Service Manual: Foreword

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

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

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

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

VARIABLE REACH TRUCK) Contents
505-20
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
EN - 9823/0300 - ISSUE 1 - 01/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
Copyright 2018 © JCB SERVICE

78 - After Sales
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9823/0300-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
505-20 505-20
EN 9823/0300 EN 9823/0300
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
505-20 505-20
EN 9823/0300 EN 9823/0300
9823/0300-1
Notes:
9823/0300-1
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-17
01-06-06 Using the Manual ........................................................................................................... 01-18
01-09 Description
01-09-00 General ........................................................................................................................... 01-21
01-09-03 Log Moving/Object Handling .......................................................................................... 01-23
01-09-06 Optional Equipment and Attachments ........................................................................... 01-24
01-09-12 Main Component Locations ........................................................................................... 01-25
01-09-15 Service Point Locations ................................................................................................. 01-26
01-30 Towing
01-30-00 General ........................................................................................................................... 01-31
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-37
9823/0300-1
2017-11-16
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9823/0300-1
2017-11-16
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01 - 1 9823/0300-1 01 - 1
Notes:
01 - 2 9823/0300-1 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

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

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

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

the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9823/0300-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual there are safety notices. Each notice

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

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

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

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

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

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.
Figure 1. The safety alert system symbol
01 - 4 9823/0300-1 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. Ensure that you receive the correct training drop and injure you if the hydraulic system fails
before operating any machinery. Failing to do so will or if the control is operated (even with the engine
result in incorrect operation of the machine and you stopped).
will be putting yourself and others at risk. In some Make sure that no-one goes near the machine while
markets, and for work on certain jobsites, you may you install or remove the mechanical device.
be required to have been trained and assessed in
accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements – it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9823/0300-1 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9823/0300-1 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300°C
(571.6°F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (571.6°F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.
01 - 7 9823/0300-1 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety Worksites

Worksites can be hazardous. Examine the site
Introduction before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
Training and hidden debris, logs, ironwork etc. Any of these
Make sure that you have had adequate training and could cause you to lose control of your machine.
that you are confident in your ability to operate the Check for utilities such as electric cables (overhead
machine safely before you use it. Practice using the and underground), gas and water pipes etc. Mark
machine and its attachments until you are completely the positions of the underground cables and pipes.
familiar with the controls and what they do. With Make sure that you have enough clearance beneath
a careful, well trained and experienced operator, overhead cables and structures.
your machine is a safe and efficient machine. With Communications
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others, Bad communications can cause accidents. Keep
at risk by using the machine irresponsibly. Before you people around you informed of what you will be
start to work, tell your colleagues what you will be doing. If you will be working with other people,
doing and where you will be working. On a busy site, make sure any hand signals that may be used are
use a signalman. understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Before doing any job not covered in this manual, find
out the correct procedure. Your local JCB distributor Parking
will be glad to advise you. An incorrectly parked machine can move without an
Fuel operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Banks and Trenches
leak is suspected. Do not smoke while refuelling or Banked material and trenches can collapse. Do not
working on the fuel system. Do not refuel with the work or drive too close to banks and trenches where
engine running. Completely wipe off any spilt fuel there is danger of collapse.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. Safety Barriers
Machine Condition Unguarded machines in public places can be
dangerous. In public places, or where your visibility
A defective machine can injure you or others. Do not is reduced, place barriers around the work area to
operate a machine which is defective or has missing keep people away.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Sparks
Machine Limits Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Operating the machine beyond its design limits can machine in closed areas where there is flammable
damage the machine, it can also be dangerous. material, vapour or dust.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Hazardous Atmospheres
unapproved modifications or additional equipment. This machine is designed for use in normal out
Engine/Steering Failure door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
If the engine or steering fails, stop the machine as Do not use the machine in a potentially explosive
quickly as possible. Do not operate the machine until atmosphere, i.e. combustible vapours, gas or dust,
the fault has been corrected. without first consulting your JCB dealer.
Exhaust Gases Regulations
Machine exhaust gases can harm and possibly kill Obey all laws, worksite and local regulations which
you or bystanders if they are inhaled. Do not operate affect you and your machine.
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
01 - 8 9823/0300-1 01 - 8
01 - Machine
03 - Safety
18 - Operating Safety
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine.
the machine or its attachments too close to electrical When using the machine, keep your hands and feet
power cables. clear of moving parts. Keep your hands and feet
You are strongly advised to make sure that the safety within the operator compartment while the vehicle is
arrangements on site comply with the local laws in motion.
and regulations concerning work near electric power Controls
lines.
You or others can be killed or seriously injured
Before you start using the machine, check with your if you operate the control levers from outside the
electricity supplier if there are any buried power machine. Operate the control levers only when you
cables on the site. are correctly seated.
There is a minimum clearance required for working Passengers
beneath overhead power cables. You must obtain
details from your local electricity supplier. Passengers in or on the machine can cause
accidents. Do not carry passengers.
Working Platform
Fires
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured. If your machine is equipped with a fire extinguisher,
Never use the machine as a working platform make sure it is checked regularly. Keep it in the
unless with approved man-basket or man-crate (if correct machine location until you need to use it.
applicable). Do not use water to put out a machine fire, you could
Machine Safety spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
Stop work at once if a fault develops. Abnormal extinguishers. Contact your nearest fire department
sounds and smells can be signs of trouble. Examine as quickly as possible.
and repair before resuming work.
Roll Over Protection
Hot Components
If the machine starts to roll over, you can be crushed
Touching hot surfaces can burn skin. The engine and if you try to leave the cab. If the machine starts to roll
machine components will be hot after the unit has over, do not try and jump from the cab. Stay in the
been running. Allow the engine and components to cab, with your seat belt fastened.
cool before servicing the unit.
Confined Areas
Travelling at High Speeds
Pay extra attention to proximity hazards when
Travelling at high speeds can cause accidents. operating in confined areas. Proximity hazards
Always travel at a safe speed to suit working include buildings, traffic and bystanders.
conditions.
Safe Working Loads
Hillsides
Overloading the machine can damage it and make it
Operating the machine on hillsides can be unstable. Study the specifications in the Operator's
dangerous if the correct precautions are not taken. Manual before using the machine.
Ground conditions can be changed by rain, snow, ice
etc. Check the site carefully. When applicable, keep Lightning
all attachments low to the ground. If you are inside the machine during a lightning storm
Visibility stay in the machine until the storm has passed. If
you are outside of the machine during a lightning
Accidents can be caused by working in poor visibility. storm stay away from the machine until the storm
Use your lights to improve visibility. Keep the road has passed. Do not attempt to mount or enter the
lights, windows, mirrors and cameras clean (when machine.
fitted).
If the machine is struck by lightning do not use the
Do not operate the machine if you cannot see clearly. machine until it has been checked for damage and
Modification of the machine's configuration by the malfunction by trained personnel.
user (e.g. the fitting of large and non-approved
attachments) may result in a restriction of the
machine visibility.
01 - 9 9823/0300-1 01 - 9
01 - Machine
03 - Safety
21 - Worksite Safety
21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on
the site. Ban smoking, make sure that all naked
lights are extinguished and switch off any engines
which may be running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.
01 - 10 9823/0300-1 01 - 10
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 11 9823/0300-1 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12 For: 505-20 [T4F] ...................... Page 01-12
Health and Safety .......................................... 01-14 For: 505-20 [T4F] ...................... Page 01-12
(For: 505-20 [T4F])

Figure 2.
A
A Boom lowered
1. Park the machine on level, solid ground.
2. Lower the boom.
3. Put the attachment flat on the ground.
4. Stop the engine and remove the starter key.
5. Disconnect the battery to prevent accidental
operation of the engine.
6. Make sure there are no loose articles in the
enclosure.
7. If necessary, put chocks against the two sides of
the wheels before you get below the machine.
(For: 505-20 [T4F])

If you raise the boom to get access for maintenance,
you must install the maintenance strut on the boom.
Figure 3.
A Boom raised
01 - 12 9823/0300-1 01 - 12
01 - Machine
03 - Safety
Installing the Maintenance Strut Stop as soon as the weight of the boom is on the
strut.
1. Park the machine on level, solid ground.
2. Retract the boom. operation of the engine.
3. Raise the boom. 10. If necessary, put blocks against the two sides of
the wheels before you get below the machine.
4. Stop the engine and remove the ignition key.
5. Remove the maintenance strut from its stowage Removing the Maintenance Strut
position.
1. Raise the boom to take the weight off of the strut.
Figure 4.
3. Remove the maintenance strut.
A 4. Secure the strut in its stowage position.
5. Lower the boom to the ground.
A Maintenance strut
6. Install the maintenance strut.
7. Place the strut around the lift ram piston rod.
Secure it in position with the strap.
Figure 5.
A Strap
8. To prevent any chance of the boom creeping
down and trapping your fingers, the boom should
be lowered onto the strut. Lower the boom
carefully, to prevent possible damage to the strut.
01 - 13 9823/0300-1 01 - 13
01 - Machine
03 - Safety
Health and Safety

Communications
Bad communications can cause accidents. If two
or more people are working on the machine, make
sure each is aware of what the others are doing.
Before starting the engine make sure the others are
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured
if these precautions are not taken.
WARNING! Maintenance must be done only by
suitably qualified and competent persons.Before
doing any maintenance make sure the machine
is safe, it must be correctly parked on solid,
level ground.To prevent anyone starting the engine,
remove the ignition key. Disconnect the battery when
you are not using electrical power. If you do not take
these precautions you could be killed or injured.
WARNING! Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect the
battery.
Make the machine safe before you start a

maintenance procedure.
You can complete most of the maintenance

procedures with the lift arm lowered. Unless a
maintenance procedure instructs you differently, you
must lower the lift arm.
01 - 14 9823/0300-1 01 - 14
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-17

01-06-06 Using the Manual ........................................................................................................... 01-18
01 - 15 9823/0300-1 01 - 15
Notes:
01 - 16 9823/0300-1 01 - 16
01 - Machine
03 - Model and Serial Number
03 - Model and Serial Number
Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
505-20 2457001
01 - 17 9823/0300-1 01 - 17
01 - Machine
06 - Using the Manual
06 - Using the Manual
Introduction
Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification
Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included information is contained within another PIL reference
under a set of standard headings such as a cross reference is provided.
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System 30-00-50 Schematic Circuit
Electrical System 33-03-03 Battery - Isolator Switch
33-09-00 Power Distribution (including fuses
and relays)
33-00-50 Schematic Circuit
Electronic Diagnostic 33-57 Electronic Diagnostic (including
Servicemaster)
Machine Variants • Use the applicable Servicemaster diagnostics

tools. Refer to PIL 33-57-03.
Where information is different depending on machine
variant, the applicable information sets are included Torque Tightening
within the same PIL reference. Headings are
included to identify which information is for which When you replace components, always tighten the
variant. Make sure you use the correct information. applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
Diagnostics procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified,
Information in this manual can help you diagnose use the standard torque tightening values. Refer
machine faults. to Fasteners and Fixings, Screws, Bolts, Nuts,
Technical Data (PIL 72-00). For the torque setting to
Before attempting to diagnose possible faults check be effective, do the following before you install the
the following. fixings.
• Ensure that the operator understands the • Make sure that all the applicable component
machine controls, functions and use. Refer to assemblies are correct.
the applicable Operator Manual. • Make sure that the applicable fixings are to the
• Check that the maintenance record complies correct specification. If necessary discard the
with the applicable schedule for the operating original fixings and replace them with new ones.
environment. Refer to PIL 78-24. The relevant procedures indicate when this is
• Check that the fluids in use comply with the necessary.
standards specified. Refer to PIL 75-00. • Make sure that the applicable fixings and
• Ensure that the machine electronic set-up is threaded holes are free from contamination.
applicable. Use the applicable Servicemaster This includes dirt, debris, old sealants and
vehicle set-up tool. Refer to PIL 33-57-03. compounds, fluids and lubricants.
01 - 18 9823/0300-1 01 - 18
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-00 General ........................................................................................................................... 01-21

01-09-03 Log Moving/Object Handling .......................................................................................... 01-23
01-09-06 Optional Equipment and Attachments ........................................................................... 01-24
01-09-12 Main Component Locations ........................................................................................... 01-25
01-09-15 Service Point Locations ................................................................................................. 01-26
01 - 19 9823/0300-1 01 - 19
Notes:
01 - 20 9823/0300-1 01 - 20
01 - Machine
09 - Description
00 - General
00 - General Introduction
Introduction .................................................... 01-21 The JCB Loadall is a self propelled, seated operator,
Operation ....................................................... 01-22 wheeled machine for operation on unimproved
natural terrain and disturbed terrain.
A main structural support is designed to carry an

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

loads by extending/retracting, raising/lowering the
boom.
01 - 21 9823/0300-1 01 - 21
01 - Machine
09 - Description
00 - General
Operation
The machine is intended to be used in normal

conditions for the applications described in this
manual. If the machine is used for other applications
or in dangerous environments, for example in
a flammable atmosphere or in areas with dust
containing asbestos, special safety regulations must
be obeyed and the machine must be equipped for
use in these environments.
01 - 22 9823/0300-1 01 - 22
01 - Machine
09 - Description
03 - Log Moving/Object Handling
03 - Log Moving/Object Handling
Introduction
Do not use the machine to move or handle logs

unless sufficient log protection is installed. You could
cause serious injury to yourself and damage to the
machine. For more information, contact your JCB
dealer.
01 - 23 9823/0300-1 01 - 23
01 - Machine
09 - Description
06 - Optional Equipment and Attachments
06 - Optional Equipment and

Attachments
Introduction
A wide range of optional attachments are available

to increase the versatility of your machine. Only the
JCB approved attachments are recommended for
use with your machine. Contact your JCB dealer for
the full list of approved attachments available.
01 - 24 9823/0300-1 01 - 24
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Component Identification
Figure 6.
A B
C
E
A Hydraulic tow hitch (option) B Mechanical tow hitch (option)

C Boom D ROPS (Roll-Over Protective Structure)/FOPS
(Falling Object Protective Structure) cab
E Door F Carriage
01 - 25 9823/0300-1 01 - 25
01 - Machine
09 - Description
15 - Service Point Locations
Engine Compartment
Figure 7.
G E
A Air filter B Expansion bottle

C Radiator D Fuel filter
E Engine oil dipstick F Engine fuel filter
G Fuel pump
01 - 26 9823/0300-1 01 - 26
01 - Machine
09 - Description
Battery Compartment Hydraulic Oil Level Indicator

Figure 8. Figure 9.
B A
B
A
A Battery
B Battery isolator
A Hydraulic tank filler cap
B Hydraulic oil level indicator
Axles
Figure 10.
B A B
A Axle fill/level plug B Beneath plug
01 - 27 9823/0300-1 01 - 27
01 - Machine
09 - Description
Filling the Fuel Tank

Figure 11.
A Fuel cap
01 - 28 9823/0300-1 01 - 28
01 - Machine
30 - Towing
30 - Towing
Contents Page No.
01-30-00 General ........................................................................................................................... 01-31
01 - 29 9823/0300-1 01 - 29
Notes:
01 - 30 9823/0300-1 01 - 30
01 - Machine
30 - Towing
00 - General
00 - General
Introduction
Consumables Figure 12.

Description Part No. Size
JCB Threadlocker 4101/0250 0.01L A B
and Sealer (Medium 4101/0251 0.05L
Strength)
Special MPL-EP 4003/1501 0.4kg
Grease 4003/1506 12.5kg
4003/1510 50kg
Towing
A Screw
Towing a machine too far or too fast can damage the B Front of front axle
transmission. When towing prepare the machine as
described below. Failure to comply will result in lack Figure 13.
of lubrication and seizure of the transmission motor
and pump. A
The vehicle may only be towed out of the immediate
area (maximum 100m) at a maximum speed of 1km/
h (0.6mph), without removing the prophafts.
Use a rigid drawbar. If a towing chain must be

used, then use two towing vehicles. One towing B
vehicle should be coupled to the front of the disabled
machine. The other towing vehicle should be coupled A Screw
to the rear of the disabled machine, to provide B Rear of front axle
braking power. The towing vehicle must have enough
pulling and braking power to move and stop the 6.4. Remove the shims.
machine. 6.5. Tighten the screws.
1. Make the machine safe, refer to (PIL 01-03). 7. When the towing is complete:
2. Using suitable lifting equipment, remove any 7.1. Slacken the screws on the front axle.
payload from the machine.
7.2. Install the shims.
3. Place blocks both sides of each wheel.
7.3. Tighten the screws to the required torque
4. Attach a rigid tow bar between a suitable value.
connection point on the machine and the towing Torque: 95–115N·m
vehicle.
7.4. Remove the wheel blocks from each wheel.
5. When the propshafts are disconnected, the hand
brake is still applied, before towing you must Propshaft Removal and Installation
put the hand brake into the emergency released
state. WARNING Make sure that the blocks and
towing vehicle will prevent the machine from
6. In the case of emergency handbrake release: moving because when the driveshafts have been
disconnected the park brake cannot prevent
6.1. Make sure the axles are blocked. the machine from moving. It is necessary
6.2. Release the parking brake on the front axle. to work under the machine to remove the
driveshafts. This job should be done by a qualified
6.3. Slacken the brake screws from the front mechanic. Anyone working underneath, or near
axle. the machine, could be killed or seriously injured if
the machine moves.
01 - 31 9823/0300-1 01 - 31
01 - Machine
30 - Towing
00 - General
Remove 3. Remove the front, centre and rear undershields

when you work under the machine.
This procedure should only be carried out by
a qualified engineer. If you have any queries 4. Support the front propshaft and remove the strap
concerning this procedure, consult your local JCB retaining bolts and the straps from the axle yoke.
dealer.
5. Use a crows foot ring spanner to remove the
When disconnecting the propshafts the park brake is nuts.
still active but as an advisory it is recommended to 6. Support the rear propshaft.
chock all 4 wheels.
7. Use a crows foot ring spanner to remove the
1. Make the machine safe. nuts.
2. Before you remove the propshafts, always mark 8. Remove the nuts and slide the propshaft off the
both companion flanges and sliding joints prior to securing studs.
removal.
Figure 14. Constructional Propshaft

G
F H
A E
B C
A Front propshaft bearing strap B Front propshaft screws

C Front propshaft D Screws (x4)
E Speed sensor ring F Rear propshaft
G Rear propshaft bearing strap H Rear propshaft screws
Figure 15. Agricultural Propshaft

G
F H
A E
B C
A Front propshaft bearing strap B Front propshaft screws

C Front propshaft D Set screws (x8)
01 - 32 9823/0300-1 01 - 32
01 - Machine
30 - Towing
00 - General
E Speed sensor ring F Rear propshaft

G Rear propshaft bearing strap H Rear propshaft screws
01 - 33 9823/0300-1 01 - 33
01 - Machine
30 - Towing
00 - General
Install
Installation is the opposite of the removal procedure.
During the replacement procedure do this work also:
1. On installation, after lubricating the sliding joints

with JCB HP or MPL grease, align the shafts
against identification marks previously made or,
in the case of a shaft being renewed, use the
manufacturer's alignment markings. Apply JCB
threadlocker and sealer to threads of all flange
bolts.
Consumable: Special MPL-EP Grease
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
2. The front propshaft retaining straps stretch with
use, therefore these straps must always be
installed with new ones.
3. The propshaft must have both ends exactly on
the same plane. The yokes must not be at right
angles or at an intermediate angle.
4. Tighten the screws to the required torque value.
5. If the studs are damaged install with the new
studs. Apply JCB threadlocker and sealer to the
stud threads.
Figure 16.
A Equal angle propshaft

B Right angle propshaft
C Intermediate propshaft
01 - 34 9823/0300-1 01 - 34
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-37
01 - 35 9823/0300-1 01 - 35
Notes:
01 - 36 9823/0300-1 01 - 36
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-37 or other chemicals, you must adhere to
Preparation .................................................... 01-38 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
the machine inoperable. Remove dirt using a
brush or damp cloth.
Clean the product with water and/or steam. Do not

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

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

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

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

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

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.
01 - 37 9823/0300-1 01 - 37
01 - Machine
33 - Cleaning
00 - General
Notice: The engine and other components could Preparation

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

after pressure washing or steam cleaning.
01 - 38 9823/0300-1 01 - 38
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-33 Fork
03-33-00 General ............................................................................................................................. 03-7
03-33-03 Carriage .......................................................................................................................... 03-10
03-82 Jib
03-82-00 General ........................................................................................................................... 03-13
03-82-06 Shackle ........................................................................................................................... 03-14
03-84 Hook
03-84-06 Snatch Block .................................................................................................................. 03-17
03-88 Work Platform
03-88-00 General ........................................................................................................................... 03-19
9823/0300-1
2017-07-27
Notes:
9823/0300-1
2017-07-27
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9823/0300-1 03 - 1
Notes:
03 - 2 9823/0300-1 03 - 2
00 - Attachments
00 - General
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.
Some attachments are supplied complete with

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

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

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

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

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

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

until the machine hydraulic oil has reached its normal
working temperature.
03 - 3 9823/0300-1 03 - 3
00 - Attachments
00 - General
Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty.
Attachments
If you have an attachment which is not covered in the
Operator's Manual do not install it, use it or remove
it until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.
03 - 4 9823/0300-1 03 - 4
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-7

03-33-03 Carriage .......................................................................................................................... 03-10
03 - 5 9823/0300-1 03 - 5
Notes:
03 - 6 9823/0300-1 03 - 6
33 - Fork
00 - General
Introduction ...................................................... 03-7 Forks can be installed on many different types of
Health and Safety ........................................... 03-8 agricultural or construction machines. Forks can be
Adjust .............................................................. 03-8 directly mounted on to a lift arm or carriage or
mounted to a lift arm via a quickhitch assembly.
There are a vast amount and size of forks used for
numerous applications.
Forks can be used to lift, raise and carry heavy things

and stack them where required.
03 - 7 9823/0300-1 03 - 7
33 - Fork
00 - General
Health and Safety Adjust

DANGER Using the forks alone as a working WARNING Loads can fall off incorrectly spaced
platform is hazardous; you can fall off and be forks. Always space the forks correctly for the
killed or injured. Never use the forks as a working load. Make sure the forks are completely under
platform. the load before lifting.
WARNING Loads can fall off incorrectly spaced CAUTION To prevent unintentional detachment
forks. Always space the forks correctly for the of forks during travel or transportation, the forks
load. Make sure the forks are completely under must not overlap the lower removal notch or be
the load before lifting. secured in the central two positions on top of the
carriage.
WARNING If the fork/locking pin is not fully
engaged, the fork could become unintentionally CAUTION The forks are heavy. Make sure
disengeged. suitable lifting equipment is used to support and
transport them.
WARNING Do not try to correct the alignment
of the fork tips by bending the forks or adding WARNING If the fork/locking pin is not fully
shims. Never repair damaged forks by heating or engaged, the fork could become unintentionally
welding. Forks are made of special steel using disengeged.
special procedures. Always replace the damaged
forks.
Repositioning the Forks
WARNING Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation Industrial Carriage Fork Adjustment
capacity.
WARNING The forks project in front of the 1. Make the machine safe. Apply the park brake (if
machine. Make sure there is enough clearance installed).
for the forks when making turns.
2. Lower the forks as required to enable the use of
CAUTION A load lifted on one fork can slip off. suitable lifting equipment to move the forks.
Never lift a load with one fork.
3. Stop the engine. Remove the ignition key.
CAUTION Never unload the forks by stopping the
machine suddenly. Follow the procedures in the 4. Release the locking pins and slide the forks to the
Operator Manual for unloading. desired position using suitable lifting equipment.
CAUTION The forks are heavy. Make sure Your machine will have either 'twist and pull'
suitable lifting equipment is used to support and or 'pull' type fork locking pins. Forks must not
transport them. overlap the lower removal notch or be secured in
the central two positions on top of the carriage,
CAUTION Do not exceed the total rated load see shaded 'no fork' zone.
capacity of the forks being used. Forks can break
resulting in a loss of load and possible injury.
CAUTION Loads stacked on uneven ground can
topple. Never stack loads on uneven ground.
03 - 8 9823/0300-1 03 - 8
33 - Fork
00 - General
Figure 17.
A Locking pins
B Lower removal notch
C 'No fork' zone
5. Re-engage the locking pins. Make sure the pins
and forks are correctly located.
6. Remove the lifting equipment.
03 - 9 9823/0300-1 03 - 9
33 - Fork
03 - Carriage
03 - Carriage
Remove and Install
6. Remove the lock nut and bolt from the pivot pin
Remove trunnion.
1. Position the lift arm so that the fork carriage can 7. Remove pivot pin from its location.
be safely supported when it is disconnected from
8. Remove the fork carriage.
the boom assembly.
2. Make the machine safe, refer to (PIL 01-03). Install
3. Discharge the hydraulic pressure, refer to (PIL 1. Replacement is the opposite of the removal
30-00-00). procedure.
4. Support the fork carriage. 2. Renew locknuts and tighten fastenings to the
correct torque.
5. Remove the tilt ram pivot pin lock nut and bolt
and then remove pivot pin. Make sure you do not
damage the tilt ram piston rod.
Figure 18. (3, 4 and 5 Stage Lift Arms )
A Fork carriage B Nut and bolt- pivot pin

C Pivot pin D Lock nut and bolt- pivot pin
E Pivot pin
03 - 10 9823/0300-1 03 - 10
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-13

03-82-06 Shackle ........................................................................................................................... 03-14
03 - 11 9823/0300-1 03 - 11
Notes:
03 - 12 9823/0300-1 03 - 12
82 - Jib
00 - General
00 - General
Introduction
Safety
Read and understand all the warning messages.
Follow all the safety instructions given in this
Operator Manual. Do not install/operate an
attachment until you are sure that you can operate it.
Use the attachment only if it carries up to date test

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

attachment, check the appropriate load chart in
the cab and understand the lift capacities.
• Make sure the machine is in a level position.
If necessary, reposition the machine using
chassis levelling control or stabilisers (if fitted).
• Use the lifting shackle which is suitable for the
job, in good condition and proof tested where
necessary.
• Always sling the load safely and in accordance
with any local regulations.
• Make sure that the hook safety catch is closed
correctly to prevent the sling(s) from slipping off
the hook.
• Always lift the load carefully, to avoid snatching
the sling(s).
• Keep yourself and other people clear of a
suspended load, especially from beneath the
load.
• Always remember that the effective length of
the boom is increased when an attachment is
installed. Before manoeuvring the machine with
an attachment make sure you have sufficient
clearance.
• You must be careful while carrying a suspended
load. Keep the load as low to the ground
as possible. If necessary, use guide ropes to
prevent the load from swinging.
• Always travel in 1st gear at walking speed when
carrying a suspended load. Wherever possible,
travel on firm, level ground. Avoid rough or
excessively uneven ground.
• Do not carry suspended loads on public roads.
• Always be aware of the affects of wind velocity
on the load being handled.
03 - 13 9823/0300-1 03 - 13
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 20.

reach and height. This attachment is supplied with
test certificates for its fabrication, its hook and its D
shackle. The safe working load is stamped on a plate
mounted on the attachment.
Figure 19.
A F
G
A Roof truss jib
B Hook B
Installing/Removing
A
The attachment is heavy. Take care when lifting
and handling it. Use suitable lifting equipment. Make
sure the lifting equipment is in good condition. Make C
sure the lifting equipment complies with all relevant
regulations. Wear gloves and safety shoes. A Skid
B Lynch pin
The installation will be easier if the attachment is C Pin
rested on wooden blocks. D Jib- fully extended
E Jib- extended position 1
Store the attachment carefully to prevent damage F Jib- extended position 2
and corrosion. G Jib- fully retracted
Extending the Jib 1. Remove the load and lower the jib to the ground.
2. Make sure the skid is supporting the weight of
The jib may be extended to one of four positions:
the jib.
3. Remove the lynch pin, then pin.
4. Move the jib extension to the required position;
fully extended or fully retracted.
5. Insert the pin and secure with lynch pin.
Changing the Jib Angle

The angle of the jib may be set in one of two
positions.
03 - 14 9823/0300-1 03 - 14
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 21.
A B
D F
C E
C
A Placing position B Travel position

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

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

2. Make sure the skid is supporting the weight of
the jib.
3. Remove the lynch pin, then pin.
4. Use the tilt control in the cab to rotate the carriage
until the holes align in the required position.
Stops will prevent excessive movement of the jib.
5. Insert the bar and secure with lynch pin.
03 - 15 9823/0300-1 03 - 15
84 - Hook
84 - Hook
Contents Page No.
03-84-06 Snatch Block .................................................................................................................. 03-17
03 - 16 9823/0300-1 03 - 16
84 - Hook
06 - Snatch Block
06 - Snatch Block 3.3. Install the locking bar and secure with lynch
pin.
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 22.
C A
A Mounting sockets
B Lynch pin
C Locking bar
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Lower the attachment so that it just clears the
ground.
3. Apply the park brake and stop the engine.
4. Remove the attachment.
4.1. Remove the lynch pin and locking bar.
4.2. Carefully slide the attachment off the forks.
4.3. Install the locking bar and secure with lynch
pin.
4.4. Store the attachment carefully to prevent
damage and corrosion.
Install
1. Space the forks, equally on either side of the
machine centreline, so that the mounting sockets
can be slid onto them.
2. Tighten the fork clamping screws to prevent
movement.
3. Install the attachment.
3.1. Remove the lynch pin and locking bar.
3.2. Slide attachment over the forks so that the
rear of the attachment butts against the
heels of the forks.
03 - 17 9823/0300-1 03 - 17
88 - Work Platform
88 - Work Platform
Contents Page No.
03-88-00 General ........................................................................................................................... 03-19
03 - 18 9823/0300-1 03 - 18
88 - Work Platform
00 - General
00 - General
Introduction
DANGER Using the forks alone as a working
platform is hazardous; you can fall off and be
killed or injured. Never use the forks as a working
platform.
The use of work platforms with this machine is

subject to legislation which varies from territory
to territory. It is the responsibility of the owner/
operator and supplier of the work platform to
ensure compliance with the relevant legislation in
the relevant territory. In the case of uncertainty,
guidance should be sought from the relevant local or
government authority.
JCB supply integrated work platforms solely for use

in Europe which comply with the requirements of
European Directive 2006/42/EC. Contact your dealer
for further details. Health and safety legislation also
varies from territory to territory. Customers should
check the latest health and safety legislation for the
territory in which the work platform is to be used prior
to operation.
03 - 19 9823/0300-1 03 - 19
Notes:
03 - 20 9823/0300-1 03 - 20
Contents Page No.
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-7
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-11
06-06-06 Engine Compartment ..................................................................................................... 06-12
06-06-09 Hydraulic Compartment ................................................................................................. 06-17
06-06-13 Side Cover ..................................................................................................................... 06-18
06-06-14 Rear Cover ..................................................................................................................... 06-19
06-06-39 Cab/Canopy ................................................................................................................... 06-21
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-27
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-36
06-12-18 Angle Indicator ............................................................................................................... 06-37
06-12-21 Proximity Switch ............................................................................................................. 06-38
06-12-24 Shim ............................................................................................................................... 06-40
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-47
06-54 Fender
06-54-00 General ........................................................................................................................... 06-51
06-57 Counterweight
06-57-00 General ........................................................................................................................... 06-55
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-57
06-63-03 Machine .......................................................................................................................... 06-58
06-63-06 Engine ............................................................................................................................ 06-60
06-63-09 Axle ................................................................................................................................ 06-61
06-63-12 Gearbox .......................................................................................................................... 06-62
06-63-15 Operator Protective Structure ........................................................................................ 06-63
06-66 Tools
06-66-00 General ........................................................................................................................... 06-65
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-67
06-69-03 Lift Arm ........................................................................................................................... 06-69
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-71
06-89 Window Guard
06-89-00 General ........................................................................................................................... 06-73
9823/0300-1
2018-01-12
Acronyms Glossary

HVAC Heating Ventilation Air Conditioning
LLMC Longitudinal Load Moment Control
PIN Product Identification Number
TXV Thermal Expansion Valve
9823/0300-1
2018-01-12
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9823/0300-1 06 - 1
Notes:
06 - 2 9823/0300-1 06 - 2
00 - General
CAUTION Waxoyl contains turpentine substitute
Introduction ...................................................... 06-3 which is flammable. Keep flames away when
Preparation ...................................................... 06-4 applying Waxoyl. Waxoyl can take a few weeks
to dry completely. Keep flames away during the
drying period.
Do not weld near the affected area during the
drying period. Take the same precautions as for
oil to keep Waxoyl off your skin. Do not breathe
the fumes. Apply in a well-ventilated area.
You must grease the machine regularly to keep

it working efficiently. Regular greasing will also
lengthen the machine's working life.
Refer to the individual condition checks throughout

the Maintenance section.
The machine must always be greased after pressure

washing or steam cleaning.
Greasing must be done with a grease gun. Normally,

two strokes of the grease gun is sufficient. Stop
greasing when fresh grease appears at the joint.
Use only the recommended type of grease. Do not

mix different types of grease, keep them separate.
Attach the dust caps after greasing (if installed).
06 - 3 9823/0300-1 06 - 3
00 - General
Preparation
WARNING You will be working close into the
machine for these jobs. Lower the attachments.
Remove ignition key and disconnect the battery.
This will prevent the engine being started.
Make the machine safe before you start a greasing

procedure.
You can complete most of the greasing procedures

with the boom lowered. If you raise the boom
to get access for greasing, you must install the
maintenance strut on the boom.
06 - 4 9823/0300-1 06 - 4
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 5 9823/0300-1 06 - 5
Notes:
06 - 6 9823/0300-1 06 - 6
03 - Chassis
00 - General
Introduction ...................................................... 06-7 The chassis is the underpart of the vehicle or
Health and Safety ........................................... 06-8 machine, consisting of the frame on which the body
or cab is mounted.
06 - 7 9823/0300-1 06 - 7
03 - Chassis
00 - General
Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
06 - 8 9823/0300-1 06 - 8
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-11

06-06-06 Engine Compartment ..................................................................................................... 06-12
06-06-09 Hydraulic Compartment ................................................................................................. 06-17
06-06-13 Side Cover ..................................................................................................................... 06-18
06-06-14 Rear Cover ..................................................................................................................... 06-19
06-06-39 Cab/Canopy ................................................................................................................... 06-21
06 - 9 9823/0300-1 06 - 9
Notes:
06 - 10 9823/0300-1 06 - 10
00 - General
00 - General
Introduction
When moved to their maintenance position, the

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

of the access panels are correctly in their closed or
installed positions.
06 - 11 9823/0300-1 06 - 11
06 - Engine Compartment
06 - Engine Compartment Component Identification

Component Identification ............................... 06-12
Open and Close ............................................ 06-13
Remove and Install ....................................... 06-14
Figure 23.
A B
A Coolant radiator B Coolant expansion bottle

C Air filter D Engine oil dipstick
E Drive belt
06 - 12 9823/0300-1 06 - 12
Open and Close
Open
WARNING The engine has exposed rotating
parts. Switch off the engine before working in the
engine compartment. Do not use the machine
with the engine cover open.
Access to the engine compartment is provided by

opening the engine cover.
Before you stop the engine, you must let the engine
run at low idle for 4min. The delay lets the coolant
temperature to stabilise before you open the engine
cover.
1. Make the machine safe.

2. Unlock and release the latch. Allow the cover to
raise on its gas strut. Keep hold of the cover while
it rises.
Figure 24.
A B
A Engine cover
B Latch
Close
1. Push the cover down.
2. Make sure the cover is correctly latched.
3. Make sure to lock the engine cover.
06 - 13 9823/0300-1 06 - 13
Remove and Install
4. Remove the strut from the support bracket.

Remove 5. Remove the hinge bolts.
6. Using the lifting equipment remove the engine
2. Follow the care and safety procedures. Refer to cover clear of the machine.
(PIL 01-03).
7. Support the pod base.
CAUTION! Beware of the hot exhaust system 8. Remove the bolts and washers and lower the pod
even with the engine stopped. complete with the guards to the ground.
3. Remove gas strut mount securing nut.
Figure 25.
B
D
A Engine cover B Hinge bolts
06 - 14 9823/0300-1 06 - 14
C Support bracket D Nut

E Pod F Bolts and washers
06 - 15 9823/0300-1 06 - 15
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
1.1. Tighten the hinge bolts to the specified
torque value.
1.2. Tighten the strut mount securing nut.
Table 3. Torque Values

Item Description Nm
B Hinge bolts 18
D Nut 18
06 - 16 9823/0300-1 06 - 16
09 - Hydraulic Compartment
09 - Hydraulic Compartment Hydraulic Filter Cover

Remove
Remove and Install
Valve Block Cover 2. Raise the lift arm and install the maintenance
strut. Refer to (PIL 06-69).
Remove 3. Support the cover and remove the bolts and
washers.
CAUTION! The exhaust pipe becomes
extremely hot when the engine is running and 4. Remove the cover from the machine.
will remain so for some time after the engine is
stopped. If you touch the hot pipe you could be Figure 27.
severely burned.

A
2. Support the cover.
3. Remove the bolts.
4. Remove the cover from the machine.
Figure 26.
B B
A Cover
B Washers
Install
1. Installation is opposite of the removal procedure
and additionally do the step below.
A
2. Tighten the bolts to the correct torque value.
Refer to (PIL 72-06).
A Bolts
B Cover
Install
1. Installation is opposite of the removal procedure.
Additionally do the following step.
06 - 17 9823/0300-1 06 - 17
13 - Side Cover
13 - Side Cover Install

1. Installation is opposite of the removal procedure.
Remove and Install Additionally do the following step.
Cab Side Cover Refer to (PIL 72-06).
Remove
2. Raise the lift arm and install the maintenance
strut. Refer to (PIL 06-69).
3. Support the cover and remove the bolts and
washers.
4. Remove the side cover from the machine.
Figure 28.
A Washers
B Side cover
06 - 18 9823/0300-1 06 - 18
14 - Rear Cover
14 - Rear Cover
Remove and Install
3. Support the chassis cover.

