the bottom face
of the oil seal is level with the face of the gear housing.
3. With the gear end of the pump body face down on a

press, position the drive gear into the correct position.
Use a suitable adaptor to press the drive shaft through
the oil seal and into drive gear so that there is a 1,5
mm (0.060 in) gap between the drive gear and the top

face of the drive gear pocket.
4. Use a suitable adaptor to press the bearing (A8) onto

the drive shaft, until it is against its shoulder.
S45374
Figure 70-120-15
A tool (C) can be manufactured to press the new seal into
position. The tool should be made of a suitable material
to the dimensions shown below:
A 54,0 mm (2.125 in) E 44,0 mm (1.732 in)

B 6,0 mm (0.236 in) F 18,00 mm (0.708 in)
C 10,0 mm (0.393 in) G 54,00 mm (2.125 in)
D 48,0 mm (1.889 in)
7. Turn the pump over onto the gear end and with the
widest end of the coolant seal towards the oil seal,
push the seal onto the shaft until it is in contact with
the coolant seal counterbore. Ensure that the seal is
square with the bore and with a suitable adaptor press
the seal into the counterbore, until the outer flange is
in contact with the pump body. Continue to apply force
for approximately ten seconds to ensure that the seal
remains in position.
S45214
8. Press the impeller onto the shaft so that it is level with
the top of the drive shaft.
5. Put the impeller end of the pump body face down on
a press. Fit the new circlip (A6), with the bevel edge 9. Fit a new cover joint and fit the cover. Fit the set
away from the oil seal to retain the bearing assembly screws and tighten to 22 N•m (16 Ibf ft) 2,2 kgf m.
in the body of the pump. Fit the circlip (A7) to the drive
shaft to retain the bearing assembly to the drive shaft
of the pump.

COOLING SYSTEM (CONT’D) Fan Drive
Fan Removal
Removal 1. Loosen the pivot fasteners of the alternator and the

fasteners of the alternator adjustment link. Remove
Remove the locknuts and remove the fan from the studs. the drive belt(s), see Operation 14 - 3.
The fan extension and the pulley can now be removed
from the studs, if fitted. 2. Release the locknuts and remove the fan, see
Operation 12-8. Remove the fan extension, if fitted,
Installation and the pulley.
Clean thoroughly the rear of the fan where the fan fits 3. Check the end-float of the drive shaft. If it is more than
onto the fan extension. Ensure that all paint is removed 0,25 mm (0.010 in), the fan drive assembly must be
from this area. Fit the pulley onto the studs, and fit the fan renewed.
extension, if removed. Clean the front face of the fan
extension. Fit the fan and the locknuts, refer to the Data 4. Release the set screws and remove the fan drive.
and dimensions for “Special torques for set screws and
nuts”. Installation
1. Fit the fan drive and tighten the set screws to
44 N•m (33 Ibf ft) 4,5 kgf m.
2. Fit the fan, see Operation 12 - 8.

3. Fit the belt(s) and adjust the tension, see Operation
14 - 3 and Operation 14 - 2.

COOLING SYSTEM (CONT’D) Installation
Lubricating Oil Cooler 1. Renew the joint, ensure that all the joint faces are
clean.
Removal
2. Fit the oil cooler.
1. Drain the cooling system.
3. Fit all the set screws and tighten to the correct torque.
2. Place a suitable container under the oil cooler.
Figure 70-120-17
Figure 70-120-18

S45216
S45217
NOTE: Do not remove set screws (A1), as these set

screws hold the oil cooler element to the 5. Check the oil level on the dipstick (A1). Refill to the
cover. correct level with new lubricating oil of an approved
grade.
3. Release the set screws that retain the oil cooler to the
cylinder block. 6. Operate the engine and check for leakage of coolant
or oil.
4. Remove the oil cooler and the joint.

COOLING SYSTEM (CONT’D) Assembly
Lubricating Oil Cooler (Cont’d) Figure 70-120-20
Disassembly
1. Remove the oil cooler from the cylinder block. (See

Lubricating Oil Cooler on Page 70-120-11.)
Figure 70-120-19
S45375
1. Renew the joints (B1) on the flanges of the element.
2. Fit the element to the cover and tighten the set

screws (A1) to the correct torque.

S45218
3. Fit the oil cooler. (See Lubricating Oil Cooler on Page
70-120-11.)
2. Remove the four set screws (A1) from the oil cooler
and remove the cooler element.
WARNING: Do not allow compressed air to

contact your skin. If compressed air enters your
skin, obtain medical help immediately.
3. Clean the element and check for cracks. If a solution

is used to clean the outside of the element, ensure
that this does not enter the element. Check that there
are no restrictions to the flow of lubricating oil through
the element of the oil cooler. If the inside of the
element needs to be cleaned, use a solvent which is
suitable for copper. Dry the element with low pressure
air and then flush it with clean engine lubricating oil.

COOLING SYSTEM (CONT’D) Installation
Coolant Bypass Pipe Figure 70-120-22
Consumable products
grease
Removal
Figure 70-120-21
S45376
1. Fit new O-rings (B1) and (B2) and lubricate with

POWERPART Red rubber grease.
2. Carefully fit bypass pipe into the cylinder head,

ensure that the O-ring is correctly fitted.
3. Fit the two set screws (A1) and tighten to the correct
torque.
S45219
1. Remove the two set screws (A1).
2. Carefully pull the coolant bypass pipe from the

cylinder head. Remove and discard the O-rings.
3. Remove and discard the O-rings.

Oil Cooler / Radiator Removal And Installation
Raise the lift arms and install an approved lift arm

support device.
1
Drain the coolant from the radiator.
Drain the hydraulic reservoir.

2
Remove the grill frame and engine cover.
Figure 70-120-23
P136626

2
Figure 70-120-26

1
1
2
P136625
Remove both bolts and washers (Item 1). Remove the

plate (Item 2).
Figure 70-120-24
P136628
Remove the bolt and washer (Item 1) and the hose clamp
(Item 2).
P136627

Oil Cooler / Radiator Removal And Installation

(Cont’d)
Figure 70-120-27
P136629
Remove the bolt (Item 1), clamp (Item 2) and the hose P136630
(Item 3).

Figure 70-120-28 radiator.
Figure 70-120-30
1
2
3
P136631
1
Remove the bolt (Item 1), clamp (Item 2) and the hose
(Item 3).
P136632
Remove both bolts (Item 1) from the radiator rim side

sheets.
Remove the radiator sub-assembly.
NOTE: If required, radiator and coolers can be

removed as individual items.


FLYWHEEL AND HOUSING Figure 70-130-1
General Description
The steel flywheel is fitted with a hardened starter ring.

The starter rings have either 115 or 126 teeth.
The flywheel housing is normally made of cast iron, but

certain flywheel housings are made of aluminum alloy.
Flywheel
WARNING: The flywheel is heavy. Use lift

equipment or get help to assist with the lift
operation before removal of the flywheel
fasteners.
S45220
Removal
1. Remove two opposite set screws from the flywheel. Figure 70-130-2
Fit temporarily two guide to ensure that the flywheel
can be removed and fitted safely.
2. Remove the remainder of the set screws and washers

and remove the flywheel.
3. Check the flywheel and ring gear for damage and

renew, if necessary.
Installation
1. Ensure that the location faces of the crankshaft, and

the flywheel are clean and free from damage.
2. Fit a hardened steel washer to each of the ten set S45377

screws. Fit the flywheel over the guide studs and
secure in place with eight of the set screws. Do not
fully tighten the set screws. Tighten the set screws,
see “Specific torque values”.
3. Remove the temporary studs and fit the remaining

two set screws. Tighten the set screws, see “Specific'
torque values”.
4. Check the flywheel run-out with a dial test indicator

(A). This must be less than 0,30 mm (0.012 in) total
indicator reading.
5. Check the alignment of the flywheel face (B). The

error in alignment must not be more than 0,03 mm
(0.001 in) total indicator reading for every 25 mm (1.0
in) of the flywheel radius from the crankshaft axis to
the indicator plunger. During this check, keep the
crankshaft pressed toward the front of the engine to
remove the effect of crankshaft end-float.

FLYWHEEL AND HOUSING (CONT’D)
Ring Gear
Removal
WARNING: Wear eye protection and suitable

protective clothing during this operation.
Before the ring gear is removed, check the position of the

chamfer on the teeth. To remove the ring gear use a
hammer and a chisel to break the ring. Ensure that the
flywheel is not damaged during this operation.
Installation
The ring gear is heated onto the flywheel. When a new

gear is to be fitted, ensure that it is not heated to more
than 250°C (480°F). Ensure that the chamfer on the teeth
of the gear is in the correct direction.

FLYWHEEL AND HOUSING (CONT’D) Figure 70-130-3
Flywheel Housing
WARNING: The flywheel housing is heavy, use

lift equipment or get help to assist with the lift
operation before removal of the flywheel
housing fasteners.
Removal
1. Remove the starter, (See Starting Aid (Glow Plug) on

Page 70-140-7.) and the flywheel. (See Flywheel on
Page 70-130-1.)
2. Release the housing set screws and with a soft face S45221
hammer, hit carefully the housing to remove it from
the dowels.
Figure 70-130-4
Installation
1. Ensure that the rear face of the cylinder block and the
faces of the housing are clean and free from damage.
Ensure that the location dowels are fitted correctly. If

a felt seal is fitted to the rear flange of the sump,
renew the seal.
2. Fit the housing onto the dowels and lightly tighten the
set screws.
3. Check the housing concentricity with a dial test

indicator (A). The run-out limit is given in the relevant
Data and dimensions for the “Flywheel and housing”.
If any adjustment is necessary, it must be made on S45378
the housing and the concentricity checked again.
4. Tighten the set screws to the torque recommended in

“Specific torque values”.
5. Check the housing alignment (B). The maximum

tolerance is given in the relevant Data and
dimensions for the “Flywheel and housing”. Any
necessary adjustment must be made on the housing
and not on the cylinder block.
6. Fit the flywheel, see Operation 13 - 1 and the starter

motor, see Operation 14 - 7.


ELECTRICAL SYSTEM Checking The Drive Belts
General Description 1. Check the belts for wear and damage and renew, if
necessary, in pairs.
Caution: Many of the operations in this chapter should
be done only by a person who has had training to 'Level 2. Check the belt tension. Check / adjust the tension on
2', in '1100 Series Electronic Engine Diagnostics', or both belts. To ensure maximum belt life, it is
greater. recommended that a belt tension gauge is used. Fit
the gauge (A1) at the center of the longest free length
NOTE: It may be necessary to refer to the TIPSS EST and check the tension. If a Burroughs gauge is used,
User Manual for more details. the correct tension is 535 N (120 Ibf) 54 kgf. If the
tension is equal to, or less than 250 N (56 Ibf) 25 kgf
Alternator on either belt, adjust both belts to 535 N (120 Ibf) 54
kgf. (See General Description on Page 70-140-1.)
General Description
Figure 70-140-1
The Denso A 115i 12 volt and the A 127i 12 volt and 24
volt alternators are driven from the crankshaft. pulley by
double belts. The diodes, resistors and the brushes are
fitted inside a cover to protect them against dirt and
moisture. Fans are included within the alternator casing
to cool and protect the alternator.
These alternators have solid state regulators fitted within

the rear cover. The regulators are sealed and repair is not
possible.
For any repairs to the alternator consult your nearest

Perkins Dealer / Distributor.
Caution: Do not disconnect the battery while the engine S45222

is in operation. This will cause a voltage surge in the
alternator charge system which will immediately cause
damage to the diodes or to the transistors. Figure 70-140-2
Caution: Do not disconnect an electrical wire before the

engine is stopped and all electrical switches are in the
“off” position.
Caution: Do not cause a short circuit by the connection

of electrical wires to the wrong terminals. The correct
electrical wire must be connected to the correct terminal.
A short circuit or wrong connection, which gives reverse
polarity, will immediately cause permanent damage to the
diodes and to the transistors.
Caution: Do not connect a battery into the system until it

has been checked for the correct polarity and voltage.
S45379
Caution: Do not check for current flow with a spark
contact as damage can be caused to the transistors.

ELECTRICAL SYSTEM (CONT’D) Removing And Installing The Drive Belts
Alternator (Cont’d) The drive belts are supplied as a set and must be
renewed as a set.
Adjusting The Drive Belt Tension
Figure 70-140-5
Figure 70-140-3
S45224
S45223 Figure 70-140-6

Figure 70-140-4
S45381
S45380 1. Loosen the pivot fastener (A1) of the alternator and

the adjustment link fasteners (A2) and (B1).
1. Loosen the pivot fastener (A1) of the alternator and 2. Release all of the tension from the belts and remove
the fasteners of the adjustment link (A2) and (B1). the belts.
2. Change the position of the alternator to give the 3. Fit the new belts and adjust the tension. (See General
correct tension. Tighten the adjustment link fasteners, Description on Page 70-140-1.) The belt tension must
and then tighten the pivot link fasteners. If there are be checked again after the first 1000 km (600 miles)
two pivot fasteners, tighten the front fastener and then or 20 hours of operation.
the rear fastener.
3. Check the belt tension again to ensure that it is still

correct. (See Alternator on Page 70-140-1.)

ELECTRICAL SYSTEM (CONT’D) Maintenance
Alternator (Cont’d) 1. Ensure that the drive belts are not worn and that the
belt tension is correct, see Operation 14 - 1.
Removal
2. Keep the alternator clean. To clean the alternator, use
WARNING: Ensure that the battery ground a material which is damp with kerosene or a special
connection has been removed before any fluid used for this purpose. Ensure that the fluid does
alternator connection is removed. not enter the cover of the alternator.
1. Disconnect the electrical connection. 3. Ensure that air can pass easily over the casing to
keep it cool.
2. Release all the belt tension and remove the belts.
(See Alternator on Page 70-140-1.)
3. Remove the adjustment link from the alternator and

remove the pivot bolts. Make a note of the position of
the washers and distance pieces to ensure that they
are fitted correctly. Remove the alternator.
Installation
1. Put the alternator in position and assemble loosely

the pivot fasteners and the adjustment link and its

fasteners. Ensure that the washers and the distance
pieces are fitted in their correct positions and that the
alternator pulley is aligned to the crankshaft pulley
within ± 2,4 mm (0.094 in).
2. Fit the drive belts and adjust the drive belt tension,
see Operation 14 - 2.
3. Connect the electrical connection.
4. If all of the work is complete, connect the battery

ground connection.

ELECTRICAL SYSTEM (CONT’D) If the warning lamp is not illuminated when the
ignition switch is in the “ON” position:
Alternator (Cont’d)
1. Check that the battery voltage is correct, (see the
Fault Diagnosis For The Alternator description for Normal operation), with the ignition
switch in the “OFF” position.
The alternator is designed in such a way that a flow of
current (indicated by no light at the warning lamp or a NOTE: Refer to the basic charging circuit illustration
reading shown on an ammeter) shows that the system is (A).
in correct operation. If the system is in correct operation,
no open circuit, voltage or current output checks need to 2. Check that the voltage at alternator terminal “B+” (A8)
be done on the installation unless: to ground is the same as the battery voltage. If it is not
the cables and wires may be damaged or
• - The warning lamp does not show when the disconnected. Check the connections at the
alternator is stationary and the switch is in the “ON” alternator (A7) and at the battery (A2). Check for
position or it shows a light when the alternator is in cable continuity. Check for ground continuity between
operation. the alternator casing and the alternator brackets.
• - No charge current is shown on the ammeter. 3. Check the ignition warning lamp bulb (A4) and renew
if necessary.
• - The battery is discharged.
4. With the ignition switch (A3) in the “ON” position,
• - The battery is hotter than normal which is an check the voltage between the alternator “D+”
indication of loss of voltage control. terminal (A5) and ground. If this voltage is greater

than 2V then the alternator is faulty. Renew the
If one or more of the above symptoms occur, the alternator. (See Alternator on Page 70-140-1.)
procedure indicated below should be applied.
If the warning light continues to be illuminated when
Normal Operation: the alternator is in operation:
1. Ensure that the engine has stopped and that the 1. Set the ignition switch to the “ON” position.
ignition switch is in the “OFF” position.
2. Start and run the engine at a fast Idle speed. Measure
2. Check that the battery voltage is correct, either 12V to the voltages between the alternator terminal “B+” (A8)
12.8 V (12V system), or 24V to 25.6V (24V system). and ground, and between alternator terminal “D+”
Check the condition of the battery if the voltage is not (A5) and ground. The voltages should be between
correct. 13V and 15V (12V system) and between 26V and 30V
(24V system). If the voltages are not within this range
3. Turn the ignition switch to the “ON” position and check then the alternator is faulty. Renew the alternator.
that the ignition warning lamp is illuminated. (See Alternator on Page 70-140-1.).
4. Start the engine and operate it at a fast idle. Check 3. Increase the engine to its maximum, switch on an
that the ignition warning lamp is now extinguished. electrical load (A1) such as the vehicle lights, and
measure the voltages between the alternator terminal
5. Switch on an electrical load, such as the vehicle “B+” (A8) and ground and the alternator terminal “0+”
lights, and increase the engine to its maximum speed. (A5) and ground. The voltages should be between
13V and 15V (12V system) and 26V to 30V (24V
6. The battery voltage should now rise to either 13.5V system). If these values are correct then the fault is
(12V system), or 27V (24V system). within the charging system circuit. Check that the
cables and connections are all correct. If the voltages
7. Switch off the applied electrical load and the battery are still incorrect then the alternator is faulty. Renew
voltage should rise to either 14V (12V system) or 28V the alternator. (See Alternator on Page 70-140-1.)
(24V system).

Alternator (Cont’d)
Fault Diagnosis For The Alternator (Cont’d)
Figure 70-140-7
S45225
Key to the basic charging circuit illustration [Figure

70-140-7].
1. Applied electrical load.
2. Battery.
3. Ignition switch.
4. Ignition warning light.
5. Alternator terminal “D+”.
6. Alternator terminal “W”.
7. Alternator.
8. Alternator terminal “B+”.








ELECTRICAL SYSTEM (CONT’D) Removal
Starter Motors 1. Disconnect the starter motor cables.
General Description 2. Remove the fasteners and remove the starter motor.
The Dense P95RL (12 volt) and the R4.5 (24 volt) starter Installation
motors are operated by a solenoid and have roller clutch
drives. The solenoid engages the starter drive in two NOTE: The starter motors may have an O-ring fitted
operations to ensure that the motor gets its maximum to the starter motor flange. Check the
torque only when the starter motor is engaged fully with condition of the O-ring and renew, if
the flywheel. The clutch prevents rotation of the armature necessary.
at high speed if the starter is held in the engaged
position. 1. Check that the starter motor is free from faults, oil and
grease.
WARNING: Always disconnect the battery
terminals before the removal of any component 2. Clean the flange face of the starter motor and the face
of the electrical system. of the flywheel housing.
Figure 70-140-8 3. Fit the starter motor and tighten the M10 set screws
or nuts to a torque of 44 N•m (33 Ibf ft) 4,5 kgf m.
4. Connect the starter motor cables.

Maintaining The Brush Gear And The Commutator
Repairs to the starter motor are not recommended. Your

Perkins Dealer / Distributor has specialist equipment and
personnel with the correct training to repair your starter
motor.
Test On The Engine

S45226
Ensure that the battery is fully charged.
Caution: Care must be taken to avoid damage to the Turn on the lights and operate the starter switch. If no
engine speed and timing sensor fitted to the cylinder lights are fitted to the machine, connect a voltmeter
block (A) when a starter motor is removed from, or fitted across the battery terminals and operate the starter
to, the left side of the engine. switch.
NOTE: The starter motor may be fastened to the If the starter does not operate but the lights keep their
flywheel housing by either set screws or power, or there is no voltage drop across the battery,
studs and nuts. check the switch and all the connections and wires. Slow
action of the starter can be caused by faulty connections.

ELECTRICAL SYSTEM (CONT’D) Testing
Starting Aid (Glow Plug) 1. Disconnect the glow plugs' power supply cable and
the bus-bar.
General Description
2. Apply one probe of a multi-meter that can check
The starting aid for the 1100 Series four cylinder engines continuity, to the terminal of the glow plug and apply
consists of a set of glow plugs, one on each cylinder. The the other probe to a suitable ground. If the continuity
glow plugs are fitted in the cylinder head near the is correct the multimeter will give an audible signal. If
atomizers. The tip of the glow plugs reaches into the there is no audible signal, renew the glow plug.
combustion chamber in the piston crown. Repeat this check for all of the glow plugs.
The glow plugs are operated electrically, usually through NOTE: If a multimeter is not available the following
the start switch. When the glow plugs are energized, their procedure can be used.
tips become very hot and improve the combustion
process during cold start conditions. 1. Connect a 12V test lamp between the positive
terminal of the battery and ground to check that the
Removal lamp will light.
1. Disconnect the glow plugs power supply cable. 2. Connect the test lamp between the terminal of the
glow plug, that is furthest away from the power
Figure 70-140-9 supply, and ground.
3. Operate the control switch, the test lamp should be

illuminated if the power supply is correct.
4. Disconnect the cables at each glow plug.
5. Connect the test lamp to the positive terminal of the

battery and to the terminal of a glow plug. The lamp
will be illuminated if the continuity is correct. If the test
lamp is not illuminated, renew the glow plug.
6. When all of the glow plugs have been checked,

connect the bus-bar to the glow plugs and reconnect
the power supply cable.
S45227
2. Remove the four nuts (A1) that fasten the bus-bar,

remove the bus-bar.
3. With a suitable socket, loosen, then remove the glow

plugs.
Installation
1. Ensure that the threads of the glow plugs and the

cylinder head holes are clean.
2. Fit the glow plugs into the correct holes in the cylinder
head, then gradually tighten to 18 N•m (13 Ibf ft) 1,8
kgf m.
3. Fit the bus-bar and the four nuts, tighten the nuts to 2
N•m (1.5 Ibf ft) 0,2 kgf m.
4. Connect the glow plugs power supply cable.

Starting Aid (Glow Plug) (Cont’d)
Testing (Cont’d)
1. Disconnect the glow plugs' power supply cable and

the bus-bar.
2. Connect a 50-0-50 ammeter between the power

supply cable and the terminal of a glow plug.
3. Connect a voltmeter between the glow plug terminal

and the ground.
4. Engage the control switch and check the readings of

the ammeter and the voltmeter:
• 12 volt Beru glow plugs.
With a 24 volt supply the initial current is approximately

12 amperes for each glow plug, that becomes
approximately 8.5 amperes after 8 seconds, 7 amperes
after 20 seconds and reach 6 amperes after 60 seconds.

NOTE: If the ammeter reading is low, or there is no
reading, renew the glow plug. If there is no
voltmeter reading, check the switch and the
power supply cable.
When all of the glow plugs have been checked, remove

the ammeter and the voltmeter and connect the power
supply cable. Check that the glow plugs are correctly
fitted.