Remove 4. Remove the bolts from the cover.
5. Remove the rear chassis cover from the
2. Remove the valve block cover. Refer to (PIL machine.
06-06).
Figure 29.
A B
A
A
C
A
A
A Bolts B Valve block cover

C Rear chassis cover
06 - 19 9823/0300-1 06 - 19
14 - Rear Cover
Install
steps.
06 - 20 9823/0300-1 06 - 20
39 - Cab/Canopy
39 - Cab/Canopy
Remove and Install
11.2. Plug all the open ports and hoses to

prevent contamination.
Make sure that any attachments on the machine are 12. Remove the hose clips and disconnect the heater
correctly attached. Engage the park brake, remove hoses.
has wheels use blocks to prevent unintentional 12.1. Put a label on the hoses to help
movement. installation.
Air Conditioning Maintenance 12.2. Plug all the open ports and hoses to
prevent contamination.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the 13. If the machine has air conditioning installed, do
system should be disconnected until the system not attempt to disconnect any air conditioning
has been discharged by a refrigeration engineer hoses until the refrigerant has been discharged.
or a suitably trained person. You can be severely Charging and discharging the system requires
frostbitten or injured by escaping refrigerant. special equipment and training. If necessary, use
Notice: Make sure you label all hoses / pipes and the services of a specialist refrigeration engineer.
electrical connectors (if installed) before removal to 14. Disconnect the air conditioning hoses as follows
aid identification during subsequent installation. (if applicable) after the air conditioning system
has been discharged.
Remove
14.1. Disconnect the air conditioning hoses at
1. Make the machine safe. Refer to (PIL 01-03). the TXV (Thermal Expansion Valve)
2. Raise the lift arm and install the maintenance 14.2. Disconnect the condenser pipes at the
strut. Refer to body and framework- maintenance condenser.
strut (PIL 06-69). 14.3. Remove the hose clamps.
3. Discharge the hydraulic and brake pressure. 14.4. Put a label on the hoses to help
Refer to (PIL 30-00). installation.
4. Remove the battery cover and disconnect the 14.5. Plug all the open ports and hoses to
battery. Refer to electrical system- battery (PIL prevent contamination.
33-03).
15. Disconnect the engine throttle cable. Refer to
5. Remove the cab under-shield (if installed). operator station- cables and fittings (PIL 09-28).
6. Remove the deck plate. Refer to body and 16. Disconnect the throttle pedal sensor electrical
framework- access panel (PIL 06-06). connectors. Refer to engine- sensor (PIL 15-84).
7. Remove the bolts and remove the cab front 17. Make sure that all the wheels are blocked and
cover. release the park brake.
8. Remove the floor mat. Refer to operator station- 18. Working at the park brake caliper, disconnect
floor mat (PIL 09-48). the clevis. Note the hole which is used on the
actuating lever.
9. Disconnect the bulkhead electrical connectors.
19. Remove the clip or loosen the locknut as
10. Disconnect the inching pedal electrical applicable.
connectors (if installed).
20. Disconnect the park brake cable from the bracket
11. Disconnect all the hydraulic hoses from the and note the cable routing below the cab.
steering unit.
21. Disconnect the flexible brake pipe from the
11.1. Put a label on the hoses to help chassis connector.
installation.
21.1. Plug the open ports and hose to prevent
contamination.
06 - 21 9823/0300-1 06 - 21
39 - Cab/Canopy
22. Disconnect the cab earth strap. 28. Disconnect the manual steer mode cable (if
installed). Refer to steering system- mode valve
23. Disconnect the hitch cable (if installed). (PIL 25-09).
24. Disconnect the washer hoses. 29. Remove the cab mounting bolts and nuts.
25. Remove the plate on the front left and rear 30. Attach appropriate lifting equipment to the ROPS
mount. (Roll-Over Protective Structure) and FOPS
(Falling Object Protective Structure) cage.
26. Remove the control lever. Refer to operator
station- controls (PIL 09-27). 31. Carefully lift the cab away from the machine.
Make sure that all the connections are released
27. Remove the screws and remove the varispeed/ and are clear of any obstruction.
hand throttle control panel. Disconnect the
electrical connector from the chassis harness.
06 - 22 9823/0300-1 06 - 22
39 - Cab/Canopy
Figure 30.
D
B
E
A F
V
U J
G
K
L
T
S
M
S
N
P
A Cab front cover B Condenser pipes

C Hose clamps D Screws
E Electrical connector F Control panel
G Nuts H Locknut
J Park brake cable K Clevis
L Actuating lever M Cab earth strap
N Steering unit P Flexible brake pipe
06 - 23 9823/0300-1 06 - 23
39 - Cab/Canopy
R TXV S Heater hoses

T Hitch cable U Inching pedal electrical connectors
V Bulkhead electrical connectors
06 - 24 9823/0300-1 06 - 24
39 - Cab/Canopy
Install 10. Check the hand throttle operation and adjust if

necessary. Refer to operator station- cables and
1. The installation procedure is the opposite of the fittings (PIL 09-28).
steps. 11. Check the park brake and adjust if necessary.
Refer to brakes- park brake (PIL 24-18).
2. Tighten the cab mounting bolts to the specified
torque value. Refer to fasteners and fittings- bolts
(PIL 72-06).
3. On low cab machines the right rear cab mounting
bolt is orientated as shown in figure. Refer to
Figure 31. To aid installation it is acceptable to
install the bolt as shown in figure. Refer to Figure
32.
Figure 31.
Figure 32.
4. Check the cab mounting rubbers. If damaged or

worn, replace them.
5. Make sure that all the cables are connected
and correctly adjusted. Make sure that they are
routed and secured correctly.
6. Make sure that all the electrical and hydraulic
services operate correctly.
7. Bleed the brakes. Refer to brakes- service
brakes (PIL 24-03).
8. Recharge the air conditioning system. Refer
to HVAC (Heating Ventilation Air Conditioning)-
HVAC unit (PIL 12-03) (if applicable).
9. Check the throttle cable adjustment (if
applicable). Refer to operator station- cables and
fittings (PIL 09-28).
06 - 25 9823/0300-1 06 - 25
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-27

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-36
06-12-18 Angle Indicator ............................................................................................................... 06-37
06-12-21 Proximity Switch ............................................................................................................. 06-38
06-12-24 Shim ............................................................................................................................... 06-40
06 - 26 9823/0300-1 06 - 26
12 - Lift Arm
00 - General
00 - General Health and Safety

Introduction ............................................... 06- Lifting Equipment
Health and Safety .......................................... 06-27 You can be injured if you use incorrect or faulty lifting
Technical Data ............................................... 06-28 equipment. You must identify the weight of the item to
Calibrate ........................................................ 06-28 be lifted then choose lifting equipment that is strong
Remove and Install ....................................... 06-30 equipment is in good condition and complies with all
Disassemble and Assemble .......................... 06-33 local regulations.
DANGER! Before removing the boom from the
machine, make sure that the counterweight is
adequately supported as in certain ground conditions
the machine could tip backwards. Never travel or
transport the machine with the boom removed.
CAUTION! Make sure you know the weight of the
load before trying to lift it. Raise the load only a
few centimetres at first, to check that the machine is
stable. Lower the load straight away if the machine
begins to feel unstable. Do not exceed the loading
limits shown on the Load Charts.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
WARNING! The limits shown on the load charts are
for a stationary, level machine. Do not raise or extend
the lift arm while the machine is moving. Retract the
lift arm fully and lower it as far as possible before you
travel with a load.
WARNING! Under no circumstances should
personnel be lifted into the air without using an
approved and properly secured platform. Failure to
follow this warning could result in death or serious
injury.
WARNING! Do not work under raised lift arms unless
they are adequately supported by stands and/or
slings.
WARNING! You could be killed or injured if the boom
drops while you are working under it. Install the
boom maintenance strut as instructed before doing
any maintenance work with the boom raised. Keep
people away from the machine while you install or
remove the boom maintenance strut.
WARNING! Make sure the machine cannot tip
over when this component (or components) is (are)
removed during this operation.
06 - 27 9823/0300-1 06 - 27
12 - Lift Arm
00 - General
Technical Data Calibrate
Table 4. Lift Arm Weight When the boom is assembled, do a check of

the carriage alignment to make sure that the
Item Weight
measurement is accurate.
Lift arm (fully assem- Approximately 1,100kg
bled) 1. Make the machine safe. Refer to (PIL 01-03).
Lift ram (with valve Approximately 84kg
block) 2. Make sure that the tyre pressures are correct.
3. Make sure that the machine is parked on flat level
Figure 33.
ground.
4. Check the inclinometer to make sure that the
chassis is level.
B
A Figure 34.
A
A Inclinometer
5. Measure the left and right side carriage height
from the ground to the top of the carriage and
note the dimensions.
Figure 35.
Table 5. Maximum Gap

Dimension Maximum gap X Y
A 1.5mm
B 1.5mm
X Left side dimension

Y Right side dimension
6. If there is a difference between left and right side
dimension, the front lower wear pads 1 and wear
pads 2 can be shimmed.
7. Add or remove the shim 1 and shim 2 as
necessary to align the carriage. Refer to adjust
(PIL 06-12-30).
06 - 28 9823/0300-1 06 - 28
12 - Lift Arm
00 - General
8. Make sure that the difference in shim thickness of

shim 1 and shim 2 does not exceed the specified
value.
Length/Dimension/Distance: 3.2mm
9. Make sure that the maximum wear pad clearance
does not exceed the specified value.
Length/Dimension/Distance: 3mm
Figure 36.
C F
D E
B Maximum wear pad clearance
C Lower wear pad 1
D Lower wear pad 2
E Shim 1
F Shim 2
06 - 29 9823/0300-1 06 - 29
12 - Lift Arm
00 - General
Remove and Install
Special Tools 6. Lower the lift arm onto a suitable support in the
Description Part No. Qty. semi raised position to access the lift arm rod end
Slide Hammer Kit 993/68100 1 and the displacement ram head end.
7. Support the lift arm from above ready for
Consumables removal.
Special HP Grease 4003/2017 0.4kg 7.1. Use lifting shackles of suitable capacity
4003/2006 12.5kg attached to the forward and rear lifting
points.
4003/2005 50kg
8. Support the lift ram and disconnect the lift ram
Lifting Equipment rod end by removing nut 2 and bolt 2.
9. Disconnect the electrical connectors.
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong 10. Remove the pivot pin 2.
equipment is in good condition and complies with all Special Tool: Slide Hammer Kit (Qty.: 1)
local regulations.
11. Make sure to retrieve the washers.
Hydraulic Pressure
12. Lower the ram onto the packing material to
Hydraulic fluid at system pressure can injure you. prevent damage to the piston rod.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service 12.1. Make sure not to damage the remote
hose line must be vented. Make sure the hose grease point and pipe
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be 13. Support the displacement ram and disconnect
started while the hoses are open. the head end of the ram by removing nut 1 and
bolt 1.
Raised Machine
Never position yourself or any part of your body 14. Remove the pivot pin 1.
under a raised machine which is not correctly Special Tool: Slide Hammer Kit (Qty.: 1)
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be 15. Lower the displacement ram onto packing
killed. material to prevent damage to the piston rod.
Metal Splinters 16. Disconnect the hydraulic hoses at the rear of the
You can be injured by flying metal splinters when lift arm.
driving metal pins in or out. Use a soft faced hammer
or copper drift to remove and install metal pins. 16.1. Put a label on the hoses to help
Always wear personal protective equipment. installation.
16.2. Plug all the open ports and hoses to
The lift arm does not need to be removed to replace prevent contamination.
the auxiliary and tilt hoses. Refer to (PIL 30-93).
17. Disconnect the hoses from the pipes at the pipe
Remove support bracket.
1. Make the machine safe. Refer to (PIL 01-03). 17.1. Put a label on the hoses to help
installation.
2. Discharge the hydraulic pressure. Refer to (PIL 17.2. Plug all the open ports and hoses to
30-00). prevent contamination.
3. Remove the lift arm attachments, including forks 18. Make sure that the lift arm is fully supported.
and fork bar. Refer to (PIL 03-33).
19. Remove the bolt and slide out the pivot pin 3.
4. Remove the lift arm rear cover. Refer to (PIL
06-06). Special Tool: Slide Hammer Kit (Qty.: 1)
5. Remove the deck plate. Refer to (PIL 06-06). 20. Make sure to retrieve the spacer shims.
06 - 30 9823/0300-1 06 - 30
12 - Lift Arm
00 - General
21. Check for any remaining connections and

carefully remove the lift arm clear of the machine.
Figure 37.
G
E
C
B H
D J
A
K
M
L
L N
P
M
P
A Displacement ram B Nut 1

C Bolt 1 D Pivot pin 1
E Nut 2 F Bolt 2
G Washers H Pivot pin 2
J Lift ram K Remote grease pipe
L Hydraulic hoses M Lift arm pivot bush
N Pivot pin 3 P Spacer shims
06 - 31 9823/0300-1 06 - 31
12 - Lift Arm
00 - General
Figure 38.
R R
Q R
Q Support bracket
R Hoses
Install
steps.
1.1. Check the lift arm pivot bushes and replace
if necessary.
1.2. Check the hydraulic oil level and top up if
necessary. refer to (PIL 30-00).
1.3. Apply grease on all the pivot pins.
Consumable: Special HP Grease
1.4. Check the pivot shim clearance. Refer to
(PIL 06-12).
06 - 32 9823/0300-1 06 - 32
12 - Lift Arm
00 - General
Disassemble and Assemble
CAUTION You can be injured if you use incorrect Unless the lift arm fabrications are damaged there
or faulty lifting equipment. You must identify the is normally no requirement to separate the lift arm
weight of the item to be lifted then choose lifting sections. The lift arm sections can be separated with
equipment that is strong enough and suitable for the lift arm assembly removed or installed to the
the job. Make sure that lifting equipment is in good machine as required.
condition and complies with all local regulations.
The following procedures can be carried out without
WARNING Hydraulic fluid at system pressure the need to separate the lift arm sections or remove
can injure you. Before connecting or removing the boom from the machine.
any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented. • Hose removal and replacement for the tilt ram
Make sure the hose service line has been vented and auxiliary services. Refer to (PIL 30-93-03).
before connecting or removing hoses. Do not start • Tilt ram removal and replacement. Refer to (PIL
the engine with loose or open hose connections. 30-15-11).
WARNING Never position yourself or any part • Extension ram removal and replacement. Refer
of your body under a raised machine which is to (PIL 30-15-07).
not properly supported. If the machine moves • Wear pads and shims. Refer to (PIL 06-12-30).
unexpectedly you could become trapped and • Displacement ram removal and replacement.
suffer serious injury or be killed. Refer to (PIL 30-15-08).
• Lift ram removal and replacement. Refer to (PIL
30-15-06).
06 - 33 9823/0300-1 06 - 33
12 - Lift Arm
00 - General
Disassemble
Figure 39.
H
A
D
X X Y
D D D
C E E C
A Tilt ram B Extension ram

C Hose clamps D Auxiliary hoses
E Guide channels F Wear pads
G Inner lift arm H Outer section
06 - 34 9823/0300-1 06 - 34
12 - Lift Arm
00 - General
X Arrow X Y Arrow Y
1. Make the machine safe. Refer to (PIL 01-03). 8.4. Support the front end of the inner lift arm
and draw it out from the outer section.
2. Discharge the hydraulic pressure. Refer to (PIL
30-00). 8.5. Before the inner section is all the way out
attach suitable lifting equipment. Make sure
3. Remove the fork carriage. Refer to attachments- the section is fully supported by the lifting
fork (PIL 03-33). equipment and then draw it free from the
outer section.
4. Remove the tilt ram. Refer to hydraulic system-
cylinder ram (PIL 30-15). If the lift arm assembly has been removed from the
machine, make sure that it is securely supported.
5. Remove the lift arm nose cover (if installed). When the inner lift arm section is removed, forces
Refer to body and framework- access cover (PIL may cause the whole assembly to move.
06-06).
6. Remove the extension ram. Refer to hydraulic Assemble
system- cylinder ram (PIL 30-15).
1. The assembly procedure is the opposite of
7. Remove the telescopic hydraulic service hoses. the disassemble procedure. Additionally do the
To ensure that the hoses do not become following steps.
damaged or tangled, they must be removed
before attempting to separate the lift arm 2. Check the length of the hose pairs. The hose
sections. Remove the hoses as follows: lengths must be the same or vary by no more
than the specified dimension for each service
7.1. Remove the hose clamps. pair (tilt ram pair, and auxiliary service pair).
7.2. Put label on the hoses at the steel pipes Dimension: 1mm
on the underside of the lift arm for correct
installation. 3. Do not renew individual hoses. The hoses can
stretch over time. New hoses may not be the
7.3. Disconnect and remove the hoses. same length. Renew all four telescopic service
hoses if any of the hoses are damaged.
7.4. Pull out the hoses through the guide
channels from the rear in the direction of the 4. Assemble the lift arm sections so that the lift arm
arrow X. is fully retracted.
7.5. Then pull out the hoses through the
apertures under the lift arm in the direction 5. To enable alignment of the rod end pivot of the
of the arrow Y. extension ram, install the hydraulic hoses so that
the lift arm can be extended.
7.6. Put cap on all the open hoses and ports.
6. Make sure that the hose routing is correct. Do not
7.7. Put label on the auxiliary service hoses at cover any hoses.
the steel pipes on the underside of the lift
arm and at the front of the lift arm for correct 7. The tilt ram and auxiliary service hoses pass
installation. through the guide channels in the top of the
7.8. Disconnect and remove the hoses. inner lift arm. When all the hoses are correctly
connected, install the clamps at the inside of the
7.9. Pull out the hoses in the same way as the inner lift arm.
tilt ram hoses. Refer to 7.4 and 7.5.
8. Check that the lift arm wear pad shimming is
7.10. Put cap on all the open hoses and ports. correct. Refer to body and framework- lift arm
(PIL 06-12).
8. Remove the inner lift arm.
8.1. Remove the front wear pads from the outer
lift arm.
8.2. Make sure that the lift arm assembly is fully
supported by the outer lift arm and then
remove the upper and side wear pads.
8.3. Lift the front of the inner lift arm clear of
the lower wear pads and then remove them.
Label all the wear pads and keep them
together with their shims.
06 - 35 9823/0300-1 06 - 35
12 - Lift Arm
12 - Pivot Link Lever (Upper)
12 - Pivot Link Lever (Upper)
Adjust
4. If the gap is more than the specified value, add

The figure (Refer to Figure 40. ) shows the lift arm the correct quantity of shims to get the correct
viewed from the rear of the machine. measurement. Add the shims equally at the two
sides to make sure that the lift arm is at the centre
1. Measure the gap 1 and the gap 2 as shown in the of the pivot.
figure. Refer to Figure 40.
2. Add the values of gap 1 and the gap 2. Total gap
= gap 1 + gap 2. 4.1. Later shims do not have handles.
3. Make sure that the total gap is not more than the 5. When the total gap is of the correct value, if the
specified value. shim has handles, snap the handle from the shim
at the crease.
Figure 40.
X Y
X Gap 1 Y Gap 2
Figure 41.
B
A Handled shim (earlier type)

B Crease
C Handle
06 - 36 9823/0300-1 06 - 36
12 - Lift Arm
18 - Angle Indicator
18 - Angle Indicator
Remove and Install
Remove
2. Remove the locknuts.
3. Remove the bolt 1 and the pointer arm.
4. Remove the bolts 2 to remove the dial.
Figure 42.
B C
A Locknuts
B Bolt 1
C Pointer arm
D Bolts 2
E Dial
F Decal
Install
steps.
1.1. If the scale is worn then remove the decal
and install a new decal.
1.2. Apply grease to the bolt 1, to make sure of
the smooth operation of the pointer arm.
06 - 37 9823/0300-1 06 - 37
12 - Lift Arm
21 - Proximity Switch
Remove and Install
4. Remove the sensor harness retaining clips (if

Lift Arm Retract Sensor installed).
5. Disconnect the sensor harness connector from
Removal the lift arm harness connector.
1. Make the machine safe. Refer to (PIL 01-03). 6. Remove the securing screws.
2. Extend the lift arm until the sensor flag is clear of 7. Remove the sensor and cover from the machine.
the sensor.
3. Lower the lift arm to the ground.
Figure 43. Lift Arm Retract Sensor
B
C
A Sensor flag B Lift arm retract sensor

C Securing screws D Sensor harness retaining clips
E Sensor harness retaining connector F Sensor cover
Installation 1. Make sure to route the harness correctly and

replace the harness securing clips.
Installation is opposite of the removal procedure.
Additionally do the steps below. 2. Make sure you install the sensor cover.
06 - 38 9823/0300-1 06 - 38
12 - Lift Arm
3. Calibrate the LLMC (Longitudinal Load Moment

Control) system. Refer to (PIL 33-66-00).
06 - 39 9823/0300-1 06 - 39
12 - Lift Arm
24 - Shim
24 - Shim Technical Data

Technical Data ............................................... 06-40 Make sure that the wear pads are installed correctly
Adjust ............................................................ 06-42 to prevent fouling.
Table 6. Number Of Plain Washers To Be Installed Under Bolt

Location Shim Thickness Number of Washers Number of Washers
(Front) (Rear)
Upper pads 1.6–4.2mm 3 2
4.7–6.4mm 2 1
6.9–8mm 1
Side pads 0.5–2.5mm 2
3–4.5mm 1
5–6.5mm 0
7–8mm 0
1.6–2.5mm 2
4.7–6.4mm 1
Lower front pads 2.1–4.2mm 3 NA
4.7–6.4mm 2
6.9–8mm 1
06 - 40 9823/0300-1 06 - 40
12 - Lift Arm
24 - Shim
Wear Pad Layout
Figure 44.
C C C
A-A
A D
D A
D E
A A
F F
B-B
F
G
G G
B
H
C Front top wear pads D Front side wear pads

E Front bottom wear pads F Rear top wear pads
G Rear side wear pads H Rear bottom wear pads
06 - 41 9823/0300-1 06 - 41
12 - Lift Arm
24 - Shim
Adjust Figure 46. 2 Section, 2 Stage Lift Arm
Typical shimming Procedure

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

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

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

of specification. The clearances must be measured,
the chamfer is not a guide to the amount of wear
remaining.Refer to Figure 45. A Inner boom
B Outer boom
Make sure that the threaded insert remains a tight fit Figure 47. 3 Section 3 Stage Lift Arm
in the wear pad and does not rotate when tightened.
If the insert is loose in the wear pad, install a new
wear pad and threaded insert.
On 2 stage (2 section) machines, shim the inner

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

depending on the shim thickness. Make sure you
install the correct number of washers for the
thickness of shims. Refer to Body and Framework-
Lift Arm, Technical data (PIL 06-12-30). A Intermediate lift arm
B Outer lift arm
Do not install spring washers. C Inner lift arm
Figure 45.
D
D Chamfer depth
06 - 42 9823/0300-1 06 - 42
12 - Lift Arm
24 - Shim
Figure 48. Figure 49.

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

F Shim F Shim
G Washer G Washer
1 Wear pad 1 Wear pad
2 Threaded insert 2 Threaded insert
Lower wear pads- Shimming Rear lower wear pads
Front lower wear pads 1. Rest the forks on the ground.
1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the lift arm rear cover. Refer to (PIL
06-06).
2. Follow all safety procedures. Refer to (PIL
01-03). 3. Measure the distances between lift arm lower
faces which must be in the limit given. Refer to
3. Raise the lift arm slightly so that forks are just off (PIL 06-12).
the ground.
4. If this dimension is less than the limit, then install
4. Measure the distances between the lift arm lower shims under the lower wear pads to restore the
faces which must be in the limit given. Refer to dimension.
Technical Data (PIL 06-12).
5. Raise the lift arm slightly so that forks are just off
5. If this dimension is less than the limit, then install the ground and place wedges under the inner lift
shims under the lower wear pads to restore the arm.
dimension.
6. Remove the wear pad bolts and add shims as
6. Rest the forks on the ground so that there is no required.
weight on the lower wear pads.
7. Measure the total thickness of shims under each
7. Remove the wear pad bolts and add shims as pad.
required.
8. Add or remove plain washers under the heads
8. Measure the total thickness of shims under each of wear pad bolts. Make sure that the thread
pad. engages sufficiently. Refer to (PIL 06-12).
9. Add or remove the correct number of plain 9. Do not install spring washers.
washers under the heads of wear pad bolts.
Make sure that the thread engages sufficiently. 10. Remove the wedges, install the shims again and
Use the correct number of washers. Refer to tighten the bolts to the specified torque value.
10. Do not install spring washers.
11. Install the shims again and tighten the bolts to the
specified torque value.
06 - 43 9823/0300-1 06 - 43
12 - Lift Arm
24 - Shim

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

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

The following procedure applies to both front and The following procedure applies to both front and
rear top wear pads. rear side wear pads.
1. Raise the lift arm until the inner lift arm is resting 1. Measure the distances between the lift arm side
on the lower wear pads. faces which must be in the limit given. Refer to
2. Measure the distances between the lift arm upper
faces which must be in the limit given. Refer to 2. If this dimension is less than the limit, install
(PIL 06-12-00). shims under the side wear pads to restore the
dimension.
3. If this dimension is less than the limit, install
shims under the top wear pads to restore the 3. Slacken the side wear pad bolts and install shims
dimension. as required. Divide number of shims equally each
side to ensure that inner lift arm runs centrally
4. Install or remove shims to obtain the correct within the outer lift arm.
vertical clearance.
4. Measure the total thickness of shims under each
5. Measure the total thickness of shims under each pad.
pad.
5. Add or remove the correct number of plain
6. Add or remove the correct number of plain washers under the heads of wear pad bolts.
washers under the heads of wear pad bolts. Make sure that the thread engages sufficiently.
Make sure that the thread engages sufficiently. Refer to (PIL 06-12-00).
Refer to Technical Data (PIL 06-12).
7. Install the shims again and tighten the bolts to the
8. Install the shims again and tighten the bolts to the specified torque value.
06 - 44 9823/0300-1 06 - 44
12 - Lift Arm
24 - Shim
Figure 52.
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert
Table 7. Torque Information

Item Description Torque
E For wear pads 98N·m
with M12 bolts
E For wear pads 58N·m
with M10 bolts
E 550-80 Ma- 56N·m
chines only
06 - 45 9823/0300-1 06 - 45
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-47
06 - 46 9823/0300-1 06 - 46
30 - Pivot Pins
00 - General
Introduction .................................................... 06-47 Pivot pins are a short shaft or pin that supports
Remove and Install ....................................... 06-48 something that turns. Pivot pins are installed in
numerous positions on the machine. There is usually
a greasing point associated with the pivot pin.
Make sure that the pivot points are greased at
regular intervals. Refer to the Machine Maintenance
Schedules. Refer to: PIL 78-24.
Slide Hammer Kit

The slide hammer kit is used to remove pivot pins that
must be extracted, i.e. cannot be 'knocked through'.
The purpose of this description is to explain how the
kit and the various components are used to remove
the pivot pins.
The adaptors that form part of the kit have a screwed

thread at each end. One of the threads will always
be M20 size, this is to accommodate the end stops.
The other end of the adaptor will have varying thread
sizes to suit the different size of threads in the pivot
pins.
06 - 47 9823/0300-1 06 - 47
30 - Pivot Pins
00 - General
Remove and Install Figure 53. Typical Machine
Special Tools
Description Part No. Qty.
Slide Hammer Kit 993/68100 1
C
Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
look different.
1. Prepare the pivot pin for removal, remove the

locking device e.g. pivot pin retaining bolt.
2. Prepare the slide hammer kit.
Special Tool: Slide Hammer Kit (Qty.: 1)
2.1. Install the slide hammer onto the slide bar.
2.2. Determine the thread size of the pivot pin A Adaptor
and then install the appropriate adaptor. B End stop
Use the spanner flats to securely install the C End stop
adaptor. D Spanner flats
2.3. Install an end stop onto the other end of the E Slide bar
adaptor (M20 thread size), make sure that F Slide hammer
the adaptor threads are fully engaged.
2.4. Install the slide bar into the end stop. Make
sure that the threads are fully engaged.
2.5. Finally install the other end stop at the end
of the slide bar. The slide hammer kit is now
ready to use.
3. To extract the pivot pin, slide the hammer along
the bar until it contacts the end stop. Repeat this
step until the pivot pin is released.
4. To remove the slide hammer kit, reverse steps 2
to 3.
06 - 48 9823/0300-1 06 - 48
54 - Fender
54 - Fender
Contents Page No.
06-54-00 General ........................................................................................................................... 06-51
06 - 49 9823/0300-1 06 - 49
Notes:
06 - 50 9823/0300-1 06 - 50
54 - Fender
00 - General
00 - General
Remove and Install
2. If more access is required, remove the

The procedure shown is for one mudguard assembly. roadwheel. Refer to (PIL 27-29).
The procedure is the same for all other mudguards
also. 3. Remove the mounting arm bolts from the axle
trunnion.
Remove 4. Remove the mudguard and the bracket
1. Make the machine safe. Refer to (PIL 01-03). assembly away.
Figure 54.
B
A
A Mudguard B Bracket assembly

C Bolts D Trunnion
06 - 51 9823/0300-1 06 - 51
54 - Fender
00 - General
Install
step:
1.1. Tighten the bolts to the specified torque
value.

Item Description Nm
C Bolts 74
06 - 52 9823/0300-1 06 - 52
57 - Counterweight
57 - Counterweight
Contents Page No.
06-57-00 General ........................................................................................................................... 06-55
06 - 53 9823/0300-1 06 - 53
Notes:
06 - 54 9823/0300-1 06 - 54
57 - Counterweight
00 - General
00 - General
Health and Safety

method and device.
CAUTION You can be injured if you use incorrect
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting
equipment that is strong enough and suitable for
the job. Make sure that lifting equipment is in good
condition and complies with all local regulations.
WARNING Make sure the machine cannot be
used with the counterweight removed. Make sure
the ignition key is removed and the battery is
isolated.
WARNING Make sure the machine cannot tip
over when this component (or components) is
(are) removed during this operation.
06 - 55 9823/0300-1 06 - 55
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-57

06-63-03 Machine .......................................................................................................................... 06-58
06-63-06 Engine ............................................................................................................................ 06-60
06-63-09 Axle ................................................................................................................................ 06-61
06-63-12 Gearbox .......................................................................................................................... 06-62
06-63-15 Operator Protective Structure ........................................................................................ 06-63
06 - 56 9823/0300-1 06 - 56
00 - General
00 - General
Introduction
The machine has identification plates that contain

important information relating to the specific machine
details, for example VIN or PIN number and engine
serial number. These serial numbers can help you
identify exactly what equipment has been installed
on the machine.
06 - 57 9823/0300-1 06 - 57
03 - Machine
03 - Machine
The serial number of each major unit is also shown

Machine Identification Plate on the unit itself. If a major unit is replaced by a
new one, the serial number on the identification plate
Your machine has an identification plate mounted as will be wrong. Either get a replacement identification
shown. The serial numbers of the machine and its plate from your JCB Dealer or simply remove the
major units are shown on the plate. old number. This will prevent the wrong unit number
being quoted when replacement parts are ordered.
The machine model and build specification is The machine and engine serial numbers can help
indicated by the PIN (Product Identification Number) identify exactly the type of equipment you have.
Figure 55.
Typical Product Identification Number Table 12.

Digit 7 Engine Model
The machine model and build specification are
indicated by the PIN. The PIN has 17 digits and must 1 55kW KOHLER T4F
be read from left to right.
Table 9. Typical PIN Table 13.

JCB 5A4 1 R C 12345678 Digit 8 Gearbox Model
E 3 Speed (PS750)
Table 10. F 3 Speed (PS760)
Digit 1 to 3 World Manufacturer G 4 Speed (PS750)
Identification H 4 Speed (PS760)
JCB United Kingdom J 6 Speed (PS760)
GEO Georgia, US M 4 Speed (SS700)
HAR Haryana, India N 4 Speed (PS750)
SOR Sorocaba, Brazil P HYDRO 20km/h
GET Gatersleben, Germany (12.4mph)
PUN Pune, India R HYDRO 25km/h
(15.5mph)
SHA Shanghai, China
S HYDRO 34km/h
JBP JCB Branded Products (21.1mph)
T HYDRO 40km/h
Table 11. (24.9mph)
Digit 4 to 6 V HYDRO 30km/h
Machine model and type (18.6mph)
06 - 58 9823/0300-1 06 - 58
03 - Machine
Table 14.
Digit 9
Random check letter. The check letter is used to
verify the authenticity of a machine's PIN
Table 15.
Digit 10 to 17
Machine serial number. Each machine has a
unique serial number.
06 - 59 9823/0300-1 06 - 59
06 - Engine
06 - Engine
The engine data labels are attached to the cylinder

block as shown. Refer to Figure 56.
The data label includes the engine identification

number.
Figure 56.
A
A
A Engine data label
06 - 60 9823/0300-1 06 - 60
09 - Axle
09 - Axle
The axles have a serial number stamped on a data

plate label as shown.
Figure 57.
A Data plate - front axle

Figure 58.
A
B Data plate - rear axle
06 - 61 9823/0300-1 06 - 61
12 - Gearbox
12 - Gearbox
The gearbox has a serial number stamped on a data

plate as shown.
Figure 59. Transmission - 135cc
A Data plate
A Data plate
06 - 62 9823/0300-1 06 - 62
15 - Operator Protective Structure
15 - Operator Protective Structure certification. If damage has occurred then an

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

WARNING You could be killed or seriously injured Structure) can be identified by referring to the
if you operate a machine with a damaged or cab identification plate. Work place (work site, job
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ site) risk assessment should facilitate the machine
FOGS has been in an accident, do not use the selection and the need for an machine with a ROPS.
machine until the structure has been renewed.
Modifications and repairs that are not approved Figure 61.
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification.
WARNING Machines with a ROPS, FOPS,FOGS
or TOPS are equipped with a seat belt. The
ROPS, FOPS,FOGS or TOPS is designed to give
you protection in an accident. If you do not wear
the seat belt you could be thrown off the machine
Data plate - ROPS/FOPS standards
and crushed. You must wear a seat belt when
using the machine. Fasten the seat belt before The mass shown in these data plate are a test mass
starting the engine. and the maximum operating mass of this machine
may be lower.
FOPS Data Plate
WARNING Do not use the machine if the falling
objects protection level provided by the structure
is not sufficient for the application. Falling objects
can cause serious injury.
If the machine is used in any application where there

is a risk of falling objects then a FOPS (Falling Object
Protective Structure) must be installed. For further
information, contact your JCB dealer.
The FOPS has a data plate attached. The data

plate indicates what level of protection the structure
provides.
There are two levels of FOPS:
• Level I Impact Protection - impact strength

for protection from small falling objects
(e.g. bricks, small concrete blocks, hand
tools) encountered in operations such as
highway maintenance, landscaping and other
construction site services.
• Level II Impact Protection - impact strength for
protection from heavy falling objects (e.g. trees,
rocks) for machines involved in site clearing,
overhead demolition or forestry.
ROPS Data Plate

WARNING Your machine may be installed with a
Roll-Over Protective Structure (ROPS) indicating
that the purchaser specified the machine for use
in applications where there is risk of roll-over.
ROPS is a device to protect the operator in the
event of roll-over. Any damage or modification
to the structure may invalidate the ROPS
06 - 63 9823/0300-1 06 - 63
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-65
06 - 64 9823/0300-1 06 - 64
66 - Tools
00 - General
00 - General
Introduction
All tools must be kept in the toolbox (if installed) when

not in use.
06 - 65 9823/0300-1 06 - 65
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-67

06-69-03 Lift Arm ........................................................................................................................... 06-69
06 - 66 9823/0300-1 06 - 66
00 - General
Introduction .................................................... 06-67 Before you start any service procedures on the
Remove and Install ....................................... 06-68 machine, make sure that the relevant maintenance
strut is installed in its correct position and secure.
Refer to: PIL 01-03-27.
06 - 67 9823/0300-1 06 - 67
00 - General
Remove and Install Figure 63.
Install the Maintenance Strut

2. Retract the lift arm.
B
3. Raise the lift arm.
5. Remove the maintenance strut from the stowage
position.
Figure 62.
B Strap
A Maintenance strut operation of the engine.
6. Install the maintenance strut. Refer to: PIL 33-03-00.
7. Put the strut around the lift ram piston rod. Make 12. If necessary, put blocks against the two sides of
it safe with the strap. the wheels before you get below the machine.
8. To prevent any chance of the lift arm creeping
down and trapping your fingers, lower the lift arm
Remove the Maintenance Strut
onto the strut. 1. Connect the battery.
9. Lower the lift arm carefully to prevent possible Refer to: PIL 33-03-00.
damage to the strut.
2. Raise the lift arm to take the weight off of the strut.
10. Stop as soon as the weight of the lift arm is on
the strut. 3. Stop the engine and remove the ignition key.
5. Secure the strut in its stowage position.
06 - 68 9823/0300-1 06 - 68
03 - Lift Arm
03 - Lift Arm Figure 66.
Remove and Install
If you raise the lift arm to get access for maintenance,

you must install the maintenance strut on the lift arm.
Figure 64.
A A
A Strap
A lift arm raised
8. To prevent any chance of the lift arm creeping
Installing the Maintenance Strut down and trapping your fingers, the lift arm
should be lowered onto the strut. Lower the lift
1. Make the machine safe, refer to (PIL 01-03). arm carefully, to prevent possible damage to the
strut. Stop as soon as the weight of the lift arm
2. Retract the lift arm. is on the strut.
3. Raise the lift arm. 9. Disconnect the battery to prevent accidental
operation of the engine.
10. If necessary, put blocks against the two sides of
5. Remove the maintenance strut from its stowage the wheels before you get below the machine.
position.
Figure 65. Removing the Maintenance Strut
1. Raise the lift arm to take the weight off of the strut.
A
4. Secure the strut in its stowage position.
A Maintenance strut
6. Install the maintenance strut.
7. Place the strut around the lift ram piston rod.
Secure it in position with the strap.
06 - 69 9823/0300-1 06 - 69
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-71
06 - 70 9823/0300-1 06 - 70
00 - General
00 - General
Check (Condition)
In addition to the operator check the extinguisher

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

leaks.
2. Make sure the fire extinguisher is correctly
attached.
3. Make sure that the gauge indicates that the
extinguisher is charged i.e. the needle is in the
green segment
3.1. If the needle is in or very near the red
segment at either end of the gauge, the
extinguisher must be serviced or replaced.
4. Make sure the safety pin is correctly installed.
Figure 67.
A Gauge
B Safety Pin
06 - 71 9823/0300-1 06 - 71
89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ........................................................................................................................... 06-73
06 - 72 9823/0300-1 06 - 72
89 - Window Guard
00 - General
00 - General Figure 68. Front screen guard
Remove and Install A E
Screen Guard B
Remove C
D
2. Follow all general health and safety procedures. A
3. Support the guard.
4. Remove the upper nuts, bolts and washers.
5. Remove the lower nuts and washers.
6. Remove the guard from the machine.
Installation
removal procedure.
F
G
H F
A Screen guard
B Washer
C Bolts
D Nut
E Mounting lug
F Washer
G Washer
H Nut
06 - 73 9823/0300-1 06 - 73
Notes:
06 - 74 9823/0300-1 06 - 74
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-6
09-09 Window
09-09-00 General ........................................................................................................................... 09-11
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-19
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-21
09-18 Door
09-18-03 Lock ................................................................................................................................ 09-23
09-18-12 Handle ............................................................................................................................ 09-26
09-27 Controls
09-27-27 Auxiliary Circuit .............................................................................................................. 09-29
09-30 Trim Panel
09-30-03 Roof Trim ....................................................................................................................... 09-33
09-30-09 Dashboard ...................................................................................................................... 09-34
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-39
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-41
09-44 Sunblind
09-44-00 General ........................................................................................................................... 09-43
09-48 Floor mat
09-48-03 Front Floor mat .............................................................................................................. 09-45
9823/0300-1
2017-08-16
Acronyms Glossary

LLMI Longitudinal Load Moment Indicator
9823/0300-1
2017-08-16
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-6
09 - 1 9823/0300-1 09 - 1
Notes:
09 - 2 9823/0300-1 09 - 2
00 - General

Health and Safety ........................................... 09-3 Raised Equipment
Component Identification ................................. 09-4 Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Lifting Equipment
equipment is in good condition and complies with all
local regulations.
09 - 3 9823/0300-1 09 - 3
00 - General
Figure 69.
A
R
S T
B Q
C B
E
D J
N
G
H
U
A Steering wheel B Transmission lever and gear selection

C Steer mode selector D Steering column adjustment
E Starter switch F HVAC (Heating Ventilation Air Conditioning)
controls
G Service brake pedal H Accelerator pedal
J Handbrake/parkbrake mini lever K Hand throttle controls
L Travel speed selector M Load charts
N Hydraulic tow hitch P Operating lever
09 - 4 9823/0300-1 09 - 4
00 - General
Q Instrument panel R Inclinometer