Electrical Components
General Description
Some 1100 Series 4 cylinder engines have an electronic management system. The system is controlled by an Engine
Control Module (ECM). The ECM receives signals from the sensors, and the electronic fuel injection pump, and has an
output to the electronic fuel pump. The ECM controls the engine operation to meet the operator requirements.
Figure 70-140-10

S45228
The electronic management system consists of the For engine diagnostics and fault finding; refer to the 1100
following components (A): Series Diagnostic Manual or the on-line Diagnostic
Guide.
1. Engine Control Module (ECM)
2. Diagnostic Connector
3. Machine Interface Connector (MIG)
4. Intake Manifold Air Temperature Sensor
5. Engine Coolant Temperature Sensor
6. Engine Oil Pressure Sensor
7. Intake Manifold Pressure Sensor
8. Speed and Timing Sensor
9. Crankshaft Timing Ring
10. VP30 Electronic Fuel Injection Pump
11. Voltage Load Protection Module (VLPM)

ELECTRICAL SYSTEM (CONT’D) Programming Configuration Parameters
Electrical Components (Cont’d) Passwords are divided into two groups.
Programming Configuration Parameters Factory passwords are required to perform each of the
functions listed below:
Many programmable configuration parameters affect
engine operation. These parameters may be changed by • To program a new ECM: When an ECM is renewed,
using the TIPSS-EST service tool. The parameters are the system configuration parameters must be
kept in the memory of the ECM. programmed into the new ECM. A new ECM will allow
system configuration parameters to be programmed
All parameters can be read and passwords can be used only once, without factory password. After this time,
to protect them from unauthorized changes. The they are protected by factory passwords.
parameters are divided into two groups:
System configuration parameters affect “critical settings” • To change the engine rating: This requires a change
for the engine and can only be changed with factory to the ECM software code, which is protected by
passwords, by TIPSS-EST. They do not normally need to factory passwords.
be changed during the life of the engine. A complete list
of these parameters is available from the Helpdesk. • To read a customer password: If the owner has lost
the customer password, it will not be possible to
Some examples of system configuration parameters are: program customer parameters. In this case, the
factory passwords can be used to find the customer
• Full Load Setting (FLS): This is a number which password.
represents fuel system adjustments made at the

factory. • To remove certain diagnostic codes from the memory
of the ECM: The factory passwords are needed to
• Software part number: This is the part number of the remove 'Critical event' codes from the memory of the
software that was programmed into the ECM. ECM. once-they are logged.
• Engine serial number: This should match the engine NOTE: Some other codes require customer
serial number that is stamped on the engine passwords. but most of the logged codes do
information plate. A new ECM will be supplied without not need passwords to remove them from the
the engine serial number programmed into it. memory of the ECM.
Customer configurable parameters allow the OEM to NOTE: To obtain factory passwords, either refer to
change engine parameters to match the application. the Helpdesk or proceed as if you already
They may be changed many times, if a customer have the password. At some point if the
changes his requirement. These can be changed with factory passwords are needed. TIPSS-EST
T1PSSEST. This may require a customer password, if will also need them but it will give the
one has been programmed into the ECM. information needed to obtain them.
An example of these parameters is: NOTE: If a customer password has been entered, it
will be needed to make changes to ANY
• Idle speed. customer parameter.
• This is the number that sets the engine idle speed. T1PS8-EST can be used to change customer
parameters.
To obtain a customer password, contact the supplier of
the equipment. If the owner has lost the password, it may
be found by using TIPSS-EST:
• In TIPSS-EST, go to the ' Information' menu access
'Passwords' and record the information shown.
• Go to the 'Factory Password' screen and use the
factory passwords.
• Record the customer password from the 'View
Customer Passwords' screen. The customer
password may then be used to change customer
parameters.

ELECTRICAL SYSTEM (CONT’D) 1. Check the connectors and sockets in the ECM and
the harness connector for wear or damage. If wear or
Engine Control Module (ECM) damage is found, the connectors, sockets or harness
must be renewed. Refer 'to the 1100 Series
Engine Control Module (ECM) Diagnostic Manual for the test procedures.
Caution: If an ECM is returned for repair, or under 2. Check the seal for the ECM connector, if necessary,
warranty, then the ECM connector must be covered with renew the seal.
a plastic blanking cap to prevent the entry of water and
dirt into the unit. If this blanking cap is not fitted then the Figure 70-140-12
warranty may be affected.
Caution: The ECM is protected from vibration by rubber

mountings that are fitted in the holes for the fasteners.
The fitting of the ground cable must be correct to prevent
damage to the electronic components.
Removal
1. Ensure that the engine start switch is in the OFF

position. Remove the battery terminals.
Figure 70-140-11

S45382
3. Check the rubber mountings (B2) for wear or cracks,

if wear or cracks are found, renew the mountings.
Figure 70-140-13
S45229
2. Loosen the Allen screw (A1) for the connector and

remove the connector with the plastic cover from the
ECM. care must be taken to ensure that the
connectors in the ECM socket are not damaged.
3. Loosen the four setscrews that secure the ECM to the

cylinder block. Remove the ECM from the engine.
S45230
NOTE: The position of the spacers, washers and the

ground cable (A2).
Caution: The ground cable (C2) must be fitted correctly
to prevent damage to the electronic components.
Installation
Caution: The ECM is programmed for the application.

The Electronic Service Tool (EST) will confirm the EOM
program. If a new ECM is fitted ensure that it has been
programmed correctly. Contact your nearest Perkins
Dealer / Distributor for further information.

ELECTRICAL SYSTEM (CONT’D) Caution: Ensure that the recommended Allen screw
torque for the ECM connector to the ECM is not
Engine Control Module (Cont’d) exceeded as this will damage the connector body.
Figure 70-140-14 6. Tighten the four setscrews (D2) to 22 N•m (16 Ibf ft)
2,2 kgf m.
7. Fit the harness connector to the ECM; to fit the

harness connector, engage the connector in the
ECM, push the connector fully into the ECM and
tighten the securing screw (C1) to 6,0 N•m (4 Ibf ft)
0,6 kgf m.
8. Fit the battery terminals.
S45383
Figure 70-140-15

S45384
4. Fit the ECM to the engine; ensure that the rubber

mountings (D3) and the ground cable (E1) are fitted in
the correct positions.
NOTE: The ground cable has a special washer fitted

to the cable, ensure that when the setscrew
for the ground cable is tightened that the
cable is not rotated and tension is not put on
the cable.
5. Tighten the four setscrews (D2) to 22 N•m (16 Ibf ft)

2,2 kgf m.
Caution: Do not use the connector Allen screw (C1) to

pull the connector into position. This will damage the
connector.

ELECTRICAL SYSTEM (CONT’D) Installation
Voltage Load Protection Module 1. Carefully insert the VLPM (A6) into the clips and
tighten the setscrew (A5), to 22 N•m (16 Ibf ft) 2,2 kgf
Removal m.
1. Disconnect the electrical connector from the VLPM. 2. Connect the VLPM cable to the connector within the
wiring harness, between the ECM and the fuel
Figure 70-140-16 injection pump cable.
3. Lightly pull the harness connector to ensure that it is

locked to the VLPM connector (A4).
S45231

2. Remove the setscrews (A5) that secure the connector
to the ECM.
3. Carefully remove the VLPM (A6).

ELECTRICAL SYSTEM (CONT’D) If the 'ECM replacement' feature cannot be used.
Programming A New ECM NOTE: The new ECM mayor may not be supplied with
software installed at the factory,
The new ECM must be programmed and configured.
NOTE: TIPS8-EST User Manual will provide an
• If communication with the old ECM is still possible, explanation for any errors that may occur
use the ' ECM replacement' feature in EST to get the during the programming.
configuration parameters from it, see ' Using the
TIPSS-EST ECM replacement feature'. 1. Record the engine serial number.
• If communication with the old ECM is not possible, 2. Contact the Helpdesk or go to the Perkins Secured
see ' If the ECM replacement feature cannot be used. Internet (PTMI) to obtain the configuration
parameters.
The ECM is the main component of the system. If a
problem occurs, it is easy to assume that the ECM is 3. Connect the new ECM to the ECM connectors.
faulty, this is usually the wrong diagnosis.
4. Get the part number for the 'flash file' from SPI.
Most failures occur at the wiring and connectors, or at a
sensor input or output. Follow the diagnostic test 5. Get the ' flash file' from the TIPSS CD, if it is not on
procedures and do not renew an ECM, unless it is faulty. the CD go to the Perkins Secured Internet for it.
NOTE: If a new ECM is needed, and if the suspect 6. Load the ' flash file' software into the new ECM.
ECM can communicate with TIPSS-EST, the

ECM parameters can be transferred from the 7. Check the memory of the ECM for active codes.
suspect ECM to the new ECM unless it is
faulty. 8. Program any parameters that may be needed and
have not been programmed already.
To use the TIPPS-EST ' ECM replacement feature',
NOTE: The new ECM mayor may not be supplied with

software installed at the factory,
NOTE: TIPS8-EST User Manual will provide an
explanation for any errors that may occur
during the programming.
1. Go to the ' Service I Copy Configuration' menu, select

the ' ECM Replacement' feature and load the
parameters from the faulty ECM onto EST.
2. Connect the new ECM to the ECM connectors.
3. Get the part number of the 'flash file' from SPI.
4. Get the ' flash file' from the TIPSS CD, if it is not on
the CD go to the Perkins Secured Internet for it.
5. Load the ' flash file' software into the new ECM.
6. Use the TIPSS-EST 'ECM replacement' feature to

program the new ECM.
7. Check for active codes.
8. Program any required parameters that have not been

programmed.

Speed And Timing Sensor
WARNING: The O-ring (B1) fitted to the speed

and timing sensor is made of “Viton”, see the
safety precautions for “Viton seals”.
NOTE: The engine speed and timing sensor is not

adjustable. The sensor and securing bracket
is a single unit and should not be dismantled.
The sensor must be fitted so that the securing
bracket (A2) is fully against the machined
surface of the cylinder block.
The new ECM must be programmed and configured. S45385
Removal
4. Discard the O-ring (B1).
1. Disconnect the electrical connector from the sensor.
Installation
Figure 70-140-17
1. Ensure that the sensor body and the bore in the
cylinder block are clean and free from oil and dirt.

2. Fit a new O-ring to the sensor in the first groove (B1).
Apply a small amount of clean engine oil to the O-ring.
NOTE: The second groove (B2) in the sensor is not

used.
3. Push the sensor fully into the bore of the cylinder

block (A). Do not use the setscrew to pull the sensor
into position. Align the hole in the sensor bracket to
the hole in the cylinder block and loosely fit the
setscrew (A1).
S45232
4. Tighten the setscrew to 22 N•m (16 Ibf ft) 2,2 kgf m.
2. Remove the setscrew (A1) that secures the sensor to 5. Check that the sensor bracket is fitted fully against the
the cylinder block. machined surface of the cylinder block.
3. Carefully remove the sensor (A3) from the cylinder 6. Check that the connector seal is in place, that it is
block. Do not use a lever, this can cause damage to clean and is not damaged. Renew the seal if it is
the sensor. damaged.
7. Carefully fit the electrical connector to the sensor to

ensure that the connector pins are not bent during this
operation.

locked to the sensor connector.

ELECTRICAL SYSTEM (CONT’D) 2. With a suitable spanner, loosen and then remove the
sensor from the oil filter head (A1) or the intake
Pressure Sensor manifold.
WARNING: The O-ring (B1) fitted to the speed Figure 70-140-21

and timing sensor is made of “Viton”, see the
safety precautions for “Viton seals”.
Figure 70-140-19
S45234
3. Discard the O-ring (C1 or C2).

S45233

Figure 70-140-20
S45386
There are two pressure sensors fitted to the engine. One

sensor is fitted to the oil filter head (A1) for the oil
pressure and one sensor is fitted to the intake manifold.
The pressure sensor fitted to the intake manifold (B2) has
a cable with a connector permanently connected to the
sensor.
Removal
1. For the oil pressure sensor; disconnect the electrical

connector from the sensor. For the intake manifold
pressure sensor; disconnect the electrical cable from
the wiring harness.

ELECTRICAL SYSTEM (CONT’D) 3. Fit the sensor to the oil filter head (D1) or the intake
manifold (E2), tighten the oil pressure sensor to 10
Pressure Sensor (Cont’d) N•m (7 Ibf ft) 1,0 kgf m and the intake manifold
pressure sensor to 20 N•m (15 Ibf ft) 2,1 kgf m.
Installation
4. Check that the connector seal is in place, that it is
Figure 70-140-22 clean and is not damaged. Renew the seal if it is
damaged. (See Wiring Harness on Page 70-140-20.)
5. Carefully fit the electrical connector to the sensor to

operation.

Figure 70-140-24
S45235

1. Ensure that the threads of the sensor and the threads
in the oil filter head (D1) or the intake manifold, are
dean and free from damage.
2. Fit a new O-ring (F1 or F2) to the sensor.
NOTE: The O-ring for the intake manifold pressure

sensor is yellow. The O-ring for the oil
pressure sensor is brown. (Temperature
sensor O-rings are black)
S45387
Caution: Do not use air operated tools to fit pressure

sensors as these may damage the sensor.
Figure 70-140-23
S45236

ELECTRICAL SYSTEM (CONT’D) Removal
Temperature Sensor Caution: Before the coolant temperature sensor is

removed from the cylinder head, ensure that the coolant
Figure 70-140-25 is drained to a level that is below the sensor or the
cylinder head.
1. Disconnect the connector from the sensor.
2. With a suitable spanner, loosen then remove the

sensor from the cylinder head or the intake manifold.
3. Discard the O-ring.
S45237
Figure 70-140-26

S45388
There are two temperature sensors fitted to the engine.

One sensor is fitted to the cylinder head (A1) for the
coolant temperature and one sensor is fitted to the intake
manifold (B1) for the air intake temperature.

ELECTRICAL SYSTEM (CONT’D) 5. Carefully fit the electrical connector to the sensor to
Temperature Sensor (Cont’d) operation.
Installation 6. Lightly pull the harness connector to ensure that it is

1. Ensure that the threads of the sensor and the threads
in the cylinder head or the intake manifold are clean Figure 70-140-29
and free from damage.
2. Fit a new O-ring (E1) to the sensor.
NOTE: The O-rings for the temperature sensors are

black.
Figure 70-140-27
S45390

S45238
Figure 70-140-28
S45389
3. Fit the sensor to the cylinder head (C1) and the

induction manifold (D1), tighten the sensor to 20 N•m
(15 Ibf ft) 2,1 kgf m.
4. Check that the connector seal is in place, that it is

clean and is not damaged. Renew the seal if it is
damaged, see Operation 14 - 19.

ELECTRICAL SYSTEM (CONT’D) Diagnostic Connector
Wiring Harness NOTE: If several connector pins are damaged, it is

recommended that the complete connector is
Caution: Repairs to the wiring harness should not be renewed.
carried out unless directed by the Diagnostic Manual.
 Description Repair
Caution: If a wiring harness is returned under warranty,
Damage to the connector Remove the connector
the MIC connector must be covered with a plastic
body. pins from the body and fit
blanking cap to prevent the entry of water and dirt into the
to a new connector body.
unit. If this blanking cap is not fitted then the warranty
may be affected. Damage to a connector Remove the damaged
pin. connector pin and fit a new
NOTE: A repair kit is available for all wiring harness connector pin.
repairs. Damage to the connector Renew the complete
body and the connector connector.
There are three main options for wiring harness repair, pins.
these are:
Fuel Injection Pump Connector
• Renew the complete wiring harness.
• Renew the pins or sockets, complete with wires Repairs to the fuel injection pump connector are not
attached. recommended because specialist equipment and
• Renew the connector, complete with wires personnel with the correct training are necessary. It is
attached. more cost effective to renew the wiring harness.

Repairs that are difficult, or may take a long time to ECM and MIC Connectors
repair, should not be carried out. It may be more cost
effective to renew the wiring harness. NOTE: If several connector pins or sockets are
damaged, it is more cost effective to renew
New connector pins and sockets are supplied with a the connector.
short wire attached. The end of the wire must be crimped
to the wiring harness. (See Wiring Harness on Page 70- Description Repair
140-20.)
Damage to the connector Renew the connector body.
body.
New connectors are supplied complete with pins or
sockets and short wires attached. The ends of these Damage to a connector pin Remove the damaged
wires must be crimped to the wiring harness, see [ on or socket. connector pin or socket
Page 20]. and fit a new connector pin
or socket.
The tables below show a list of repair options that are
recommended for each of the connectors and the main
wiring harness:
Sensor Connector
Description Repair
Damage to the connector Remove the connector
body. pins from the body and fit
to a new connector body.
Damage to a connector Remove the damaged
pins or sockets. connector pin and fit a new
connector pin or socket.
Damage to the connector Renew the complete
body and the connector connector.
pins or sockets.

ELECTRICAL SYSTEM (CONT’D) Caution: Do not bend the wires directly from the rear of
the connector (A1) as distortion of the rear seal will
Wiring Harness (Cont’d) result, and this will allow water to enter the connector.

Wiring Harness Caution: Ensure that all ECM and MIC connector holes,
that are not used by a wire to a socket or a pin are closed
NOTE: If several wires are damaged, it is more cost by a blanking plug (A2) to ensure a waterproof seal. The
effective to renew the wiring harness. blanking plugs must be inserted into the connector so
that the head of the blanking plug is pushed against, but
Description Repair not into, the connector end seal (A3).
Cut wire. Use a crimp to join the
wires together.
Damage to wire insulation Remove the damaged
only. section of wire, replace
with a new section of wire
and crimp to the original
wires.
Damage to wire by Remove the damaged
corrosion. section of wire, replace
with a new section of wire
and crimp to the original
wires.
Damage to the harness Repair with tape.

outer cover.
S45239

ELECTRICAL SYSTEM (CONT’D) The connectors (A) have locking wedges that are pushed
into the connectors to lock the pins or sockets in position.
Wiring Harness (Cont’d)
Sensor Connector Types
Connector Repair
Male connectors (A1).
To repair a sensor connector, the body can be renewed.
Female connectors (A2).
Individual pins and sockets can be renewed or the
connector complete with wires attached can be renewed. Connector pin (A3) with wire connected.
Connector socket (A4) with wire connected.
Figure 70-140-30

S45240
To Remove a Connector From a Sensor or Another Caution: Do not pull on the wires to separate a sensor
Connector connector.
Figure 70-140-31 1. Before a connector is removed from a sensor, or from

another connector, ensure that the connector and the
local area are clean, free from dirt, oil and grease.
2. For a male and female sensor I harness connectors;

hold the connector in two hands and press the locking
mechanism (A1) until it releases. Hold the locking
mechanism down and lightly pull the two parts of the
connector until they separate.
For a pressure or temperature sensor; hold the locking

mechanism (A2) or (A3) down and lightly pull on
the connector until it separates from the sensor.
S45241
Caution: Do not use tools to separate the two parts of a

sensor connector (A), because damage to the locking
mechanism may result.

Connector Repair (Cont’d)
To Remove a Pin From a Male Connector
1. To remove the locking wedge from a male connector,

insert a small thin screwdriver blade between the
locking wedge and the connector body. Lightly lift the
locking wedge off the connector body. Put the locking
wedge in a safe place so that it can be fitted later.
2. Release the connector pin locking mechanism and

lightly pull the wire out of the connector.
To Remove a Socket From a Female Connector
1. To remove the locking wedge from a female

connector, use thin long-nose pliers, hold the pliers
firmly in one hand and lightly pull the female
connector until the locking wedge is removed. Put the
locking wedge in a safe place so that it can be fitted

later.
2. Release the connector socket locking mechanism

and lightly pull the wire out of the connector.
To Insert a Pin or Socket Into a Female Connector
1. Hold the wire of the pin or socket that is to be inserted

into the connector approximately 25,4 mm (1.0 in)
behind the contact crimped area.
2. Hold the connector with the rear seal towards you.
3. Push the pin or socket fully into the connector seal.
4. When all contacts are in position, insert the locking

wedge and push it into place.
NOTE: For locking wedges that have an arrow, the

arrow must be fitted towards to the connector
locking mechanism.
5. To connect a new wire or connector to the wiring

harness. (See Wiring Harness on Page 70-140-20.)

Repairing A Diagnostic, An EGM, Or A MIG
It is recommended that if several pins need to be

replaced, or if the connector body is damaged, it may be
cost effective to renew the harness.
To Remove a Pin or a Socket From a Connector
NOTE: The procedure is the same for the Diagnostic,

ECM and MIC connectors.
NOTE: The tool required to remove the contact pins

or sockets from these connectors is supplied
in the wiring harness repair kit.
1. Before a connector pin or socket is removed from a

connector, ensure that the connector and the local
area are clean, free from dirt, oil and grease.
Figure 70-140-32

S45391
2. Carefully fit the removal tool (A2) onto the wire (A1)
that is attached to the pin (B1) or the socket to be
removed.
S45242

ELECTRICAL SYSTEM (CONT’D) Note: New pins and sockets are supplied with a short
length of wire fitted.
Note: Any pin or socket holes that are not used in the
Repairing A Diagnostic, AN EGM, Or A MIG (Cont’d) connector must have blanking plugs fitted.
Figure 70-140-34 Figure 70-140-35
S45392 S45243

3. Carefully push the removal tool (C1) along the wire 1. Hold the wire (D1) approximately 25,4 mm (1.0 in)
and into the seal of the connector. behind the pin or socket.
4. Carefully push the removal tool (B2) fully into the 2. Hold the connector with the rear of the connector
connector to release the connector locking towards you.
mechanism (B3).
Figure 70-140-36
5. With the removal tool (B2) fully engaged onto the pin
or the socket, carefully withdraw the pin or the socket
(B 1) with the removal tool.
Caution: After the repair of Diagnostic. ECM and MIC

connectors, ensure that the seals are fitted and are
correctly in position as damage to the connector body
can result if they are not.
To Insert a Pin or Socket Into a Connector
It is recommended that if several pins need to be

replaced, or if the connector body is damaged, it may be
cost effective to renew the harness.
S45393
Caution: Do not bend the wires directly from the rear of
the connector as distortion of the rear seal will result. And
this will allow water to enter the connector. 3. Push the pin or socket (E1) or socket through the
connector rear seal.
Caution: Ensure that all EGM and MIG connector holes
that are not used by a wire to a socket or a pin, are
closed by a blanking plug to ensure a waterproof seal.
The blanking plugs must be inserted into the connector
so that the head of the blanking plug is pushed against.
But not into, the connector end seal.
NOTE: The procedure is the same for Diagnostic,

ECM and MIC connectors.