S LLMI (Longitudinal Load Moment Indicator) T LLMC (Longitudinal Load Moment Control)
U Inching pedal
09 - 5 9823/0300-1 09 - 5
03 - Cab Frame
03 - Cab Frame Component Identification

Component Identification ................................. 09-6
Remove and Install ......................................... 09-8
Figure 70.
D
B
E
A F
V
U J
G
K
L
T
S
M
S
N
P
A Cab front cover B Condenser pipes

C Hose clamps D Screws
09 - 6 9823/0300-1 09 - 6
03 - Cab Frame
E Electrical connector F Control panel

G Nuts H Locknut
J Cable K Clevis
L Actuating lever M Cab earth strap
N Steering unit P Brake flexi pipe
R TXV (Thermal Expansion Valve) S Heater hoses
T Hitch cable U Inching pedal electrical connectors
V Bulkhead electrical connectors
09 - 7 9823/0300-1 09 - 7
03 - Cab Frame
Remove and Install 13. Install cap on all the open ports to prevent loss
of fluid and contamination.
Special Tools
Description Part No. Qty. 14. Remove the hose clips and disconnect the heater
hoses.
Plate- Assembly Aid 332/F7768 1
(Low Cab Machines) 15. If the machine is installed with an air conditioning,
do not attempt to disconnect any air conditioning
Working Under the Machine hoses until the refrigerant has been discharged.
Make the machine safe before getting beneath it. Charging and discharging the system requires
Make sure that any attachments on the machine are special equipment and training. If necessary, use
correctly attached. Engage the park brake, remove the services of a specialist refrigeration engineer.
16. Disconnect the air conditioning hoses as follows
(if applicable) after the air conditioning system
movement.
has been discharged.:
Air Conditioning Maintenance
16.1. Disconnect the air conditioning hoses at
The air conditioning system is a closed loop system the TXV (Thermal Expansion Valve)
and contains pressurised refrigerant. No part of the
system should be disconnected until the system 16.2. Disconnect the condenser pipes at the
has been discharged by a refrigeration engineer condenser.
or a suitably trained person. You can be severely 16.3. Remove the hose clamps.
frostbitten or injured by escaping refrigerant.
Notice: Make sure you label all hoses / pipes and 17. Disconnect the engine throttle cable.
electrical connectors (if installed) before removal to 18. Disconnect the throttle pedal sensor electrical
aid identification during subsequent installation. connectors.
Remove 19. Make sure that all the wheels are blocked and
release the park brake.
20. Working at the park brake caliper, disconnect
Refer to: PIL 01-03.
the clevis. Note the hole which is used on the
2. Install the safety strut. actuating lever.
Refer to: PIL 06-69. 21. Remove the clip or loosen the locknut as
applicable.
3. Discharge the hydraulic pressure.
Refer to: PIL 30. 22. Disconnect the cable from the bracket and note
the cable routing below the cab.
4. Disconnect the battery.
23. Disconnect the brake flexi pipe from the chassis
Refer to: PIL 33-03. connector.
5. Remove the cab undershield (if installed). 24. Install cap on all the open ports to prevent loss
of fluid and contamination.
6. Remove the deck plate.
Refer to: PIL 06-06. 25. Disconnect the cab earth strap.
7. Remove the bolts and remove the cab front 26. Disconnect the hitch cable (if installed).
cover. 27. Disconnect the washer hoses.
8. Remove the floor mat. 28. Remove the plate on the front left and rear
Refer to: PIL 09-48. mount.
9. Disconnect the bulkhead electrical connectors. 29. Remove the control lever.
10. Disconnect the inching pedal electrical Refer to: PIL 09-27.
connectors (if installed). 30. Remove the screws and remove the variable
11. Put label on the hoses for correct installation. speed/ hand throttle control panel. Disconnect
the electrical connector from the chassis
12. Disconnect all the hydraulic hoses from the harness.
steering unit.
09 - 8 9823/0300-1 09 - 8
03 - Cab Frame
31. Disconnect the manual steer mode cable (if 1.4. For 527-58 machines: Use the cab filter
installed). protection plate between the filter gasket
and the cab whilst the cab is lowered onto
the chassis. The lower part of the plate
32. Loosen and remove the cab mounting bolts and locates in the slot in the chassis.
nuts. Special Tool: Plate- Assembly Aid (Low Cab
Machines) (Qty.: 1)
33. Attach appropriate lifting equipment to the ROPS
(Roll-Over Protective Structure) and FOPS Figure 73.
(Falling Object Protective Structure) cage.
34. Carefully lift the cab away from the machine.
Make sure that all the connections are released
and are clear of any obstruction. W
Install
steps.
1.1. Tighten the cab mounting bolts to the
X
Refer to: PIL 72-06. Y
1.2. On low cab machines the right rear cab
mounting bolt is orientated as shown in
figure. Refer to Figure 71. To aid installation
it is acceptable to install the bolt as shown
in figure. Refer to Figure 72.
Figure 71.
1.5. Make sure that all the cables are connected

and correctly adjusted. Make sure that they
are routed and secured correctly.
1.6. Make sure that all the electrical and
hydraulic services operate correctly.
Figure 72. 1.7. Bleed the brakes.
2 1.8. Recharge the air conditioning system (if
applicable).
1.9. Check the throttle cable adjustment (if
applicable).
1.10. Check the hand throttle operation and
adjust if necessary.
1.11. Check the park brake and adjust if
1.3. Check the cab mounting rubbers. If necessary.
damaged or worn, replace them. Refer to: PIL 24-18.
09 - 9 9823/0300-1 09 - 9
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-11
09 - 10 9823/0300-1 09 - 10
09 - Window
00 - General
Introduction .................................................... 09-11 The service procedures, explain how to correctly
Health and Safety .......................................... 09-12 remove and install panes of glass that are directly
Preparation .................................................... 09-12 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-14 out any service procedure, you must always refer to
the relevant safety precautions, Health and Safety.
1. Always wear safety glasses during removal and

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

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

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

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

5°C (41.0°F).
09 - 11 9823/0300-1 09 - 11
09 - Window
00 - General
Health and Safety Preparation

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

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

otherwise they may be absorbed into the old sealant
and ultimately prevent the new glass from bonding.
New Glass
1. Make sure that the new glass correctly fits the
frame aperture.
1.1. Put two spacer blocks on to the bottom part
of the frame aperture.
Special Tool: Rubber Spacer Blocks (Qty.:
2)
1.2. Install the new glass on the spacer blocks
- Always use glass lifters. Check that there
is an equal sized gap all round the edge
of the glass. Note: The spacer blocks are
rectangular in section to give two common
gap widths. If necessary they can be
trimmed to a smaller size to give an equal
sized gap around the glass. Important: The
glass edges must not touch the frame,
otherwise movement of the frame will chip
and eventually break the newly installed
glass.
Special Tool: Glass Lifter (Qty.: 2)
09 - 12 9823/0300-1 09 - 12
09 - Window
00 - General
4. Clean the glass.

4.1. Use surface cleaner to thoroughly clean
and prime the black ceramic ink band
printed on the glass (see Note). Use a lint
A Frame aperture free cloth to apply the cleaner, allow to
B Spacer blocks dry. Important: Do not touch the glass after
C Glass lifters cleaning with the surface cleaner.
2. After checking for size, remove the new glass Duration: 5min
and place it on a purpose made glass stand. Consumable: Surface Cleaning Fluid
Small panes of glass will need locating on a
600 x 700 mm x 15 to 19 mm thick plywood 4.2. If the glass does not have a black ceramic
board, sourced locally to fit the glass stand. It is ink band, paint a band on the glass using
recommended that an access hole is cut in the Black Primer. Make sure that the band
board to accommodate the glass lifter, making it measures the correct width and that the
easier and safer to handle small panes of glass. edge is a neat straight line.
The board should be covered with felt or carpet Dimension: 25mm
to give an anti-scratch surface. Resting the glass Consumable: Black Primer/Activator
on four spacer blocks will ensure clearance of
the cartridge nozzle tip during application of the Figure 77.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 75.
5. Install the Ultra Fast Adhesive cartridge into a

suitable applicator gun:
Special Tool: Static Oven (240V) (Qty.: 1)
Special Tool: Mobile Oven (12V) (Qty.: 1)
Special Tool: Cartridge Gun (Qty.: 1)
Consumable: Polyurethane Adhesive
5.1. Remove the aluminium disc cover from
3. Make sure the glass is positioned on the stand the base of the cartridge and discard the
the correct way up (i.e. with the black ceramic dessicant capsule.
ink band upwards) ready for application of primer
etc. 5.2. Make sure that the rolled edge of the
cartridge is not damaged - if necessary, the
edges should be pressed flat, otherwise it
09 - 13 9823/0300-1 09 - 13
09 - Window
00 - General
will be difficult to remove the cartridge from Remove and Install

the applicator gun.
Special Tools
5.3. Pierce the front nozzle end of the cartridge
to its maximum diameter. Description Part No. Qty.
Glass Lifter 892/00842 2
5.4. Install the pre-cut nozzle.
Glass Extractor 892/00846 1
5.5. Install the cartridge in the applicator gun. (Handles Only)
Note: Cold material will be very difficult to Nylon Spatula 892/00847 1
extrude. The cartridges must be pre-heated
Wire Starter 892/00848 1
in a special oven for 1 hour to a temperature
of 80°C (176°F). Pre-heating the cartridges Braided Cutting Wire 892/00849 1
makes the adhesive more workable and Rubber Spacer Blocks 926/15500 2
also brings the curing time down to 30 Cut-Out Knife 992/12800 1
minutes. 'L' Blades 992/12801 1
Figure 78.
Consumables
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
Surface Cleaning Fluid 4103/1204 1L
A 12.5mm
B 9mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10min
2.1. Laminated glass - leave installed until the
Figure 79. old sealant has been cut away, after which
it will be possible to lift the broken screen
away from its frame housing in one piece.
2.2. Toughened glass - remove as much of the
shattered glass as possible prior to cutting
out the old sealant.
3. Cut out the old sealant, leaving approximately 1
to 2 mm on the cab frame. There are several tools
and techniques for doing this:
3.1. Pneumatic Knife - This provides one of the
A Nozzle guide easiest methods of removing the sealant
7. After applying the adhesive, leave a small around laminated glass. The tool, powered
amount of sealant protruding from the nozzle. by compressed air, should be sourced
This will prevent any adhesive left in the cartridge locally. Press the handle to start the knife
from curing. blade oscillating. Important: This tool must
not be used on toughened glass. Insert the
knife blade into the sealant. Slowly move
the knife along the sealant with the blade
positioned as close to the glass as possible.
09 - 14 9823/0300-1 09 - 14
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 81.

the sealant will melt.
Figure 80.
3.2. Braided Cutting Wire and Handles - This

method uses a 3-core wire, a wire starter
tube and two handles. Insert the steel tube
into the old sealant on the inside of the
glass. Insert the braided cutting wire down
the centre of the steel tube. If necessary,
from the outside, cut out local sealant at the
point of the tube to gain access to the wire.
Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the A Wire starter
glass. Secure the end of the braided cutting B Braided cutting wire
wire (found on the outer side of the glass) in C Glass extractor (handles)
the special handle. Slowly remove the steel D Glass extractor (handles)
tube. Secure the second end of the braided 3.3. Cut-out Knife - The cut-out knife can be
cutting wire in the special handle. Move the used as a left handed or right handed tool.
cutting wire backwards and forwards in a Insert the knife blade into the sealant. Make
sawing motion and at the same time gently sure that the blade of the knife is against the
push or pull the wire to cut through the old glass. Use the 'pull-handle' to pull the knife
sealant. along and cut out the old sealant.
Special Tool: Wire Starter (Qty.: 1) Special Tool: 'L' Blades (Qty.: 1)
Special Tool: Glass Extractor (Handles Special Tool: Cut-Out Knife (Qty.: 1)
Only) (Qty.: 1)
Special Tool: Braided Cutting Wire (Qty.: 1) Figure 82.
A Glass
3.4. Craft Knife - The blades are replaceable.
Insert the knife blade into the sealant. Pull
the knife along and cut out the old sealant.
09 - 15 9823/0300-1 09 - 15
09 - Window
00 - General
Figure 83. glass. Make sure the two spacer blocks are in
position. Refer to Preparation - New Glass
2. Install the glass in the frame aperture:
2.1. Always use the glass lifting tools when
moving the glass. Use a lifting strap to hold
large panes of glass in position.
Special Tool: Glass Lifter (Qty.: 2)
Figure 85. Typical Machine
A Blades
3.5. Glass Replacement Kit - This kit is
designed for removal of one pane of glass.
The kit comprises: Cartridge Polyurethane
Adhesive (310ml), Primer/Activator (10ml),
Surface Cleaner Wipe, Abrasive Pad,
Applicator Nozzle, Wool Dauber, Cutting
Wire, Rubber Blocks.
Consumable: Glass Replacement Kit
4. Laminated glass - lift out the broken pane using
glass lifters. Toughened glass - remove the cut off 2.2. Sit the bottom edge of the glass on the
sealant and all remaining particles of shattered spacer blocks.
glass. Special Tool: Rubber Spacer Blocks (Qty.:
2)
5. If necessary, trim off the remaining old sealant
to leave approximately 1 to 2 mm on the upright Figure 86.
face of the cab frame aperture.
Figure 84.
A 1.5mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures. 2.3. Make sure that the glass is correctly
positioned, then gently press around the
6.2. The old sealant was inadvertently cut back edges of the glass and ensure full adhesive
to the cab frame during the glass/sealant contact is achieved. Do not press too hard
removal procedures. or too much adhesive will squeeze out.
Installing new Glass 3. Make the inside seal smooth:
1. If the internal trim strip is damaged, renew it (cut 3.1. Wearing surgical gloves, dip your finger in
to length as required) before installing the new a soapy water solution.
09 - 16 9823/0300-1 09 - 16
09 - Window
00 - General
3.2. Use your finger to make the inside seal

smooth.
4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
caution when wiping the inside of the new glass
- pushing too hard on the inside of the glass will
affect the integrity of the bonded seal.
Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
Consumable: Surface Cleaning Fluid
5.2. Large amounts of excess sealant should be
left to cure and then cut off with a sharp
knife. Note: On completion of the glass
replacement procedures, the sealant curing
time is 30 minutes. This means that the
machine can be driven and used after 30
minutes, but it must not be used during the
curing period of 30 minutes.
5.3. Clean the glass using a purpose made
glass cleaner.
Consumable: Hand Cleaner
Consumable: JCB Glass Cleaner
6. On completion of the glass installation
procedures tidy the work area:
6.1. Remove all broken glass from the cab area.
6.2. Remove the protective covers from the cab
seat and control pedestals.
6.3. Renew all safety and instructional labels so
that the new installation conforms with the
original cab installation.
09 - 17 9823/0300-1 09 - 17
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-19
09 - 18 9823/0300-1 09 - 18
12 - Operator Seat
00 - General
00 - General
Check (Condition)
1. Check that the seat adjustments operate
correctly.
2. Check the seat is undamaged.
3. Check the seat mounting bolts are undamaged,
correctly installed and tight.
4. Make sure the seat is clear from unwanted
materials and hazards at all times.
09 - 19 9823/0300-1 09 - 19
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-21
09 - 20 9823/0300-1 09 - 20
15 - Seat Belt
00 - General
00 - General
Check (Condition)
WARNING When a seat belt is installed on your
machine replace it with a new one if it is damaged,
if the fabric is worn, or if the machine has been in
an accident.
WARNING If the seat belt does not 'lock' when
you check if the seat belt is operating correctly, do
not drive the machine. Get the seat belt repaired
or replaced immediately.
1. Make sure the seat belt can be adjusted.

2. Examine the seat belt for signs of fraying and
stretching.
3. Check that the stitching is not loose or damaged.
4. Check that the belt mounting bolts are
undamaged, correctly installed and tight.
5. Check that the buckle assembly is undamaged
and operates correctly.
09 - 21 9823/0300-1 09 - 21
18 - Door
18 - Door
Contents Page No.
09-18-03 Lock ................................................................................................................................ 09-23

09-18-12 Handle ............................................................................................................................ 09-26
09 - 22 9823/0300-1 09 - 22
18 - Door
03 - Lock
03 - Lock
Remove and Install
Consumables 5.1. Use a thin punch and hammer to tap the

Description Part No. Size securing pin from the hinge assembles.
Extreme Performance 4003/1327 0.4kg 5.2. Remove the grub screw.
Moly Grease 4003/1326 12.5kg
6. Use a thin punch and hammer to tap the hinge
pin from the hinge assembles.
Remove
7. Do steps 4 and 5 for all other hinges on the door.
8. Carefully remove the door from the hinge
2. Follow the general health and safety procedures. assembly.
9. If necessary, remove the hinge assembly by
3. Divide the doors by releasing the locking handle removing the nuts from inside the cab.
(Two piece doors only- if installed).
10. Do procedures 3 to 7 for the lower part of the
4. Make sure that the door upper is supported door. (Two piece doors only- if installed).
correctly.
11. If necessary the door catch assembly can be
5. To remove the hinge pin securing device, removed by removing the nuts, bolts and locking
depending on your machine, do one of the plate.
following actions:
09 - 23 9823/0300-1 09 - 23
18 - Door
03 - Lock
Figure 87. Two piece door assembly

C
F E
A Locking handle B Hinge assembly

C Hinge pin D Door- upper
E Door- lower F Door catch assembly
G Securing pin (or grub screw)
09 - 24 9823/0300-1 09 - 24
18 - Door
03 - Lock
Install
steps.
1.1. Lubricate the door hinge. Refer to (PIL
75-06).
Consumable: Extreme Performance Moly
Grease
09 - 25 9823/0300-1 09 - 25
18 - Door
12 - Handle
12 - Handle Figure 88.
Remove and Install A

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

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

lever.
5. Slightly tilt the handle unit to unhook the unit from
the door assembly. Retain the gasket and trim
plate.
E E
A Gasket
B Trim plate
C Latch assembly
D Handle- exterior
E Retaining screws
F Cover plate
Install
removal procedure.
09 - 26 9823/0300-1 09 - 26
27 - Controls
27 - Controls
Contents Page No.
09-27-27 Auxiliary Circuit .............................................................................................................. 09-29
09 - 27 9823/0300-1 09 - 27
Notes:
09 - 28 9823/0300-1 09 - 28
27 - Controls
27 - Auxiliary Circuit
Operation
WARNING Before operating the auxiliary control Figure 89.

system make sure that you are aware of all
safety notices that apply to the attachment you
are using. Also make sure you have installed the
attachment correctly and have read its operator's
manual.
General
The machine is installed with a hydraulic mode
switch and in combination with the control lever, this A
enables the operator to select and control 3 hydraulic
modes; AUX selection, bucket control system and
constant flow mode.
The machine is installed with one auxiliary circuit

(AUX I). A second circuit (AUX II) is available as B
an option. An optional trailer pickup hitch is also
available.
AUX I can be set to provide a constant flow to the

attachment connected. A Thumb switch
B Button - activate
To enable the operator to identify which auxiliary
mode is selected, the dash will display a series of
icons. Auxiliary I (AUX I)
1. Turn on the hitch/auxiliary selector switch, if
Before you operate the controls identify which
installed.
auxiliary mode is selected.
2. The dash should not display auxiliary symbol on
Single Lever Control the display.
The auxiliary control switch is a proportional roller 3. Roll the thumb switch forwards or backwards
type. It is spring loaded to it's central position. The depending on the attachment installed and the
speed of operation depends on how far the switch is function required.
moved.
Constant Flow Mode
When using motorised attachments for a prolonged
period (30min) a maximum constant flow of 65%
should be selected.

installed.
2. To activate the constant flow mode:
2.1. Set the hydraulic mode switch to position 2.
2.2. Press the button on the control lever, a
symbol will be displayed on the screen.
2.3. On selecting the button the constant
auxiliary system will resume to the speed
and direction previously stored.
2.4. Use the thumb switch to adjust the speed
and direction.
09 - 29 9823/0300-1 09 - 29
27 - Controls
2.5. The main screen will display the percentage Bucket Control System
of flow available.
2.6. When in constant flow mode, pressing the The bucket control system allows the operator to
button or moving the thumb switch will automatically oscillate the bucket, in order to assist
activate the display. Subsequent operations with the discharge of material.
of button, will activate and then deactivate
1. Set the hydraulic mode switch to position 3, a
constant flow mode.
symbol will be displayed on the screen.
3. The constant flow mode symbol on the screen
2. Press the button on the control lever.
will indicate the active and inactive mode.
3. Move the control lever to required direction.
4. Use the thumb switch to adjust the speed and
direction of the constant flow mode. The amount and type of oscillation will change
5. To exit the constant flow mode: depending on the distance or the direction selected
with the control lever, and the amount of engine revs
5.1. Press the button on the control lever. The used. The oscillation varies in the ways as follows:
symbol on the main display screen will go
grey. Figure 90.
5.2. Set the hydraulic mode switch to position 1. FM
C D
The symbol on the main display screen will
extinguish. A
B
Auxiliary II (AUX II) E

installed.
2. Set the hydraulic mode switch to position 1.
3. To enter the AUX II mode, press the button.
4. Roll the thumb switch forwards or backwards A Control lever direction
depending on the attachment installed and B Control lever direction
function required. E Button
5. To exit the AUX II, press the button. The symbol

on the main display screen will extinguish.
Table 16.
C band The bucket will oscillate with a larger amplitude, and tend to crowd more over
time. This has been designed for assisting the operator with flicking material up
and out of the bucket
D band The bucket will oscillate with a larger amplitude, and tend to dump more over
time. This has been designed for assisting the operator for discharging sticky
material
FM band Small amount of oscillation, the bucket will tend to oscillate around the original
position of the bucket (this will depend on the type and amount of material). This
has been designed to assist the operator with the fine metering of material
The oscillation will cease at any point when the

operator releases the button, but the bucket will
continue to move in the selected joystick direction.
09 - 30 9823/0300-1 09 - 30
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-03 Roof Trim ....................................................................................................................... 09-33

09-30-09 Dashboard ...................................................................................................................... 09-34
09 - 31 9823/0300-1 09 - 31
Notes:
09 - 32 9823/0300-1 09 - 32
30 - Trim Panel
03 - Roof Trim
03 - Roof Trim
Remove and Install

Notice: Take care during the removal and
replacement of the roof liner. Make sure your
hands and clothes are clean. The roof liner is
easily damaged.
Remove
2. With the aid of one more person hold the roof
liner and remove the screws.
3. Lower the liner to get access to the electrical
connectors at the interior lights and audio
speakers (if installed).
4. Disconnect the electrical connectors from the
interior lights and audio speakers.
5. Remove the roof liner.
6. Put the roof liner into a clean plastic bag and keep
it in a safe place. The roof liner is damaged easily.
Figure 91.
A A A A
C
C
D D
B
A A A
A Screws
B Roof liner
C Interior lights
D Audio speakers
Install
1. The installation procedure is the opposite of
step.
1.1. If seals are attached to the panel, make
sure they are in good condition. If damaged,
replace the seals.
09 - 33 9823/0300-1 09 - 33
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
16. Remove the screw 7, screw 8 and screw 9.

Remove 17. Remove the lower left hand panel.
Figure 92.
2. Remove the steering wheel. C C
3. Remove the two button head screws 1.
4. Remove the steering column lower surround.
5. Remove the two button head screws 2 and the D B D
two screws 1.
12
6. Remove the steering column upper surround.

9 3
7. Remove the two screws 2 that hold the centre

display panel in place, disconnect all connections
and remove the panel.
00: 00: 05
8. If the steer mode select switch has a lockable

surround, then remove it as follows.
-
8.1. Remove the two screws that secure the

steer mode select switch panel. A
8.2. Disconnect all connections and remove the
panel. A Button head screw 1
B Button head screw 2
8.3. Remove the steer mode control knob. C Screw 1
9. Remove the heater control panel. D Screw 2
Refer to: PIL 33-24. Figure 93.
10. Remove the radio (if installed).
11. Remove the right hand Instrument panel.
12. Remove the left hand switch panel.
13. Remove the centre display panel. E
14. Remove the screw 3, screw 4, screw 5 and screw
6 and then remove the upper right hand panel. F
Take care not to damage the harness when you
move it through the hole in the panel. E Steer mode select switch panel
F Steer mode control switch
15. The screw 5 is removed from the front of the
panel, i.e. the opposite side to that shown.
09 - 34 9823/0300-1 09 - 34
30 - Trim Panel
09 - Dashboard
Figure 94.
G Q H
M
N
G Screw 3 H Screw 4
J Screw 5 K Screw 6
L Screw 7 M Screw 8
N Screw 9 P Lower left hand panel
Q Upper right hand panel
09 - 35 9823/0300-1 09 - 35
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 36 9823/0300-1 09 - 36
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-39
09 - 37 9823/0300-1 09 - 37
Notes:
09 - 38 9823/0300-1 09 - 38
00 - General
00 - General
Health and Safety

WARNING Safety labels on the machine warn
you of particular hazards. You can be injured if
you do not obey the safety instructions shown.
The safety labels are strategically placed around the

machine to remind you of possible hazards.
If you need eye-glasses for reading, make sure you

wear them when reading the safety labels. Do not
over-stretch or put yourself in dangerous positions to
read the safety labels. If you do not understand the
hazard shown on the safety label, then refer to Safety
Label Identification.
Keep all of the safety labels clean and readable.

Replace a lost or damaged safety label. Make
sure the replacement parts include the safety labels
where necessary. Each safety label has a part
number printed on it, use this number to order a new
safety label from your JCB dealer.
09 - 39 9823/0300-1 09 - 39
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-41
09 - 40 9823/0300-1 09 - 40
36 - Steering Wheel
00 - General
00 - General 1.1. If the key becomes damaged during the

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

splined shaft.
3. Take out the steering wheel centre cap from the
wheel.
G
4. Remove the steering wheel securing nut.
5. Remove the washer.
6. Remove the steering wheel away from the
splined shaft.
7. Make sure to retain the key.
8. Remove the foam collar (if installed).
Figure 95.
A
B
H
C
G Column trim panel
H Foam collar
D
A Steering wheel center cap

B Steering wheel securing nut
C Washer
D Key
E Steering wheel
F Shaft
Install
steps.
09 - 41 9823/0300-1 09 - 41
44 - Sunblind
44 - Sunblind
Contents Page No.
09-44-00 General ........................................................................................................................... 09-43
09 - 42 9823/0300-1 09 - 42
44 - Sunblind
00 - General
00 - General
Remove and Install
Remove
2. Follow the general health and safety procedures.
3. Make sure that both the blinds are fully retracted.
4. Support the blinds.
5. Remove trim panel screws from each end of the
trim panel.
6. Detach the trim panel and remove the blind
assembly.
Figure 97.
A A
A Screws
B Trim panel
C Blind assembly
Install
removal procedure.
09 - 43 9823/0300-1 09 - 43
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-45
09 - 44 9823/0300-1 09 - 44
48 - Floor mat
03 - Front Floor mat
03 - Front Floor mat
Remove and Install
Remove
2. Remove the nuts and remove the pedal pads
from the machine.
3. Remove the bolts and the retaining plate.
4. Remove the screws and the kick strips.
5. Remove the trim retainers from the front section
of the mat.
6. Remove the mat from the machine.
Figure 98.
A
D E
C F
G D
A Pedal pads
B Nuts
C Kick strips
D Screws
E Bolts
F Retaining plate
G Trim retainers
Install
removal procedure.
09 - 45 9823/0300-1 09 - 45
Notes:
09 - 46 9823/0300-1 09 - 46
12 - Heating, Ventilating and
Air-Conditioning (HVAC)
Contents Page No.
12-00 Heating, Ventilating and Air-Conditioning (HVAC)

12-00-00 General ............................................................................................................................. 12-3
12-03 HVAC Unit
12-03-00 General ........................................................................................................................... 12-23
12-03-03 Evaporator ...................................................................................................................... 12-30
12-03-06 Pressure Switch ............................................................................................................. 12-31
12-03-09 Expansion Valve ............................................................................................................. 12-34
12-03-12 Blower Motor .................................................................................................................. 12-35
12-03-15 Thermostat ..................................................................................................................... 12-36
12-03-18 Heater Coil ..................................................................................................................... 12-37
12-04 Heater Unit
12-04-00 General ........................................................................................................................... 12-39
12-04-12 Blower Motor .................................................................................................................. 12-45
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-47
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-49
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-53
12-18 Filter
12-18-00 General ........................................................................................................................... 12-59
12-21 Heater Valve
12-21-00 General ........................................................................................................................... 12-61
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-65
9823/0300-1
2017-12-21
Acronyms Glossary
ECU Electronic Control Unit

FEAD Front End Accessory Drive
PAG Polyalkyline Glycol
RPM Revolutions Per Minute
9823/0300-1
2017-12-21
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9823/0300-1 12 - 1
Notes:
12 - 2 9823/0300-1 12 - 2
00 - General
Introduction ...................................................... 12-3 To maintain optimum operator comfort in warm
Health and Safety ........................................... 12-4 climates or during seasons of high ambient
Technical Data ................................................. 12-5 temperature, the air conditioning system delivers
Component Identification ................................. 12-6 cool, dehumidified air into the cab. Cooling is
provided by passing the warm ambient air, together
Fault-Finding .................................................... 12-9 with recirculated air, over an evaporator matrix in the
Discharge and Pressurise ............................. 12-12 air conditioning unit.
Check (Operation) ......................................... 12-15
Check (Pressure) .......................................... 12-19 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Adjust ............................................................ 12-19 changing from gas to liquid and back to gas again,
Lubricate ........................................................ 12-20 as it is forced through the system. The major
components of the system are the:
• Compressor
• Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9823/0300-1 12 - 3
00 - General
Health and Safety • DO NOT steam clean refrigerant system

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

is used and that charging is done only by
qualified personnel. It is illegal to discharge
the refrigerant into the atmosphere but as
a precaution in case of accidental leakage,
discharging and charging of the vehicle
refrigerant system must be conducted in a well-
ventilated area.
• Containers of refrigerant should be stored in a
cool environment away from direct sunlight.
• DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least
0.5m from hoses).
12 - 4 9823/0300-1 12 - 4
00 - General
Technical Data
Table 17. Binary pressure switch settings

Item Specification
Low pressure 2bar (29.0psi)
High pressure 26bar (376.8psi)
Table 18. Thermostatic switch settings

Item Specification
Cut out 0.2–1.4°C (32.4–34.5°F)
Cut in 3.4–4.8°C (38.1–40.6°F)
Table 19. Refrigerant

Item Specification
Type R134a gas
Charge amount (maxi- 1.3kg
mum)
(1)
Charge amount (maxi- 1.7kg

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

(2) Systems with roof mounted condenser.
Table 20. Oil

Item Specification
Type PAG (Polyalkyline Gly-
col) oil
Charge amount
(3)
-
Complete system 0.0426L
Condenser remove and 0.0284L
install
Evaporator remove and 0.0568L
install
Hoses remove and in- 0.0085L
stall
Receiver drier remove 0.0142L
and install
Compressor remove and None- pre charged
install
(3) The quantity of oil replaced should be the same
as that taken out during `Recovery' procedure.
12 - 5 9823/0300-1 12 - 5
00 - General
Heater Only
Figure 99.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 21.
E Heater Control panel
(1)
Item Description
A Heater and ventilation (1) A typical heater control panel is shown. Refer to
unit (HV) the applicable Operator Manual for machine specific
controls.
B Heater valve
C Electrical connector
12 - 6 9823/0300-1 12 - 6
00 - General
Machines with Air Conditioning
Figure 100.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 22.
pack mounted)
Item Description H Condenser (roof mount-
A TXV (Thermal Expan- ed) (Available as an op-
sion Valve) tion on some machines).
B Evaporator matrix (1) Typical heater control panel shown. Refer to
C Compressor the correct operator manual for machine specific
D FEAD (Front End Acces- controls.
sory Drive)
Table 23. Component Locations
E Heater/air conditioning
control panel
(1)
HVAC System Location (All Ma-
F Heater/air conditioning chines)
vents HVAC (Heating Venti- Fixed to cab (RHS)
lation Air Conditioning)
unit
TXV Part of HVAC unit
12 - 7 9823/0300-1 12 - 7
00 - General
HVAC System Location (All Ma-

chines)
Evaporator matrix Part of HVAC unit
Compressor Fixed to engine (RHS)
Binary switch Fixed to pipe next to
compressor
Receiver drier Fixed to chassis inside
engine compartment
Condenser - cooling Part of machine cooling
pack mount pack inside engine com-
partment
Condenser - roof mount Fixed to a frame fixed at
the rear of the cab roof.
Includes electric cooling
fans
12 - 8 9823/0300-1 12 - 8
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 24. Page 12-9
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 25. Page 12-9
Compressor clutch continually cuts out Table 26. Page 12-9
Poor performance- Compressor function tests Table 27. Page 12-10
Compressor not achieving 24 bar pressure Table 28. Page 12-10
No air conditioning Table 29. Page 12-10
Table 24. Poor performance (For system diagnosis using test gauges, refer to Check Operation, PIL
12-03)
Cause Remedy
Condenser matrix air flow restricted Remove debries from matrix using compressed air
HVAC (Heating Ventilation Air Conditioning) Unit air Refer to (PIL 12-18)
intake filter blocked
Compressor drive belt too slack Refer to (PIL 15-18)
Low system pressure Discharge and recharge the system
Table 25. Warm air or slightly cool air emitted from unit
Cause Remedy
Expansion valve stuck open or closed Renew expansion valve. Refer to (PIL 12-03)
Table 26. Compressor clutch continually cuts out

Cause Remedy
Condenser matrix blockage Remove debris from matrix or
Overcharging of refrigerant system Discharge and recharge the system. Refer to (PIL
12-00)
Blocked expansion valve or condenser Clear blocked component. Refer to (PIL 12-03)
Compressor fault Do compressor function tests. Refer to (PIL 12-03)
12 - 9 9823/0300-1 12 - 9
00 - General
Table 27. Poor performance- Compressor function tests

Cause Remedy
(1) Is the compressor rotation smooth? With the YES = Check (2), NO = Renew compressor
engine having been turned off for 5 minutes, turn
the compressor shaft by turning the armature plate
by hand. Check for smooth rotation. Grinding or
hanging during shaft rotation is caused by a broken
component within the compressor.
(2) Is the field coil receiving greater than 7.5 V? YES = Check (3), NO = Rectify electrical problem
This test should be conducted with the electrical
system on and clutch engaged. Unplug the electrical
connector and measure on the machine side.
(Reversing polarity will short diode resulting in blown
fuses).
(3) Is the field coil resistance between 3 and 4 ohms? YES = Check (4), NO = Renew compressor
Coil resistance out of this range will not engage
or will cause fused circuits to open. Unplug the
electrical connector, measure on compressor side.
(4) Is compressor capable of producing 24 bar or YES = Compressor is functioning correctly, No =
more? To check this do the pressure tests. Refer Follow the pressure fault finding table (Compressor
to (PIL 12-03). Excessive high pressure can be not achieving 24 bar pressure).
artificially produced by preventing air flow across
the condenser. Preventing air flow through the
condenser minimises heat removal from the system
resulting in high pressure.
Table 28. Compressor not achieving 24 bar pressure

Cause Remedy
Low refrigerant charge - possible leakage, suction TEST = Discharge and recharge the system,
and discharge pressure are low. ACTION = Repair leak & check system pressures
(Compressors with dirt/oil build up at hose
connections are most likely to have damaged 'O'
rings. Check for leaks and replace 'O' rings.
System high pressure side blockage - flow to the TEST = Check suction pressure is 0.35 bar or less,
compressor is stopped or limited. ACTION = Compressor is functioning correctly,
remove the system blockage.
Compressor failure - internal compressor damage. TEST = Suction pressure high, discharge pressure
low, do compressor function tests (See table 4),
Action = Renew compressor
Test performed below 10 ºC - Low ambient TEST = Move machine to area where temperature is
temperature limits pressure. higher, ACTION = Check system pressures
Table 29. No air conditioning

Cause Remedy
(1) Are the controls set correctly, i.e. air conditioning YES = Check (2), NO = Reset controls and retest
selected, heater control set to coldest position and
blower switched on?
(2) Is the air conditioning (evaporator) blower YES = Check (30), NO = Reset controls and retest
working?
(3) Is the compressor running (visual check of pulley/ YES = Check (10), NO = check (5)
clutch)?80 % or betetr
(4) Is the air conditioning fuse(s) blown? For details YES = Renew fuses and retest, NO = Check (9)
of the electrical circuit and connections, Refer to (PIL
33-00-50)
(5) Is there a 12V supply to the binary pressure YES = Check (6), NO = Check (7)
switch harness?
12 - 10 9823/0300-1 12 - 10
00 - General
Cause Remedy
(6) Does the compressor clutch engage with binary YES = Replace binary pressure switch assembly, NO
pressure switch assembly bypassed? = Check (8)
(7) Does the clutch engage with freeze thermostat YES = Renew freeze thermostat switch and retest,
switch bypassed? NO = Check all electrical connections.
(8) Is there a 12V supply at the compressor? YES = Renew the compressor clutch and re-test, NO
= Renew the compressor relay and re-test.
(9) Are blower switch and wiring OK? YES = Renew blower unit complete, NO = Renew
switch or wiring.
(10) Is the system correctly charged with refrigerant YES = Check (11), NO = Charge check required by
OK? refrigeration engineer or suitably trained person.
(11) Is condenser air flow blocked? YES = Clean condenser and radiator, NO = Check
(12).
(12) Is evaporator air flow blocked? YES = Clean/Replace HVAC Unit Air Intake filter.
Refer to (PIL 12-03), NO = If necessary replace the
evaporator. Call in refrigeration engineer or suitably
trained person.
12 - 11 9823/0300-1 12 - 11
00 - General
Discharge and Pressurise 10. Close the valves and remove all equipment.
Figure 101.
system should be disconnected until the system
or a suitably trained person. You can be severely
Refer to the Health and Safety section. Refer to: PIL

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

purity.
The JCB recommended Javac unit only recovers

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

A Low pressure hose (blue)
2. Make sure that the engine is OFF and the engine B High pressure hose (red)
is cool. C Hose (yellow)
D Filter
3. Remove the ignition key. E Javac unit
F Empty receiver bottle
4. Connect the manifold to the system with the blue
hose connected to the system low pressure port.
Do not connect the red hose. Make sure that both Evacuate
valves are closed.
This procedure follows on from the Recovery
5. Connect the yellow hose to the Javac unit filter. process and is necessary to make sure that the
system is correctly refilled with refrigerant. To avoid
6. Connect the filter to the Javac unit. leakage in the vacuum system itself, Do not use
extensions to the yellow hose (use standard 2 metre
7. Connect the Javac unit to an empty receiver length).
bottle. Weigh the bottle before and after filling to
assess the system capacity. Note: Do not fill the 1. Recover all refrigerant from the system, refer to
receiver bottle to more than 80% by weight. refrigerant recovery.
8. Switch on Javac unit and open the low pressure 2. Close all valves and connect the manifold.
manifold valve. Note: If the high pressure Connect the blue hose to the system low
warning light on the Javac unit comes on, throttle pressure port and the red hose to the high
back the manifold low pressure valve to provide pressure port.
a restriction.
3. Connect the yellow hose to the vacuum pump.
9. The Javac unit will automatically switch off when Note: If the Electronic vacuum gauge is used
a pressure balance exists between the system connected as shown. Refer to Electronic Vacuum
and the receiver bottle. Switch off Javac unit at Gauge for further information.
main switch, but leave the system connected.
Switch on after the specified time and the Javac 4. Open the manifold valves.
unit will restart if residual pressure remains.
5. Switch on the vacuum pump until 740mm (29
Duration: 10min in) mercury vacuum reads on both gauges.
12 - 12 9823/0300-1 12 - 12
00 - General
Note: achievable vacuum will vary with altitude. 6. Switch on the vacuum pump and open the high
Maximum gauge reading will be 25mm (1 in) less pressure side valve.
for every 305 metres (1000 feet) above sea level.
7. Unscrew the oil injector cap and add the specified
6. Maintain suction for approximately the specified quantity of refrigerant oil.
time. Note: If the vacuum falls rapidly the system
is leaking. Check all connections and reseal. If 8. When 740mm (29 in) mercury shows on the
the point of leakage is not obvious, recharge the vacuum gauge, open the oil injector valve to
system and test again. allow the oil into the system.
Duration: 30min 9. If more oil is needed repeat the above procedure.
The quantity of oil should be the same as that
7. Close the valves and remove all equipment. taken out during the Recovery procedure. Note:
Figure 102. Use only PAG oil in R-134a systems.
Figure 103.