ELECTRICAL SYSTEM (CONT’D) 2. Remove the insulation from the end of the wires that
are to be joined.
Figure 70-140-38
Repairing A Diagnostic, An EGM, Or A MIG (Cont’d)
Figure 70-140-37
S45244
3. Put the wires (A2) into the connector sleeve (A) and
using a crimping tool, crimp the middle area (A1).
S45394

4. Apply enough heat to the heat-shrink part of the
connector (A3) to seal the wires inside the connector
4. Push the pin or socket (F2) into the connector until the
sleeve.
pin or socket is against the locking mechanism (F1).
Figure 70-140-39
5. Push the pin or socket (F3) until the locking
mechanism (F4) is in position behind the pin or
socket.
6. Carefully pull on the wire to test that the pin or socket

is locked in position. If the pin or socket pulls out of the
connector, repeat the procedure from stage 1.
Caution: After the repair of Diagnostic. EGM and MIG

connectors, ensure that the seals are fitted and are
correctly in position as damage to the connector body
can result if they are not.
Connecting A New Wire Or Connector To The Wiring
S45395
Caution: Do not solder the wires to the wiring harness.
The wires must be correctly crimped.
NOTE: If more than one wire is to be crimped to the
NOTE: Connector sleeves that are supplied in the wiring harness the connector sleeves (B 1)
wiring harness repair kit have a heat-shrink must be fitted at different lengths from the
cover that has sealant applied to the inner connector.
surface.
NOTE: The new pins, sockets, and complete

connectors that are supplied in the wiring
harness kit. all have short wires connected to
them.
1. Cut the original wire to give the correct length when

the new wire is connected.

AUXILIARY EQUIPMENT Adaptor For A Hydraulic Pump Or A Steering Pump
General Description Removal
The power take-off (PTO) adaptor provides a means to Figure 70-150-1

use the engine power to operate auxiliary equipment.
The idler gear drives the splined shaft of the adaptor.
Power Steering Pump
Removal
1. Disconnect the pipes at the power steering pump and

fit covers to the open ends of the pipes.
2. Release the set screws and remove the pump.
Installation
1. Renew the O-ring and lubricate it with clean engine

lubricating oil.
2. Check the drive coupling, or the gear, for wear and

damage. Renew if necessary.

3. Fit the pump and tighten the set screws.
4. Remove the covers from the open ends of the pipes

and fit the pipes.
S45245
1. Remove the Allen screws (A1) and remove the

adaptor assembly from the rear of the timing case.
2. Remove the set screws (A8) and the rear cover (A

10).
3. Check the gear (A4), the spline drive and the bearings
(A3 and A9) for wear and damage, renew the
components if necessary.
Installation
1. Fit a new O-ring (A7) in its recess in the housing (A6)

and lightly lubricate it with clean engine lubricating oil.
Lubricate the bearings (A3) and (AS) with clean
engine lubricating oil. Fit the rear cover (A10) and fit
the adaptor assembly to the timing case and tighten
the cap screws.

AUXILIARY EQUIPMENT (CONT”D)
Adaptor For A Hydraulic Pump Or A Steering Pump

(Cont’d)
Disassembly
Figure 70-150-2

S45246
1. Remove the circlip (A5). Provide a support for the

Range face of the housing (A6). Use a suitable
adaptor on the front bearing (A9) to press the gear
and bearings out of the housing.
2. Remove the bearings (A3 and A9) from the gear (A4)
with a suitable puller.

AUXILIARY EQUIPMENT (CONT”D) 2. Apply a narrow ring of POWERPART Retainer (oil
tolerant) to the inner surface of the front bearing (A9)
Adaptor For a Hydraulic Pump or a Steering Pump in the position shown (A2). Provide a support for the
(Cont’d) bearing. With the small diameter of the gear (A4)
toward the bearing, press the gear into the bearing
Assembly until the gear is against its shoulder.
Special Requirements 3. Apply a narrow ring of POWERPART Retainer (oil

tolerant) to the outer surface and to the inner surface
Consumable products of the rear bearing (A3) in the positions shown (A2).
Description Part number Ensure that the support is under the front bearing.
Use a suitable adaptor on the outer ball race of the
POWERPART Retainer 21820603 bearing to press the bearing into the housing and onto
(oil tolerant) the shoulder on the gear (A4). Remove any excess
retainer. Fit the circlip (AS) into its groove in the
Figure 70-150-3 housing.
4. Check the backlash between the power take-off gear

and the idler gear. The backlash is 0,11 - 0,17 mm
(0.004 - 0.007 in).

S45247
1. Apply a narrow ring of POWERPART Retainer (oil

tolerant) to the outer surface of the front bearing (A9)
in the position shown (A2). Provide a support for the
front face of the housing. Use a suitable adaptor on
the outer race of the bearing to press the front bearing
onto the shoulder in the housing. Remove any excess
retainer.

AUXILIARY EQUIPMENT (CONT”D)
Exhauster
Removal
1. Disconnect the lubricating oil and vacuum pipes from

the exhauster and fit covers to the open ends of the
pipes.
2. Release the set screws and remove the exhauster.
Installation
1. Ensure that the joint faces of the exhauster and the

timing case are clean and renew the joint. Fit the
exhauster to the timing case and tighten the set
screws.
2. Remove the covers from the open ends of the pipes

and connect the oil pipe and the vacuum pipe to the
exhauster.

SPECIAL TOOLS
List Of Special Tools
S45248

SPECIAL TOOLS (CONT’D)
List of Special Tools (Cont’d)
S45249

S45250

S45251

REAR HAND THROTTLE LEVER Figure 70-170-3
Cable Adjustment Procedure
Figure 70-170-1
1 2
1
P135166
P135166
2
Loosen the bolt (Item 1) and pull the cable (Item 2)

S45446
S45446 through a few mm (inches), depending on how much
adjustment is needed.
To access the throttle pedal and linkage under the cab, Tighten the bolt to 25 N•m (18.4 ft-lb) torque. Start the
remove the four bolts (Item 1) and cover (Item 2). engine and check what the minimum engine speed

achievable with the hand throttle is, it should be 2300
Figure 70-170-2 rpm.
Repeat the adjustment procedure if necessary.
Reinstall the cover.
S47132
Move the rear hand throttle lever (Item 1) to the low idle
position.


ACCELERATOR PEDAL Figure 70-180-3
Figure 70-180-1
1
1
P136091

P136089
Figure 70-180-4
Loosen the nuts (Item 1).
Figure 70-180-2

1
P136092
Remove the accelerator rope (Item 1) from the engine

P136090 bracket.
Figure 70-180-5
Remove the cotter pin (Item 1) from the fork.
P135797

ACCELERATOR PEDAL (CONT’D) Figure 70-180-8
Figure 70-180-6
P135803

P135799
Figure 70-180-9
Loosen the nut (Item 1).

Figure 70-180-7
1 P135804
Remove the nuts (Item 1).

P135801
Figure 70-180-10
P135805
Remove the bolts (Item 1) and remove the pedal.

ACCELERATOR PEDAL (CONT’D)
Cable Adjustment Procedure
Figure 70-180-11
P135325
The adjustment point can be found behind the fuel

injection pump (Item 1).

Figure 70-180-12
P135326
If the engine speed is too low, adjust the nuts on the

bracket (Item 1) to shorten the length of the cable
between the bracket and the fuel injection pump.
To confirm the correct engine speed, start the engine and

observe the low idle RPM. Then press the throttle pedal
to confirm high idle (no load). The correct settings are:
• Low idle: 800 rpm

• High idle: 2300 ± 50 rpm
Re-adjust the cable length if needed until the correct

engine speed settings are achieved.


EXHAUST Figure 70-190-3

support device.
Open the engine cover.
Remove the engine side covers.
Figure 70-190-1
P135314

P135313
Figure 70-190-4
Figure 70-190-2
1
P135315
P135313
Remove the clamp (Item 1) and the hose (Item 2).
Remove the three bolts and washers (Item 1).

EXHAUST (CONT’D)
Figure 70-190-5

1
P135316
Remove the four bolts and washers (Item 1).
Remove the silencer pipe (Item 2)

AIR FILTER Figure 70-200-3
Housing Removal And Installation

support device.
Remove the grill frame.
Remove the engine cover.
Figure 70-200-1
2
P135320
Remove the terminals (Item 1).
Figure 70-200-4

P135318
Remove the clamp (Item 1) and rain cap (Item 2).
Figure 70-200-2
1
2
2 P135321
1
Remove the clamp (Item 1) and hose (Item 2).
P135319
Remove the clamp (Item 1) and remove the pre-filter pipe

(Item 2).

AIR FILTER (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 70-200-5

P135322
Remove the two nuts and bolts (Item 1) from the plate.
Then remove the plate (Item 2).
Remove the air filter housing.

ENGINE Figure 70-210-2
Park the machine on firm level ground, engage the

parking brake and set transmission to neutral.
Raise the lift arms and install the approved lift arm
support device.
Rotate the battery disconnect switch. 1

2
Remove the grill frame.

P136053
Remove the coolers.
Remove the air filter. Remove the nut (Item 1) and the wire (Item 2).
Remove the exhaust. Figure 70-210-3
Label and remove all electrical connections, the number

of connectors will vary depending on the ancillary

equipment fitted to the engine. Typical connectors are;
starter motor, alternator, coolant temperature switch, 1
engine oil pressure switch, air conditioning compressor
etc.
Figure 70-210-1
P136054
1
Figure 70-210-4
2
1
P136052
Remove the bolt (Item 1) and the wire (Item 2).
P136055
Loosen the clamp (Item 1) and remove the hose (Item 2).

ENGINE (CONT’D) Figure 70-210-7
Figure 70-210-5
1 P136058

P136056
Figure 70-210-8
Remove the nut and washer (Item 1). Remove the wire
(Item 2).

Figure 70-210-6
P136059
1
P136057 Figure 70-210-9
Remove the two nuts and washers (Item 1). Remove the
1
two wires (Item 2).
P136060

Figure 70-210-10
1
1
P136063
Remove the cotter pin (Item 1).

P136061
Figure 70-210-13
Figure 70-210-11

1
P136064

P136062
Figure 70-210-14
P136065
Release the accelerator rope (Item 1).

Figure 70-210-15
1
2
P136068
1
Loosen the two clamps (Item 1) and remove the two

P136066 hoses (Item 2).
Figure 70-210-18
Figure 70-210-16

1
1 2
P136069
P136067 Loosen the clamp (Item 1) and remove the hose (Item 2).
Figure 70-210-19
P136070
Loosen the clamp (Item 1) and remove the hose (Item 2).

Figure 70-210-20
P136100
Install jack stands to support the transmission.

P136071
Figure 70-210-23
Remove the fuel hose (Item 1).

1

Figure 70-210-21
1
P136101
Remove the two bolts (Item 1) and the cover Item 2).
P136072
Install a lifting strap to lift and support the engine.

Figure 70-210-24
P136104
Figure 70-210-27
P136102

torque plate and then remove the torque plate.

Figure 70-210-25
P136105
Remove the twelve bolts (Item 1).

1
Figure 70-210-28
P136103
Remove the twelve bolts, lock washers and washers

(Item 1) and remove the torque plate (Item 2).
P136106
Remove the four nuts and washers (Item 1) from the

plates which positioned each corner of the engine.

ENGINE (CONT’D)
Figure 70-210-29
P136107
Remove the four bolts (Item 1) from the plates which

positioned each corner of the engine.

Figure 70-210-30
P136108
Lift and remove the engine.


HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
HVAC UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-7


HVAC UNIT Figure 80-10-2
Removal
Remove seat, seat bracket and floor mats. 1
Figure 80-10-1
1
1
1
P135231
2
Figure 80-10-3
3
1

P135232
Remove the four screws (Item 1) from each corner of the

P135230
instrument clusters.
Mark the location of the electrical connectors under the

instrument clusters for correct assembly.
Remove the operators seat (Item 1), seat bracket (Item
2), and floor mats (Item 3).
Instrument clusters and right console must be

disassembled before the heater.