B High pressure hose (red)
C Hose (yellow) F
D Vacuum pump
E Electronic vacuum gauge
B High pressure hose (red)
Re-lubricate C Hose (yellow)
D Vacuum pump
Re-lubrication is essential after recovering the
E Oil injector
system refrigerant, vacuuming and component
F Low pressure point
flushing. The system should be evacuated to a
vacuum of 740mm (29 in) of mercury before re-
lubricating. Charge
1. Make sure that the engine is OFF and the engine This procedure is the industry recommended
is cool. practice for refilling air conditioning systems with
refrigerant. Evacuate the system beforehand to
2. Remove the ignition key. 740mm (29 in) of mercury.
3. Close all valves and connect the manifold as 1. Close all valves and connect the manifold
shown, with the blue hose connected to the oil as shown. Connect the blue hose to system
injector and the red hose to the system high low pressure and the red hose to system
pressure port. high pressure. Connect the yellow hose to the
refrigerant cylinder.
4. Connect the yellow hose to the vacuum pump.
2. Invert the single valve cylinder on the scales and
5. Connect the other end of the oil injector to the zero the scale reading. Note: Some refrigerant
system low pressure point. cylinders have separate valves for gas and liquid.
12 - 13 9823/0300-1 12 - 13
00 - General
Be sure to connect to the liquid port when Figure 105.

following the above procedure. Note: Refrigerant
can be used either in gas or liquid form. If
recharging with gas follow the manufacturers
instructions and recharge only via the low
pressure port. Do not use liquid refrigerant at the
low pressure port.
3. Slowly open the high pressure valve and allow
the vacuum to draw-in refrigerant to the specified
weight for the system. Refer to Technical
Data. Add refrigerant until the scales indicate
the specified weight for the system or the
weight obtained when the system refrigerant
was previously recovered. Note: To speed up
the process a thermostatically controlled thermal
blanket can be used around the replenishing
cylinder.
4. Close all valves and remove the equipment.
Figure 104.
A396790
Table 30.
Gauge Reading Description
ATM/BAT Normal atmospheric
pressure reading. Bat-
tery condition.
15"/510mbar 381mm (15 in)Hg. Par-
tial vacuum- Vacuum
system is operating.
29"/980mbar 736mm (29 in)Hg. No
vacuum drawn- Possible
system leakage.
8000 8.0mm (0.31 in)Hg. Par-
tial vacuum - If the read-
ing does not progress
the system may have a
slow leak.
1000 1.0mm (0.039 in)Hg.
A Low pressure hose (blue) Deeper vacuum.
B High pressure hose (red) 600 0.6mm (0.023 in)Hg.
C Hose (yellow) Deep vacuum.
D Refrigerant cylinder 400 0.4mm (0.015 in)Hg.
E Scales Deep vacuum.
F Thermal blanket
200 0.2mm (0.0078 in)Hg.
Deep vacuum.
Electronic Vacuum Gauge
25 0.025mm (0.00098
The CPS VG100 vacuum gauge is an electronic type in)Hg. Pump Test. Max-
using LED's to indicate various states of vacuum. It imum sustainable vacu-
is used in place of or to supplement the gauge on the um.
vacuum pump. Before connecting into the system,
switch on to check that the first LED lights to show
that the battery is in good condition.
Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).
12 - 14 9823/0300-1 12 - 14
00 - General
Check (Operation)
Attach the manifold gauge block to the service ports

to check the condition of the air conditioning system.
Figure 106. Typical Installation

F G
A Manifold gauge block B Service ports

C Low pressure/temperature gas (Blue) D High pressure/temperature gas (Red)
E High pressure liquid F Low side(LS) gauge
G High side(HS) gauge
Normally functioning air conditioning the valves are closed and the readings are stable and
system the system has a full charge.
Normal gauge readings will depend on system

components and ambient conditions. Make sure that
Table 31. Normally functioning air conditioning system gauge readings

Ambient tempera- Relative humidi- Suction pressure Discharge pres- Vent temperature
ture ty(%) (Low side) sure (High side)
18°C (64.4°F) 55 1.32bar (19.1psi) 8.76bar (127.0psi) 8°C (46.4°F)
25°C (77.0°F) 55 1.53bar (22.2psi) 10.8bar (156.5psi) 8.8°C (47.8°F)
12 - 15 9823/0300-1 12 - 15
00 - General
The pressures on the manifold at 25°C (77.0°F) No refrigerant circulation

and 55% relative humidity with the engine at
1500 RPM (Revolutions Per Minute), the blower
on maximum, the heater turned off with the door Table 34.
closed and 10minallowed for stabilisation, should be
Gauge Pressure
approximately 1.53bar (22.2psi) for the low side and
10.8bar (156.5psi) for the high side. Generally the Low side (LS) Zero to negative (-1bar
high pressure is 6 to 8 times more than the low (-14.5psi))
pressure. High side (HS) Low (5.4bar (78.3psi))
Low R-134a Charge Other symptoms
Table 32. Receiver Drier- Frost or moisture on tubes before

and after receiver-drier.
Gauge Pressure
Low side (LS) Low (0.5bar (7.2psi)) Reason
High side (HS) Low (9.8bar (142.0psi))
Refrigerant flow obstructed by dirt, moisture or gas
Reason leakage from expansion valve heat sensing tube.
System slightly low on R-134a, due to leak or Remedy

incorrect charge.
1. Discharge the air conditioning system.
Remedy 2. Check heat sensing tube at expansion valve.
Replace expansion valve if necessary.
1. Leak test the system.
3. Remove expansion valve and try to remove dirt. If
dirt cannot be removed, replace expansion valve.
3. Repair system leaks.
4. Replace receiver drier.
4. Charge system with R-134a.
5. Operate system and check performance.
Poor refrigerant circulation Insufficient cooling of condenser or
Table 33. refrigerant over charge
Gauge Pressure
Low side (LS) Zero to negative (-1bar Table 35.
(-14.5psi)) Gauge Pressure
High side (HS) Low (5.4bar (78.3psi)) Low side (LS) High (13bar (188.4psi))
High side (HS) High ( 22.1bar
Other symptoms (320.3psi))
Receiver Drier- Frost on tubes from receiver-drier to
evaporator unit. Reason
Refrigerant overcharge, condenser cooling fins
Reason clogged with dirt or cooling fans malfunctioning.
Refrigerant flow blocked by dirt, receiver-drier
clogged. Remedy
1. Clean the condenser cooling fins.
Remedy
2. Check the cooling fan operation.
2. Replace the receiver-drier.
12 - 16 9823/0300-1 12 - 16
00 - General
Air in system 4. Charge system with R-134a.

Table 36.
Gauge Pressure
Compressor malfunction
Low side (LS) High (2.8bar (40.6psi)) Table 38.
Gauge Pressure
(320.3psi))
Low side (LS) High (4.9bar (71.0psi))
Other symptoms High side (HS) High ( 8.3bar (120.3psi))
Pipes- Low pressure pipes are hot to the touch. Reason
Reason Internal compressor leak or compressor

mechanically broken.
Air is present in the system, possible from
inadequate discharge procedure. Remedy
Remedy 1. Discharge the air conditioning system.
1. Discharge the air conditioning system. 2. Repair or replace compressor.
2. Check compressor oil for contamination. Check 3. Charge system with R-134a.
compressor for proper oil amount. Correct if
necessary.
3. Charge system with R-134a. Some moisture in the system
4. Operate system and check performance. Table 39.
Gauge Pressure
Expansion valve improperly mounted
Low side (LS) Normal, then some-
times drops to below ze-
Table 37. ro (-2.1bar (-30.4psi))
High side (HS) Normal, then sometimes
Gauge Pressure
goes high ( 14.8bar
Low side (LS) High (3.5bar (50.7psi)) (214.5psi))
(320.3psi)) Reason
Other symptoms Moisture in system freezes, temporarily stopping
cycle, normal system operation returns when ice
Pipes- Large amount of frost on low side pipes. melts.
Reason Remedy
Excessive refrigerant in low side pipes possible from 1. Discharge the air conditioning system.
expansion valve being opened too wide.
2. Replace receiver-drier.
Remedy 3. Remove moisture by repeatedly evacuating
1. Leak test the system. system.
2. Discharge the air conditioning system. 4. Charge system with R-134a.
3. Repair system leaks. 5. Operate system and check performance.
12 - 17 9823/0300-1 12 - 17
00 - General
Table 40. Further diagnosis table

High pressure Low pressure Cycle Engage Disengage Possible cause
Too high Too low Compressor running continuously Condenser dirty
Too high Normal to too Compressor running continuously Engine over-
high heating
Normal to too Normal Compressor running continuously Air or foreign
high matter in system
or excess refrig-
erant.
Too high Too high Too fast Too short Normal Excess refriger-
ant
Normal to too Normal Too slow or too Too long or con- Normal or non- Dirt or excess
low low tinuously existent refrigerant oil in
circuit
Normal to too Too high Too fast Too short Normal Faulty thermo-
low stat
Normal to too Too high Compressor running continuously Compressor
low faulty
Normal to too Normal to too Compressor running continuously Low pressure
low high line blocked
Normal to too Normal Too fast Too short Normal Evaporator
low blocked
Normal to too Normal Too fast Too short Too short Insufficient re-
low frigerant
Normal to too Normal Too fast Too short Too long Evaporator feed
low line blocked
12 - 18 9823/0300-1 12 - 18
00 - General
Check (Pressure) Adjust

Air Conditioning Maintenance For compressor drive belt adjustment, please see
The air conditioning system is a closed loop system (PIL 15-18).
or a suitably trained person. You can be severely
WARNING! Leak testing of Air Conditioning systems
should only be carried out in well ventilated areas.
The refrigerant is heavier than air and will leak

downwards from the defective component. Check in
a well ventilated area.
Hose or pipe connections are likely leakage points of

any refrigerant circuit.
It is essential that an electronic leak detector is used

to locate leaks accurately. However, if a leak detector
is not available, an approximate source can be found
by applying soap solution to the suspect area.
To test for leaks in the high pressure side of

the system i.e. from the compressor output to the
expansion valve, run the air conditioning for a few
minutes then switch off the engine and test for
leakage using an electronic leak detector or soapy
water.
To test for leakage in the low pressure side of the

system, switch off the air conditioning and leave for
a new minutes before you do the test.
Tightening leaking hoses

The refrigerant hoses have crimped ferrule end
fittings. The hose connectors have an O-ring seal
which compresses when the connection is tight and
create an air tight seal.
Hoses are used to connect the inlets and outlets

of the compressor, condenser, receiver drier and
expansion valve (the evaporator coil is connected to
the expansion valve within the air conditioning unit
using rigid pipes).
If leakage is detected from a hose connector, either

by means of an electronic leak detector or soapy
water, tighten the connector up and repeat the
leakage test. If leakage is still evident, it will be
necessary to discharge the system and renew the
connector O-ring seal.
12 - 19 9823/0300-1 12 - 19
00 - General
Lubricate
Refer to discharge and pressurise (PIL 12-03-00).
12 - 20 9823/0300-1 12 - 20
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-00 General ........................................................................................................................... 12-23

12-03-03 Evaporator ...................................................................................................................... 12-30
12-03-06 Pressure Switch ............................................................................................................. 12-31
12-03-09 Expansion Valve ............................................................................................................. 12-34
12-03-12 Blower Motor .................................................................................................................. 12-35
12-03-15 Thermostat ..................................................................................................................... 12-36
12-03-18 Heater Coil ..................................................................................................................... 12-37
12 - 21 9823/0300-1 12 - 21
Notes:
12 - 22 9823/0300-1 12 - 22
03 - HVAC Unit
00 - General
00 - General Operation
Operation ....................................................... 12-23 The air conditioning system is a closed circuit
Operation (Electrical) ..................................... 12-27 through which the refrigerant is circulated, its state
Diagram ......................................................... 12-29 changing from gas to liquid and back to gas again,
as it is forced through the system.
The major components of the system are as follows.
• Compressor
• Receiver drier
• Binary pressure switch
• TXV (Thermal Expansion Valve)
Operate the air conditioning as described in the

operator manual.
Air conditioning system power is generated from

the engine, through an electromagnetic clutch to
the compressor. Switches, connected in series, are
included in the clutch supply line, all must be closed
for the clutch and therefore the air conditioning
system to operate.
The compressor draws in low pressure refrigerant

gas from the suction line (evaporator to
compressor) and increases refrigerant pressure
through compression. This process also increases
the refrigerant temperature.
High pressure refrigerant is forced from the

compressor to the condenser. Ambient air is drawn
across the condenser by the engine- driven cooling
fan. In the condenser, the refrigerant changes state
to a high pressure, high temperature liquid but with
a lower heat content.
The refrigerant passes through the receiver drier,

which contains a desiccant to remove moisture from
the system. The receiver drier serves as a tank for
refrigerant and also includes a filter to remove foreign
particles from the system.
12 - 23 9823/0300-1 12 - 23
03 - HVAC Unit
00 - General
Figure 107. valve. If the air conditioning system has been left
open or has been leaking for a prolonged period of
F time, the desiccant will become saturated and the
E
receiver drier will need to be replaced with new one.
The high temperature, high pressure refrigerant

is forced by compressor action into the TXV,
which meters the amount of refrigerant entering
the evaporator. In the TXV the refrigerant
B instantaneously expands to become a low pressure,
low temperature liquid.
The refrigerant is drawn through the evaporator

matrix by the suction of the compressor. The
temperature of refrigerant is now considerably below
that of the air being drawn across the evaporator
A C matrix by the blowers. Heat is transferred from the
D
ambient and re circulated air to the refrigerant,
A Compressor causing the low pressure liquid to vaporise and
B Condenser matrix become a low pressure gas. Moisture in the air
C Receiver drier condenses on the evaporator matrix and is drained
D Binary pressure switch away through condensate.
E TXV
F Evaporator matrix Cool de-humidified air is emitted through air vents
into the cab.
The receiver drier can only hold a limited amount of
moisture, additional moisture can lead to icing and The low temperature, low pressure, high heat
ultimately blockage of the thermostatic expansion content refrigerant gas, is now drawn by suction back
to the compressor, where the cycle is completed.
Figure 108.
X F Y
C E A
A Compressor B Condenser matrix

C Receiver drier D Binary pressure switch
E TXV F Evaporator matrix
X Refrigerant is in liquid state Y Refrigerant is in gas state
12 - 24 9823/0300-1 12 - 24
03 - HVAC Unit
00 - General
System control 2. The high and low level binary pressure switch
located in the pipework near to the compressor.
The system is a manual control type and is set to on This switch is not adjustable.
or off by switch. There is no automatic control of the
cab air temperature. 3. The freeze protection thermostat switch located
inside the HVAC (Heating Ventilation Air
Refrigerated air will be heated by the heater matrix If Conditioning) unit. This switch is not adjustable.
the heater control is not set to ‘cold’.
When the air conditioning switch is set to on
You can control the system by activating and the refrigeration system is active. The system
deactivating the compressor electromagnetic clutch. operates within fixed temperature and pressure limits
When current is fed to the field coil of the compressor controlled by the freeze protection thermostat switch
clutch, a magnetic field develops between the field and the binary pressure switch. The system does not
coil and the armature which pulls the field coil, respond to changes in the cab air temperature.
complete with clutch assembly, onto the compressor
rotor. Since the clutch assembly is turned constantly If the compressor runs continuously condensate
by the crankshaft pulley drive belt, the compressor on the evaporator matrix will freeze and the
armature turns, starting the refrigeration cycle. system will not be effective. The freeze protection
thermostat switch has its sensor probe installed
Current is fed to the field coil through a series of in the evaporator matrix. When the temperature
switches. of the probe is near 0°C (32.0°F) the thermostat
switch contacts open. The compressor clutch
1. The manual air conditioning on/off switch in the disengages, closing down the refrigeration cycle.
control console. As the temperature of the probe increases the
thermostat switch contacts close. The compressor
clutch engages and refrigeration re-starts.
12 - 25 9823/0300-1 12 - 25
03 - HVAC Unit
00 - General
Figure 109.
D Binary pressure switch G Manual air conditioning on/off switch

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

pressure limit or falls below the lower limit,
the contacts of the binary switch open and the
compressor clutch disengages, closing down the
refrigeration cycle.
12 - 26 9823/0300-1 12 - 26
03 - HVAC Unit
00 - General
Operation (Electrical)
The schematic shown is for illustration purposes only.

For electrical details of individual devices refer to (PIL
33-12).
Figure 110.
P049
RC01
RC15 RC13 1
12
P049 P015
RC01
RC16 RC14 1
15
F
P015
7 8
1
2 J1-3
3 A 1K J2-5
ECU
J1-15
P071/72
P019 P042
P039
C004
12
P033
E024-1
P039
E024-2 C004
SE03
35
E025
A Resistor E024-1 Binary switch 1
12 - 27 9823/0300-1 12 - 27
03 - HVAC Unit
00 - General
E024-2 Binary switch 2 E025 Air conditioning compressor

F Secondary fuse P015 Condenser fans 1 and 2 relay
P019 Heater fan/air conditioning on/off P033 Heater connector
switch
P039-C004 Panel harness to chassis harness P042 Freeze valve relay
connector 3
P049-RC01 Panel harness to rear cab harness P071-72 Right hand display cluster ECU
connector (Electronic Control Unit)
RC13-15 Roof air conditioning condenser RC14-16 Roof air conditioning condenser
fan 1 fan 2
12 - 28 9823/0300-1 12 - 28
03 - HVAC Unit
00 - General
Diagram
Figure 111. Connector Pins
7 8
A 3.3K ECU
1 J2-18
2
3
2
4 J1-15 J2-9
5
A
6 2K
FUSE
2 3
A+ 2 1
+
ECU MODULE 3PWM
B- 4+
4 1
3
2
3
1 Heater blower switch 2 RHC ECU (Electronic Control Unit)

3 Blower fan motor 4 Linear driver
A Resistor
12 - 29 9823/0300-1 12 - 29
03 - HVAC Unit
03 - Evaporator
03 - Evaporator
Introduction
The evaporator works in the opposite way as the

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

Ventilation Air Conditioning) unit.
12 - 30 9823/0300-1 12 - 30
03 - HVAC Unit
06 - Pressure Switch
06 - Pressure Switch Introduction

Introduction .................................................... 12-31 The binary pressure switch assembly has a low and
Check (Operation) ......................................... 12-32 high pressure switch designed to operate at specified
Remove and Install ....................................... 12-33 pressure values.
When the refrigerant pressure is within the specified

limits, the pressure switches will be closed and if the
thermostat and on/of switches are closed, current
will be supplied to the field coil of the clutch. Due
to the electromagnetic action the field coil clutch will
be pulled towards the compressor's clutch and the
refrigeration cycle will start.
12 - 31 9823/0300-1 12 - 31
03 - HVAC Unit
Check (Operation) Figure 112.
Air-Conditioning Binary Switch

The binary pressure switch is located in the
air conditioning system pipework. Refer to HVAC
(Heating Ventilation Air Conditioning)- HVAC unit,
refer to (PIL 12-03).
Before testing the binary pressure switch, check the

refrigerant charge level. If the refrigerant charge level
is satisfactory, test the switch as described below:
1. Park the machine and make it safe. Refer to (PIL

01-03).
2. Follow the general safety precautions. Refer to
(PIL 01-03).
3. Switch off the engine and remove the harness
connectors from the pressure switch.
4. Connect a link wire between the two harness
connectors (effectively bypassing the pressure
switch).
5. Switch on the engine and air conditioning
system. If the system operates, one of the
switches inside the binary pressure switch
assembly is faulty.
6. Install new pressure switch assembly. If the
clutch still fails to operate, check the harness A Binary pressure switch
electrical wiring for damage and open or short B Harness connectors
circuits.
12 - 32 9823/0300-1 12 - 32
03 - HVAC Unit
Remove and Install Install

1. Screw the pressure switch into the threaded port
and tighten sufficiently to form a gas-tight seal.
and contains pressurised refrigerant. No part of the 2. Connect the harness connectors.
has been discharged by a refrigeration engineer 3. Charge the air conditioning system. Refer to (PIL
or a suitably trained person. You can be severely 12-03).
frostbitten or injured by escaping refrigerant. 4. Operate the air conditioning system and check
CAUTION! When working on the HVAC System around the pressure switch for leaks.
gloves, eye protection and protective clothing must
be worn. Refrigerant may be released which can be 4.1. If leaks are found, tighten the pressure
harmful to your skin or eyes. switch further until the leaking stops.
Remove
1. Make the machine safe with the lift arm lowered.
2. Discharge the air conditioning system. Refer to
(PIL 12-03).
3. Remove the harness connectors.
4. Remove the screws and then remove the
pressure switch assembly.
Figure 113.
A Pressure switch
B Harness connectors
12 - 33 9823/0300-1 12 - 33
03 - HVAC Unit
09 - Expansion Valve
09 - Expansion Valve
Introduction
The purpose of the expansion valve is to remove

pressure from the liquid refrigerant and to allow the
refrigerant to change from liquid to vapour in the
evaporator. The expansion valve is located in the
HVAC unit.
12 - 34 9823/0300-1 12 - 34
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 41. Page 12-35
Blower does not operate Table 42. Page 12-35
Table 41. Blower operates on fan speed 3 only

Cause Remedy
Blower resistor defective. Install new resistor
Blower motor defective. Remove and install new blower motor unit.
Table 42. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 35 9823/0300-1 12 - 35
03 - HVAC Unit
15 - Thermostat
15 - Thermostat Figure 115.
Remove and Install F
Remove
3. Remove the heater blanking plate.
4. Put label and disconnect the electrical
connections from the heater assembly.
5. Put label on the air condition hoses to help
installation.
C
6. Disconnect the hoses.
7. Support and remove the set screws attaching the
heater unit to the heater mounting plates.
C Heater unit
8. Carefully remove the heater unit from the F Thermostat
machine.
9. Carefully remove the thermostat and the Install
thermostat sensor from the heater unit. Note the
routing of the sensor probe. Do not make sharp 1. The installation procedure is the opposite of the
bends in the sensor probe. removal procedure. Additionally do the following
steps.
Figure 114.
1.1. If a new thermostat is to be installed,
carefully remove the protective sleeve from
E the new sensor. Do not make sharp bends
in the sensor probe.
1.2. Make sure that the heater cover sealing
gasket locates correctly.
B
D C
A Bolt
B Heater blanking plate
C Heater unit
D Heater mounting plate
E Set screw
12 - 36 9823/0300-1 12 - 36
03 - HVAC Unit
18 - Heater Coil
18 - Heater Coil
Introduction
The heater coil is a tube and fin construction, with the

inlet and outlet on one end of the coil. Hoses connect
the coil to the engine.
The heat energy for heating cab air comes from the
hot engine coolant. The heater systems are designed
to transfer heat energy from the engine coolant to the
air in the cab.
12 - 37 9823/0300-1 12 - 37
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-39

12-04-12 Blower Motor .................................................................................................................. 12-45
12 - 38 9823/0300-1 12 - 38
04 - Heater Unit
00 - General
Operation ....................................................... 12-39 Fresh air is supplied to the cab interior through the
Diagram ......................................................... 12-43 cab air vents. The heater and ventilation unit (HV)
Fault-Finding .................................................. 12-44 uses a blower fan to increase the air speed. The
air can also be heated by the heat exchange matrix
housed within the HV unit.
On machines with air conditioning, the unit also

houses the air conditioning evaporator matrix to
become a combined HVAC (Heating Ventilation Air
Conditioning) unit. Refer to (PIL 12-03).
The machine operator can control the air

temperature and speed from within the cab on the
heater control panel. For operation of the heater
controls refer to the applicable Operator Manual.
The operator uses the fan speed switch to select

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

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

through which the refrigerant is circulated, its state
changing from gas to liquid and back to gas again,
as it is forced through the system.
The major components of the system are as follows.
• Compressor
• Receiver drier
• Binary pressure switch
• TXV (Thermal Expansion Valve)
Operate the air conditioning as described in the

operator manual.
Air conditioning system power is generated from

the engine, through an electromagnetic clutch to
the compressor. Switches, connected in series, are
included in the clutch supply line, all must be closed
for the clutch and therefore the air conditioning
system to operate.
The compressor draws in low pressure refrigerant

gas from the suction line (evaporator to
compressor) and increases refrigerant pressure
through compression. This process also increases
the refrigerant temperature.
High pressure refrigerant is forced from the

compressor to the condenser. Ambient air is drawn
across the condenser by the engine- driven cooling
12 - 39 9823/0300-1 12 - 39
04 - Heater Unit
00 - General
fan. In the condenser, the refrigerant changes state The receiver drier can only hold a limited amount of
to a high pressure, high temperature liquid but with moisture, additional moisture can lead to icing and
a lower heat content. ultimately blockage of the thermostatic expansion
valve. If the air conditioning system has been left
The refrigerant passes through the receiver drier, open or has been leaking for a prolonged period of
which contains a desiccant to remove moisture from time, the desiccant will become saturated and the
the system. The receiver drier serves as a tank for receiver drier will need to be replaced with new one.
refrigerant and also includes a filter to remove foreign
particles from the system. The high temperature, high pressure refrigerant
is forced by compressor action into the TXV,
Figure 116. which meters the amount of refrigerant entering
the evaporator. In the TXV the refrigerant
E F instantaneously expands to become a low pressure,
low temperature liquid.
The refrigerant is drawn through the evaporator

matrix by the suction of the compressor. The
temperature of refrigerant is now considerably below
that of the air being drawn across the evaporator
B matrix by the blowers. Heat is transferred from the
ambient and re circulated air to the refrigerant,
causing the low pressure liquid to vaporise and
become a low pressure gas. Moisture in the air
condenses on the evaporator matrix and is drained
away through condensate.
A C Cool de-humidified air is emitted through air vents

D
into the cab.
A Compressor
B Condenser matrix The low temperature, low pressure, high heat
C Receiver drier content refrigerant gas, is now drawn by suction back
D Binary pressure switch to the compressor, where the cycle is completed.
E TXV
F Evaporator matrix
Figure 117.
X F Y
C E A
12 - 40 9823/0300-1 12 - 40
04 - Heater Unit
00 - General
A Compressor B Condenser matrix

C Receiver drier D Binary pressure switch
E TXV F Evaporator matrix
X Refrigerant is in liquid state Y Refrigerant is in gas state
System control 2. The high and low level binary pressure switch
located in the pipework near to the compressor.
The system is a manual control type and is set to on This switch is not adjustable.
or off by switch. There is no automatic control of the
cab air temperature. 3. The freeze protection thermostat switch located
inside the HVAC unit. This switch is not
Refrigerated air will be heated by the heater matrix If adjustable.
the heater control is not set to ‘cold’.
When the air conditioning switch is set to on
You can control the system by activating and the refrigeration system is active. The system
deactivating the compressor electromagnetic clutch. operates within fixed temperature and pressure limits
When current is fed to the field coil of the compressor controlled by the freeze protection thermostat switch
clutch, a magnetic field develops between the field and the binary pressure switch. The system does not
coil and the armature which pulls the field coil, respond to changes in the cab air temperature.
complete with clutch assembly, onto the compressor
rotor. Since the clutch assembly is turned constantly If the compressor runs continuously condensate
by the crankshaft pulley drive belt, the compressor on the evaporator matrix will freeze and the
armature turns, starting the refrigeration cycle. system will not be effective. The freeze protection
thermostat switch has its sensor probe installed
Current is fed to the field coil through a series of in the evaporator matrix. When the temperature
switches. of the probe is near 0°C (32.0°F) the thermostat
switch contacts open. The compressor clutch
1. The manual air conditioning on/off switch in the disengages, closing down the refrigeration cycle.
control console. As the temperature of the probe increases the
thermostat switch contacts close. The compressor
clutch engages and refrigeration re-starts.
12 - 41 9823/0300-1 12 - 41
04 - Heater Unit
00 - General
Figure 118.
D Binary pressure switch G Manual air conditioning on/off switch

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

pressure limit or falls below the lower limit,
the contacts of the binary switch open and the
compressor clutch disengages, closing down the
refrigeration cycle.
12 - 42 9823/0300-1 12 - 42
04 - Heater Unit
00 - General
Diagram
Figure 119.
SP19
P60
SP20 L
P04 M
H
P49
P33
P36
P33 Heater connector P36 Earth point

P49 Heater fan speed switch P60 Heater fan on/off switch
P04 Secondary fuse box C
12 - 43 9823/0300-1 12 - 43
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 43. Page 12-44
Blower does not operate Table 44. Page 12-44
Table 43. Blower operates on fan speed(3) only

Cause Remedy
Blower resistor failed Replace the resistor.
Blower motor failed Replace the complete blower motor unit.
Table 44. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 44 9823/0300-1 12 - 44
04 - Heater Unit
12 - Blower Motor
12 - Blower Motor
Figure 120.
C
A
D
E
A HVAC (Heating Ventilation Air Conditioning) unit B Blower fan motor

C HVAC cover D Fan motor linear driver
E Electrical connector
12 - 45 9823/0300-1 12 - 45
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-47
12 - 46 9823/0300-1 12 - 46
09 - Compressor
00 - General
00 - General
Introduction
The compressor is located at the front of the engine,

it is the heart of the air conditioning system since it
produces the refrigerant flow.
The compressor is driven by the engine drive belt.
Refer to Component Identification.
12 - 47 9823/0300-1 12 - 47
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-49
12 - 48 9823/0300-1 12 - 48
12 - Receiver Drier
00 - General
Introduction .................................................... 12-49 The Receiver/Drier is a device that removes
Check (Condition) .......................................... 12-50 moisture from the refrigerant as well as filtering any
contaminants or particulates from it. It also acts as a
tank to store excess coolant.
Refer to Component Identification. Refer to: PIL

12-00-00.
12 - 49 9823/0300-1 12 - 49
12 - Receiver Drier
00 - General
Check (Condition) Figure 122.

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

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

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

of charging. Some slight bubbling is to be
expected when R134a refrigerant is used. Refer
to Figure 122.
12 - 50 9823/0300-1 12 - 50
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-53
12 - 51 9823/0300-1 12 - 51
Notes:
12 - 52 9823/0300-1 12 - 52
15 - Condenser
00 - General
Introduction .................................................... 12-53 A condenser is a component used to condense
Clean ............................................................. 12-54 a substance from its gaseous to its liquid state,
Check (Condition) .......................................... 12-54 typically by cooling it. In so doing the latent heat is
Remove and Install ....................................... 12-55 given up by the substance, and will transfer to the
condenser coolant.
12 - 53 9823/0300-1 12 - 53
15 - Condenser
00 - General
Clean Check (Condition)
When you are cleaning take extra care not to damage 1. Inspect the condenser coil for a build of dirt. If
the condenser fins or tubes. Damaged fins must necessary, clean the condenser coil.
be straightened out to make sure of a good airflow Refer to: PIL 12-15-00.
through the coil.
2. Inspect the condenser fins or tubes for damage.
1. Make the machine safe. Straighten out the damaged fins and make sure
Refer to: PIL 01-03. of a good airflow through the coil.
2. Raise the grille at the rear of the machine. The working environment of the machine can build
up airborne particles on the condenser coil over a
3. Use compressed air or low pressure water to period of time. This restricts the airflow around the
back flow through the coil fins. Make sure that the condenser coil and reduces the heat dissipation from
fins are not damaged. the refrigerant to the air. This results in poor air
conditioning performance.
4. Start the HVAC (Heating Ventilation Air
Conditioning) system and check the cooling The heavy build up on the condenser coil leads to
performance. over pressurisation of the system. This can cause
the high pressure cut-out switch to operate and
switch off the system. The internal blockage of the
condenser coil can also operate the high pressure
cut-out switch.
12 - 54 9823/0300-1 12 - 54
15 - Condenser
00 - General
Remove and Install 8. Disconnect the harness connector.

9. Disconnect both the pipes from the condenser.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting Figure 125.
local regulations.
D
Remove F
CAUTION This component is heavy. It must only E
method and device.
To remove the complete air conditioning unit,

evacuate the refrigerant.
H
G J
2. Discharge the air conditioning system. Refer to
(PIL 12-03). D Pipes
E Cable ties
F Nuts
3. Support the protective cover and remove the G Worklight harness
fasteners. Lower the cover to the ground. H Bolt 1
J Clamp
4. Clean the condenser. Brush off all debris from the
tubes and fins using a soft bristle brush. 10. Using lifting equipment support the weight of the
condenser unit.
Figure 124.
11. Unscrew the condenser support nuts and bolts 2.
A
12. Lift the condenser unit and support bracket clear
of the machine.
13. Remove the screws and lift the support bracket
from the condenser unit.
B
Figure 126.
K
A Condenser
B Protective cover
C Fasteners
5. Cut the cable ties and release the worklight
harness.
6. Remove the worklight securing screws and lift
the lights and brackets clear of the machine.
6.1. To prevent damage to the worklights
or harness when lifting or installing the K Harness connector
condenser unit, make sure that the lights
and harness are out of the way
7. Remove the bolt 1 securing the pipe clamp.
12 - 55 9823/0300-1 12 - 55
15 - Condenser
00 - General
Figure 127.
N
P
L
L Bolts 2
M Screws
N Condenser unit
P Support bracket
Install
step:
1.1. Recharge the air conditioning system and
check for leaks.
12 - 56 9823/0300-1 12 - 56
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-59
12 - 57 9823/0300-1 12 - 57
Notes:
12 - 58 9823/0300-1 12 - 58
18 - Filter
00 - General
00 - General
Introduction
CAUTION The filter may be filled with dust. Wear
goggles and a face mask when removing the filter.
The air conditioning filter assemblies are designed to

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

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

cleaning/changing more often than detailed in the
maintenance schedule.
12 - 59 9823/0300-1 12 - 59
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-61
12 - 60 9823/0300-1 12 - 60
21 - Heater Valve
00 - General
00 - General
Remove and Install
The cab heater valve is part of the heater assembly 5. Align the marks on the control cable outer and
installed on the external part of the cab. the valve body.
6. Remove the clip 1.
Remove
7. Be careful, when you remove the hoses from the
valve, some amount of engine coolant will leak.
8. Loosen the clip 2 and remove the hoses from the
2. Remove the ignition key. valve.
3. If the engine is hot let it cool for one hour. 9. Disconnect the control cable from the valve lever.
4. Secure the heater hoses with clamps.
Figure 128.
A
C
D
E
G
H
B
B
F
A Cab heater valve B Heater hoses

C Control cable outer D Valve body
E Clip 1 F Clip 2
G Control cable H Valve lever.
12 - 61 9823/0300-1 12 - 61
21 - Heater Valve
00 - General
Install
steps.
1.1. Align the marks on the control cable outer
and valve body and then install a new clip 1.
1.2. Check the level of the engine coolant.
After installation
1. Start the engine and operate the cab heater at
the maximum temperature.
2. Operate the engine for the specified time.
Duration: 5min
3. Stop the engine and check for any coolant leaks.
12 - 62 9823/0300-1 12 - 62
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-65
12 - 63 9823/0300-1 12 - 63
Notes:
12 - 64 9823/0300-1 12 - 64
96 - Pipe
00 - General
Introduction .................................................... 12-65 The refrigeration pipes are responsible for carrying
Check (Condition) .......................................... 12-66 the refrigerant ( liquid and gas) around the closed
loop air conditioning system. There are usually 4
pipes that connect the system components:
• Suction Line-Evaporator to Compressor, the

low pressure refrigerant gas line.
• Discharge Line-Compressor to Condensor, the
high pressure, hot gas line coming out of the
compressor.
• Condenser drain line-Condensor to Receiver
drier
• Liquid line-Receiver drier to Evaporator
12 - 65 9823/0300-1 12 - 65
96 - Pipe
00 - General
Check (Condition)
2. Check all the visible pipes and connectors.
3. Look for areas where the hoses flex or are
fastened, clamped, connected, bent or go
through panels. All these areas are potential
wear and damage points.
4. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
5. Tighten the pipes and adaptors to the correct
torque value.
12 - 66 9823/0300-1 12 - 66
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-23
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-29
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-35
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-41
15-12-03 Main Bearing .................................................................................................................. 15-45
15-12-06 Front Oil Seal ................................................................................................................. 15-49
15-12-12 Pulley .............................................................................................................................. 15-52
15-12-15 Phonic Wheel ................................................................................................................. 15-53
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-55
15-18 Engine Belt
15-18-03 Drive Belt ....................................................................................................................... 15-61
15-18-21 Tensioner ........................................................................................................................ 15-63
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-65
15-24 Air Filter
15-24-00 General ........................................................................................................................... 15-73
15-24-03 Outer Element ................................................................................................................ 15-77
15-24-09 Dust Valve ...................................................................................................................... 15-78
15-27 Crankcase Ventilation Filter
15-27-00 General ........................................................................................................................... 15-81
15-30 Valve
15-30-00 General ........................................................................................................................... 15-87
15-30-09 Valve Bridge ................................................................................................................... 15-91
15-33 Connecting Rod
15-33-00 General ........................................................................................................................... 15-93
15-33-06 Big-End Bearing ............................................................................................................. 15-99
15-36 Piston
15-36-00 General ......................................................................................................................... 15-103
15-36-03 Piston Ring ................................................................................................................... 15-111
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-115
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-117
15-42-01 Rocker Arm .................................................................................................................. 15-126
15-42-03 Rocker Shaft ................................................................................................................ 15-127
9823/0300-1
2017-12-15
15-42-06 Rocker Cover ............................................................................................................... 15-128
15-42-09 Push Rod ..................................................................................................................... 15-131
15-42-21 Tappet ........................................................................................................................... 15-133
15-42-24 Tappet Cover ................................................................................................................ 15-139
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-141
15-45-03 Drain Plug .................................................................................................................... 15-145
15-45-09 Dipstick ......................................................................................................................... 15-146
15-45-10 Dipstick Pipe ................................................................................................................ 15-147
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-149
15-51-03 Crankshaft Gear ........................................................................................................... 15-150
15-51-06 Camshaft Gear ............................................................................................................. 15-153
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-154
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-157
15-51-22 Rear Case .................................................................................................................... 15-160
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-165
15-54-03 Housing ........................................................................................................................ 15-167
15-54-09 Gear Ring ..................................................................................................................... 15-168
15-57 Oil Filler
15-57-00 General ......................................................................................................................... 15-171
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-175
15-60-06 Pressure Relief Valve ................................................................................................... 15-182
15-63 Mount
15-63-00 General ......................................................................................................................... 15-189
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-193
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-201
15-72-03 Pulley ............................................................................................................................ 15-208
15-72-06 Voltage Regulator ......................................................................................................... 15-209
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-211
15-75-03 Solenoid ....................................................................................................................... 15-220
15-75-06 Brush Gear ................................................................................................................... 15-221
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-223
15-84-03 Crankshaft Position ...................................................................................................... 15-226
15-84-06 Camshaft Position ........................................................................................................ 15-231
15-84-09 Knock ........................................................................................................................... 15-236
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-238
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-241
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-244
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-248
15-84-19 Exhaust Temperature ................................................................................................... 15-251
15-84-21 Engine Oil Pressure ..................................................................................................... 15-254
15-84-24 Fuel Temperature ......................................................................................................... 15-257
15-84-26 Fuel Pressure ............................................................................................................... 15-260
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-262
9823/0300-1
2017-12-15
15-84-30 Hand Throttle Control ................................................................................................... 15-265
15-84-33 Coolant Temperature .................................................................................................... 15-269
15-84-42 Engine Oil Temperature ............................................................................................... 15-271
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-274
15-86 Solenoid
15-86-00 General ......................................................................................................................... 15-279
15-86-03 Engine Shut-off Solenoid (ESOS) ................................................................................ 15-280
15-86-09 Cold Start Advance ...................................................................................................... 15-284
15-87 Switch
15-87-00 General ......................................................................................................................... 15-289
15-88 Cold Start Heater
15-88-00 General ......................................................................................................................... 15-291
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-299
9823/0300-1
2017-12-15
Acronyms Glossary
CAN Controller Area Network

CCV Crankcase Ventilation
DC Direct Current
DCU Dosing Control Unit
ECM Engine Control Module
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
LMS Loadall Monitoring System
PTO Power Take-Off
PWM Pulse Width Modulation
SCR Selective Catalytic Reduction
TDC Top Dead Centre
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
9823/0300-1
2017-12-15
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9823/0300-1 15 - 1
Notes:
15 - 2 9823/0300-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-5 engine assembly. For specific engine technical
Technical Data ................................................. 15-6 information refer to the technical data section.
Component Identification ................................. 15-7
Make sure that the correct engine service tools,
Operation ....................................................... 15-10 consumables and torque figures are used when you
Diagram ......................................................... 15-14 perform service procedures.
Fault-Finding .................................................. 15-15
Drain and Fill ................................................. 15-18 Replacement of oil seals, gaskets, etc., and any
component that show signs of wear or damage, is
Clean ............................................................. 15-19 expected as a matter of course.
Check (Pressure) .......................................... 15-20
Remove and Install ....................................... 15-20 It is expected that components will be cleaned and
lubricated where required, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The Kohler KDI engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition
(C.I.). The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The

starter motor turns the engine via a pinion and teeth
on the engine flywheel.
When the engine runs the crankshaft drives the

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

pressure fuel pump via gears. The pump is part of the
electronically controlled common rail fuel injection
system.
Air is drawn into the engine through the inlet

manifold and exhaust gases exit through the exhaust
manifold. The engine uses a variable geometry
turbocharger which pressurises the air at the inlet
manifold.
A mechanical lubrication oil pump is driven by the

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

coolant circulation pump and alternator.
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
15 - 3 9823/0300-1 15 - 3
15 - Engine
00 - Engine
00 - General
Figure 129.
G D
B
A
A Crankshaft B Crankshaft gear

C Intermediate gear D Camshaft gear
E Camshaft F Tappet
G Push rod H Valve

C D M
Q
N
P
L
K
H
J
A B G
A Crankshaft G Rocker arm push rod

B Crankshaft gear H Valve
C Intermediate gear M Articulation control valve
D Camshaft control gear N Valve control bridge
J Camshaft phonic wheel P Hydraulic tappet
K Intermediate gear pin Q Rocker arm
L Phonic wheel positioning reference pin on
camshaft
15 - 4 9823/0300-1 15 - 4
15 - Engine
00 - Engine
00 - General
Health and Safety accordance with local regulations. Use authorised

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system.Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 5 9823/0300-1 15 - 5
15 - Engine
00 - Engine
00 - General
Technical Data
Table 45.
Description
Engine Type KDI 2504 TCR
Emission compliance US-EPA Tier 4 final, EU
Stage IIIB
Max. operating speed 2200 RPM (Revolutions
Per Minute)
Power Output 55kW at 2200 RPM
Weight (Dry) 233kg
Number of cylinders 4
Nominal bore size 88mm
Stroke 102mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.482L
Compression ratio 17: 1
Direction of rotation Counterclockwise
(viewed from flywheel
end)
Valves 4 per cylinder
Tappets Hydraulic
Lubricating oil pressure 1–2.8bar (14.5–40.6psi)
(Dependent on engine
temperature and speed)
Filter type Screw-on canister
Pressure to open by- 2.5 ± 0.5bar
pass valve (36.2 ± 7.2psi)
Oil pressure switch set-0.8 ± 0.1bar
ting (11.6 ± 1.4psi) falling
Oil pump
(1)
Integral unit with relief
valve
Combustion system Common rail direct In-
jection
High pressure fuel pump High pressure with elec-
tronically controlled fuel
metering
(1) The oil pump is a non-serviceable part
15 - 6 9823/0300-1 15 - 6
15 - Engine
00 - Engine
00 - General
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 132.
L
K
N
G
F
E
A
P B
C D
A Flywheel housingRefer to: PIL 15-54-03. B FlywheelRefer to: PIL 15-54-00.

C Fuel filterRefer to: PIL 18-09-00. D Fuel filter drain plugRefer to: PIL 18-09-00.
E DipstickRefer to: PIL 15-45-09. F Oil filterRefer to: PIL 15-21-00.
G Oil coolerRefer to: PIL 15-69-00. H PTO (Power Take-Off) cover (If installed)
J High pressure fuel pumpRefer to: PIL K Inlet manifoldRefer to: PIL 18-24-03.
18-18-15.
L Catalytic converterRefer to: PIL 18-24-18. M EGR (Exhaust Gas Recirculation) valveRefer to:
PIL 18-27-06.
N Engine harness P ECM (Engine Control Module)
15 - 7 9823/0300-1 15 - 7
15 - Engine
00 - Engine
00 - General
Figure 133.
B
P
D
N
M
E K
L
H
F
G J
A ThermostatRefer to: PIL 21-12-00. B Oil filler capRefer to: PIL 15-57-00.
C Cooling pumpRefer to: PIL 21-09-00. D Drive beltRefer to: PIL 15-18-03.
E Crankshaft phonic wheelRefer to: PIL F Oil sumpRefer to: PIL 15-45-00.
15-12-15.
G Timing gear caseRefer to: PIL 15-51-21. H AlternatorRefer to: PIL 15-72-00.
J Oil sump drain plugRefer to: PIL 15-45-03. K CrankcaseRefer to: PIL 15-03-00.
L BedplateRefer to: PIL 15-09-00. M Crankcase ventilation filterRefer to: PIL
15-27-00.
N Starter motorRefer to: PIL 15-75-00. P Oil pressure sensorRefer to: PIL 15-84-21.
Q Cylinder headRefer to: PIL 15-06-00. R Outlet manifoldRefer to: PIL 18-24-04.
15 - 8 9823/0300-1 15 - 8
15 - Engine
00 - Engine
00 - General
Figure 134.
H
J
K G
B
C D
A InjectorRefer to: PIL 18-18-03. B Rocker coverRefer to: PIL 15-42-06.

C Turbocharger actuatorRefer to: PIL 18-35-00. D TurbochargerRefer to: PIL 18-35-00.
E Turbocharger linkRefer to: PIL 18-35-00. F Oil filler capRefer to: PIL 15-57-00.
G Low pressure fuel return pipesRefer to: PIL H EGR coolerRefer to: PIL 18-27-09.
18-96-06.
J High pressure fuel pipesRefer to: PIL K Fuel railRefer to: PIL 18-18-12.
18-96-03.
15 - 9 9823/0300-1 15 - 9
15 - Engine
00 - Engine
00 - General
Operation
Firing Order
The Four Cylinder Cycle
A cylinder is said to be firing, when the fuel/air mixture
This section describes the cycle sequence for the 4 ignites and the piston is about to start its power
cylinder engine. stroke.
With the crankshaft positioned as shown, the pistons From the stages described, it can be seen that
in numbers 1 and 4 cylinders are at top dead centre number 1 cylinder will be next to fire. Number 3
and pistons in numbers 2 and 3 cylinders are at cylinder is starting its compression stroke and is next
bottom dead centre. in the cycle, followed by cylinders 4 and 2. The firing
order is therefore; 1, 3, 4, 2.
It is important to note that number 1 cylinder is firing
and about to start its Power stroke. Rotating the The stages in the four stroke cycle for each cylinder
crankshaft a further full rotation would position the are as follows:
pistons as described but the engine would be at a
different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
Table 46. The Four Stroke Cycle

Cylinder number Piston operation Valve operation
1 The piston is at the top of its Compression stroke Inlet and exhaust valves closed
and is about to start its Power stroke.
2 The piston is at the bottom of its Power stroke and Inlet valves closed, exhaust
is about to start its Exhaust stroke. valves about to open
3 The piston is at the bottom of its Induction stroke Exhaust valves closed, inlet
and is about to start its Compression stroke. valves about to close.
4 The piston is at the top of its Exhaust stroke and Valve Operation Exhaust valves
is about to start its Induction stroke. about to close, inlet valves about
to open
15 - 10 9823/0300-1 15 - 10
15 - Engine
00 - Engine
00 - General
Figure 135. Typical Four Cylinder Engine

CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
15 - 11 9823/0300-1 15 - 11
15 - Engine
00 - Engine
00 - General
Four Stroke Cycle The temperature rises to a point at which the fuel/air
mixture ignites. A cylinder is said to be firing when
Induction the fuel/air mixture ignites.
As the piston travels down the cylinder, it draws This combustion causes a very rapid rise in
filtered air at atmospheric pressure and ambient both temperature and pressure. The high pressure
temperature through an air filter and inlet valves into generated propels the piston downwards turning the
the cylinder. crankshaft and producing energy.
Compression Exhaust
When the piston reaches the bottom of its stroke, the Once the piston has reached the bottom of its travel,
inlet valves close. The piston then starts to rise up the the exhaust valves open and momentum stored
cylinder compressing the air trapped in the cylinder. in the flywheel forces the piston up the cylinder
This causes the temperature and pressure of the air expelling the exhaust gases.
to rise. Fuel is injected into the cylinder when the
piston is near to TDC (Top Dead Centre). In a running engine, these four phases are
continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle of a
Power
four stroke engine, the crankshaft revolves twice.
The piston continues to rise after the start of fuel
injection, causing a further increase in pressure and
temperature.
Figure 136.
3
2
C
B
1 4
746030
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC
15 - 12 9823/0300-1 15 - 12
15 - Engine
00 - Engine
00 - General
Figure 137.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
C Camshaft lobe - Exhaust valve operation
15 - 13 9823/0300-1 15 - 13
15 - Engine
00 - Engine
00 - General
Diagram
Electrical Operation and Schematics signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
The schematic diagram shows a typical system. CAN (Controller Area Network)bus to tell the Engine
For machine specific schematics, refer to electrical ECU that the transmission is in Neutral.
system- general, refer to (PIL 33-00).
The engine ECU provides power to the engine
The schematic is shown with the ignition switch compartment fusebox to energise the start relay, the
set to position III and the transmission set to N. A fuel pump relay, the starter motor and the fuel pump.
Figure 138.
Charge
D+
W
A
ECU
F
M
D
+VE -VE
3
4
5 H
1 6
2 7 M
E 8
9 K
10
J
C ECU
+VE G -VE
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU
15 - 14 9823/0300-1 15 - 14
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Warning YELLOW light turn on Table 47. Page 15-15
The engine does not start Table 48. Page 15-15
Engine starts but stops Table 49. Page 15-15
RPM (Revolutions Per Minute) instability at idle speed Table 50. Page 15-15
Low idle speed Table 51. Page 15-15
Blue smoke Table 52. Page 15-16
Excessive fuel consumption Table 53. Page 15-16
Inadequate performance Table 54. Page 15-16
Slow acceleration Table 55. Page 15-16
Engine jerking Table 56. Page 15-16
Engine overheats Table 57. Page 15-16
Table 47. Warning YELLOW light turn on

Cause Remedy
ECM (Engine Control Module)has detected Contact JCB Service
malfunctions
Table 48. The engine does not start

Cause Remedy
Sulphated/corroded battery terminals Clean the battery terminals
Battery voltage too low Recharge or replace the battery
Low fuel level Refuel
Frozen fuel Contact JCB Service
Clogged fuel filter Replace the filter
Air suction in fuel system Contact JCB Service
Clogged air filter Replace the filter
Clogged pipes Contact JCB Service
Open fuse Replace with a new fuse, if the problem persists,
contact JCB Service
Intake or exhaust system clogged Contact JCB Service
Table 49. Engine starts but stops

Cause Remedy
Inefficient electrical connections Clean the electrical contacts, if the problem persists,
contact JCB Service
Sulphated battery terminals Clean the battery terminals
Clogged fuel filter Replace the filter and clean the tank
Clogged fuel pipes Contact JCB Service
Table 50. RPM (Revolutions Per Minute) instability at idle speed

Cause Remedy
Table 51. Low idle speed

Cause Remedy
Poor quality fuel Clean the tank and refuel with quality fuel
15 - 15 9823/0300-1 15 - 15
15 - Engine
00 - Engine
00 - General
Table 52. Blue smoke

Cause Remedy
High oil sump level Replace the engine oil, if the problem persists,
contact JCB Service
Table 53. Excessive fuel consumption

Cause Remedy
contact JCB Service
Table 54. Inadequate performance

Cause Remedy
Poor quality fuel Clean the tank and refuel with quality fuel
contact JCB Service
Clogged fuel filter Replace the filter and clean the tank
Air or water in the fuel supply circuit Drain the fuel system and clean the tank, If the
problem persists, contact JCB Service
The tank cap vent hole is clogged Clean the cap
Piston rings worn or sticking Replace the piston rings, If the problem persists,
contact JCB Service
Worn cylinder Contact JCB Service
Crankshaft/Connecting rod bearings worn out Replace the bearings, If the problem persists, contact
JCB Service
Damaged cylinder head gasket Replace the gasket, If the problem persists, contact
JCB Service
Defective timing system Correct the timing system, If the problem persists,
contact JCB Service
Damaged injector Replace the injector
Damaged high-pressure fuel injection pump Replace the fuel injection pump
Wrong injector IMA codes Contact JCB Service
Table 55. Slow acceleration

Cause Remedy
Clogged fuel filter Replace the fuel filter
Table 56. Engine jerking

Cause Remedy
Table 57. Engine overheats

Cause Remedy
Piston rings worn or sticking Replace the piston rings, If the problem persists,
contact JCB Service
Worn cylinder Contact JCB Service
Damaged cylinder head gasket Replace the gasket, If the problem persists, contact
JCB Service
Defective timing system Correct the timing system, If the problem persists,
contact JCB Service
15 - 16 9823/0300-1 15 - 16
15 - Engine
00 - Engine
00 - General
Cause Remedy
Damaged injector Replace the injector, If the problem persists, contact
JCB Service
Insufficient coolant level Fill up to the level
contact JCB Service
Clogged radiator Clean the radiator, if the problem persists, contact
JCB Service
Defective thermostatic valve Replace the thermostatic valve
Defective or worn coolant pump Replace the coolant pump
15 - 17 9823/0300-1 15 - 17
15 - Engine
00 - Engine
00 - General
Drain and Fill CAUTION! Oil will gush from the hole when the
drain plug is removed. Keep to one side when
you remove the plug.
Oil
Oil is toxic. If you swallow any oil, do not induce 6. Remove the oil dipstick.
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin 7. Remove the oil sump drain plug and O-ring from
cancer. Do not handle used engine oil more than both sides of the oil sump.
necessary. Always use barrier cream or wear gloves
8. Drain the engine oil into an suitable container.
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol, 9. Clean and install the drain plug with a new O-
diesel fuel or paraffin to clean your skin. ring. Tighten the plug to the correct torque value.
or the ground. Clean up all spilt fluids and/or 10. Through one of the filler points, fill the engine with
lubricants.Used fluids and/or lubricants, filters and the recommended oil to the MAX mark on the
contaminated materials must be disposed of in dipstick.
accordance with local regulations. Use authorised Figure 140.
Engine oil replacement must be completed in

accordance with the service schedules. Failure to
replace the oil replacement at the recommended
interval could cause serious engine failure.
A
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained
with the oil.

A Oil filler cap
2. Park the machine on a hard level surface for
accurate measurement of the oil level. Figure 141.
3. Get access to the engine.

4. Place a container of suitable size beneath the
drain plug. D
5. Remove the oil filler cap.
Figure 139. E
A
D Dipstick
E Maximum level mark
F Minimum level mark
11. Wipe off any spilt oil, install the filler cap and
make sure it is secure.
C
B 12. Operate the engine, until the oil pressure low
warning light has extinguished.
A Oil filler cap
B Drain plug 13. Check for oil leakage.
C O-ring 14. When the oil has cooled, check the oil level
again, and if necessary top up with clean engine
oil.
15 - 18 9823/0300-1 15 - 18
15 - Engine
00 - Engine
00 - General
Clean 9. When the pressure washing is complete, move

the machine away from the wash area, or
Notice: Clean the engine before you start engine alternatively, clean away the material washed
maintenance. Obey the correct procedures. from the machine.
Contamination of the fuel system will cause
damage and possible failure of the engine. 10. Before working on specific areas of the engine,
use a compressed air jet to dry off any moisture.
Notice: The engine and other components could When the area is dry, use a soft clean brush to
be damaged by high pressure washing systems. remove any sand or grit particles that remain.
Special precautions must be taken if the machine
is to be washed using a high pressure system. 11. When removing components, be aware of any
Make sure that the alternator, starter motor and dirt or debris that may be exposed. Cover any
any other electrical components are shielded open ports and clean away the deposits before
and not directly cleaned by the high pressure proceeding.
cleaning system. Do not aim the water jet directly
Additional cleaning must be carried out prior to
at bearings, oil seals or the engine air induction
working on the high pressure fuel system. Refer to
system.
Fuel System, General, Clean.
Before carrying out any service procedures that

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

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

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

2. Make sure that all electrical connectors are
correctly connected. If connectors are open
install the correct caps or seal with water proof
tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and brush to soak
off mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical and electronic
components such as the engine electronic
control unit (ECU), alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine.
Distance: 600mm
15 - 19 9823/0300-1 15 - 19
15 - Engine
00 - Engine
00 - General
Check (Pressure) Remove and Install

Special Tools Lifting Equipment
Pressure Gauge (0-40 892/00278 1 You can be injured if you use incorrect or faulty lifting
Bar) equipment. You must identify the weight of the item to
1. Make the machine safe with the excavator/lift
arm lowered.
local regulations.
The lifting equipment used must be an approved
2. Make sure that the engine oil and fuel are at the type and capable of lifting the engine safely. The
correct level. recommended lifting equipment is shown. Use a
spreader bar when lifting the engine. Never attempt
3. Remove the pressure switch. to manually lift heavy components on your own.
Refer to: PIL 15-84-21. Always use lifting equipment, or obtain the help of
an assistant. Inspect the lifting brackets for signs
4. Connect a pressure gauge to the pressure switch of damage. The brackets must be correctly torqued
fitting. to the crankcase. Make sure the lifting equipment
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) does not damage any of the engine dressing and the
rocker cover.
Figure 142.
There will be some component differences
depending on the machine variant. Before attempting
A to remove the engine ensure that all the necessary
components have either been removed, or safely
disconnected from the engine.
Before Removal
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Position the machine on firm level ground. Make
the machine safe.
5. Start the engine. 3. Get access to the engine.
6. Monitor the oil pressure with respect to the oil Refer to: PIL 06-06-06.
temperature.
7. The oil pressure should be more than the Remove
specified value. 1. Disconnect and remove the battery.
Pressure: 1.5bar (21.7psi) Refer to: PIL 33-03-00.
8. Stop the engine and allow it to cool. 2. Drain the engine oil.
9. Remove the pressure gauge and install the Refer to: PIL 15-00-00.
pressure switch.
3. Drain the engine cooling system.
4. Remove the cooling pack.
15 - 20 9823/0300-1 15 - 20
15 - Engine
00 - Engine
00 - General
6. Drain the hydraulic tank. Disconnect and plug Figure 143.

the hydraulic pipes. Label the hoses to help
installation.
7. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to help installation.
8. Disconnect the exhaust system.
B B
9. Label the cab heater hoses at the engine
crankcase. Release the hose clips and remove
the hoses.
10. Disconnect the wiring connections from the A
starter motor. A
Refer to: PIL 15-75-00. A Lifting eye
B Sling
11. Disconnect the wiring connections from the
alternator. 20. Take the weight of the engine on the hoist and
Refer to: PIL 15-72-00. remove the engine mounting bolts.
12. Disconnect the wiring connections from the 21. Withdraw the engine in a level attitude until it is
engine sensors and actuators. clear of the chassis. Raise the engine to lift it
clear of the machine.
22. Lower the engine into a suitable stand that is
13. Disconnect the fuel supply line at the fuel lift capable of supporting the weight of the engine.
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt. Install
14. Disconnect the electrical harness at the engine 1. Replacement is a reversal of the removal
harness. procedure. Note the following:
15. Uncouple the electrical harness at the 2. Fill the cooling system with the correct mix of
ECM (Engine Control Module) machine side coolant fluid.
connector. Important: DO NOT touch the
connector pins on the ECM or harness Refer to: PIL 75-00-00.
connectors. Cover the connectors to prevent
contamination. 3. Fill and Check the hydraulic fluid level.
16. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way. 4. Fill and Check the engine oil level.
17. Disconnect and plug the hoses at the hydraulic Refer to: PIL 15-00-00.
pump.
5. On completion, check the hydraulic and cooling
18. Disconnect the wiring to the hydraulic pump. system for leakage and levels.
19. Attach slings to the engine lifting eyes. 6. Check the function of the drive and hydraulic
services.

Item Nm
A 25
15 - 21 9823/0300-1 15 - 21
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-23
15 - 22 9823/0300-1 15 - 22
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-23 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-24 The enclosure forms the largest cavity in the engine
Clean ............................................................. 15-25 and is located below the cylinders. It is integral with
Calibrate ........................................................ 15-26 the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
Remove and Install ....................................... 15-27 attached with a gasket and bolted joint.
The crankcase protects the crankshaft and

connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 144.
A
A Crankcase
B Crankshaft
15 - 23 9823/0300-1 15 - 23
15 - Engine
03 - Crankcase
00 - General
Technical Data
Fourth stage 20N·m

Fifth stage 35N·m
Table 59. Crankcase and Bedplate Data
(1) Torque information must be used in conjunction
Main bearing bolts with recommended procedures contained in this
torque
(1)
manual. Failure to use the appropriate and correct
First stage 40N·m removal, replacement, dismantle and assembly
Second stage 70N·m procedures may result in an engine failure in service.
Third stage 120N·m Refer also to the procedures for the correct bolt
tightening sequence.
Peripheral bolts
Table 60. Cylinder bore Data

Dimensional Class Cylinder Diameter Piston Diameter Clearance
(1) (1) (1) (1)
STD 88.003mm 87.943mm 0.046mm

(3.4647in)-88.017mm (3.4623in)-87.957mm ( 0.0018in)-0.074mm
(3.4652in) (3.4628in) (0.0029in)
R+0.1 88.103mm 88.043mm
(3.4686in)-88.117mm (3.4663in)-88.057mm
(3.4691in) (3.4668in)
+0.5 88.503mm 88.443mm
(3.4843in)-88.517mm (3.4820in)-88.457mm
(3.4849in) (3.4826im)
+1 89.003mm 88.943mm
(3.5041in)-89.017mm ( 3.5017in)-88.957mm
(3.5046in) (3.5022in)
(1) This table shows the reference values and their classification applicable for new engines only.
15 - 24 9823/0300-1 15 - 24
15 - Engine
03 - Crankcase
00 - General
Clean
2. Put a pipe cleaner in all the open ports to clean

Oil pipes the oil pipes,as shown.
Important: Make sure you keep a safe distance from 3. Use a compressed air line to remove any
all of the open ports. remaining oil.
4. Install all the plugs with Loctite.
1. Remove all the plugs.
Figure 145.
A Plug B Oil pipe
15 - 25 9823/0300-1 15 - 25
15 - Engine
03 - Crankcase
00 - General
Calibrate
4.2. When reconditioning, make sure that the

Cylinder check working angle is between the specified
value.
1. Place the crankcase on a workbench. Angle: 45–55°
2. Measure the diameter at all the points shown in 4.3. Make sure that the average roughness (Ra)
the figure using a dial gauge. is between 0.25-0.5.
3. Rotate the dial gauge by the specified angle 5. The cylinders can be oversized by 0.50mm
and measure again the diameter at all the points (0.01968in)-1.00mm (0.03937in), in compliance
shown in the figure. with the manufacturer's specifications.
Angle: 90° 6. Do not finish the internal surface of the cylinders
4. Refer to the technical data of the crankcase for using an emery cloth.
the class and approved dimensional values. 7. Lubricate the contact surfaces to prevent
Refer to: PIL 15-03. oxidation.
4.1. If the cylinder is oval or wear is greater than
0.05mm (.00197in), the cylinder must be
reconditioned.
Figure 146. Measurement points
15 - 26 9823/0300-1 15 - 26
15 - Engine
03 - Crankcase
00 - General
Remove and Install
Refer to Bedplate - Remove and Install. Refer to: PIL

15-09-00.
15 - 27 9823/0300-1 15 - 27
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-29
15 - 28 9823/0300-1 15 - 28
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-29 The cylinder head is located above the cylinders
Remove and Install ....................................... 15-30 on top of the crankcase. It closes in the top of the
cylinder, forming the combustion chamber. This joint
is sealed by a cylinder head gasket.
The cylinder head also provides the space for the

passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves and fuel injectors.
15 - 29 9823/0300-1 15 - 29
15 - Engine
06 - Cylinder Head
00 - General
Consumables B
Description Part No. Size C
Cleaner/Degreaser 4104/1557 0.4L A
- General purpose
solvent based parts
cleaner

method and device.
Before Removal A Cylinder head

B Bolt
1. This procedure requires service parts. Make sure C Eye-bolt
you have obtained the correct parts before you
2. Carefully lift the cylinder head from the
start, refer to Parts Catalogue.
crankcase. Only use the eye-bolts installed on
2. Make sure that the engine is safe to work on. If the cylinder head to move the cylinder head.
3. Remove and discard the head gasket.
Figure 148.
4. Remove the thermostat. D
5. Remove the exhaust manifold.
6. Remove the inlet manifold.
7. Remove the rocker cover.
D Head gasket
8. Remove the rocker assembly.
4. Using a suitable cleaning agent, carefully remove
Refer to: PIL 15-42-00. all traces of the head gasket material from the
cylinder head and crankcase mating faces.
Remove Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Make sure that the engine is at ambient temperature
before you remove the cylinder head, to prevent 5. Check the cylinder head and crankcase mating
deformation. faces for signs of damage and distortion.
1. Remove the bolts that attach the cylinder head Refer to: PIL 15-06-00.
to the crankcase. Note that the bolts must not be
re-used. Discard the bolts. Before Assembly
1. Measure the injector projection.
2. Obtain the correct new cylinder head bolts. Note
that the original bolts must not be re-used.
3. Obtain the correct replacement head gasket.
Note the number of identification holes as shown
in Refer to Table 61.
15 - 30 9823/0300-1 15 - 30
15 - Engine
06 - Cylinder Head
00 - General

M Q
D
N
M
L Piston
M Crankcase D Head gasket
N Measuring points M Crankcase
P Centering bushings
3.1. Turn the crankshaft to put the piston at TDC Q Identification holes
(Top Dead Centre).
3. Lower the cylinder head on to the crankcase.
3.2. Put a dial gauge on the crankcase and Make sure that the cylinder head is correctly
measure the piston protrusion from the aligned with the bushings.
crankcase surface.
Figure 151.
3.3. Do step 3.2 again for all the pistons.
A
3.4. Record the highest mean value by applying
the fraction given in Refer to Table 61.
4. Make sure that all items are clean and free from
damage and corrosion. P
P
Table 61.
Fraction Number of identifica-
tion hole
0.03–0.126mm
A Cylinder head
0.127–0.25mm P Bushings
4. Install the new cylinder head bolts.
5. Tighten the bolt to the correct torque value.
0.251–0.375mm
Strictly follow the torque sequence shown.
Figure 152.
10
Assemble
1. Replacement is the reversal of the removal
procedure. 7 5 1 3 9
2. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed in the correct orientation and correctly
aligned with the bushings.
4 2 6 8
15 - 31 9823/0300-1 15 - 31
15 - Engine
06 - Cylinder Head
00 - General
6. Tighten the bolts in six stages, use the torque and

angle method.
6.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-10) to the 1st stage pre-torque.
6.2. Then, further tighten the bolts, starting
with the middle pair and working outwards
(in sequence 1-10) to the 2nd stage pre-
torque.
6.3. Then, re-tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1-10) to the 3rd stage pre-torque.
6.4. Use the angle gauge to angle tighten the
bolts, starting with the middle pair and
working outwards (in sequence 1-10) to the
4th stage pre-torque. As a visual check,
match mark the bolts to the cylinder head
before you start. When the bolts have
been angle tightened, the match marks will
appear as shown.
Figure 153.
0° + 90° + 90° + 90°
6.5. Then, further angle tighten the bolts,

starting with the middle pair and working
outwards (in sequence 1- 10) to the 5th
stage pre-torque.
6.6. Finally, angle tighten the bolts, starting with
the middle pair and working outwards (in
sequence 1- 10) for the final stage torque.
Table 62.
Description Torque Value
Cylinder head to crankcase bolts 1-10
- first stage torque 40N·m
- second stage torque 70N·m
- third stage torque 100N·m
- fourth stage torque 90°
- fifth stage torque 90°
- final stage torque 90°
15 - 32 9823/0300-1 15 - 32
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-35
15 - 33 9823/0300-1 15 - 33
Notes:
15 - 34 9823/0300-1 15 - 34
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-35 The bedplate acts as the main strength component
Remove and Install ....................................... 15-36 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 154.
1
1 Bedplate
2 Crankcase
15 - 35 9823/0300-1 15 - 35
15 - Engine
09 - Bedplate
00 - General
Remove and Install Refer to: PIL 18-18-15.
Consumables 16. Remove the fuel injection drive gear.

Description Part No. Size Refer to: PIL 15-51-00.
Cleaner/Degreaser 4104/1557 0.4L
- General purpose 17. Remove the intermediate drive gear.
solvent based parts Refer to: PIL 15-51-00.
cleaner
18. Remove the high duty PTO (Power Take-Off)
CAUTION This component is heavy. It must only device (if installed).
method and device. 19. Remove the fuel injectors.
Before Removal 20. Remove the rocker cover.
1. This procedure requires service parts. Make Refer to: PIL 15-42-06.
sure you have obtained the correct service parts
21. Remove the rocker assembly including the push
before you start, refer to Parts Catalogue.
rods
2. Make sure that the engine is safe to work on. If Refer to: PIL 15-42-00.
you start the service work. 22. It is not necessary to remove the cylinder head
assembly to remove the bedplate. If however,
3. Get access to the engine. the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
4. Remove the drive belt. for example) remove it now.
Refer to: PIL 15-18-03. Refer to: PIL 15-06-00.
5. Remove the oil sump. 23. Position the engine upside down in a suitable jig
Refer to: PIL 15-45-00. or fixture, supported at the front of the crankcase.
6. Remove the turbocharger(if installed).
Remove
7. Remove the exhaust manifold.
1. Remove the main bearing bolts in the sequence
Refer to: PIL 18-24-04. shown.
8. Remove the starter motor. Figure 155.
9. Remove the flywheel housing.
B
10. Remove the crankshaft rear oil seal flange.
11. Remove the EGR (Exhaust Gas Recirculation) (if
installed).
12. Remove the inlet manifold.
A
A Bedplate
13. Disconnect and remove the high and low B Main bearing bolts (x10)
pressure fuel pipes.
Refer to: PIL 18-96-00. 2. Remove the bedplate peripheral bolts in the
sequence shown.
14. Remove the timing gear front case.
15. Remove the fuel injection pump.
15 - 36 9823/0300-1 15 - 36
15 - Engine
09 - Bedplate
00 - General
Figure 156. sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The
parts must be installed and tightened to the correct
torque value within 5min minutes (with a maximum
permissible time of 15min).
Important: Before installing the bedplate: Do not

rotate the crankshaft. Make sure that the upper main
bearing shells are flush with the bottom face of the
crankcase.
C
Install
Important: The crankshaft half bearings are made of
special material. Therefore, they must be replaced
every time they are removed to prevent seizures.
C Peripheral bolts (x17) The lower and upper crankshaft half bearings cannot
be replaced singularly, and both halves must be
3. Carefully separate the bedplate from the replaced together.
crankcase. Use suitable lifting equipment (if the
bedplate is lifted manually, two people will be 1. Make sure that all items are clean and free from
required). Do not use a lever to separate the damage and corrosion.
bedplate.
2. Use a suitable degreasing agent to clean both
4. Carefully remove the lower bearing shells from sides of the lower bearing shells.
the bedplate.
Consumable: Cleaner/Degreaser - General
Figure 157. purpose solvent based parts cleaner
3. Install the lower bearing shells into the bedplate.
A Make sure that the reference notches are at the
correct location.
Figure 158.
D
D
A Bedplate
D Lower bearing shells (x5)
Before Installation A
1. Clean off all traces of the old sealant compound A Bedplate
from the crankcase and bedplate mating faces. D Lower bearing shells (x5)
E Reference notch
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate 4. Lubricate the lower bearing shells with clean
and crankcase. Take care not to block the oil engine oil.
ways or the piston cooling jets.
5. Install the two shoulder half-rings onto the lower
Consumable: Cleaner/Degreaser - General crankcase. Apply two dots of ITP GX100 grease
purpose solvent based parts cleaner to hold the rings in position.
Important: Anaerobic sealant will not start to cure

whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are
put together) it will immediately start to harden. Make
15 - 37 9823/0300-1 15 - 37
15 - Engine
09 - Bedplate
00 - General
B
D
G
D Lower bearing shells (x5)
A
F Shoulder half-rings (x2)
G Guide pins
12. Install the bedplate peripheral bolts (x17).
6. Apply a 1.0mm (0.04in) thick bead of Loctite 5188
around the crankcase/bedplate mating face as 13. Tighten the bolts to the correct torque value in
shown. two stages. Strictly follow the torque sequence
shown.
Figure 160.
Figure 162.
L
H
K C
H Crankcase
J Loctite 5188
K Oil feed holes
L Return oil grooves
7. Make sure that you do not block the oil feed holes
and the return oil grooves. Important: If the parts have not been tightened to the
correct torque value within the maximum 15min time
8. Assemble the bedplate to the crankcase. Make period, then the parts must be separated, thoroughly
sure that the guide pins on the crankcase are cleaned and fresh sealant should be applied.
engaged properly in the slots on the bedplate.
9. Note: The bedplate is heavy. Two people will be
After Installation
required to lift and rotate the bedplate safely on 1. Check that the crankshaft can be freely rotated
to the crankcase. by hand.
10. Install the main bearing bolts (x10). 2. Measure the crankshaft end float. Make sure that
11. Tighten the bolts to the correct torque value in the end float is between 0.18mm (0.007in) and
three stages. Strictly follow the torque sequence 0.38mm (0.015in).
shown. 3. Carry out the procedures listed in the 'Before
Removal' section in reverse order.
15 - 38 9823/0300-1 15 - 38
15 - Engine
09 - Bedplate
00 - General

Item Description Nm
B Main bearing bolts (x10) (1st 40
Stage)
B Main bearing bolts (x10) (2nd 70
Stage)
B Main bearing bolts (x10) (3rd 120
Stage)
C Peripheral bolts (x17) (4th 20
Stage)
C Peripheral bolts (x17) (5th 35
Stage)
15 - 39 9823/0300-1 15 - 39
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-41

15-12-03 Main Bearing .................................................................................................................. 15-45
15-12-06 Front Oil Seal ................................................................................................................. 15-49
15-12-12 Pulley .............................................................................................................................. 15-52
15-12-15 Phonic Wheel ................................................................................................................. 15-53
15 - 40 9823/0300-1 15 - 40
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-41 Figure 163.
Technical Data ............................................... 15-42
Operation ....................................................... 15-43
Check (Condition) .......................................... 15-44
A
A Crankcase
B Crankshaft
15 - 41 9823/0300-1 15 - 41
15 - Engine
12 - Crankshaft
00 - General
Technical Data Component Identification
Table 64. Figure 164.