HVAC UNIT (CONT'D) Figure 80-10-6
Removal (Cont'd)
Figure 80-10-4
2
1
1
P135235
Remove the three screw caps (Item 1).

P135233
Figure 80-10-7
Loosen the locknut (Item 1) and remove knob (Item 2).

Figure 80-10-5
1 1
2
P135236
Remove the three screws (Item 1) and polyester cover

P135234 (Item 2).
There is no need to remove the hand throttle to

Loosen the bolt and remove the knob (Item 1). disassemble the right console, but hand throttle’s rope
must be separated from the right console.

Removal (Cont'd)
Figure 80-10-8
P135239
There is a slot (Item 1) in the panel to separate the hand

P135237 throttle’s rope from the right console.
Figure 80-10-11
Figure 80-10-9

1
1
2
1
P135240
P135238 Remove the two bolts and washers (Item 1).
Figure 80-10-12
Remove the three screws (Item 1). Then disassemble the
polyester (Item 2) with hand throttle.
1
P135241
Remove the three screws (Item 1).

Removal (Cont'd)
Figure 80-10-13
P135244
Figure 80-10-16
P135242
Remove the bolt / washer (Item 1) from the right console.

1

Remove the right console.
1
Figure 80-10-14
P135245
Remove the two nuts (Item 1) from the heater box

assembly (both sides).
Remove the heater box assembly.
P135243
The A/C unit and the heater have exactly the same view.
Label all the hoses for correct installation before
removing them all from the heater.

Removal (Cont'd)
Figure 80-10-17
1
P135248
Open the engine cover and remove the snap hook (Item
P135246 1).
Figure 80-10-20
support device. Rotate both engine cover lock switches 1 2 1

(Item 1).
Figure 80-10-18
1
1
1
1
P135249
Remove the six bolts (Item 1) and grille assembly (Item

2).
P135247
Remove both engine covers (Item 1).

Removal (Cont'd)
Figure 80-10-21
P135252
2
Remove the four bolts (Item 1).
Figure 80-10-24

1
P135250
P135253
With the help from an assistant, remove the nut (Item 1)

and gas strut (Item 2). Remove the two bolts (Item 1).
Figure 80-10-22 Remove the grille frame.
1
1
P135251
Remove the four nuts and bolts (Item 1).

Installation
Figure 80-10-25
P135256
Snap the air conditioning unit and hoses into the A/C /
heater slot in the cab (as shown).
Figure 80-10-28

1
1
P135254
Install the hose (Item 1) onto the A/C unit (Item 2).
Figure 80-10-26 P135257
Install and tighten the two nuts (Item 1) (both sides).
Figure 80-10-29
2
2
2
1
1
P135255
1
Cut four duct hoses p/n 7290427 to a length of 400 mm
(15.75 in).
P135258
Install the four duct hoses (Item 1) onto the A/C unit using
the four clamps (Item 2).
Install the four duct hoses (Item 1) onto the vents using
the four clamps (Item 2).

Installation (Cont'd)
Figure 80-10-30
P135261
Figure 80-10-33
P135259
2
Reinstall the heater return and inlet hoses.

NOTE: The A/C unit and the heater have exactly the
same view. Pay special attention to assemble
the hoses which are labeled and
disassembled from the heater to the air
conditioner unit. The installation process of
these hoses is a reverse process of removing
1
hoses from the heater. There’s no difference
between inlet ports which are located on the
A/C unit or the heater.
P135262
Figure 80-10-31
1 The duct hoses that are placed under the service cover
will need to have the cover (Item 1) installed as well as
1 the insulation (Item 2).
2
P135260
Remove the five bolts (Item 1) and cover (Item 2).

Figure 80-10-34
1
1
1
P135265
Install the blower plate to the seat bracket using the two
P135263 bolts (Item 1).
Figure 80-10-37
Figure 80-10-35

1
P135266
P135264
Install the A/C unit into the seat bracket in the position
Install the heater hoses (Item 1). shown, and install the hose (Item 1).

Figure 80-10-38
P135269
Remove the bolt and washers and bracket (Item 1).

P135267
Save hardware for later use.
Install the A/C unit / seat bracket assembly in to the cab. Figure 80-10-41
Figure 80-10-39

1
P135270
1
P135268
Figure 80-10-42
Install the two bolts and washers (Item 1).
1
P135271
Install bracket (Item 1) using hardware from previous

step.

Figure 80-10-43 2 1
1
1 1
P135274
Remove the four bolts / washers / lock washers (Item 1).

P135272
Remove the fan (Item 2).
The right side radiator isolation plate should be replaced Figure 80-10-46
with the new one (Item 1), which is shorter to allow hose
installation.

1
Figure 80-10-44
2 2
P135275
Remove the fan adapter (Item 1).

P135273
Figure 80-10-47
Install the condenser (Item 1) to the oil coolers using the

bolts (Item 2).
NOTE: For photo clarity the radiators / coolers are 1

removed. It is not necessary to remove the
radiator and coolers for installation of the belt
and belt pulley.
P135276
Install the belt pulley (Item1).

Figure 80-10-48 1
P135278
Install the compressor bracket (Item 1) using the bolts

P135275 and washers (Item 2).
Figure 80-10-51
Install the fan adapter (Item 1).

Figure 80-10-49
1 2
4 3
2 1 P135279
P135274 Install the compressor assembly (Item1) to the bracket

(Item 2) using the bolt and washer (Item 3) and washer
and locknut (Item 4).
Install the fan (Item 1) using the bolts / washers / lock
washers (Item 2).
NOTE: It is recommended to use new bolts.

Figure 80-10-52
1
2 2
1
P135282
Install the bolt, washers, and locknut (Item 1).

P135280
Figure 80-10-55
Install the upper bracket (Item 1) to the engine using the

bolt, washers, and nut (Item 2).

Figure 80-10-53 3 2
1
1
P135283
Install the clamp (Item 3) to the drier (Item 1) with the bolt
(Item 2).
P135281
Install the A/C belt (Item 1).

Figure 80-10-56

P135286
P135284
Connect hose (Item 6) and (Item 8) and to the drier.

Install the clamp and drier assembly (Item 1) using the
washer and bolt (Item 2). Figure 80-10-59
Figure 80-10-57
5
6
4
1
3 5
2
T2
7
7
T1
P135287
8
P135285
Connect hose (Item 5) and (Item 7) to the compressor.
Connect the hoses as shown.
See following steps:

Figure 80-10-60 4
P135290
8
Connect hose (Item 4) and (Item 3) to the A/C unit.

P135288
Figure 80-10-63
Connect hose (Item 7) and (Item 8) to the condenser.

Figure 80-10-61
3
4
2
6 1
T1
2 1
T2 P135291
Connect the hoses routed earlier to the Tee Fitting (Item

P135289 T1) and (Item T2).
Figure 80-10-64
Connect hose (Item 1) and (Item 2) to the A/C unit under
seat.
P135292
Remove the tie strap (Item 1) [Figure 80-10-64].

Figure 80-10-65
2
P135296
Figure 80-10-68
P135293
Figure 80-10-66
2

1
P135295
Remove the two wires (Item 1) from the connector (Item

P135294 2).
Figure 80-10-69
Connect the terminal (Item 1) of the compressor to the
new harness terminal (Item 2).
2
1 1
P135297
Connect the two wire terminals (Item 1) to the drier (Item

2).

1
Figure 80-10-70
2
1
2 3
P135301
Figure 80-10-73
P135298
NOTE: The electrical connections for the heater are

different from the air conditioner, all wires

must be removed from the connector (Item 1)
and the thin red wire (Item 2) must be installed
into the connector (Item 3) in the position
shown.
1
Figure 80-10-71
P135302
1
3 Connect the connector (Item 1) from the harness to the
additional A/C unit connector (Item 1).
P135300
Install the thick red wire (Item 1) and black wire (Item 2)
(removed earlier) into the new connector (Item 3) p/n
7308580.

Figure 80-10-74
4
1
3
2
P135305
Figure 80-10-77
P135303
Pass the end of the harness through the opening in the

floor next to the A/C hoses to reach the A/C unit. 1

3
Figure 80-10-75
4 P135306
Each wire that belongs to the A/C unit is labeled with

numbers to avoid confusion. To correctly install the
electrical connectors see the following figures.
P135304 Black wire (Item 1)

Red wire (Item 2)
Wire #1 (Item 3)
The connectors can now be seen. Wire #2 (Item 4)
Red & Red / Blue wire (Item 1)

Red wire (Item 2)
Wire #34 (Item 3)
Wire #29 (Item 4)

Figure 80-10-78
1
P135309
Connect the A/C control panel connector to the A/C unit.

P135307
Figure 80-10-81
Connect the connector (Item 2) of the harness to

connector (Item 1) of the A/C unit.

Figure 80-10-79
P135310
1
Install the cover.
P135308 Charge the system with R-134a refrigerant.
Connect the connector (Item 3) of the harness to the

connector (Item 1) of the A/C unit.


MAIN FRAME
BACKHOE BOOM / SWING LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-10-1

BACKHOE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-20-1

LOADER BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21-1

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-30-1
CAB (B750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-40-1

CAB (B730) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-50-1

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-60-1

ENGINE SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-70-1

FRONT MUDGUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-80-1

PARKING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-90-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100-1

GRILL FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-110-1

GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-120-1
KINGPOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-130-1
SIDE SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-140-1


STICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-150-1
FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-160-1

STABILIZER WEAR PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-170-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-170-1

BACKHOE BOOM / SWING LOCK
Figure 90-10-1
P135562

Figure 90-10-2
P135563
Pull the lever back (Item 1) then remove the locking

mechanism (Item 2).


BACKHOE BUCKET TEETH Figure 90-20-3
Figure 90-20-1
1 1
P135566
P135564 Remove the teeth (Item 1).
Remove the two nuts, bolts and washers (Item 1).
Figure 90-20-2

P135565


LOADER BUCKET TEETH
Figure 90-21-1
P135620
Remove the two nuts, bolts and washers (Item 1).
Figure 90-21-2

1
P135621
Remove the bucket teeth (Item 1).


BOOM Figure 90-30-3
Remove the stick.
Lower the boom to the ground. 1
Stop the engine.
Operate the backhoe control levers to relieve hydraulic

pressure.
Remove the boom cylinder.
Figure 90-30-1 P135861

boom.
Figure 90-30-4
2

1
P135859
1
Remove the nuts (Item 1) and the clamp (Item 2).
Figure 90-30-2
P135862
Remove both bolts and washers (Item 1).
P135860
After removing the hose connections, install plugs to the

hoses.

BOOM (CONT’D)
Figure 90-30-5
P135863
Remove both bolts and washers (Item 1).

Then remove the boom.

CAB (B750) Figure 90-40-3
Remove the front mudguards
Remove the engine side covers

1
Remove the accelerator pedal and accelerator rope.
Release the parking lever rope.
Remove the steering column and unit.
Figure 90-40-1
P135965
Figure 90-40-4

1
1
P135963
Remove the clamp.
Remove all the joystick hoses (rear left).

P135966
P135964 P135967

CAB (B750) (CONT'D) Figure 90-40-9
Figure 90-40-6
P135971

P135968
Figure 90-40-10
Figure 90-40-7

1
P135972
P135969
Figure 90-40-11
Figure 90-40-8
P135973

P135970

CAB (B750) (CONT'D) Remove all the loader joystick hoses.
Removal And Installation (Cont’d) Figure 90-40-15
Figure 90-40-12
1
1
P135977
P135974
Figure 90-40-16
Figure 90-40-13

P135978
P135975
Remove the hoses (Item 1). Figure 90-40-17
Figure 90-40-14
1
1
P135979
P135976
Remove the clamps (Item 1).