Main bearing journal di-
ameter (x4)
- min 63.981mm (2.5189in)
- max 64.00mm (2.5196in)
Connecting rod bearing
journal diameter
- min 54.035mm (2.1274in)
- max 54.066mm (2.1286in)
Maximum wear and
ovality on journals
(1)
Crankshaft end float

B
- min 0.18mm ( 0.0070in)
- max 0.38mm ( 0.0149in)
(1) No visible damage/wear or marks
A
A Crankcase
B Crankshaft
15 - 42 9823/0300-1 15 - 42
15 - Engine
12 - Crankshaft
00 - General
Operation
Lubrication transfer to cross drillings in the crankshaft to feed

each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
diameter of the upper main bearing shell allows oil engine.
Figure 165.
1 Main gallery 2 Drillings (x5)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
15 - 43 9823/0300-1 15 - 43
15 - Engine
12 - Crankshaft
00 - General
Check (Condition)
1. Check the main bearing surfaces for damage and Blocked or restricted oilways will cause oil
excessive wear. starvation at the big end bearings.
2. Measure the crankshaft diameters to confirm 4. Check that the piston cooling oil sprayers are
they are within service limits. clear (if installed). If the sprayers cannot be
Refer to: PIL 15-12-00. cleared remove the fixing screws. Remove the
sprayers and discard them.
3. Check that the oilway cross drillings in the
crankshaft are clear and free from debris.
Figure 166.
B D
A Crankshaft B Shoulder half-rings

C Oil spray jets (if installed) D Fixing screws
E Main bearing shells
15 - 44 9823/0300-1 15 - 44
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-45 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-46 bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 167.
A Main bearing
B Crankshaft
15 - 45 9823/0300-1 15 - 45
15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition) Remove and Install

Special Tools
1. Check the bearing shell surfaces for signs of Description Part No. Qty.
damage and excessive wear.
Torque Wrench 993/70111 1
2. Measure the crank pin diameters to confirm they (10-100Nm)
are within service limits.
Refer to: PIL 15-33-00. Before Removal
3. Measure the bearing journal diameters to confirm 1. This procedure requires service parts. Make
they are within service limits. sure you have obtained the correct service parts
4. Replace any parts that are worn or not within the the engine has been running, let it cool before
specified tolerances. you start the service work.
4. Remove the fuel injectors.
6. Drain the oil from the engine.
7. Remove the oil sump.
8. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
Important: The connecting rod and the main bearing

cap have been fracture split and must be kept
together as a set. Utmost care must be taken to avoid
contamination and or damage to the fracture split
surfaces.
15 - 46 9823/0300-1 15 - 46
15 - Engine
12 - Crankshaft
03 - Main Bearing
Remove Figure 169.
Figure 168.
X
Z
3
1 2
1 1 Main bearing caps

2 Main bearing cap bolts
6. Remove the bearing shells.
6
6.1. Lift out the bearing shells from the main
2 bearing caps.
1 Piston rings 6.2. Carefully rotate the crank to disengage from
2 Piston the connecting rods and gain access to the
3 Connecting rod upper bearing shells.
4 Main bearing cap
5 Bolts 6.3. Lift out the upper bearing shells.
6 Big end bearing shells 6.4. The bearing shells must be replaced every
Z Fracture split surfaces time they are removed.
1. It is recommended that the main bearing caps are 7. Carefully rotate the crankshaft to position the
removed in pairs according to the firing cycle. main bearing caps of cylinders 1 and 3.
1.1. Cylinder 2 8. Make sure that the crankshaft does not hit the
1.2. Cylinders 1 and 3 connecting rod of cylinder 2.
2. Put marks on the main bearing caps to make sure 9. Do the steps 4 to 6 to remove the bearing caps
that they are installed in their original positions and bearing shells for cylinders 1 and 3.
on assembly.
10. Inspect the main bearings for signs of damage
3. Rotate the crankshaft so that the main bearing and excessive wear.
caps on cylinder 2 are positioned at the top. Refer to: PIL 15-12-03.
4. Remove the bolts and lift off the main bearing
caps from the connecting rods. Install
5. Make sure that the bolts are not used again. 1. Replacement is the reversal of the removal
Discard the bolts. procedure.
15 - 47 9823/0300-1 15 - 47
15 - Engine
12 - Crankshaft
03 - Main Bearing
3. Install the upper bearing shell to the connecting

rod. Lubricate the bearing shell with clean engine
oil.
4. Install the lower bearing shell to the main bearing
cap. Lubricate the bearing shell with clean engine
oil.
5. Use compressed air to clean the fracture
surfaces of the main bearing caps before
assembly.
6. Install the main bearing cap to the connecting
rod.
7. Replace the fixing bolts.
8. Tighten the new bolts in two stages to the correct
torque value.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
9. Make sure that the crankshaft rotates smoothly
and the connecting rods have axial play.
10. After you perform the check, rotate the
crankshaft to position the first cylinder at TDC
(Top Dead Centre).
After Installation
1. Install the oil sump.
2. Install the rocker cover.
3. Install the fuel injectors.
4. Fill the engine with engine oil.

Item Description Nm
2 1st Stage 40
2 2nd Stage 85
15 - 48 9823/0300-1 15 - 48
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 170.

Crankshaft Front Oil 892/01157 1 C
Seal Installation Tool
B
Before Removal
1. This procedure requires service parts. Make
3. Get access to the engine. A
4. Remove the drive belt, refer to (PIL 15-18).

5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
A Crankshaft oil seal
Remove B Crankcase
C Crankshaft hub
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not Install
to scratch or damage the counterbore or the 1. Make sure that the counterbore and the
crankshaft hub. Damaged or dirty sealing faces crankshaft hub are clean and free from damage
will cause the oil seal to fail. and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 171.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
171.
15 - 49 9823/0300-1 15 - 49
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 171.
F D A
G G
E
A Crankshaft oil seal B Crankcase

C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw
4. Turn the screw to push the seal squarely into Figure 172.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. B
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore A
within the specified tolerance. Refer to Figure
172. G
Dimension: -0.5 -0/+0.5mm
C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
15 - 50 9823/0300-1 15 - 50
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
15 - 51 9823/0300-1 15 - 51
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
Remove and Install removal procedure. Additionally do the following
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1. This procedure requires service parts. Make 1)
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
you start the service work. Figure 174.

4. Remove the drive belt. Refer to (PIL 15-18).
Remove
1. Remove the fixing bolts and withdraw the pulley C
from the crankshaft.
Figure 173.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 66.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·m
2 (Final stage) 180°
A
B
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
15 - 52 9823/0300-1 15 - 52
15 - Engine
12 - Crankshaft
15 - Phonic Wheel
15 - Phonic Wheel
Introduction
The crankshaft position sensor is installed on the

timing gear case. The sensor reads the signal from
the phonic wheel that is installed on the engine
pulley. The sensor sends an analogue signal to the
ECM (Engine Control Module). The sensor produces
a 5V square wave signal with Hall effect when the
motor is rotating. This data, together with the signal
from the sensor, allows the ECM to control the fuel
injection with respect to the TDC (Top Dead Centre)
of the piston.
For gap adjustment. Refer to: PIL 15-84-00.
15 - 53 9823/0300-1 15 - 53
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-55
15 - 54 9823/0300-1 15 - 54
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-55 The relationship between the rotation of the camshaft
Technical Data ............................................... 15-56 and the rotation of the crankshaft is of critical
importance.
Since the valves control the flow of the air/fuel

mixture intake and exhaust gases, they must be
opened and closed at the appropriate time during the
stroke of the piston.
For this reason, the camshaft is connected to the

crankshaft through a gear mechanism.
When the engine runs the crankshaft drives the

camshaft through the gears. The camshaft opens
and closes the inlet and exhaust valves through the
push rods in time with the four stroke cycle.
15 - 55 9823/0300-1 15 - 55
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 67. Camshaft Data

Camshaft lobe diameter
Inlet 32.638mm (1.2850in) - 32.700mm (1.2874in)
(1)
Exhaust 32.998mm (1.2991in) - 33.060mm (1.3016in)

(1)
(1) If the dimensions of cam lobe are lower than the values shown by 0.1 mm (maximum dimension), replace
the camshaft.
Figure 175. Camshaft Dimensions

G
A1 B1 C1 D1 E1
F Intake lobe diameter G Exhaust lobe diameter
Table 68. Housing and Camshaft Journal Dimensions

Item Dimensions Clearance Wear Limit
A 44.000mm - 44.025mm
A-A1 = 0.040mm - 0.085mm
A1 43.940mm - 43.960mm
B 43.000mm - 43.025mm
B-B1 = 0.060mm - 0.105mm
B1 42.920mm - 42.940mm
C 42.000mm - 42.025mm
C-C1 = 0.060mm - 0.105mm 0.120mm
C1 41.920mm - 41.940mm
D 41.000mm - 41.025mm
D-D1 = 0.060mm - 0.105mm
D1 40.920mm - 40.940mm
E 36.000mm - 36.025mm
E-E1 = 0.060mm - 0.105mm
E1 35.920mm - 35.940mm
15 - 56 9823/0300-1 15 - 56
15 - Engine
15 - Camshaft
00 - General
Figure 176. Housing Dimensions
D E
B C
A
Table 69. Timing system phasing angles

INTAKE EXHAUST
opens 10° before P.M.S. opens 20° before P.M.I.
closes 14° after P.M.I. closes 4° after P.M.S.
15 - 57 9823/0300-1 15 - 57
15 - Engine
15 - Camshaft
00 - General
Figure 177.
H K
L N
H Intake opening J P.M.S

K Exhaust closure L Intake closure
M P.M.I N Exhaust opening
15 - 58 9823/0300-1 15 - 58
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-03 Drive Belt ....................................................................................................................... 15-61

15-18-21 Tensioner ........................................................................................................................ 15-63
15 - 59 9823/0300-1 15 - 59
Notes:
15 - 60 9823/0300-1 15 - 60
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Health and Safety

Notice: A drive belt that is loose can cause
Health and Safety .......................................... 15-61 damage to itself and/or other engine parts.
Check (Condition) .......................................... 15-62
15 - 61 9823/0300-1 15 - 61
15 - Engine
18 - Engine Belt
03 - Drive Belt
Check (Condition)
At the recommended service interval, visually inspect

the drive belt for damage.

2. Stop the engine and let it cool down.
3. Replace the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
15 - 62 9823/0300-1 15 - 62
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner 5. Install the tightening screw on to the plate, up to

the stop on the pulley pin.
Remove and Install 6. Tension the drive belt.

Figure 179.
This procedure is applicable for machines installed A
with Poly-V drive belt.
Important: The drive belt must always be replaced E

every time it is removed, even if it has not reached
the scheduled hours for replacement.
Remove
C
1. Make the machine safe. B
2. Remove the drive belt. D
Refer to: PIL 15-18-03. A Tensioning screw
3. Remove the tensioning screw. B Screw
C Tightening pulley
4. Remove the screw that secures the tightening D Pulley pin
pulley. E 32mm
5. Remove the tightening pulley.

Figure 178.
A Tensioning screw
B Screw
C Tightening pulley
Install
1. Insert the screw in the tightening pulley.
2. Manually tighten the screw on to the pulley pin up
to the stop; Loosen the screw again by one turn.
3. The screw must be out by the specified distance
from the surface of the tightening pulley.
Distance: 32mm
4. Install the drive belt.
15 - 63 9823/0300-1 15 - 63
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-65
15 - 64 9823/0300-1 15 - 64
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-65 The oil filter is a spin on type which screws on to the
Health and Safety .......................................... 15-66 filter head. The oil filter and cooler are incorporated in
Technical Data ............................................... 15-66 a housing that is bolted to the side of the crankcase.
The housing allows transfer of lubricating oil from the
Check (Leaks) ............................................... 15-68 crankcase to the oil cooler and the oil filter head.
Check (Level) ................................................ 15-68
15 - 65 9823/0300-1 15 - 65
15 - Engine
21 - Oil Filter
00 - General
Health and Safety Technical Data

Oil Table 70.
Oil is toxic. If you swallow any oil, do not induce
Maximum operating 4bar (58.0psi)
pressure
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than Max flow rate 3.17L/min
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
accordance with local regulations. Use authorised
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 66 9823/0300-1 15 - 66
15 - Engine
21 - Oil Filter
00 - General
Component Identification Figure 182.
Figure 180.
H
B
B
E
A
A Oil Filter
B Element
Figure 181.
B
F G
A Cartridge holder cover

B Oil filter support
E Oil filter cartridge
F Outgoing fitting from filter
G Water/oil heat exchanger
H Crankcase
C
A Cartridge holder cover

B Oil filter support
C Oil returning into the circuit
D Oil returning to the crankcase
15 - 67 9823/0300-1 15 - 67
15 - Engine
21 - Oil Filter
00 - General
Check (Leaks) Check (Level)
Before you start the machine, do a check for oil leaks: Engine oil and oil filter replacement must be
completed in accordance with the service schedules.
1. Make the machine safe. Failure to replace the oil and filter at the
recommended interval could cause serious engine
2. Get access to the engine compartment (if failure.
applicable)
3. Check the engine and the area below for oil
leaks. Refer to: PIL 01-03-27.
4. Close the engine cover (if applicable). 2. Park the machine on a hard level surface for
accurate measurement of the oil level.
5. If necessary, contact your JCB dealer.
4. Check that the oil level is between the two marks
on the dipstick.
Figure 183.
C
A Dipstick
B Maximum level mark
C Minimum level mark
5. If necessary, add recommended oil through one
of the filler points.
Figure 184.
D Oil filler caps
15 - 68 9823/0300-1 15 - 68
15 - Engine
21 - Oil Filter
00 - General
G
Before Removal
1. Drain the engine oil.
J
Remove and Install

1. Remove the clamps and remove the pipes from K
the oil cooler unit.
Figure 185.
G Element holder cap
J Element
F K Seal
6. Remove and replace the seals.
E
7. Apply clean oil on the seals.
8. Put the element on the cap.
9. Install the cap on the oil filter support.
D 10. Tighten the cap to the correct torque value.

11. Install the pipes on the support.
D Clamps
E Pipes 12. Secure the pipes with the clamps.
F Oil cooler
13. Through one of the filler points, fill the engine with
2. Use a suitable container to recover any residual the recommended oil to the MAX mark on the
oil. dipstick.
3. Loosen the element holder cap. Figure 188.
Figure 186.
G L
H L Oil filler caps

G Element holder cap 14. Wipe off any spilt oil, install the filler cap and
H Oil filter support make sure it is secure.
J Element
15. Operate the engine, until the oil pressure low
4. Remove the cap and the oil filter element from warning light has extinguished.
the oil filter support.
16. Check for oil leakage.
5. Remove the cartridge from the cap and discard.
15 - 69 9823/0300-1 15 - 69
15 - Engine
21 - Oil Filter
00 - General
17. When the oil has cooled, check the oil level
oil.

Item Nm
B 35
G 25
15 - 70 9823/0300-1 15 - 70
15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ........................................................................................................................... 15-73

15-24-03 Outer Element ................................................................................................................ 15-77
15-24-09 Dust Valve ...................................................................................................................... 15-78
15 - 71 9823/0300-1 15 - 71
Notes:
15 - 72 9823/0300-1 15 - 72
15 - Engine
24 - Air Filter
00 - General
Introduction .................................................... 15-73
Health and Safety .......................................... 15-74
Introduction
Component Identification ............................... 15-75 Engine performance and durability will be severely
Check (Condition) .......................................... 15-76 affected if the quality of the air intake is poor.
A dirty and blocked air filter will reduce the amount
of air entering the combustion chamber which can
cause engine misfiring, black smoke and low output
power.
A dirty and blocked air filter can also lead to abrasion

of the cylinder bores and valves (referred to as
dusting). This will cause excessive oil consumption,
black smoke, low output power and a reduced engine
life.
This is a dry-type air filter with a replaceable paper

filter cartridge.
15 - 73 9823/0300-1 15 - 73
15 - Engine
24 - Air Filter
00 - General
Health and Safety

Notice: Do not run the engine when the element
has been removed.
Notice: The outer element must be renewed
immediately if the warning light on the instrument
panel illuminates.
15 - 74 9823/0300-1 15 - 74
15 - Engine
24 - Air Filter
00 - General
Figure 189.
A
B
C D
F
G
A Filter cover B Air filter cartridge

C Air filter safety cartridge D Filter support
E Pre-filter cap F Filter cover hook
G Dust exhaust valve
15 - 75 9823/0300-1 15 - 75
15 - Engine
24 - Air Filter
00 - General
The air filter element (s) should be changed at Remove

the recommended service interval, refer to the
Maintenance Schedules. Refer to: PIL 78-24. The appearance of the air cleaner installed may differ
slightly on your machine.
Check all the hose connections for loose installations
and damaged hose clamps, look specifically for splits 1. Make the machine safe.
or cracks in the hoses. Pay particular attention to the
connections on the air intake to turbo compressor Refer to: PIL 01-03-27.
and on the crossover tube.
2. Open the engine compartment cover.
Renew any damaged components. Refer to: PIL 06-06-06.
In addition, most air filter housings will be installed 3. Release the two hooks and remove the cover
with a vacuum switch. The switch will detect if there from the filter body.
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual 4. Remove the outer and safety cartridge.
indicator.
Figure 190.
B C
E
D
A
A Hook
B Cover
C Outer cartridge
D Safety cartridge
E Filter body
Install
1. The safety cartridge must always be replaced if
it is dirty or damaged.
2. Put the safety cartridge inside the outer cartridge.
3. Put both the cartridges inside the filter body.
4. Install the cover on the body with the hooks.
15 - 76 9823/0300-1 15 - 76
15 - Engine
24 - Air Filter
03 - Outer Element
03 - Outer Element
Remove and Install
Notice: The outer element must be renewed 4. If the safety element is to be changed, lift up pulls
immediately if the warning light on the instrument and remove the safety element.
panel illuminates.
5. Clean the prefilter element housing and main
element housing. Make sure that the air holes on
Do not attempt to clean or wash the elements - they the prefilter housing are clear.
must only be renewed.
6. Make sure that the aspirator hose is securely
A new inner element must be installed at least installed and is in good condition.
every other time the outer element is changed. As a
reminder, mark the inner element with a felt tipped 7. Put the new safety element and main element
pen each time the outer element is changed. into the housing. Push them firmly in so that they
seated correctly.
8. Install the prefilter element. Make sure that the
2. Unclip and remove the prefilter element. aspirator hose mates with the spigot.
3. Remove the main element. Take care not to tap
or knock the element.
Figure 191.
F
D
C
G
H
B
A
E
A Vacuator valve B Bracket assembly

C Safety element assembly D Main element assembly
E Tube elbow F Cover assembly
G Body 8in. twist lock H Indicator
15 - 77 9823/0300-1 15 - 77
15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve
Check (Condition)
• Check the dust valve for rips/tears.
• Check there are no obstructions.
• Check that the dust valve is free of dirt and dust.
• Check that the dust valve securely attached to
the air filter housing.
15 - 78 9823/0300-1 15 - 78
15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ........................................................................................................................... 15-81
15 - 79 9823/0300-1 15 - 79
Notes:
15 - 80 9823/0300-1 15 - 80
15 - Engine
00 - General
Introduction .................................................... 15-81 The engine is installed with a filtered open loop CCV
Component Identification ............................... 15-82 (Crankcase Ventilation) system.
Check (Condition) .......................................... 15-83
Remove and Install ....................................... 15-84 Crankcase emissions are created during the
combustion process. These emissions include
unburned fuel and 'blow by gases' which contain
hydrocarbon and engine oil contaminates. A large
proportion of these emissions are prevented from
entering the atmosphere by the CCV filter assembly.
A series of ports in the crankcase, cylinder head

and rocker cover allow pressure to vent from
the crankcase. The vapour from the crankcase
flows from the rocker cover to the filter assembly.
Combined two stage filter elements remove around
90% of contaminates as the vapour passes from the
inside to the outside of the filter elements. Trapped oil
is allowed to drain back to the sump via a non return
valve. The filtered vapour vents to the atmosphere.
If the pressure inside the filter assembly rises due

to a blocked filter non return valve in the oil drain
line prevents vapour being forced back into the
crankcase. Refer to: PIL 15-60.
15 - 81 9823/0300-1 15 - 81
15 - Engine
00 - General
Figure 192.
F
B
A
C
G
A
A Clamp B Crankcase ventilation filter

C Pipe D Pipe 1
E Clamp 1 F Cutting point
G Pipe 2
15 - 82 9823/0300-1 15 - 82
15 - Engine
00 - General
Check (Condition)
3. Check the condition of the CCV (Crankcase
Ventilation) pipes. If necessary, replace them.
4. Make a note that the blocked CCV hose causes
pressurisation of the crankcase and the oil sump.
5. Clean the CCV filter as required.
6. Check the condition of the CCV filter. If
necessary, replace it.
15 - 83 9823/0300-1 15 - 83
15 - Engine
00 - General
Remove and Install
Remove
Before removal
1. Remove the clamps.
2. Disconnect all of the pipes from the crankcase
Refer to: PIL 01-03-27. ventilation filter.
2. Make sure that the engine is safe to work on. If 3. Carefully cut the clamp1 at the point as shown in
the engine has been running, let it cool before figure.
4. Remove the crankcase ventilation filter from the
3. Get access to the engine. crankcase.
Figure 193.
F
B
A
C
G
A
A Clamp B Crankcase ventilation filter

C Pipe D Pipe1
E Clamp1 F Cutting point
G Pipe2
15 - 84 9823/0300-1 15 - 84
15 - Engine
00 - General
Install
1. Install the crankcase ventilation filter and then
attach onto the holder with the clamp1.
2. Connect all the pipes to the crankcase ventilation
filter.
3. Attach the clamps.
After installation
1. Start the engine and check for any leaks.
15 - 85 9823/0300-1 15 - 85
15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ........................................................................................................................... 15-87

15-30-09 Valve Bridge ................................................................................................................... 15-91
15 - 86 9823/0300-1 15 - 86
15 - Engine
30 - Valve
00 - General
Introduction .................................................... 15-87 The valve train system opens and closes the
Technical Data ............................................... 15-88 valves with correct timing in relation to the piston
Adjust ............................................................ 15-88 movements.
Calibrate ........................................................ 15-89
Each push rod has one end in a valve tappet and
the other end under a rocker arm, or as applicable.
Hydraulic tappets are used which automatically
adjust the clearance between the valve and push
rods.
The valves extend through the cylinder head. The

valves are made from a special metal to provide a
long service life. Damaged or worn valves cannot be
lapped or reground and must be replaced with new
ones. Each valve stem has an oil seal.
The Valve seat inserts are pressed into the cylinder

head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.
15 - 87 9823/0300-1 15 - 87
15 - Engine
30 - Valve
00 - General
Technical Data Adjust
Table 72. Inlet and Exhaust Valve Data There is no valve adjustment possible on this engine.
Max lift Inlet 9.64mm @ 101° After
TDC (Top Dead Centre)
Max lift Exhaust 9.84mm @ 115° Before
TDC
Inlet opens (top of ramp) 6° Before TDC
Inlet closes 28° After TDC
Exhaust opens 41° Before TDC
Exhaust closes 6° After TDC
Valve stem diameter
- Inlet 6.928–6.943mm
- Exhaust 6.918–6.933mm
Valve spring free length 51.1mm
Valve guide bore diame-
ter
- min 6.958mm
- max 6.973mm
Valve face angle
- Inlet 60.5°
- Exhaust 45.17°
Valve length 131.9–132.4mm
Valve sealing Stem seal with sealing
washer
Valve head depth (below
cylinder head surface)
- Inlet 0.89–1.39mm
- Exhaust 0.95–1.45mm
Valve rim thickness 2.98–3.38mm
Valve Clearances (en-
gine cold)
- Inlet 0.19–0.27mm
(1)
- Exhaust 0.56–0.64mm
(1)
(1) The values refer to the tappet adjuster end of the

valve rockers.
15 - 88 9823/0300-1 15 - 88
15 - Engine
30 - Valve
00 - General
Calibrate Valve Springs

1. Use a vernier caliper to measure the free length
Valve Seat check of the spring.
1. Thoroughly clean the valves and their seats with 2. With a dynamometer, subject the spring to two
suitable degreasing agent. different loads and check that the length of the
spring corresponds to the values given in the
2. Measure the seal width of each valve and the table below.
valve recess from the cylinder head.
Table 74.
Table 73. Item Load (Kg) Length (mm)
Valve Recess Wear Limit Z Without load 48.35
0.110-0.150mm 1.100mm (0.0433in) Z1 20.4 30.00
(0.0043-0.0059in) Z2 34.8 22.00
If the dimensions measured do not comply with the
above- mentioned values, replace the valves. Figure 195.
The seats must be replaced by a rectification
workshop.
Make sure you always lubricate the valve and valve Z

seat contact surfaces to prevent oxidation.
Figure 194.
A Z1
Z2
A Valve spring
C B Valve Guides Check
1. With a micrometer, measure the diameter of the
valve stem.
2. With a internal dial gauge, measure the diameter
of the valve guides.
3. After the guides are installed in the cylinder head,
measure the height of the guides from the rocker
A arm support surface.
4. Make sure you take the measurements in
different points to find any ovalisation and/or
concentrated wear.
Table 75.
D Item Dimension Clearance Wear limit
(mm) (mm) (mm)
D 5.978 -
5.990 0.040 -
0.100
E 5.030 - 0.064
A Valve Seat 6.042
B Cylinder head
C Valve recess F 7.000 -
D Seal width 7.020
15 - 89 9823/0300-1 15 - 89
15 - Engine
30 - Valve
00 - General
F
C
B
A
D
A Valve guide diameter

B Valve guide housing diameter
A Valve guide
B Valve stem
C Rocker arm support surface
D Valve stem diameter
E Valve guide diameter
F Valve guide height
Valve Guides Replacement

The intake and exhaust guides are both made out
of grey iron with pearlitic phosphoric matrix and they
have the same dimensions.
The guides are not pre-finished, so they must be

processed after press-fitting along with the seats.
Contact a workshop for these operations.
Table 76.
Item Dimensions (mm)
A 10.000 - 10.015
B 10.045 - 10.054
15 - 90 9823/0300-1 15 - 90
15 - Engine
30 - Valve
09 - Valve Bridge
09 - Valve Bridge
Remove and Install
The Valve Bridge- Remove and Install procedure is

given in the Rocker Assembly- Remove and Install
procedure. Refer to: PIL 15-42-00.
15 - 91 9823/0300-1 15 - 91
15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ........................................................................................................................... 15-93

15-33-06 Big-End Bearing ............................................................................................................. 15-99
15 - 92 9823/0300-1 15 - 92
15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................... 15-93 The connecting rod connects the piston to the
Technical Data ............................................... 15-94 crankshaft. They form a simple mechanism that
Component Identification ............................... 15-95 converts reciprocating motion into rotating motion.
Check (Condition) .......................................... 15-95
Connecting rods are usually made of high strength
Calibrate ........................................................ 15-96 steel. They are not rigidly fixed at either end, so that
Remove and Install ....................................... 15-97 the angle between the connecting rod and the piston
Disassemble and Assemble .......................... 15-98 can change as the rod moves up and down and
rotates around the crankshaft.
The small end of the connecting rod attaches to the

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

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

the big end of the connecting rod so that pressurised
lubricating engine oil squirts out on to the thrust
side of the cylinder wall to lubricate the travel of the
pistons and piston rings.
15 - 93 9823/0300-1 15 - 93
15 - Engine
33 - Connecting Rod
00 - General
Technical Data
Table 77. Connecting Rods Data

Connecting rod type Split fracture
Table 78. Connecting Rods Dimension

Item Dimension Clearance Wear Limit
A 169.980mm-170.020mm
(6.6921-6.6937in)
B 30.020-30.030mm 0.025-0.030mm 0.060mm (0.0024in)
(1.1819-1.1823in) (0.0010-0.0012in)
D 29.995-30.000mm
(1.1809-1.1811in)
C 54.035-54.066mm
(2.1274-2.1286in)
E 67.700-68.000mm
(2.6654-2.6772in)
F 29.750-29.790mm
(1.1713-1.1728in)
(1) Split fracture type connecting rods MUST NOT be dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
Figure 198.
E
D
Table 79. Gudgeon Pin-Parallel Deviation

Gudgeon pin axis devia- 0.015-0.030mm
tion (0.0006-0.0012in)
15 - 94 9823/0300-1 15 - 94
15 - Engine
33 - Connecting Rod
00 - General
Component Identification Check (Condition)

Figure 199. 1. Check the connecting rods for signs of bending.
In the event of sufficient liquid entering the
engine, a hydraulic lock can occur. This may
result in bending of one or more of the connecting
rods. Bending of a connecting rod(s) can occur
even when the engine is cranked by the starter
motor. Bending of the connecting rod may be
1 very slight and can be checked prior to a full
engine strip down. For the checking procedure
refer to Calibration (PIL 15-36-00)
2. Check the connecting rod for signs of damage
and excessive wear.
2
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
3
6
5
1 Piston rings
2 Piston (refer to PIL 15-36)
3 Connecting rod
4 Bearing cap (refer to PIL 15-12)
5 Bolts (refer to PIL 15-12)
6 Bearing shells (refer to PIL 15-12)
15 - 95 9823/0300-1 15 - 95
15 - Engine
33 - Connecting Rod
00 - General
Calibrate Figure 200.

D
Dimension Check
A
Make sure that the connecting rod contact surfaces B
are perfectly clean and not damaged.
Mark some references on the connecting rods, caps,

pistons and gudgeon pins to avoid unintentionally
mixing up the components during the assembly C
phase. Failure to do this action will result in engine
malfunction.
The connecting rod and crankshaft half-bearings

must be replaced every time they are disassembled
to prevent seizure,as they are made of special lead-
free material.
1. Install the new half-bearings in the connecting

rod cap and the big end.
A Gudgeon pin
2. Install the connecting rod cap on the big end with B Connecting rod small end
the screws. C Connecting rod large end
D Dial gauge
3. Tighten the screws to the correct torque value.
Torque: 25N·m 3. Check the axis parallelism of the connecting rod
large end and small end with a dial gauge.
4. Measure the diameters and length with a suitable
measuring instrument. 4. Parallel deviation must not exceed
0.015-0.030mm (0.0006-0.0012in) at the end of
5. Make sure the measurements are within the the gudgeon pin.
allowable limits.
5. If the parallel deviation do not comply within the
Refer to: PIL 15-33-00. specified limit, replace the connecting rod with a
new one.
6. Make sure that the connecting rod and
crankshaft half-bearings are coupled properly.
Connecting rod-piston-gudgeon pin
7. The connecting rod half-bearings are also assembly weight check
supplied with undersized dimensions, with
respect to the nominal dimension of 0.25mm and Before carrying out the pre-assembly,check that the
0.50mm. weight difference between the two connecting rod-
piston-gudgeon pin assembly does not exceed 8 g,
8. If the connecting rod small end diameter does not to prevent abnormal weight imbalances.
match perfectly with that of the gudgeon pin, then
it is necessary to replace the small end bearing
to obtain the correct coupling.
9. Lubricate the contact surfaces with oil to prevent
oxidation.
Gudgeon pin axis deviation check

1. Lubricate the gudgeon pin and the seat of the
connecting rod small end.
2. Put the gudgeon pin into the connecting rod small
end.
15 - 96 9823/0300-1 15 - 96
15 - Engine
33 - Connecting Rod
00 - General
Figure 201. Remove and Install
The removal and installation procedure for one

piston and connecting rod assembly is exactly the
same. Refer to: PIL 15-36-00.
15 - 97 9823/0300-1 15 - 97
15 - Engine
33 - Connecting Rod
00 - General
The disassemble and assemble procedure for one

piston and connecting rod assembly is exactly the
same. Refer to: PIL 15-36-00.
15 - 98 9823/0300-1 15 - 98
15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
06 - Big-End Bearing Introduction

Introduction .................................................... 15-99 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-100 bearings at the big-end of the connecting rod.
15 - 99 9823/0300-1 15 - 99
15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
Check (Condition)
1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
3. Renew any parts that are worn or not within the
specified tolerances.
15 - 100 9823/0300-1 15 - 100

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-103

15-36-03 Piston Ring ................................................................................................................... 15-111
15 - 101 9823/0300-1 15 - 101

Notes:
15 - 102 9823/0300-1 15 - 102

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-103 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-104 expanding combustion gases in the combustion
Component Identification ............................. 15-106 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-107 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-108
Disassemble and Assemble ........................ 15-108 The pistons are cast from aluminium alloys for
increased strength and improved fatigue life.
The connecting rod is attached to the piston by a

swivelling piston pin. This pin is mounted within the
piston, The pin itself is of hardened steel and is fixed
in the piston, but free to move in the connecting rod.
The pins are prevented from moving sideways and
the ends of the pin digging into the cylinder wall by
circlips.
15 - 103 9823/0300-1 15 - 103

15 - Engine
36 - Piston
00 - General
Technical Data
Table 80. Piston ring end gap

Piston ring Ring end gap (H)
Top ring 0.100-0.300mm (0.0039-0.0118in)
Middle ring 0.250-0.500mm (0.0098-0.0197in)
Bottom ring 0.250-0.400mm (0.0098-0.0157in)
Figure 202.
Table 81. Piston ring clearance

Item no Piston ring Clearance
A Top ring 0.110-0.150mm (0.0043-0.0059in)
B Middle ring 0.070-0.115mm (0.0027-0.0045in)
C Bottom ring 0.030-0.065mm (0.0012-0.0025in)
15 - 104 9823/0300-1 15 - 104

15 - Engine
36 - Piston
00 - General
Figure 203.
Table 82. Piston Height

Piston height above crankcase (cold) 0.030-0.375mm (0.0012-0.0148in)
15 - 105 9823/0300-1 15 - 105

15 - Engine
36 - Piston
00 - General
Figure 204.
A TOP
2
B 3
TOP
C
4a
TOP
1
4
6
1 Piston 2 Piston ring compression (no 1)

3 Piston ring compression (no 2) 4 Piston ring compression (oil control ring)
5 Connecting rod 6 Piston pin
7 Circlips
15 - 106 9823/0300-1 15 - 106

15 - Engine
36 - Piston
00 - General
Operation
The groove around the diameter of the upper The sprayers spray oil directly to the under side of
main bearing shells allows oil transfer to an oil the pistons effectively transferring heat away from
sprayer located in the cylinder block bearing saddle. the top of the pistons. Oil spray also enters the small
Sprayers are installed at four of the main bearing end bearing bushes via a feed hole on the top of each
positions. Since only four oil sprayers are required connecting rod.
(one for each piston) there is no sprayer at the main
bearing next to the flywheel end of the crankshaft.
Figure 205.
A Groove B Oil sprayer

C Pistons D Bearing bushes
E Crankshaft
15 - 107 9823/0300-1 15 - 107

15 - Engine
36 - Piston
00 - General
Check (Condition) Disassemble and Assemble

1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
Important
diameter, piston pin bore and the clearance in • Always put labels on the piston and its related
the piston ring grooves to confirm they are within connecting rod and gudgeon pin to ensure
service limits. correct installation. If you assemble the piston
Refer to: PIL 15-36-00. and connecting rod incorrectly, this will cause
serious engine damage.
2. Check the piston pin for signs of damage and • Always replace the connecting rod big end
excessive wear. Measure the pin diameter to bearings in pairs.
confirm it is within service limits. Refer to Piston. • Make sure that all the required dimensions
for the piston, connecting rod and the
Refer to: PIL 15-36-00. gudgeon pin are strictly followed. Refer to: PIL
15-36-00. Refer to: PIL 15-33-00.
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a Disassemble
complete assembly.
1. Remove the retainer ring.
Figure 206.
A
B
A
A Retainer ring
B Gudgeon pin
C Connecting rod
D Piston
2. Remove the gudgeon pin to disconnect the
connecting rod from the piston.
3. Put labels on the piston, connecting rod and the
gudgeon pin for identification during assembly.
4. Remove the seal rings from the piston.
15 - 108 9823/0300-1 15 - 108

15 - Engine
36 - Piston
00 - General
E
E
D
D
J
D Piston D Piston
E Seal rings E Seal rings
J Gudgeon pin hole centre
Assemble
8. Loosen the screws and remove the connecting
1. Do a dimensional check of the connecting rod rod cap.
and gudgeon pin.
9. Replace the big end bearings with new bearings.
2. Do a dimensional check of the piston.
10. Put the connecting rod in position inside the
3. Do a dimensional check of the piston seal rings. piston.
4. Install the piston rings in the sequence given Figure 210.

below: K
D
Figure 208.
H
B A
L A
G
C
C
F
D A Retainer ring
B Gudgeon pin
C Connecting rod
D Piston D Piston
F Scraper ring K Connecting rod cap screws
G Middle seal ring L Big end bearings
H Top seal ring
11. Make sure the piston and the connecting rod
4.1. Scraper ring. holes are aligned.
4.2. Middle seal ring. 12. Put the gudgeon pin inside the piston through the
4.3. Top seal ring. connecting rod.
5. Make sure that the rings are installed with the

identification facing the piston crown.
6. Measure the seal ring clearance in its seat.
7. Align the end gap of each seal ring with the centre
of the gudgeon pin hole.
15 - 109 9823/0300-1 15 - 109

15 - Engine
36 - Piston
00 - General
Figure 211.
B Gudgeon pin
M Gudgeon pin seat
13. Put the locking ring inside the seat of the piston
to lock the gudgeon pin.
14. Lubricate the piston skirt and piston rings with
ITP GX100 grease.
15 - 110 9823/0300-1 15 - 110

15 - Engine
36 - Piston
03 - Piston Ring
03 - Piston Ring Introduction

Introduction .................................................. 15-111 Gas sealing inside the piston is achieved by the use
Technical Data ............................................. 15-112 of piston rings. The rings are loosely installed into
Calibrate ...................................................... 15-112 grooves in the piston. The rings are split at a point in
the rim, to allow them to press against the cylinder
with a light spring pressure.
Two types of ring are used:
- Upper rings have solid faces and provide gas

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

shaped profile, to act as oil scrapers.
15 - 111 9823/0300-1 15 - 111

15 - Engine
36 - Piston
03 - Piston Ring
Technical Data Calibrate
Refer to Piston-Technical Data PIL 15-36-00 . Piston Rings End Gap

1. Insert a seal ring in the cylinder and measure the
ring end gap which a thickness gauge.
2. Do step 1 for all the seal rings.
3. If the ring end gap values are not within the
specified range, replace the seal rings.
4. Make sure you replace the seal rings as a set.
Seal Ring Seat Clearance

1. Measure the clearance of each seal ring in its
seat with a thickness gauge.
2. If the clearance values are not within the
specified range, replace the seal rings and the
piston.
15 - 112 9823/0300-1 15 - 112

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-115
15 - 113 9823/0300-1 15 - 113

Notes:
15 - 114 9823/0300-1 15 - 114

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 115 9823/0300-1 15 - 115

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-117

15-42-01 Rocker Arm .................................................................................................................. 15-126
15-42-03 Rocker Shaft ................................................................................................................ 15-127
15-42-06 Rocker Cover ............................................................................................................... 15-128
15-42-09 Push Rod ..................................................................................................................... 15-131
15-42-21 Tappet ........................................................................................................................... 15-133
15-42-24 Tappet Cover ................................................................................................................ 15-139
15 - 116 9823/0300-1 15 - 116

15 - Engine
00 - General
Introduction .................................................. 15-117 The rocker assembly is an indirect valve actuating
Component Identification ............................. 15-118 system consisting of rocker arms and a shaft.
Operation ..................................................... 15-119
Check (Condition) ........................................ 15-120 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Remove and Install ..................................... 15-120 movement at the poppet valve to open it. One end is
Disassemble and Assemble ........................ 15-123 raised and lowered by a rotating lobe of the camshaft
via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 117 9823/0300-1 15 - 117

15 - Engine
00 - General
Figure 212.
B C D
E
A Rocker arm shaft B Rocker arm distancing spring

C Rocker arm shaft support D Exhaust rocker arm
E Intake rocker arm
Figure 213.
F
G
J K
L H
F Rocker arm body G Hydraulic tappet oil refill line

H Valve tappet lubrication line J Valve tappet
K Hydraulic tappet L Oil flow line
15 - 118 9823/0300-1 15 - 118

15 - Engine
00 - General
Operation
When the camshaft lobe raises the push-rod, the head to a small transfer gallery under the rocker
push-rod pushes the rocker arm up. Due to this the shaft pedestal. The oversize rocker shaft fixing bolt
rocker arm presses down on the valve stem to open hole allows oil to pass into a drilling in the centre of
the valve. When the rocker arm returns due to the the rocker shaft. Further cross drillings transfer oil
camshafts rotation, the valve spring closes the valve. to each of the rocker pivot bushes. A cross drilling
in each rocker transfers oil to the top of the rocker
Lubrication where it flows by gravity along a groove to the rocker
tip.
Oil is fed from the main gallery through a drilling
which passes up through the crankcase and cylinder
Figure 214.
1 Main gallery 2 Small transfer gallery

3 Shaft pedestal 4 Rocker shaft fixing bolt hole
5 Centre rocker shaft drilling 6 Cross drillings
7 Rocker pivot bushes 8 Cross drilling
9 Groove
15 - 119 9823/0300-1 15 - 119

15 - Engine
00 - General

1. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Measure
Before Removal
the rocker shaft diameter and rocker bearing 1. Make sure that the engine is safe to work on. If
bushes to confirm they are within service limits. the engine has been running, let it cool before
Refer to Technical Data. Note: The rocker you start the service work.
bearing bushes are not renewable. If a rocker
bearing bush is damaged or worn the rocker 2. Get access to the engine.
must be renewed as a complete assembly.
3. Disconnect and remove the fuel pipes from the
Refer to: PIL 15-42. fuel injectors.
2. Make sure that all oil-ways and cross drillings in Refer to: PIL 18-96.
the rocker shaft, rocker arms and pedestals are
clear and free from debris. Use an air line to blow 4. Remove the rocker cover.
through cross drillings. Refer to: PIL 15-42-06.
Remove
1. Remove the rocker shaft fixing screws.
Figure 215.
A Rocker shaft fixing screw (x4)

B Rocker arm assembly
C Cylinder head
2. Make sure that you keep all the fixing screws in
their original positions.
3. Lift the rocker arm assembly from the cylinder
head completely.
15 - 120 9823/0300-1 15 - 120

15 - Engine
00 - General
Figure 216. 5. Remove the push rods from the crankcase.

B
Before Installation
damage and corrosion. If components within the
rocker assembly are damaged or worn.
2. Make sure that all oilways and cross drillings in
the cylinder head, rocker shaft and pedestals are
clear and free from debris. Use an air line to blow
through the cross drillings.
C 3. Use a suitable degreasing agent to clean the top
of the cylinder head.
Install
steps.
2. Insert the push rods into the crankcase. Make
sure that they engage with the camshaft tappets.
Figure 218.
E E
C Cylinder head
4. Lift off the valve bridge pieces from the pairs of
F
inlet and exhaust valves.
Figure 217.
D
E Push rod
F Camshaft tappet
E
3. Install the bridge pieces on to the pairs of inlet
and exhaust valves in the cylinder head.
D Valve bridge (x6)

E Push rod (x6)
15 - 121 9823/0300-1 15 - 121

15 - Engine
00 - General
Figure 219. 6. Make sure that the rocker arm assembly is

D seated properly on the push rod.
D
7. Make sure that you put the crankshaft gear key
in the position as shown to avoid the rocker arm
rod bending at the time of tightening the fixing
screws.
Figure 222.
C
C Cylinder head
D Valve bridge
4. Align the rocker arm assembly on a level surface.
5. Make sure that you install the rocker arm
assembly on the cylinder head with respect to the
plug and the holder.
J
Figure 220.
J Gear key
E H
8. Put the rocker arm fixing screws and tighten the
screws in the sequence shown.
Figure 223.
A
2 1 3
4
E Push rod
H Plug
Figure 221.
B
A Rocker shaft fixing screw

B 9. Tighten the screws to the correct torque value.
After Installation
G 1. Measure and adjust the valve clearances.
B Rocker arm assembly Refer to: PIL 15-42-06.
G Holder
15 - 122 9823/0300-1 15 - 122

15 - Engine
00 - General
3. Install and connect the fuel pipes to the fuel Disassemble and Assemble
injectors.
Refer to: PIL 18-96. Special Tools
Table 83. Torque Values Insertion Pliers for 892/12425 1
Hydraulic Tappets
Item Nm
A 25
Before Disassembly
2. Remove the rocker assembly.
Disassemble
1. Remove the retainer ring.
Figure 224.
B
A
C
D
A Discharge rocker arm

B Hydraulic tappet
C Retainer
D Shoulder ring
2. Remove the shoulder ring.
3. Remove the rockers and the holders from the
rocker shaft.
15 - 123 9823/0300-1 15 - 123

15 - Engine
00 - General
F
J
E
H
G
A
B
E Rocker shaft
F Holder
B Hydraulic tappet
G Holder 1
H Chamber
4. Label the rockers and the holders to make sure J Pad
that they are installed in the correct positions on
2.4. Position the rocker arm in the pliers.
assembly.
2.5. Use the pliers to push the tappet through
5. Remove the tappets from the rocker. the rocker arm until the tappet is properly
inserted.
Figure 226.
3. Lubricate the rocker shaft with clean engine oil.
4. Install the rocker arms in the correct position, turn
the rocker shaft with the lower height towards the
timing gear system side.
5. Put the lock ring into the seat of the rocker shaft.
Figure 228.
B A D
L
E

B Hydraulic tappet
K
6. Check (Condition) of the rocker arm assembly for
E C
signs of damage and excessive wear.
Assemble C
C Retainer
1. The assembly procedure is the opposite of D Shoulder ring
the disassembly procedure. Additionally do the E Rocker shaft
following steps. K Seat
L Rocker shaft lower height
2. Install the tappets into the rocker arm.
6. Position the fixing screw support surface facing
2.1. Insert the tappets into the hydraulic tappet
upwards.
insertion pliers.
Special Tool: Insertion Pliers for Hydraulic 7. Put the two shoulder rings on the rocker shaft.
Tappets (Qty.: 1)
8. Sequentially put the suction rocker arm, the
2.2. Fill the chamber of the tappet with oil. holder and the discharge rocker arm on the
2.3. Put the pad on the tappet. rocker shaft.
15 - 124 9823/0300-1 15 - 124

15 - Engine
00 - General
Figure 229.
E
M
C A
N
G F

C Retainer
D Shoulder ring
E Rocker shaft
F Holder
G Holder 1
M Spring
N Suction rocker arm
9. The discharge rocker arm is shorter than the
suction rocker arm.
10. Install the spring on the rocker shaft.
11. Do the steps 8 and 10 for all the remaining rocker
arms.
12. Install the holder 1 with the last pair of rocker arm
towards the flywheel.
13. The spring makes sure that the holder and the
holder 1 are kept in place.
14. Make sure that the rockers are installed in their
original positions along the rocker shaft.
15. Put the shoulder rings and the lock ring to lock all
the components on the rocker shaft.
After Assembly
1. Install the rocker assembly.
15 - 125 9823/0300-1 15 - 125

15 - Engine
01 - Rocker Arm
01 - Rocker Arm
Remove and Install
Refer to Rocker Assembly-Remove and Install. Refer

to: PIL 15-42-00.
15 - 126 9823/0300-1 15 - 126

15 - Engine
03 - Rocker Shaft
03 - Rocker Shaft
Remove and Install
Refer to Rocker Assembly-Remove and Install and

Disassemble-Assemble PIL 15-42-00 .
15 - 127 9823/0300-1 15 - 127

15 - Engine
06 - Rocker Cover
06 - Rocker Cover Introduction

Introduction .................................................. 15-128 The rocker arm cover is installed over the rocker and
Remove and Install ..................................... 15-129 fittings. It carries the engine oil for the lubrication of
the rocker components.
15 - 128 9823/0300-1 15 - 128

15 - Engine
06 - Rocker Cover
Special Tools 5 1 3 7
Rocker Arm Cover 892/12426 1
Mounting Studs
Before Removal
8 4 2 6
2. Clean the engine.
Figure 236. 8. Lift the rocker cover from the cylinder head
A 9. Discard the gasket.
10. The rocker cover injector seals must be replaced.
B
Install
1. Remove all oil and sludge contamination from
inside the valve chamber.
C 2. Use a new rocker arm cover gasket.

3. Make sure you align the gasket on the cylinder
A Rocker arm cover head with the rocker cover fastening screws.
B Screws 4. Locate the two guide pins before mounting the
C Gasket rocker arm cover.
Remove Special Tool: Rocker Arm Cover Mounting Studs

(Qty.: 1)
5. Put sleeves/covers on the four injectors to
2. Remove the high pressure fuel pipes. prevent from damage.
Refer to: PIL 18-96-03. 6. Apply a Vaseline lubricant to the seals.
3. Remove the fuel bleed off fuel pipes.
4. Disconnect the electrical connectors at the fuel
injectors.
5. Disconnect the electrical connector at the coolant
temperature sensor.
6. Move the electrical harness away from the rocker
cover.
7. Progressively remove the rocker arm cover
screws from 1 to 8 in reverse order, starting at
bolt 8.
15 - 129 9823/0300-1 15 - 129

15 - Engine
06 - Rocker Cover
Figure 238.
B
E
D
F
A
C
D
A Rocker arm cover
B Screws
C Gasket
D Guide pins
E Seal (lubricate upper part)
F Seal (lubricate inner part)
7. Install the rocker arm cover and put the screws
in sequence from 1 to 8.
9. Remove the sleeves/covers.
After Installation
1. The high pressure fuel pipes must be replaced
with new parts.
2. Start the engine and check for oil and fuel leaks.

Item Nm
B 10
15 - 130 9823/0300-1 15 - 130

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

Introduction .................................................. 15-131 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-132 and close the valves. They are moved by the cams
on the camshaft. One end is pushed up by the cam
and the other end makes contact with the rocker
arms which rotates and pushes the valve open.
15 - 131 9823/0300-1 15 - 131

15 - Engine
09 - Push Rod
Remove and Install
Refer to Rocker Assembly-Remove and Install PIL

15-42-00
15 - 132 9823/0300-1 15 - 132

15 - Engine
21 - Tappet
21 - Tappet Introduction
Introduction .................................................. 15-133
Technical Data ............................................. 15-134
Hydraulic Tappet
Component Identification ............................. 15-135 A hydraulic tappet is a device for maintaining zero
Operation ..................................................... 15-136 valve clearance in an internal combustion engine.
Check (Condition) ........................................ 15-137 The zero tolerance allows the valve train to operate
with zero clearance leading to quieter operation,
Calibrate ...................................................... 15-137
longer engine life, and eliminating the need for
Remove and Install ..................................... 15-138 periodic adjustment of valve clearance.
15 - 133 9823/0300-1 15 - 133

15 - Engine
21 - Tappet
Technical Data
Tappets Dimensions
Figure 239.
A
C
B
Table 85.
Item Dimension Aspect Dimension
A Perpendicularity 0.02mm (max)
B Length 46.5 ± 0.2mm
Clearance between Tappet and Housing

Figure 240.
F
D
E
E Tappet
F Tappet housing
Table 86.
Item Dimensions Clearance Wear Limit
C 11.966-11.984mm
0.060-0.105mm 0.080mm
D
(1)
12.000-12.018mm
(1) Measure the diameter at two points. The difference between the two values measured must not be more
than be 0.02mm.
15 - 134 9823/0300-1 15 - 134

15 - Engine
21 - Tappet
Figure 241.
F
E
H B
A Low pressure chamber B High pressure chamber

C Hydraulic tappets oil refill pipe D Retaining ring
E Piston F Unidirectional valve
G Tappet body H Spring
15 - 135 9823/0300-1 15 - 135

15 - Engine
21 - Tappet
Operation requires the removal and replacement of oil and

hydraulic tappets.
Hydraulic Tappet
The operating principle of the hydraulic tappet is
based on the incompressibility of the liquid and on
controlled leakage between the piston and the tappet
body.
A constant supply of pressurised oil is provided to the

low pressure chamber. The pressurized oil can only
get the access to the high pressure chamber through
the unidirectional (non-return) valve.
The high pressure chamber is filled when the rocker

arm is on the base radius of the cam and the spring
holds the piston against the valve stem preventing
from system play as well as vibration and noise.
Due to the spring movement, the tappet extends.

This creates a small pressure decrease in the high
pressure chamber to open the non-return valve. Oil
is then transferred from the low pressure chamber
to the high pressure chamber to restore the proper
amount of oil required to eliminate any play in the
valves.
Difficult Operating Conditions

For proper operation of the hydraulic tappets it is
essential that the low pressure chamber of the piston
is always full of oil.
In some conditions this may not occur (due to the

fact that oil leaks away when the engine is switched
off, which can also partially drain the tappets): this
situation will result in play that will occur with a typical
noise similar to ticking, not to be confused with the
normal ticking of the injectors.
When the engine is cold, the tappet filling time could

be very long if the oil used is not suitable for the
specific environmental conditions.
If the engine is very hot or at idle speed, oil pressure

may be low, and small air bubbles could form in
the circuit. Because of this, the lubricant becomes
compressible, thus compressing the tappet slightly
and producing valve play which is responsible for the
ticking sound.
In all cases, the ticking should not last too long (max
5 minutes) if not, the problem will surely be due to
the poor quality of the oil, wear or impurities that,
transported by the oil, can infiltrate between the ball
valve and its seat inside the piston This affects the
operation of the tappet itself. In these cases you must
replace the oil or the hydraulic tappets.
Continuous ticking or abnormal sound for prolonged

periods is a symptom of a possible malfunction, and
15 - 136 9823/0300-1 15 - 136

15 - Engine
21 - Tappet
Check (Condition) Calibrate
Tappets and Tappet Housing Check Tappets Dimensions

1. Put the tappet on a V-notch surface plate. Use a surface plate and a dial gauge as shown.
Check the perpendicularity of the plate, making the
2. Measure the following dimensions of the tappet tappet rotate in the direction of the arrow. With a
and tappet housing. gauge, check the length of the tappet to assess wear.
2.1. Perpendicularity of the base with a dial The values measured must be within tolerances.
gauge. Refer to: PIL 15-42-21.
2.2. Length of the tappet to assess the wear. Figure 242.

2.3. Diameter of the tappet housing with an
internal dial gauge.
3. Make sure that you measure the housing
diameter at two locations and the difference A
between the two values should not be more than C
0.02mm. B
4. Measure the clearance between the tappet and

the tappet housing from the values derived in
step 2.
5. Make sure that all the values are within the
allowable limits.
A Tappet diameter
B Tappet length
C Perpendicularity
Clearance between Tappet and Housing

Use an internal dial gauge to measure the diameter
of the tappet housings. Measure quota in two
different points. The difference between the two
values measured must be within tolerance. Refer to:
PIL 15-42-21.
Figure 243.
F
D
E
D Quota
E Tappet
F Tappet housing
15 - 137 9823/0300-1 15 - 137

15 - Engine
21 - Tappet
Remove and Install
The tappets can be taken out when the engine is

inverted and when the camshaft is removed. Refer
to Camshaft- Remove and Install PIL 15-15-00 .
15 - 138 9823/0300-1 15 - 138

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

steps.
It is not necessary to remove the tappet covers 2. Inspect the tappet cover seals for signs of
unless a new rocker cover is to be installed. It is damage. Replace any damaged seals.
necessary to remove the tappet covers to measure
and adjust the valve clearances. Refer to Valve- 3. Install the tappet covers. Tighten the screws to
Adjust, Valve Clearances (PIL 15-30). the correct torque value.
Remove Table 87. Torque Values

Item Nm
the engine has been running, let it cool before A 9
3. Clean the tappet covers and the adjacent areas
of the rocker cover. Refer to Engine - Clean.
Important: Make sure that the screws do not fall
into the engine.
4. Remove the tappet cover screws.
5. Keep the screws away from the engine.
6. Use a screwdriver in the slot to remove the tappet
covers. Make sure that dirt or debris does not fall
into the engine.
Figure 244.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 139 9823/0300-1 15 - 139

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-141

15-45-03 Drain Plug .................................................................................................................... 15-145
15-45-09 Dipstick ......................................................................................................................... 15-146
15-45-10 Dipstick Pipe ................................................................................................................ 15-147
15 - 140 9823/0300-1 15 - 140

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-141 Figure 245.
Technical Data ............................................. 15-142
Component Identification ............................. 15-142
Remove and Install ..................................... 15-143
A
A Oil Sump
15 - 141 9823/0300-1 15 - 141

15 - Engine
45 - Oil Sump
00 - General

Oil sump type Wet
Oil sump capacity 7.5L
A
A Oil Sump
15 - 142 9823/0300-1 15 - 142

15 - Engine
45 - Oil Sump
00 - General
Remove and Install 6. Remove the oil intake pipe and the gasket.
Discard the gasket.
Oil Figure 248.
Oil is toxic. If you swallow any oil, do not induce F
contains harmful contaminants which can cause skin H
cancer. Do not handle used engine oil more than
to prevent skin contact. Wash skin contaminated with G
waste disposal sites. F Screw
CAUTION! Oil will gush from the hole when the drain G Oil intake pipe
plug is removed. Keep to one side when you remove H Gasket
the plug.
7. Remove the oil vapour pipes.
Before Removal Figure 249.
J
2. Drain the engine oil.
Remove
1. Remove the screws that attach the oil sump to
the bedplate.
2. Insert plates in the areas shown by the arrows.
Figure 247.
E E J Oil vapour pipes
Install
D 1. Apply Loctite 648 on the threads of the oil vapour
pipes.
2. Install the oil vapour pipes.
3. Put a new gasket in the seat of the oil intake pipe.
4. Attach the oil intake pipe onto the bedplate with
E E the screws.
D Oil sump 5. Tighten the screws to the correct torque value.

E Plate insertion areas
6. Make sure that the oil sump is clean and free from
3. Lift the plates to remove the oil sump. contamination.
4. Remove the remaining sealant from the oil sump 7. Make sure that the contact faces on the oil sump
and bedplate contact surfaces. and bedplate are clean.
5. Remove the screws that attach the oil intake

pipe.
15 - 143 9823/0300-1 15 - 143

15 - Engine
45 - Oil Sump
00 - General
8. Apply a bead of sealant (Loctite 5660) on the oil 16. Operate the engine, until the oil pressure low
sump contact surface to the specified thickness. warning light has extinguished.
Dimension: 2.5mm 17. Check for oil leakage.
Figure 250. 18. When the oil has cooled, check the oil level
M again, and if necessary top up with clean engine
L oil.
K Table 89. Torque Values

Item Nm
K
B 35
F 10
L 25
K Mounting studs
L Screw
M Sealant application surface
9. Install the mounting studs to help you to position
the oil sump.
10. Put the oil sump on the bedplate. Make sure that
the screw holes are aligned.
11. Strictly follow the torque tightening sequence.
Tighten the screws to the correct torque value.
Figure 251. Torque Sequence
4 3 2 20 19
5 18
6 17
7 16
8 15
9 14
10 11 1 12 13
12. After you tighten all of the screws, loosen screw

no.1 and tighten again to the correct torque
value.
13. Clean and install the drain plugs with a new O-
ring. Tighten the plug to the correct torque value.
the recommended oil to the MAX mark on the
dipstick.
make sure it is secure.
15 - 144 9823/0300-1 15 - 144

15 - Engine
45 - Oil Sump
03 - Drain Plug
03 - Drain Plug Figure 258.
Remove and Install

Oil
Oil is toxic. If you swallow any oil, do not induce
contains harmful contaminants which can cause skin
oil thoroughly in warm soapy water. Do not use petrol, B C
CAUTION! It is illegal to pollute drains, sewers B Drain plug
or the ground. Clean up all spilt fluids and/or C O-ring
contaminated materials must be disposed of in Install
waste disposal sites. 1. Clean and install the drain plug with a new O-ring.
Remove 2. Tighten the plug to the correct torque value.

Drain the oil when the engine is warm as
the recommended oil to the MAX mark on the
contaminants held in suspension will then be drained
dipstick.
with the oil.
1. Gain access to the oil sump. make sure it is secure.
2. Place a container of suitable size below the drain 5. Operate the engine, until the oil pressure low
plug. warning light has extinguished.
3. Remove the oil filler cap. 6. Check for oil leakage.
Figure 257. 7. When the oil has cooled, check the oil level
oil.

A Item Nm
B 35
A Oil filler cap
CAUTION! Oil will gush from the hole when the

drain plug is removed. Keep to one side when
you remove the plug.
4. Remove the oil sump drain plug and O-ring. Let

the oil drain out.
15 - 145 9823/0300-1 15 - 145

15 - Engine
45 - Oil Sump
09 - Dipstick
09 - Dipstick
Check (Level)
1. Remove the engine oil dipstick.
2. Make sure that the oil level is at the MAX mark
on the dipstick.
3. If the oil level is below the required quantity, fill
the engine with the recommended oil through the
oil filler point.
Figure 259.
A Oil filler cap

Figure 260.
D Dipstick
E Maximum level mark
F Minimum level mark
15 - 146 9823/0300-1 15 - 146

15 - Engine
45 - Oil Sump
10 - Dipstick Pipe
10 - Dipstick Pipe 2. Attach the oil dipstick pipe to the crankcase with
the screw.
Before removal
Remove C F
B
1. Remove the screw.
2. Pull out the oil dipstick pipe in the direction of the
B Dipstick pipe
arrow.
C Screw
Figure 261. F Manifold
3. Tighten the pipe on the manifold.
A 4. Check the gaskets are correctly installed.

Figure 264.
A
C
B
G
B
A Dipstick
B Dipstick pipe
C Screw
Install
A Dipstick
1. Put the new gasket on the seat of the pipe. B Dipstick pipe
G Gasket
Figure 262.
5. Put the dipstick into the pipe.
After installation
B
D 1. Start the engine and check for any leakage.
B Dipstick pipe
D Seat
E Gasket
15 - 147 9823/0300-1 15 - 147

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-149

15-51-03 Crankshaft Gear ........................................................................................................... 15-150
15-51-06 Camshaft Gear ............................................................................................................. 15-153
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-154
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-157
15-51-22 Rear Case .................................................................................................................... 15-160
15 - 148 9823/0300-1 15 - 148

15 - Engine
51 - Timing Gear
00 - General
00 - General
Introduction
The timing gears are located inside a casing at the

front end of the engine.
The engine must be timed so that the camshaft

operates the valves at the correct time relative to the
crankshaft position.
Valve timing is achieved by ensuring that the

camshaft drive gear is meshed to the crankshaft gear
at their correct angular positions, Refer to Engine-
General, Operation, The Four Stroke Cycle for more
information about valve timing.
15 - 149 9823/0300-1 15 - 149

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

3. Remove the flywheel housing. Refer to (PIL
Crankshaft / 892/01148 2 15-54).
Camshaft Timing Pin
(444/448/672 Engine) 4. Rotate the crankshaft until the camshaft locking
pin can be inserted through the gear and into the
Note: The illustrations show the engine inverted. If aligning hole in the rear gear case. Note: The
the drive gear components are being removed prior camshaft and crankshaft locking pins must be
to crankshaft or camshaft removal the engine must in position to lock the crankshaft and camshaft
be inverted. If the gear components only are being before removing the crankshaft gear.
removed (for inspection/renewal) then the engine
need not be inverted. Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 2)
Before Removal 5. Remove the taper blanking plug and insert the
crankshaft locking pin.
1. Remove the starter motor. Refer to (PIL 15-75).
15 - 150 9823/0300-1 15 - 150

15 - Engine
51 - Timing Gear
Figure 265.
7 T1
T2
6
1 Drive gear and flywheel hub fixing bolt 2 Flywheel hub

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

Make sure you retrieve the location dowel.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub.
15 - 151 9823/0300-1 15 - 151

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

Item Nm
1 47
6 11
15 - 152 9823/0300-1 15 - 152

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

the end of the camshaft and cannot be removed
individually. If the gear is damaged or worn the
complete camshaft and gear assembly must be
replaced. Refer to Camshaft- Remove and Install
(PIL 15-15).
15 - 153 9823/0300-1 15 - 153

15 - Engine
51 - Timing Gear
09 - Fuel Injection Pump Gear
Remove and Install
Note: The illustrations show the engine inverted. If 2. Loosely install the high pressure fuel pump and
the drive gear components are being removed prior fixing nut, retain the gear.
to crankshaft or camshaft removal the engine must
be inverted. If the gear components only are being 3. Remove the starter motor. Refer to (PIL 15-75).
removed (for inspection/renewal) then the engine
need not be inverted. 4. Remove the flywheel. Refer to (PIL 15-54).
Before Removal 15-54).
1. Remove the high pressure fuel injection pump.
15 - 154 9823/0300-1 15 - 154

15 - Engine
51 - Timing Gear
Figure 266.
1 Drive gear - high pressure fuel pump 2 Fixing nut - drive gear - high pressure fuel pump
Remove Install
1. Remove the fixing nut and lift out the gear. 1. Use the fixing nut to loosely install the high
pressure fuel pump and the drive gear. DO NOT
2. If the rear timing case is to be removed, remove lock the gear to the taper on the fuel pump drive
the high pressure fuel pump. shaft.
2. Follow the procedures listed under Before
Removal in reverse order. Note that the gear
fixing nut is torque tightened as part of the
15 - 155 9823/0300-1 15 - 155

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

15 - 156 9823/0300-1 15 - 156

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
Remove and Install
The illustrations show the engine inverted. If the 2. Remove the starter motor. Refer to (PIL 15-75).
drive gear components are being removed prior to
crankshaft or camshaft removal the engine must 3. Remove the flywheel. Refer to (PIL 15-54).
be inverted. If the gear components only are being
removed (for inspection / renewal) then the engine 4. Remove the flywheel housing. Refer to (PIL
need not be inverted. 15-54-03).
Before Removal
15 - 157 9823/0300-1 15 - 157

15 - Engine
51 - Timing Gear
Figure 267.
1 Z
6
5 W
4 W
X
2
Y
3
1
2
1 High duty PTO idler gear 2 Idler gear hub

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

screws and lift out the hub.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub. DO NOT remove the crankshaft Inspect
gear.
1. Check the idler gear teeth and idler gear bearing
2. Lift the High duty PTO (Power Take-Off) idler bush for signs of damage or excessive wear.
gear from the hub.
15 - 158 9823/0300-1 15 - 158

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

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

Item Nm
3 65
5 47
15 - 159 9823/0300-1 15 - 159

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

Description Part No. Qty. device (if installed).
Template for Sealant 892/01176 1 7. Remove the low duty PTO device (if installed).
Flywheel Housing to
Gear Case (4 Cyl and 6 8. Remove the flywheel. Refer to (PIL 15-54).
Cyl Elec)
Before Removal 15-54).
1. Drain the oil from the engine. Refer to (PIL 10. Remove the fuel injection pump drive gear. Refer
15-21). to (PIL 15-51).
2. Disconnect and remove the fuel pipes from the 11. Remove the oil pump. Refer to (PIL 15-60).
injectors. Refer to (PIL 18-96). 12. Remove the high duty PTO idler drive gear (if
3. Remove the fuel injection pump. Refer to (PIL installed). Refer to (PIL 15-51).
18-18). 13. Remove the crankshaft drive gear. Refer to (PIL
4. Remove the fuel lift pump. Refer to (PIL 18-21). 15-51).
5. Remove the starter motor. Refer to (PIL 15-75). 14. Remove the camshaft. Refer to (PIL 15-15).
15 - 160 9823/0300-1 15 - 160

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 268.
2
T1
3
T1
1
Y B (T2) C (T2) X X
P1 5 A (T2)
X
P1 1
Y
Y
P1 Y
X X
Z V
1 Timing gear case - rear 2 Timing case fixing bolts (x19)

3 Crankcase/bedplate assembly 4 Dowel
5 Dowel - with flats P1 Anaerobic sealant
T1 Alignment pins (Locally manufacture) T2 Sealant template (comprises: Main template
- A, Long gallery template - B, Short gallery
template - C
15 - 161 9823/0300-1 15 - 161

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

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

whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 1. Replace all the components listed under Before
put together) it will immediately start to harden. Make removal in reverse order.
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The Table 94. Torque Values
parts must be installed and torque tightened within
Item Nm
5 minutes (with a maximum permissible time of 15
minutes). 2 37
Install
1. Carefully remove all traces of the old sealing
compound from the timing case and crankcase/
bedplate assembly mating faces. Make sure
that the mating faces are clean and free from
damage. Clean the inside of the timing case
using a suitable degreaser.
2. Install two alignment pins T1 to the crankcase/
bedplate assembly.
3. Make sure that dowels are correctly located in the
crankcase. Note: Dowel 5 has flats which must
be positioned relative to dowel 4, as shown at
W. This ensures correct alignment of the timing
cover.
4. The sealant template T2 comprises three pieces.
Locate parts B and C using the holes in the
templates and fixing bolts at positions Y as
shown.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl and 6 Cyl Elec)
(Qty.: 1)
5. Use the templates B and C as a guide apply a
continuous 1.5 mm (0.060 in.) bead of sealant
P1 to the case. Remove the bolts from positions
Y. Remove the templates make sure you do not
smudge the sealant. Discard the templates.
6. Locate part A of the template T2 using the holes
in the template and bolts at positions X as shown.
7. Use the template A as a guide apply a continuous
1.5 mm (0.060 in.) bead of sealant P1 to the case.
Do not follow the template at V, instead apply a
continuous bead Z (inboard of the fixing hole).
Remove the bolts from positions X. Remove the
template make sure you do not smudge the
sealant. Discard the template.
8. Locate the timing case on the alignment pins T1
and install the timing case fixing bolts (remove
15 - 162 9823/0300-1 15 - 162

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-165

15-54-03 Housing ........................................................................................................................ 15-167
15-54-09 Gear Ring ..................................................................................................................... 15-168
15 - 163 9823/0300-1 15 - 163

Notes:
15 - 164 9823/0300-1 15 - 164

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-165 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-166 systems, where the energy source is not continuous.
In such cases, the flywheel stores energy when
torque is applied by the energy source, and it
releases stored energy when the energy source is
not applying torque to it.
In a reciprocating engine, a flywheel is used to

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

stores energy when torque is exerted on it by a firing
piston, and it releases energy to its mechanical loads
when no piston is exerting torque on it.
15 - 165 9823/0300-1 15 - 165

15 - Engine
54 - Flywheel
00 - General
Figure 269.
1 Flywheel
2 Flywheel gear ring
15 - 166 9823/0300-1 15 - 166

15 - Engine
54 - Flywheel
03 - Housing
03 - Housing Figure 271.

C
B
Remove and Install
method and device.
Remove
The flywheel housing is very heavy. Be careful while
you remove it in order to prevent it from dropping or A D
falling, as this will have serious effect on the engine
operation.
A Bolt
1. Make the machine safe. B Flywheel housing
C Reference pins
Refer to: PIL 01-03-27. D Crankcase
2. Remove the flywheel assembly. 3. Make sure that the reference pins on the
Refer to: PIL 15-54-00. crankcase are aligned with the holes in the
housing.
3. Remove the bolts that attach the housing.
4. Install the bolts.
4. Remove the flywheel housing.
5. Tighten the bolt, strictly to the following torque
Figure 270. sequence, to the correct torque value.
A Figure 272. Torque Sequence
9 8
5 6
3 2
B 1 4
7 10
A Bolt
B Flywheel housing
Install 6. Install the flywheel assembly.

1. Make sure that the housing and crankcase Table 95. Torque Values
contact surfaces are clean and free from
contamination. Item Nm
A 50
2. Install the flywheel housing.
15 - 167 9823/0300-1 15 - 167

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an oven
Before Removal to make sure that the heat is applied evenly
around the circumference. Do not heat the gear
1. This procedure requires service parts. Make ring above
sure you have obtained the correct service parts Temperature: 200°C (391.7°F)
before you start.
3. When sufficiently heated, install the gear ring into
2. Remove the flywheel from the crankshaft hub. position over the flywheel. Make sure that the
gear ring is installed the correct way around.
Figure 276.
X After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 168 9823/0300-1 15 - 168

15 - Engine
57 - Oil Filler
57 - Oil Filler
Contents Page No.
15-57-00 General ......................................................................................................................... 15-171
15 - 169 9823/0300-1 15 - 169

Notes:
15 - 170 9823/0300-1 15 - 170

15 - Engine
57 - Oil Filler
00 - General
Introduction .................................................. 15-171 The oil filler cap covers a hole in the crankcase where
Health and Safety ........................................ 15-172 the recommended engine oil can be added.
There are two locations on this engine:
• Top of the rocker cover

Figure 277.
A Rocker cover filler

• Side of the timing gear case
Figure 278.
AA
L Side oil filler
15 - 171 9823/0300-1 15 - 171

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

Notice: The oil level must be checked with the
machine level, otherwise a false indication of the Side Oil Filler
amount of oil will be given.
Remove
3. Remove the clamp from the side oil filling flange.
4. Remove the screws that attach the side oil filling
flange to the timing gear case.
5. Remove the side oil filling flange with its related
gasket.
Figure 279.
K Clamp
L Side oil filling flange
M Screw
Install
1. Put a new gasket on the side oil filling flange.
2. Attach the flange on the crankcase with the
screws.
15 - 172 9823/0300-1 15 - 172

15 - Engine
57 - Oil Filler
00 - General
Figure 280.
AA
L Side oil filling flange
M Screw
AA Gasket
4. Install the clamp on the side oil filling flange.

Item Description Nm
M Side oil filling flange screw 8
15 - 173 9823/0300-1 15 - 173

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-175

15-60-06 Pressure Relief Valve ................................................................................................... 15-182
15 - 174 9823/0300-1 15 - 174

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-175 The oil pump is a rotor type pump. The pump is driven
Component Identification ............................. 15-176 by the crankshaft.
Operation ..................................................... 15-177
Check (Condition) ........................................ 15-178 The pump consists of two rotors, one running inside
the other. The outer rotor has one lobe more than the
Remove and Install ..................................... 15-179 inner rotor, and turns on a different axis.
The pump body is mounted on the timing gear case.

It is essential to install the rotors with the reference
marks facing outwards.
Figure 281.
A Reference marks
1 Inner rotor
2 Outer rotor
3 Timing gear case
15 - 175 9823/0300-1 15 - 175

15 - Engine
60 - Oil Pump
00 - General
Figure 282.
A
D
C
A Timing gear case
B Oil pump
C Inlet port
D Outlet port
Figure 283.
G
F
E
E Inner rotor
F Outer rotor
G Oil pump crankcase
Figure 284. Oil Pressure Valve
K J H
H Cap
J Spring
K Piston
15 - 176 9823/0300-1 15 - 176

15 - Engine
60 - Oil Pump
00 - General
Operation
pressure of spring. In practice the spool opens

When rotated, the gap between the inner, and outer and closes continuously to maintain the correct oil
rotor lobes increases, which creates suction to draw pressure value. The valve is not adjustable.
oil in through the inlet port. The fluid is carried by the
gears to the discharge side of the pump. After half Lubrication
rotation, the gap reaches a maximum, the inlet port
is closed and the outlet port opens. The oil pump is driven by the crankshaft on the timing
system side. All the parts of the system shown in
Further rotation causes the gap between the lobes to green on the diagram represents, the oil is in intake
decrease, which forces the oil out through the outlet means oil is not under pressure.
port.
Table 98.
The tight clearances, along with the speed of
rotation, effectively prevent the fluid from leaking Colour Description
backwards. Green Oil in intake
Red Oil under pressure
A pressure valve assembly is installed on the timing
gear case to regulate the oil pressure. As oil pressure Amber Oil returning to the oil
increases, it acts on a piston to overcome the sump
Figure 285.
G
H E F H
J
M
D D N
K P
C C
L
A
A B
B
A Oil pump rotors B Oil sump

C Crankshaft D Camshaft
E Turbocharger F Rocker arm pin
G Hydraulic tappets H Rocker arm cover
J Cylinder head K Upper crankcase
L Lower crankcase M Oil filter
N Water/oil heat exchanger P PTO (Power Take-Off) 3rd/4th gear housing
15 - 177 9823/0300-1 15 - 177

15 - Engine
60 - Oil Pump
00 - General
If even one of the conditions described below is not

satisfied, replace the oil pump unit and timing gear C
case.
1. Use a thickness gauge to measure the clearance

between the teeth of the rotors. The maximum
permitted clearance should not be more than the
specified value.
Dimension: 0.24mm
Figure 286.
C Work surface
A
A Rotors
B Thickness gauge
2. Make sure that the work surfaces of the rotors
and pump body are not worn.
Figure 287.
C Work surface
15 - 178 9823/0300-1 15 - 178

15 - Engine
60 - Oil Pump
00 - General
This procedure requires service parts. Make sure

C
you have obtained the correct service parts before
you start, refer to Parts Catalogue.
Before Removal
B
A
2. Drain the oil from the engine.
A Timing gear case
3. Remove the drive belt. B Pump semi-crankcase
Refer to: PIL 15-18-03. C Screws
4. Remove the starter motor. 4. Remove the rotors.
Refer to: PIL 15-75-00. Figure 291.
5. Remove the crankshaft position sensor.