Figure 90-40-18
P135983
Figure 90-40-22
P135980
Figure 90-40-19

1
P135984
Figure 90-40-23
P135981
Figure 90-40-20
P135985
P135982

Figure 90-40-24
P135989

P135986
Remove all the joystick hoses (rear right).
Figure 90-40-25

1
P135990
P135987
Figure 90-40-29
Figure 90-40-26
P135991
P135988

Figure 90-40-30
P135995

P135992
Figure 90-40-34
Figure 90-40-31

1
P135996
P135993
Figure 90-40-35
Figure 90-40-32
P135997

P135994

Figure 90-40-36
P136000
Figure 90-40-39
P135998
Figure 90-40-37

P136001

P135999
Figure 90-40-40
P136002
Remove the stabilizer joystick hoses.

Figure 90-40-41
P136006

P136003
Figure 90-40-45
Figure 90-40-42

1
P136007
Figure 90-40-46
P136004
Figure 90-40-43
P136008
P136005

Figure 90-40-47
P136011

P136009
Figure 90-40-50
Figure 90-40-48

1
P136012
P136010
1
2
P136013
Remove the bolt (Item 1) and battery cable (Item 2).

Figure 90-40-52
P136016
1

P136014
Figure 90-40-55

Figure 90-40-53
P136017
1

P136015
Figure 90-40-56
Remove the hose (Item 1) and terminals (Item 2).
P136018

Figure 90-40-57
P136021

P136019
Figure 90-40-60
Figure 90-40-58

1
P136022

P136020
Figure 90-40-61
P136023
Install a hoist and lifting apparatus to lift and support the

cab.

Figure 90-40-62
P136026
1
2
Figure 90-40-65
P136024
Remove the four nuts (Item 1) and washers (Item 2).

Figure 90-40-63
P136027
1
Lift and remove the cab.
P136025
Remove the four bolts (Item 1) from each side of the cab.

CAB (B730) Figure 90-41-3
Remove the front mudguards.
Remove the accelerator pedal and accelerator rope.
Release the parking lever rope.
Remove the steering column and unit. 1
Remove instrument clusters.

P135907
Raise the rear of the machine.
Figure 90-41-1 Remove the three screw caps (Item 1).
Figure 90-41-4

1
1
2
P135908
P135905
Loosen the nut (Item 1) and remove the knob (Item 2). Remove the three screws (Item 1) and the polyester
cover (Item 2).
Figure 90-41-2
Figure 90-41-5
P135906
P135909
Loosen the bolt (Item 1) and remove the knob (Item 2).

There is no need to remove the hand throttle to

disassemble the right console but the hand throttle’s rope
must be separated from the right console.
Figure 90-41-6 1
2 P135912
1
Remove the two bolts and washers (Item 1).
Figure 90-41-9
P135910
1

Remove the three bolts (Item 1). Then disassemble the
polyester (Item 2) with the hand throttle.
Figure 90-41-7
P135913
1
Figure 90-41-10
P135911
There is a slot (Item 1) which is used for separating the 1

hand throttle’s rope from the right console.
P135914
Remove the bolt and washer (Item 1). Then disassemble

the right console.

Figure 90-41-11
P135917
Remove the snap rings (Item 1).

P135915
Figure 90-41-14
Remove the loader control valve sticks (Item 1) as shown

in the following photos.

2
Figure 90-41-12
P135918
Remove the pins (Item 1) from the forks. Then loosen the
nuts (Item 2) and remove the sticks.
P135916
Figure 90-41-15
P135919

Figure 90-41-16
1 1
1 P135922
Figure 90-41-19
P135920
Remove the three nuts, washers and bolts (Item 1). The
rear right tire may have to be removed if it’s hard to reach

the nuts.
2 1
Figure 90-41-17
1 P135923
Figure 90-41-20
P135921
2
Remove the mechanism tower (Item 1).

1
P135924
Loosen the nuts (Item 1) then remove the knobs (Item 2).
Remove the bellows (Item 3).

Figure 90-41-21
1 1
P135927
Remove the screws (Item 1).

P135925
Figure 90-41-24
Remove the knobs (Item 1).

Figure 90-41-22
P135928
1
Remove the plate (Item 1).
P135926
Figure 90-41-25
Remove the bellows (Item 1).
P135929
Remove the locking lever (Item 1).

Figure 90-41-26
1
P135932
Figure 90-41-29
P135930

Figure 90-41-27
P135933
3 Remove the bolt and washer (Item 1).
2 Figure 90-41-30
4
P135931
Remove the four nuts and bolts (Item 1) and remove the
two bolts (Item 2). Then remove the extension pedal
(Item 3) and the joint (Item 4).
P135934

Figure 90-41-31
P135937

P135935
Figure 90-41-34
Remove the polyester (Item 1).

Figure 90-41-32
1
1
P135938
Remove the cover plate (Item 1).

P135936
Figure 90-41-35
1 2
P135939

Figure 90-41-36
1
1
P135942

P135940
Figure 90-41-39

Figure 90-41-37
1
1
2
1
P135943
Remove the hoses (Item 1) and terminals (Item 2).

P135941
Figure 90-41-40
Remove the bolt (Item 1) and battery cable (Item 2).
P135944

Figure 90-41-41
P135947

P135945
Figure 90-41-44

Figure 90-41-42
P135948

P135946
Figure 90-41-45
P135949

Figure 90-41-46
1
2
1
P135953
Remove the nuts (Item 1) and washers (Item 2) from

P135950 each side of the cab.
Figure 90-41-50
Figure 90-41-47

1
P135954
P135951 Remove the four bolts (Item 1).
Figure 90-41-51
Figure 90-41-48
1
1
P135952
P135955

cab.

Figure 90-41-52
3
2
P135958
Remove the bolt (Item 1) and the two hoses (Item 2).
P135956 Then remove the connectors (item 3).
Figure 90-41-55
Lift and remove the cab.
NOTE: If the machine has air condition option, A/C

connections must be removed as shown in
following photos.
Figure 90-41-53
P135959
1 Remove the clamp (Item 1) and the hose (Item 2).
Figure 90-41-56
P135957
Remove the front cover (Item 1) with its mounting pieces.

1
P135960
Remove the clamp (Item 1) and the hose (Item 2).

CAB (B730) (CONT'D)
Figure 90-41-57
P135961

Figure 90-41-58
P135962

COUNTERWEIGHT Figure 90-50-3
Remove the grill.

1
Remove the grill frame and engine cover.
Figure 90-50-1
P136619
Remove the nut and washer (Item 1).
Figure 90-50-4
1

P136617
Install a hoist and lifting strap to lift and support the 1

counterweight (Item 1).
Figure 90-50-2
P136620
1 Remove both bolts (Item 1) from the counterweight.
Figure 90-50-5
P136618
Remove the nut and washer (Item 1).
P136621
Remove the counterweight.


ENGINE COVER Figure 90-60-2

support device. 1
Figure 90-60-1
P135581
1
Remove both nuts (Item 1) and release both dashpots

P135580 (Item 2).
Figure 90-60-3
Remove the snap hook (Item 1).
P135582
Remove the four nuts and bolts (Item 1).


ENGINE SIDE COVERS

support device.
Figure 90-70-1

P135583
Rotate both engine cover lock switches (Item 1).
Figure 90-70-2
P135584
Remove both engine covers (Item 1).


FRONT MUDGUARD
Figure 90-80-1
P136178
Remove both bolts (Item 1).

Remove the front mudguard.


PARKING LEVER Figure 90-90-3
Figure 90-90-1
P136398
1

P136396
Figure 90-90-4

Figure 90-90-2
1 P136399
Remove the terminal (Item 1).

P136397
Figure 90-90-5
P136400
Loosen the nut (Item 1).

PARKING LEVER (CONT’D) Figure 90-90-8
Figure 90-90-6
1
2
P136403
1
If you need to remove the rope from the parking lever,

P136401 remove the nut (Item 1).
Remove the cotter pin (Item 1) and the pin (Item 2).
Release the parking brake rope.

Figure 90-90-7
1
P136402
Remove the two bolts (Item 1) and the nut (Item 2).
Remove the parking brake lever.

FUEL TANK Figure 90-100-3
Figure 90-100-1
3 4 2 1
1
1 2
P135587

P135585
Figure 90-100-4
Loosen the screws (Item 1) and remove the clamps (Item

2), hoses (Item 3) and the connector (Item 4).

Figure 90-100-2
P135588
P135586 Figure 90-100-5
Remove the drain plug (Item 1).
Drain the fuel tank.
P135589
Remove the two nuts (Item 1).

FUEL TANK (CONT'D) Figure 90-100-8
Removal And Installation (Cont'd)
Figure 90-100-6
2
1
P135592
1
Remove the fuel tank (Item 1).
P135590
Remove the two nuts (Item 1) and plate (Item 2).

Figure 90-100-7
P135591

GRILL FRAME Figure 90-110-2

support device.
Remove the grill.
Figure 90-110-1

P135596
1
Figure 90-110-3
P135595
Release the snap hook (Item 1).
P135597
Remove the four bolts (Item 1) and nuts.

GRILL FRAME (CONT'D) Figure 90-110-5
Figure 90-110-4
P135599
1

Remove the grill frame (Item 1).
P135598

GRILL

support device.
Figure 90-120-1

P135593
Release the six bolts (Item 1) from the grill.
Figure 90-120-2
P135594
Remove the grill.


KINGPOST Figure 90-130-2
Remove the boom.
Remove the backhoe boom / swing lock.

1
Figure 90-130-1
P135611
Remove both pivot pin retainer bolts (Item 1).
Figure 90-130-3

1
P135612
P135614
Remove both pivot pins (Item 1).

kingpost.

KINGPOST (CONT'D) Figure 90-130-6
Figure 90-130-4

P135613 P135615

Figure 90-130-5
Figure 90-130-7
P135616

1
P135614

KINGPOST (CONT'D) Figure 90-130-10
Figure 90-130-8
P135617

Figure 90-130-9
P135619
1 Remove the kingpost.
P135618
Remove both pivot pins (Item 1).


SIDE SHIFT Figure 90-140-3
Remove the boom.
Remove swing cylinders.

1
Figure 90-140-1
P135626
Remove the twelve nuts (Item 1) from each corner of the

side shift.
Figure 90-140-4
P135624

Install a hoist and lifting strap to support the kingpost and
side shift.
Figure 90-140-2
P135627
P135625
Remove the twelve bolts (Item 1) from each corner of the

Remove the pipes (Item 1) from both left and right side of side shift.
the side shift.

SIDE SHIFT (CONT’D)
Figure 90-140-5
P135628
Remove the side shift and kingpost assembly from the

frame.

Remove the kingpost.
If necessary you can remove the clamp cylinders from

the side shift.

STICK Figure 90-150-3
Remove the backhoe bucket. (See Operation &

Maintenance Manual for correct removal procedure.)
Lock the boom. (See Operation & Maintenance Manual

for correct adjustment.)
Figure 90-150-1
P135659
Install a hoist and lifting strap to lift and support the stick
cylinder.
Figure 90-150-4

P135657
Install jack stand under boom.

2
Figure 90-150-2 1
P135660
Figure 90-150-5
P135658 1
Install a hoist and lifting strap to lift and support the stick.
P135661

STICK (CONT’D) Figure 90-150-8
Figure 90-150-6
2
1
1
P135664
Remove the nuts (Item 1) and the clamp (Item 2).

P135662
Figure 90-150-9

3

Figure 90-150-7
2
P135665
1
Remove the nuts (Item 1) and clamp (Item 2). After

P135663 removing the hose connections (Item 3) install plugs to
the hoses.
Remove the nuts and clamps (Item 1). NOTE: Mark hoses for correct installation.

STICK (CONT’D) Figure 90-150-12
Figure 90-150-10
2
P135668

P135666
Figure 90-150-13
Install a hoist and lifting strap to lift and support the stick.

Figure 90-150-11
1
2
P135669

P135667
Remove the stick.


FRONT CONSOLE Figure 90-160-4
Figure 90-160-1
1 2
P136164
Remove the nut (Item 1) and the steering wheel (Item 2).
P136161
Figure 90-160-5
Remove the steering wheel hub (Item 1).

Figure 90-160-2
P136165
Remove the screw (Item 1).

P136162
Figure 90-160-6
Figure 90-160-3
P136166
P136163

FRONT CONSOLE (CONT’D) Figure 90-160-9
Figure 90-160-7
2 1
1 P136169
Remove the switch connectors (Item 1).

P136167
Figure 90-160-10
Remove all buttons (Item 1) and switch connectors (Item

2).

Figure 90-160-8
1
1 P136170
Remove the two bolts (Item 1). Remove the polyester

(Item 2).
P136168
Figure 90-160-11
Remove the indicator board (Item 1).
P136171

FRONT CONSOLE (CONT’D) Figure 90-160-14
Figure 90-160-12
1
2
1
P136174

P136172
Figure 90-160-15
Remove the bolt (Item 1) and remove the polyester (Item

2).

Figure 90-160-13
1
P136175
P136173 Disassemble blowers from the front console.
Remove the front console.



STABILIZER WEAR PADS
Adjustment
You need to check stabilizer wear pads periodically.
Figure 90-170-1
P136480

Check the wear pads.
Figure 90-170-2
P136481
If necessary tighten the adjustment bolt.


ALPHABETICAL INDEX
ACCELERATOR PEDAL . . . . . . . . . . 70-180-1 FRONT MUDGUARD . . . . . . . . . . . . . .90-80-1

AIR CLEANER SERVICE . . . . . . . . . . . 20-60-1 FRONT SHAFT . . . . . . . . . . . . . . . . . . .50-21-1
AIR FILTER . . . . . . . . . . . . . . . . . . . . 70-200-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .70-110-1
APPROVED LIFT ARM SUPPORT  FUEL TANK . . . . . . . . . . . . . . . . . . . .90-100-1
DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-1
ASPERATION SYSTEM . . . . . . . . . . . . 70-90-1 GENERAL INFORMATION . . . . . . . . . .70-10-1
AUXILIARY EQUIPMENT . . . . . . . . . . 70-150-1 GRILL FRAME . . . . . . . . . . . . . . . . . .90-110-1
AXLE TOE-IN ADJUSTMENT . . . . . . . 20-40-1 GRILL . . . . . . . . . . . . . . . . . . . . . . . . .90-120-1
BACKHOE BOOM / SWING LOCK . . . 20-70-1 HVAC UNIT . . . . . . . . . . . . . . . . . . . . . .80-10-1
BACKHOE BOOM / SWING LOCK . . . 90-10-1 HYDRAULIC CYLINDERS . . . . . . . . . .30-30-1
BACKHOE BUCKET TEETH . . . . . . . . 90-20-1 HYDRAULIC PUMP . . . . . . . . . . . . . . .30-40-1
BACKHOE CONTROL VALVE (B730) HYDRAULIC RESERVOIR . . . . . . . . . .30-80-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
HYDRAULIC SYSTEM 
BACKHOE CONTROL VALVE (B750) INFORMATION . . . . . . . . . . . . . . . . . . .30-10-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
HYDRAULIC SYSTEM . . . . . . . . . . . . .30-20-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
INSTRUMENT CLUSTERS . . . . . . . . .40-50-1
BOOM CYLINDER . . . . . . . . . . . . . . . . 30-60-1
KINGPOST . . . . . . . . . . . . . . . . . . . . .90-130-1

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . 90-30-1
LIFT CYLINDERS . . . . . . . . . . . . . . . . .30-64-1
BRAKE PEDAL AND BOOSTER . . . . . 30-70-1
LIFTING AND BLOCKING THE BACKHOE
BUCKET CYLINDER . . . . . . . . . . . . . . 30-61-1 LOADER . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
CAB (B730) . . . . . . . . . . . . . . . . . . . . . 90-41-1 LOADER BUCKET TEETH . . . . . . . . . .90-21-1
CAB (B750) . . . . . . . . . . . . . . . . . . . . . 90-40-1 LOADER CONTROL VALVE (B730) . . .30-91-1
CLAMP CYLINDERS . . . . . . . . . . . . . . 30-62-1 LOADER CONTROL VALVE (B750) . . .30-90-1
CLAMSHELL CYLINDER . . . . . . . . . . . 30-63-1 LUBRICATION OF THE BACKHOE 
COOLING SYSTEM . . . . . . . . . . . . . . 70-120-1 LOADER . . . . . . . . . . . . . . . . . . . . . . .20-100-1
COUNTERWEIGHT . . . . . . . . . . . . . . . 90-50-1 LUBRICATION SYSTEM . . . . . . . . . .70-100-1
CRANKSHAFT ASSEMBLY . . . . . . . . . 70-50-1 LUBRICATION . . . . . . . . . . . . . . . . . . .20-50-1
CYLINDER BLOCK ASSEMBLY . . . . . 70-70-1 MACHINE INFORMATION . . . . . . . . . .10-10-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 70-30-1 MAIN COMPONENTS . . . . . . . . . . . . .10-30-1
ELECTRICAL SYSTEM - B730 . . . . . . 40-10-1 MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1
ELECTRICAL SYSTEM - B750 . . . . . . 40-11-1 MANUAL USE . . . . . . . . . . . . . . . . . . .60-10-1
ELECTRICAL SYSTEM . . . . . . . . . . . . 40-20-1 PARKING LEVER . . . . . . . . . . . . . . . . .90-90-1
ELECTRICAL SYSTEM . . . . . . . . . . . 70-140-1 PISTON AND CONNECTING ROD
ENGINE ALTERNATOR / FAN BELT AND AIR ASSEMBLIES . . . . . . . . . . . . . . . . . . . .70-40-1
CONDITIONER BELT (IF EQUIPPED) 20-80-1 POSITION OF MACHINE . . . . . . . . . . .10-40-1
ENGINE COVER . . . . . . . . . . . . . . . . . 90-60-1 REAR AXLE - B730 AND B750 . . . . . .50-40-1
ENGINE SIDE COVERS . . . . . . . . . . . 90-70-1 REAR HAND THROTTLE LEVER . . .70-170-1
ENGINE TIMING . . . . . . . . . . . . . . . . . 70-80-1 REAR SHAFT . . . . . . . . . . . . . . . . . . . .50-22-1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . 70-210-1 RELAY . . . . . . . . . . . . . . . . . . . . . . . . .40-41-1
EXHAUST . . . . . . . . . . . . . . . . . . . . . 70-190-1 RETURN LINE CHECK VALVE . . . . . .30-21-1
FLYWHEEL AND HOUSING . . . . . . . 70-130-1 SAFETY INSTRUCTION . . . . . . . . . . .10-50-1
FRONT AXLE - B730 AND B750 . . . . . 50-20-1 SAFETY INSTRUCTIONS . . . . . . . . . .50-30-1
FRONT CONSOLE . . . . . . . . . . . . . . 90-160-1 SAFETY INSTRUCTIONS . . . . . . . . . .60-20-1
853 of 856 INDEX-01 B730 & B750 Service Manual

SAFTEY INSTRUCTIONS . . . . . . . . . .50-10-1
SERVICE BRAKE . . . . . . . . . . . . . . . . .50-50-1
SIDE SHIFT . . . . . . . . . . . . . . . . . . . .90-140-1
SPECIAL TOOLS . . . . . . . . . . . . . . . .70-160-1
SPECIFICATIONS . . . . . . . . . . . . . . . .70-20-1
STABILIZER CYLINDERS . . . . . . . . . .30-65-1
STABILIZER WEAR PADS . . . . . . . . .90-170-1
STEERING COLUMN AND UNIT . . .30-100-1
STICK CYLINDER . . . . . . . . . . . . . . . .30-66-1
STICK . . . . . . . . . . . . . . . . . . . . . . . . .90-150-1
STORAGE . . . . . . . . . . . . . . . . . . . . . .10-60-1
SWING CYLINDERS . . . . . . . . . . . . . .30-67-1
TECHNICAL PROPERTIES . . . . . . . . .10-20-1
TILT CYLINDERS (B730) . . . . . . . . . . .30-69-1
TILT CYLINDERS (B750) . . . . . . . . . . .30-68-1
TIMING CASE AND DRIVE 
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .70-60-1
TIRE MAINTENANCE . . . . . . . . . . . . .20-90-1
TOWING THE BACKHOE 

LOADER . . . . . . . . . . . . . . . . . . . . . . . .20-30-1
TRANSMISSION - B730 AND B750
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
854 of 856 INDEX-02 B730 & B750 Service Manual

855 of 856
Bobcat®, the Bobcat logo and the colors of the Bobcat machine are registered trademarks of
Bobcat Company in the United States and various other countries.
856 of 856

Bobcat Loader Bachkhoe B730 B750 Service Manual - 7310058

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Bobcat Loader Bachkhoe B730 B750 Service Manual - 7310058

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Service Manual

B730 & B750 Backhoe Loader

(B730) S/N B4B611001 & Above

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

B-10731a B-16768 B-16738

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-16730 B-16746 B-16719

WRONG WRONG WRONG

B-16571 B-16731 B-6589

1-1 B730 & B750 Service Manual

1-2 B730 & B750 Service Manual

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 856 1-3 B730 & B750 Service Manual

6 of 856 1-4 B730 & B750 Service Manual

MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

TECHNICAL PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Dealer Copy -- Not for Resale

MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

POSITION OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

SAFETY INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

7 of 856 10-01 B730 & B750 Service Manual

8 of 856 10-02 B730 & B750 Service Manual

Dealer Copy -- Not for Resale

9 of 856 10-10-1 B730 & B750 Service Manual

Dealer Copy -- Not for Resale

10 of 856 10-10-2 B730 & B750 Service Manual

Dealer Copy -- Not for Resale

11 of 856 10-10-3 B730 & B750 Service Manual

B750 Specification (Cont’d)

Dealer Copy -- Not for Resale

12 of 856 10-10-4 B730 & B750 Service Manual

Make & Model PERKINS 1104C-44T

Battery 12 volt / 120 Ah

Dealer Copy -- Not for Resale

Type Open center

13 of 856 10-20-1 B730 & B750 Service Manual

B730 Specifications (Cont’d)

Type (Front and Rear) ZF

Front 2WD / 4WD - standard 12.5 - 18

Dealer Copy -- Not for Resale

Maximum bucket break - out force 59,1 kN (13277 lbf)

14 of 856 10-20-2 B730 & B750 Service Manual

B730 Specifications (Cont’d)

Steering type 2 wheel hydraulic

MAXIMUM CAPACITY SERVICE CAPACITY

Dealer Copy -- Not for Resale

Operating Weight 7800 kg (17196 lb)

15 of 856 10-20-3 B730 & B750 Service Manual

Make & Model PERKINS 1104C-44T

Battery 12 volt / 120 Ah

Dealer Copy -- Not for Resale

Type Open Center

16 of 856 10-20-4 B730 & B750 Service Manual