6. Remove the camshaft position sensor.
Remove
1. Remove the timing gear case. D
Figure 289.
D Rotors
5. Inspect the oil pump for wear and damage.
Install
A Timing gear case 1. Apply oil on the seat of the rotors, on the oil pump
2. Find the oil pump assembly inside the timing gear crankcase and the two rotors.
case. 2. Put the two rotors inside the seat.
3. Remove the screws and remove the pump semi-
crankcase from the timing gear case.
15 - 179 9823/0300-1 15 - 179

15 - Engine
60 - Oil Pump
00 - General
B A
D C
B Pump semi-crankcase
D Rotors
F
3. Make sure that the reference points on the rotors A Timing gear case
face outwards. B Pump semi-crankcase
C Screws
Figure 293. F Locating pins
E 8. Lubricate and install the gasket in the seat of the
oil pump.
Figure 295.
E Rotor reference points

4. Make sure that the 2 locating pins are engaged
properly in the timing gear case.
5. Put the oil pump on the timing gear case with
reference to the locating pins. G Gasket
6. Attach the oil pump to the timing gear case with 9. Install the timing gear case.
the screws.
After Installation
1. Install the camshaft position sensor.
2. Install the crankshaft position sensor.
3. Install the stater motor.
5. Fill the engine with engine oil.
15 - 180 9823/0300-1 15 - 180

15 - Engine
60 - Oil Pump
00 - General

Item Nm
C 10
15 - 181 9823/0300-1 15 - 181

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

Introduction .................................................. 15-182 The oil pressure relief valve is used to control the
Technical Data ............................................. 15-183 oil pressure of the engine. Oil pressure can build
Component Identification ............................. 15-184 up due to an engine malfunction, low volume of oil,
Check (Condition) ........................................ 15-185 instrument or equipment failure.
Remove and Install ..................................... 15-186 The relief valve is designed or set to open at
a predetermined set pressure to protect pressure
vessels and other equipment from being subjected to
pressures that exceed their design limits. When the
set pressure is exceeded, the relief valve becomes
the path of least resistance, as the valve is forced
open and a portion of the fluid is diverted through the
auxiliary route.
15 - 182 9823/0300-1 15 - 182

15 - Engine
60 - Oil Pump
Technical Data
Table 100.
Spring free length 47.91mm
15 - 183 9823/0300-1 15 - 183

15 - Engine
60 - Oil Pump
Figure 296. Component identification
D
C
B
A
A Cap B Gasket
C Spring D Piston
15 - 184 9823/0300-1 15 - 184

15 - Engine
60 - Oil Pump
Check (Condition)
The oil pressure valve is located in the timing system 1. Measure the free length of the spring with a
crankcase. Remove the cap and gasket then take out gauge. Make sure the length is of the specified
the spring. value.
Figure 297.
D
C
B
A
A Cap B Gasket
C Spring D Piston
E Spring free length
2. If the length is not of the specified value then

replace the spring with a new one.
15 - 185 9823/0300-1 15 - 185

15 - Engine
60 - Oil Pump
Before removal
the engine has been running, let it cool before F B
E
Remove D
C
1. Remove the cap with the gasket. A
2. Remove the spring from the seat. A Cap

B Gasket
Figure 298.
C Spring
D Piston
E Seat
F Crankcase
D C B
A 3. Install the gasket on the cap.
4. Always replace the gasket after each assembly.
5. Clamp the cap on the seat of the crankcase and
tighten it to the correct torque value.
After installation
1. Start the engine and check for any leakage.
A Cap
B Gasket
C Spring
D Piston
3. Check the condition of the spring, if broken then
replace with a new one.
4. Remove the valve piston using a magnet from
the seat.
Install
1. Lubricate the piston and fully insert the piston into
the seat.
2. Put the spring into the seat.
15 - 186 9823/0300-1 15 - 186

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-189
15 - 187 9823/0300-1 15 - 187

Notes:
15 - 188 9823/0300-1 15 - 188

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-189 Engine mounts support the engine and in some
Remove and Install ..................................... 15-190 cases the transmission, they dampen noise and
vibration. The mounts isolate the engine and
transmission from the chassis so that vibrations and
noise are not transmitted to the rest of the machine.
Most engine mounts consist of metal attachment

plates and large rubber insulator blocks. The rubber
portions of the mount are flexible and provide the
cushioning that dampens the engine vibrations.
The metal bracket part of the mount provides the
mechanical support and attachment points for the
engine mounts.
15 - 189 9823/0300-1 15 - 189

15 - Engine
63 - Mount
00 - General
Remove and Install
Remove
3. Remove the engine compartment cover.
4. Remove the engine.
5. Remove the engine mounts.
Install
removal procedure.
15 - 190 9823/0300-1 15 - 190

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-193
15 - 191 9823/0300-1 15 - 191

Notes:
15 - 192 9823/0300-1 15 - 192

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-193 The oil cooler and filter are incorporated in a housing
Component Identification ............................. 15-194 that is bolted to the side of the crankcase. The
Operation ..................................................... 15-195 housing allows transfer of lubricating oil from the
Check (Condition) ........................................ 15-195 crankcase to the oil cooler and filter head.
15 - 193 9823/0300-1 15 - 193

15 - Engine
69 - Oil Cooler
00 - General
Figure 300. Component identification
A Oil cooler unit B Gasket

C Gasket
15 - 194 9823/0300-1 15 - 194

15 - Engine
69 - Oil Cooler
00 - General
Operation Check (Condition)
The oil cooler housing allows transfer of lubricating 1. Inspect the sealing faces on the oil cooler matrix,
oil from the crankcase to the oil cooler and filter head. oil cooler housing and the crankcase. Make sure
The cooled and filtered oil then passes back into the that the faces are clean and free from scale or
main oil gallery into the crankcase. damage.
2. Inspect the sealing gasket and o-rings for signs
of damage. If in doubt, renew the gasket or O-
rings.
15 - 195 9823/0300-1 15 - 195

15 - Engine
69 - Oil Cooler
00 - General
Remove and Install 2. Remove the inlet and outlet pipe from the oil
cooler unit.
Oil 3. Make sure you use a suitable container to store
Oil is toxic. If you swallow any oil, do not induce any oil.
contains harmful contaminants which can cause skin 4. Remove the screws and then remove the oil
cancer. Do not handle used engine oil more than cooler unit from the crankcase.
necessary. Always use barrier cream or wear gloves Figure 302.
or the ground. Clean up all spilt fluids and/or E
contaminated materials must be disposed of in D G
Before removal F

you start the service work. D Oil cooler unit
E Cartridge holder cap
2. Position the machine on firm level ground. Make F Screw
the machine safe. G Crankcase
Refer to: PIL 01-03-27. 5. Remove the oil filter.
3. Get access to the engine. Refer to: PIL 15-21.
4. Drain the engine oil 6. Remove both gaskets from the oil cooler unit.
5. Drain the coolant.
Remove
D
Figure 301.
B
J
D Oil cooler unit
H Gasket
J Gasket
D Install
A C 1. If removed, install the fitting on the crankcase and
tighten the fitting to the correct torque value.
A Clamp
B Inlet pipe
C Outlet pipe
D Oil cooler unit
15 - 196 9823/0300-1 15 - 196

15 - Engine
69 - Oil Cooler
00 - General
G
H
G Crankcase D Oil cooler unit

K Fitting H Gasket
L Gasket J Gasket
2. Lubricate and put the gasket on the fitting. 5. Lubricate and put both new gaskets respectively
in the seats of the oil cooler unit.
3. Check that the surface on the oil cooler unit and
on the crankcase are free from impurities. 6. Attach the oil cooler unit to the crankcase with
the screws.
4. Always replace both of the oil cooler unit gaskets
after each removal. 7. Tighten the screws to the correct torque value.
Figure 306.
G
H
F J
D Oil cooler unit

F Screw
G Crankcase
H Gasket
J Gasket
15 - 197 9823/0300-1 15 - 197

15 - Engine
69 - Oil Cooler
00 - General
8. Attach the inlet and outlet pipe to the cooler unit

with the clamp.
9. Install the oil filter.
After installation
1. Fill the engine with the recommended coolant.
2. Fill the engine with the recommended oil .
3. Start the engine and check for any leakage.

Item Nm
F 10
K 25
15 - 198 9823/0300-1 15 - 198

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-201

15-72-03 Pulley ............................................................................................................................ 15-208
15-72-06 Voltage Regulator ......................................................................................................... 15-209
15 - 199 9823/0300-1 15 - 199

Notes:
15 - 200 9823/0300-1 15 - 200

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-201 The alternator is a three phase generator having a
Health and Safety ........................................ 15-202 rotating field winding and static power windings.
Technical Data ............................................. 15-203
Check (Condition) ........................................ 15-204 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Remove and Install ..................................... 15-206 warning light to the field winding. This creates
Disassemble and Assemble ........................ 15-207 a magnetic field which supplements the residual
magnetism in the rotor poles. As the engine is
started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 201 9823/0300-1 15 - 201

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

• Ensure that the battery negative terminal is
connected to the earthing cable.
• Never make or break connections to the battery
or alternator, or any part of the charging circuit
whilst the engine is running. Disregarding this
instruction will result in damage to the regulator
or rectifying diodes.
• Main output cables are 'live' even when the
engine is not running. Take care not to earth
connectors in the moulded plug if it is removed
from the alternator.
• During arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables installed, remove the
cables).
• If slave starting is necessary, connect the
second battery in parallel without disconnecting
the vehicle battery from the charging circuit.
The slave battery may then be safely removed
after a start has been obtained. Take care to
connect batteries positive to positive, negative
to negative.
15 - 202 9823/0300-1 15 - 202

15 - Engine
72 - Alternator
00 - General
Technical Data
Table 102.
Voltage 12V
Current 80A
Rotation Ratio 1:1.6
15 - 203 9823/0300-1 15 - 203

15 - Engine
72 - Alternator
00 - General
Check (Condition) 1. Stop the engine and turn the ignition switch to
OFF.
2. Withdraw the alternator plug and connect the
Charging Circuit Test Multimeter between the large terminals and
1. Make sure that all the battery and alternator earth. With the Multimeter set to measure,
connections are in place, secure and making Voltage: 12V
good metal - to - metal contact, especially the
earth connections to chassis and engine. Figure 308.
2. Adjust the alternator drive belt tension if

necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If 2.1. The Multimeter should show battery
the oil pressure warning remains on stop the voltage.
engine Immediately and investigate the engine
lubrication system. 2.2. If the reading is zero, check the cables
for continuity, particularly at the starter
Check 1 terminals.
3. If the voltage is correct, check the alternator.
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
Alternator Charging Test
If they operate normally, check the warning light bulb Figure 309.
for a blown filament.
Simultaneous failure of all items indicates a fault at

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

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 307.
1. Make sure that all battery and alternator

connections are in place, secure and making
good metal to metal contact, especially the earth
connections to chassis and engine.
2. Make sure that the alternator drive belt tension is
correctly adjusted.
3. If the battery is in a fully charged condition, before
Check 2
commencing the test switch on the working lights
The following checks should be made using an for
analogue (moving pointer) type Multimeter. Duration: 3min
15 - 204 9823/0300-1 15 - 204

15 - Engine
72 - Alternator
00 - General
4. Alternatively, operate the starter for a few 12.6. Open or short circuited power (stator)
moments with the ESOS (Engine Shut-Off windings.
Solenoid) fuse removed.
13. To check for a fault, disconnect the capacitor and
5. Install an open type shunt between the battery repeat the charging test. Renew the capacitor if
positive lead and the battery positive terminal. necessary.
Current: 100A 14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
6. Connect a Multimeter positive lead to machine
assembly. Check the condition of the brushes
side of the shunt and negative lead to battery side
and, if necessary, clean the slip rings using extra-
of the shunt.
fine glass paper. The regulator may only be
7. Connect the leads to the Multimeter and set the renewed.
Multimeter to the relevant range as follows.
15. Faults with the rectifier, rotor and stator may be
8. AVO 2002 checked only by removing and dismantling the
alternator for further testing.
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
8.3. Right side slider to DC (Direct Current)
voltage.
8.4. Left side slider,Refer to Figure 309.
9. AVO 2003
9.1. Red lead to amps socket (A) on the
Multimeter.
9.2. Black lead to negative on Multimeter.
9.3. Right side slider to DC voltage
9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
conditions. These are listed in the order of
probability.
12.1. Defective suppression capacitor.
12.2. Dirty slip rings or worn brushes.
12.3. Defective regulator.
12.4. Defective rectifier.
12.5. Open or short circuited field (rotor)
windings.
15 - 205 9823/0300-1 15 - 205

15 - Engine
72 - Alternator
00 - General
Remove and Install Figure 311. Alternator with

Poly-V Belt Configuration
Before Removal A

B
2. Lower the engine cover to gain access to the
alternator.
3. Disconnect the battery leads. Make sure you
disconnect the earth lead first.
D
Refer to: PIL 33-03-00. C
4. Remove the fan belt from the alternator drive A Alternator
pulley. B Upper mounting bolt
C Lower mounting bolt
Remove D Washer
1. Disconnect the electrical connections from the Install

alternator.
1. Put the lower mounting bolt into the alternator.
2. Support the alternator and remove the mounting
bolts and washer. 2. Put the washer on the lower mounting bolt.
3. Remove the alternator from the engine. 3. Put the alternator in position and install both the
mounting bolts.
Figure 310. Alternator with
Original Belt Configuration 4. Do not tighten the bolts at this stage.
5. Install the fan belt on to the pulley.
D
6. Adjust the fan belt.
7. Tighten the mounting bolts. Make sure that the
bolt below the alternator is tightened last.
B
8. Connect the electrical connections.
C
A After Installation
1. Connect the battery leads. Make sure you
A Alternator connect the earth terminal last.
B Lower mounting bolt Refer to: PIL 33-03-00.
C Washer
D Upper mounting bolt 2. Close the engine cover.

Item Description Nm
D-B Upper mounting bolt 25
B Lower mounting bolt 40
C Lower mounting bolt 25
15 - 206 9823/0300-1 15 - 206

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

1. The voltage regulator and brush set is a
combined assembly. Refer to (PIL 15-72-06).
Drive Pulley
1. Refer to (PIL 15-72-03).
15 - 207 9823/0300-1 15 - 207

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

complete alternator. Refer to: PIL 15-72-00.
15 - 208 9823/0300-1 15 - 208

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

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

complete alternator. Refer to: PIL 15-72-00.
15 - 209 9823/0300-1 15 - 209

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-211

15-75-03 Solenoid ....................................................................................................................... 15-220
15-75-06 Brush Gear ................................................................................................................... 15-221
15 - 210 9823/0300-1 15 - 210

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-211 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-212 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-213 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-214 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-214 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-216 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-218 pinion with the starter ring gear on the flywheel of the
engine.
The solenoid also closes high current contacts for the

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

use, the electrical components are designed only
to operate for a time period of 30 seconds before
overheating.
15 - 211 9823/0300-1 15 - 211

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

WARNING Make the machine safe before
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
15 - 212 9823/0300-1 15 - 212

15 - Engine
75 - Starter Motor
00 - General
Technical Data
Table 104.
Voltage 12V
Power 2kW
Direction of rotation Clockwise
15 - 213 9823/0300-1 15 - 213

15 - Engine
75 - Starter Motor
00 - General

Figure 312. Before carrying out the multimeter tests, check
the battery condition and make sure that all the
1 applicable electrical connections are clean and tight.
Make sure that the starter motor fixing bolts are
tightened to the correct torque.
To prevent the engine starting during the tests make

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

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

terminals.
Figure 313.
1.1. Reading in start position approximately

Voltage: 10V
Voltage: 20V
1.2. Minimum permissible reading in start
position
Voltage: 9.5V
Voltage: 18V
1.3. A low reading probably indicates a fault in
the starter motor.
2. Connect the multimeter between the starter main
terminal and the commutator end bracket. In the
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5V
Voltage: 1V
15 - 214 9823/0300-1 15 - 214

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

B Commutator end bracket (Starter earth B Starter earth connection
connection) C Solenoid terminal
2.1. Minimum permissible reading in start D Start relay feed
position E Start relay switched output
H Battery positive and solenoid connection
Voltage: 9V
Voltage: 17V 4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
2.2. If the reading is within this limit, continue to
and earth.
3. If the reading is outside the limit, proceed
to 4. 4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage
3. Connect the multimeter between the solenoid increases to
terminal and a good earth. Minimum permissible
reading in start position Voltage: 8V
Voltage: 16V
Voltage: 8V
Voltage: 16V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 315. or in the wiring between the solenoid, starter
switch, and the start relay, if the reading
between terminal and earth is less than
Voltage: 8V
Voltage: 16V
5. Connect the multimeter between battery
negative and starter earth connection. The
reading in the start position should be practically
zero, maximum permissible reading
Voltage: 0.25V
Figure 317.
C Solenoid terminal
4. If the reading is less than specified, connect
the multimeter between the start relay switched
output and earth. A fault is indicated with the
wiring from the start relay to the solenoid if the
reading increases to
Voltage: 8V
Voltage: 16V
B Starter earth connection
15 - 215 9823/0300-1 15 - 215

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

permissible voltage, a high resistance in the
earth lead or connections is indicated.
6. Connect the voltmeter between battery positive
Remove
and the starter main terminal. With the starter 1. Disconnect the battery leads. Make sure you
switch off, the voltmeter should indicate battery disconnect the earth lead first.
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum Refer to: PIL 33-03-00.
permissible reading
2. Disconnect the starter motor electrical
Voltage: 0.25V connections.
Figure 318. 3. Support the starter motor and remove the
mounting bolts.
4. Disengage the pinion from the flywheel gear
teeth and remove the stater motor.
Figure 320.
B
A
A Starter main terminal

7. If the reading is above the maximum permissible
voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the
multimeter between the battery positive and
solenoid connection. If the multimeter now reads
zero with the switch closed, the fault is in the
solenoid.
Figure 319.
B
A Stater Motor
B Bolts
Install
1. Put the starter motor in position and align the
pinion in the flywheel gear teeth.
H Battery positive and solenoid connection
2. Install the mounting bolts.
8. Finally install the engine stop fuse.
3. Connect the electrical connections.
4. Connect the battery terminals. Make sure you
connect the earth lead last.
15 - 216 9823/0300-1 15 - 216

15 - Engine
75 - Starter Motor
00 - General

Item Nm
B 45
15 - 217 9823/0300-1 15 - 217

15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor. For cleaning cover.
and checking purposes only, dismantle the motor as
1.6. Carefully install the commutator end cover,
follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 218 9823/0300-1 15 - 218

15 - Engine
75 - Starter Motor
00 - General
Figure 321.
A
F C A
B
D P
E N
P G
H
K
M
743740-C1 J
L
A Starter solenoid B Screws - starter solenoid (3 off)

C Sealing ring - solenoid D Solenoid actuator rod
E Pinion lever arm F Tie bolts (2 off)
G Commutator end cover H Screws - commutator end cover (2 off)
J Brush set K Commutator
L Sealing ring - commutator end cover M Wave washer
N Cable connector post P Pinion gear
15 - 219 9823/0300-1 15 - 219

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

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

the complete starter motor.
15 - 220 9823/0300-1 15 - 220

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

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

the complete starter motor.
15 - 221 9823/0300-1 15 - 221

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-223

15-84-03 Crankshaft Position ...................................................................................................... 15-226
15-84-06 Camshaft Position ........................................................................................................ 15-231
15-84-09 Knock ........................................................................................................................... 15-236
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-238
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-241
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-244
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-248
15-84-19 Exhaust Temperature ................................................................................................... 15-251
15-84-21 Engine Oil Pressure ..................................................................................................... 15-254
15-84-24 Fuel Temperature ......................................................................................................... 15-257
15-84-26 Fuel Pressure ............................................................................................................... 15-260
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-262
15-84-33 Coolant Temperature .................................................................................................... 15-269
15-84-42 Engine Oil Temperature ............................................................................................... 15-271
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-274
15 - 222 9823/0300-1 15 - 222

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-223 The engine sensors continually send signals to the
Technical Data ............................................. 15-224 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-224 control the smooth running of the engine and related
components.
The ECM processes signals from the sensors

continually and its response will be based on an
evaluation of the combination of sensor signals.
After removal from the engine, protect the sensors

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

be replaced in the event of damage.
15 - 223 9823/0300-1 15 - 223

15 - Engine
84 - Sensor
00 - General

Crankshaft Position Sensor
Type Hall effect
Air gap value 0.2mm (0.008in) and
1.2mm (0.047in)
Table 107.
Camshaft Position Sensor
Type Hall effect D
Air gap value 0.2mm (0.008in) and C
1.2mm (0.047in)
A
Table 108.
Coolant Temperature Sender
Type Temperature dependant resis-
tance
Tightening 20N·m max
torque
B
Temperature Vs Resistance Table
Temperature °C Rm min K Ω Rm max K Ω
A Crankshaft position sensor
(°F)
B Camshaft position sensor
-40 (-39.9) 38,313 52,926 C Oil pressure sensor
0 (32.0) 5,227 6,623 D Coolant temperature sensor
140 (283.8) 67 76
Figure 323.
Table 109.
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP)
Fixing screw 6N·m max E
tightening
torque
Temperature Sensor
Type Temperature dependant resistor
Table 110.
Rail Pressure Sensor F
Type The rail pressure sensor
is integral with the com- E TMAP (Temperature Manifold Air Pressure)
mon rail sensor
Table 111. F Fuel temperature sensor
Fuel Temperature Sensor

Type The fuel temperature
sensor is integral with
the high pressure fuel
pump
Table 112.
Oil Pressure Switch
Set pressure 0.8 ± 0.1bar
(11.6 ± 1.4psi)
Switch mode Normally closed
Tightening torque 35N·m max
15 - 224 9823/0300-1 15 - 224

15 - Engine
84 - Sensor
00 - General
Figure 324.
G Fuel rail pressure sensor
15 - 225 9823/0300-1 15 - 225

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

Introduction .................................................. 15-226 The crankshaft position sensor is a device used
Operation ..................................................... 15-227 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-228 crankshaft. This information is used by the ECM
Adjust .......................................................... 15-228 (Engine Control Module) to control the ignition
system timing and other engine parameters.
Figure 325.
A Crankshaft position sensor

B Phonic wheel
15 - 226 9823/0300-1 15 - 226

15 - Engine
84 - Sensor
Operation
The crankshaft position sensor is installed on the square wave signal with Hall effect when the motor
timing gear case. The sensor reads the signal from is rotating.
the phonic wheel installed on the engine pulley.
This data, together with the signal from the sensor,
The sensor sends an analogue signal to the ECM allows the ECM to control the fuel injection with
(Engine Control Module). The sensor produces a 5V respect to the TDC (Top Dead Centre) of the piston.
Figure 327.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

3 Camshaft phonic wheel 4 Crankshaft position sensor
5 Crankshaft phonic wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse-injector solenoid coil D1-D2 Fuel Injection
TDC TDC
15 - 227 9823/0300-1 15 - 227

15 - Engine
84 - Sensor
Check (Operation) Adjust
Carefully inspect the sensor. If it is found to be Adjust the crankshaft position sensor as follows:
defective, replace the sensor.
1. Measure the distance between the top surface
of the bracket and the external diameter of the
phonic wheel.
Figure 328.
A Bracket
B Phonic wheel
C Measurement 1
2. Measure the distance between the surfaces of
the sensor as shown.
Figure 329.
D Sensor
E Measurement 2
3. The difference between the two measurements
gives the air gap value.
15 - 228 9823/0300-1 15 - 228

15 - Engine
84 - Sensor
Before Removal
2. Clean the sensor and the adjacent area of the
timing gear case.
D
F
Remove
1. Get access to the crankshaft position sensor.
2. Disconnect the electrical connector from the
D Sensor sensor.
F Air gap
Figure 332.
4. The air gap value should be between 0.2mm
(0.008in) and 1.2mm (0.047in).
A
5. If required insert one or two spacers based on
the air gap value calculated.
Figure 331.
G A Electrical connector
3. Remove the screw, the sensor, and the spacer.
Figure 333.
D Sensor
G Spacer B
6. The spacers have a calibrated thickness of C
0.2mm (0.008in).
D
B Screw
C Sensor
D Spacer
The crankshaft position sensor is a non-serviceable

item. If the sensor is defective it must be replaced.
15 - 229 9823/0300-1 15 - 229

15 - Engine
84 - Sensor
Install
1. Installation is the opposite of the removal
sequence.
2. Make sure you adjust the sensor air gap before
the final installation.
3. Tighten the screw to the correct torque value.

Item Nm
B 8
15 - 230 9823/0300-1 15 - 230

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

Introduction .................................................. 15-231 The camshaft position sensor is a device that detects
Operation ..................................................... 15-232 the passing of a gap on the camshaft phonic wheel. It
Check (Operation) ....................................... 15-233 sends a signal to the ECM (Engine Control Module)
Adjust .......................................................... 15-233 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
Figure 336.
A Camshaft position sensor

B Camshaft gear
C Phonic wheel
15 - 231 9823/0300-1 15 - 231

15 - Engine
84 - Sensor
Operation
The camshaft position sensor is installed on the The signal is read through the phonic wheel phased
timing gear case. The purpose of the camshaft on the camshaft.
position sensor is to identify the position of the
camshaft with respect to the engine crankshaft and The ECM (Engine Control Module) will select the
consequently the position of the pistons. correct cylinder for fuel injection.
Figure 338.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

3 Camshaft phonic wheel 4 Crankshaft position sensor
5 Crankshaft phonic wheel 6 Fuel injector
A Camshaft sensor signal B Crankshaft position sensor signal
C1-C2 Current pulse - injector solenoid coil D1-D2 Fuel Injection
TDC TDC (Top Dead Centre)
15 - 232 9823/0300-1 15 - 232

15 - Engine
84 - Sensor
Check (Operation) Adjust

1. Carefully inspect the sensor. If it is found to be Adjust the camshaft position sensor as follows:
defective, replace the sensor.
1. Measure the distance between the top surface of
2. Inspect the sealing O-ring, if it is defective, the timing gear case and the tooth surface on the
replace it. phonic wheel.
Figure 339.
A
A Timing gear case

B Tooth surface
C Measurement 1
2. Measure the distance between the surfaces of
the sensor as shown.
Figure 340.
D Sensor
E Measurement 2
3. The difference between the two measurements
gives the air gap value.
15 - 233 9823/0300-1 15 - 233

15 - Engine
84 - Sensor

F
Before Removal
engine block.
Remove
1. Get access to the camshaft position sensor.
D sensor.
Figure 343.
D Sensor
F Air gap A
4. The air gap value should be between 0.2mm

(0.008in) and 1.2mm (0.047in).
5. If required insert one or two spacers based on
the air gap value calculated.
Figure 342. A Electrical connector
3. Remove the screw, the sensor, and the spacer.
D
Figure 344.
B
G
D C
D Sensor
G Spacer
6. The spacers have a calibrated thickness of B Screw
0.2mm (0.008in). C Sensor
D Spacer
The camshaft position sensor is a non-serviceable

item. If the sensor is defective it must be replaced.
15 - 234 9823/0300-1 15 - 234

15 - Engine
84 - Sensor
Install
Figure 345.
C
D
B
E
B Screw
C Sensor
D Spacer
E Crankshaft
F Phonic wheel tooth
1. Rotate the crankshaft until a tooth on the phonic
wheel, which is installed on the camshaft, is
visible from the timing case hole.
2. Adjust the camshaft position sensor air gap.
3. Install the required quantity of spacers on the
sensor.
4. Attach the sensor onto the timing case with the
screw.

Item Nm
B 8
15 - 235 9823/0300-1 15 - 235

15 - Engine
84 - Sensor
09 - Knock
09 - Knock Operation
Operation ..................................................... 15-236 The knock sensors detect pre-ignition (knock) by
Check (Operation) ....................................... 15-237 means of sensing engine vibration. The vibration
signal is sent to the engine ECM (Engine Control
Module)where the ECM will adjust the fuel timing to
give optimum performance, economy and driveability
and prevent engine damage. The voltage signal is
proportional to engine vibration/acceleration.
15 - 236 9823/0300-1 15 - 236

15 - Engine
84 - Sensor
09 - Knock
Check (Operation)
1. For the full inspection and testing procedure,
refer to the help files in ServiceMaster.
15 - 237 9823/0300-1 15 - 237

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

Introduction .................................................. 15-238 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-239 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-239 cylinder 3 and 4 exhaust outlet ports.
Figure 349. Exhaust manifold
temperature sensor location
15 - 238 9823/0300-1 15 - 238

15 - Engine
84 - Sensor
Operation Check (Operation)
The exhaust manifold temperature sensor measures For the full inspection and testing procedure, refer to
the exhaust gas temperature from the engine, before the help files in ServiceMaster.
it reaches the turbocharger. The analogue voltage
signal is 1–4.5V.
15 - 239 9823/0300-1 15 - 239

15 - Engine
84 - Sensor
Remove and Install

Special Tools
Deep Socket 892/12351 1
Before Removal
Figure 350.
A
N
A Exhaust manifold temperature sensor
Remove
2. Disconnect the electrical connector at the
exhaust manifold temperature sensor.
3. Use the special tool to remove the sensor from
the exhaust manifold.
Special Tool: Deep Socket (Qty.: 1)
4. Discard the sealing washer.
The exhaust manifold temperature sensor is a non-

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

Item Nm
N 45
15 - 240 9823/0300-1 15 - 240

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

Introduction .................................................. 15-241 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-242 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-242 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-243 (Engine Control Module) Controlled engine.
The sensor is mounted in the rear section of the

rocker cover.
Figure 351.
C Exhaust manifold pressure sensor
15 - 241 9823/0300-1 15 - 241

15 - Engine
84 - Sensor
The exhaust manifold pressure sensor informs 1. For the full inspection and testing procedure,
the ECM (Engine Control Module) of the exhaust refer to the help files in ServiceMaster.
manifold pressure. To attain an accurate and stable
reading the take-off point is piped from the exhaust
manifold between cylinders 3 and 4. This is fed
to a sample chamber in the corner of the rocker
cover where the sensor is screwed directly into the
pressure path.
The sensor produces an analogue signal from

1–4.5V which informs the ECM of the exhaust
manifold pressure. The voltage output proportional to
pressure is 0.5–4.5V.
15 - 242 9823/0300-1 15 - 242

15 - Engine
84 - Sensor
Remove and Install 3. Use the special tool to tighten the exhaust
manifold pressure sensor to the correct torque
Special Tools value.
Item Nm
Before Removal 1 22.5

Figure 352.
P1
1 Exhaust manifold pressure sensor

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

it must be renewed.
Install
steps.
15 - 243 9823/0300-1 15 - 243

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

Pressure (TMAP)
The TMAP (Temperature Manifold Air Pressure)
Introduction .................................................. 15-244 sensor is mounted in a port on top of the inlet
Operation ..................................................... 15-245 manifold. It measures the inlet manifold boost air
Check (Condition) ........................................ 15-245 pressure and temperature. The sensor incorporates
a piezo resistive element and resistor.
Check (Operation) ....................................... 15-246
Remove and Install ..................................... 15-246 Figure 353.
B
A TMAP sensor
B Intake manifold
15 - 244 9823/0300-1 15 - 244

15 - Engine
84 - Sensor
Operation Check (Condition)
The TMAP (Temperature Manifold Air Pressure) 1. Remove oil and sludge contamination from the
sensor measures the inlet manifold boost air sensor.
pressure and temperature. The sensor produces an
analogue signal voltage proportional to air pressure. 2. Carefully inspect the sensor. If it is defective,
replace it.
15 - 245 9823/0300-1 15 - 245

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

1. Remove oil and sludge contamination from the
sensor.
Before Removal
2. Carefully inspect the sensor. If it is defective,
replace it.
3. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the
inlet manifold.
sensor and cannot be replaced.
Figure 354.
A
B
A Inlet manifold
B TMAP (Temperature Manifold Air Pressure)
sensor
C Screws
Remove
sensor.
3. Remove the screws.
4. Remove the TMAP sensor.
The TMAP sensor is a non-serviceable item. If the

sensor is defective, it must be replaced.
15 - 246 9823/0300-1 15 - 246

15 - Engine
84 - Sensor
Install
Figure 355.
C
A Inlet manifold
B TMAP sensor
C Screws
1. Installation is the reversal of the removal
procedure.
2. Carefully push the sensor into its location bore in
the inlet manifold. Do not use too much force.

Item Nm
C 6
15 - 247 9823/0300-1 15 - 247

15 - Engine
84 - Sensor
18 - Temperature and Mass Air Flow (TMAF)
18 - Temperature and Mass Air Introduction

Flow (TMAF)
The TMAF (Temperature and Mass Air Flow) sensor
Introduction .................................................. 15-248 measures the amount of air coming in to the engine
Operation ..................................................... 15-249 and the air temperature. It is mounted between the
Check (Operation) ....................................... 15-249 air filter and turbo charger.
15 - 248 9823/0300-1 15 - 248

15 - Engine
84 - Sensor
The TMAF (Temperature and Mass Air Flow) sensor Faults relating to the TMAF (Temperature and Mass
produces a digital signal measuring air flow, and an Air Flow) will normally be reported by the fault codes.
analogue signal measuring inlet air temperature.
1. Remove contamination from the sensor. Do not
touch the air flow sensor area or temperature
sensor area.
2. Carefully inspect the sensor. If it is defective,
replace it.
3. Inspect the sealing O-ring. If it is defective,
replace it.
Figure 357.
1 Air flow sensor area

2 Temperature sensor area
15 - 249 9823/0300-1 15 - 249

15 - Engine
84 - Sensor

Do not install a TMAF sensor which has been
Before Removal dropped or damaged. Replace it with a new one.
1. Make sure that the engine is safe to work on. If 1. The installation procedure is the opposite of the
the engine has been running, let it cool before removal procedure. Additionally do the following
you start the service work. step.
2. Get access to the TMAF (Temperature and Mass 2. Tighten the screws to the correct torque value.
Air Flow) sensor
3. Clean the area around the sensor to prevent
Item Nm
contamination entering the engine.
2 5
Remove
Figure 358.
1 2
3
2 Screws (x2)
3 TMAF sensor
1. Disconnect the electrical connector. Do not touch
the connector pins.
2. Remove the screws (x2) which secure the TMAF
sensor to the air intake hose.
3. Remove the TMAF sensor together with the O-
ring from the air intake hose. Do not touch the air
flow sensor area or temperature sensor area.
Figure 359.
1 Air flow temperature sensor area

2 Temperature sensor area
15 - 250 9823/0300-1 15 - 250

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

Introduction .................................................. 15-251 The exhaust temperature sensor is located in the
Operation ..................................................... 15-252 exhaust system just before the SCR (Selective
Check (Operation) ....................................... 15-252 Catalytic Reduction) catalyst.
15 - 251 9823/0300-1 15 - 251

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

exhaust temperature sensor.
2. Switch the ignition on.
3. Connect the multimeter across the harness pins.
3.1. Measure the voltage, the reading should be:
Voltage: 5V
3.2. If the reading is correct, proceed to 4
3.3. If the reading is not correct, check the
harness between the sensor and the DCU
(Dosing Control Unit) for continuity.
3.4. Check the electrical connectors for integrity
and contamination.
4. Connect the multimeter across the sensor pins.
4.1. Measure the resistance, the reading should
be:
Resistance: 24,560 ± 1,228Ω
4.2. If the resistance is not within tolerance, the
sensor is faulty and must be replaced.
5. Connect the electrical connector to the exhaust
temperature sensor.
15 - 252 9823/0300-1 15 - 252

15 - Engine
84 - Sensor
Remove and Install 3. Remove the sensor from the exhaust, take care
not to damage the sensor probe.
Consumables
Description Part No. Size The exhaust temperature sensor is a non-
Graphite/Calcium 4004/7545 -
it must be replaced.
Fluoride Based Metal
Free Anti-Seize
Compound Install
Before Removal removal procedure. Additionally do the following
steps.
the engine has been running, let it cool before 2. Apply anti-seize compound to the threads of the
you start the service work. retaining nut. Make sure the correct anti-seize
compound is used to prevent damage to the SCR
2. Get access to the exhaust temperature sensor. (Selective Catalytic Reduction) system.
Remove Consumable: Graphite/Calcium Fluoride Based

Metal Free Anti-Seize Compound
Figure 360.
3. Tighten the retaining screw to the correct torque
value.

Item Nm
2 44
2
1
1 Exhaust temperature sensor

2 Retaining nut
1. Disconnect the electrical connector.
2. Undo the retaining screw.
15 - 253 9823/0300-1 15 - 253

15 - Engine
84 - Sensor
21 - Engine Oil Pressure
21 - Engine Oil Pressure Introduction

Introduction .................................................. 15-254 The engine oil pressure sensor is a device to alert the
Technical Data ............................................. 15-255 ECM (Engine Control Module) if the pressure inside
Operation ..................................................... 15-255 the engine is outside the set limits.
The sensor is mounted on the engine crankcase.
15 - 254 9823/0300-1 15 - 254

15 - Engine
84 - Sensor
Technical Data Operation
Table 129. Technical Data The oil pressure sensor is Normally Closed. The
sensor is calibrated. Refer to: PIL 15-84-21.
Intervention pressure 0.8 ± 0.1bar
(MIN.) (11.6 ± 1.4psi) When the oil pressure is low, the sensor closes the
electrical circuit and the warning lamp is switched
ON.
15 - 255 9823/0300-1 15 - 255

15 - Engine
84 - Sensor

Before Removal procedure.
1. Make sure that the engine is safe to work on. If 2. Tighten the engine oil pressure sensor to the
the engine has been running, let it cool before correct torque value.
Remove Item Nm
B 35
1. Get access to the oil pressure semsor.
engine oil pressure sensor.
Figure 361.
A Electrical connector
3. Use a deep socket to remove the sensor from the
oil cooler housing.
Figure 362.
B Oil pressure sensor

4. Put a cap on the open port to prevent loss of fluid
and ingress of dirt.
The engine oil pressure sensor is a non-serviceable

item. If the sensor is faulty or damaged it must be
renewed.
15 - 256 9823/0300-1 15 - 256

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

Introduction .................................................. 15-257 The fuel temperature sensor is an integral part of the
Operation ..................................................... 15-258 fuel injection high pressure pump.
Check (Operation) ....................................... 15-258
A Fuel temperature sensor

B Fuel pump
15 - 257 9823/0300-1 15 - 257

15 - Engine
84 - Sensor
The fuel temperature sensor detects the fuel For the full inspection and testing procedure, refer to
temperature as it enters the high pressure fuel the help files in ServiceMaster.
injection pump.
15 - 258 9823/0300-1 15 - 258

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

defective, replace the fuel injection high pressure
pump. Refer to: PIL 18-18-15.
15 - 259 9823/0300-1 15 - 259

15 - Engine
84 - Sensor
26 - Fuel Pressure
26 - Fuel Pressure Introduction

Introduction .................................................. 15-260
Operation ..................................................... 15-261
Introduction
Remove and Install ..................................... 15-261 The fuel pressure sensor is an integral part of the
high pressure pump.
Figure 364.
A Fuel pressure sensor
15 - 260 9823/0300-1 15 - 260

15 - Engine
84 - Sensor
26 - Fuel Pressure
Operation Remove and Install

The fuel pressure sensor monitors the fuel pressure It is not possible to perform any maintenance on the
in the inlet port of the high pressure pump and it is fuel pressure sensor, as it is an integral part of the
controlled by the ECM (Engine Control Module) via pump unit. Never remove the fuel pressure sensor
PWM (Pulse Width Modulation). from the pump.
The digital signal varies the valve opening in If it is defective, replace the high pressure pump.
proportion to the amount of fuel injected into the Refer to: PIL 18-18-15.
fuel injection pump and consequently manages the
excess fuel to be sent back to the fuel tank.
15 - 261 9823/0300-1 15 - 261

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

Introduction .................................................. 15-262 The fuel rail pressure sensor is an integral part of the
Operation ..................................................... 15-263 common fuel rail assembly.
Check (Operation) ....................................... 15-263
G Fuel rail pressure sensor
15 - 262 9823/0300-1 15 - 262

15 - Engine
84 - Sensor
The fuel pressure sensor measures the pressure of For the full inspection and testing procedure, refer to
the fuel in the fuel rail. The signal sent to the ECM the help files in ServiceMaster.
(Engine Control Module) is analogue. The voltage
and resistance detected by the ECM are proportional
to the fuel pressure.
15 - 263 9823/0300-1 15 - 263

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

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
15 - 264 9823/0300-1 15 - 264

15 - Engine
84 - Sensor
30 - Hand Throttle Control
30 - Hand Throttle Control Technical Data

Technical Data ............................................. 15-265
Operation ..................................................... 15-266
Throttle Position Sensor
Remove and Install ..................................... 15-267 Figure 366. Throttle Pedal Movement
A
B
Table 131.
Pedal Position Voltage Output
A Signal 1 = 0 Signal 2 = 5
B Signal 1 = 2 Signal 2 = 3
C Signal 1 = 5 Signal 2 = 0
15 - 265 9823/0300-1 15 - 265

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

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

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

and a track 2 signal. One signal varies the voltage by
the angle below the foot pedal pad. The other signal
varies the voltage by the angle above the foot pedal
pad. Both signals will always add up to 5V. Refer to
engine- sensor, refer to (PIL 15-84).
Figure 367.
B
A
C
D
A Throttle position sensor unit

B Throttle pedal
C Swing arm
D Roller
15 - 266 9823/0300-1 15 - 266

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

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

installed).
01-03). 8. Remove the nut to release the clip and the
connector from the floor.
2. Follow the general safety precautions. Refer to
(PIL 01-03). 9. Slowly remove the pedal assembly from inside
the cab.
3. Make sure that the engine cannot be started.
10. Pull the connector through the hole in the floor.
Figure 368.
D
B B
E
A
F
A Pedal assembly B Socket head bolts

C Spacer plate D Nut
E Connector F Hole in the floor
15 - 267 9823/0300-1 15 - 267

15 - Engine
84 - Sensor
Install
1. The installation is the opposite of the removal
procedure.
2. When you install do the following steps also:
2.1. Apply sealant to the thread of the bolts.
(Medium Strength)
15 - 268 9823/0300-1 15 - 268

15 - Engine
84 - Sensor
33 - Coolant Temperature
33 - Coolant Temperature Check (Operation)

Check (Operation) ....................................... 15-269 1. For the full inspection and testing procedure,
Remove and Install ..................................... 15-270 refer to the help files in ServiceMaster.
15 - 269 9823/0300-1 15 - 269

15 - Engine
84 - Sensor
33 - Coolant Temperature

Before Removal procedure.
1. Make sure that the engine is safe to work on. If 2. Tighten the coolant temperature sensor to the
the engine has been running, let it cool before correct torque value.
you start the service work. 3. Fill the cooling system with the recommended
2. Drain the coolant from the engine. coolant mixture.
4. Start the engine and check for coolant leaks.
Remove
1. Get access to the coolant temperature sensor.
Item Nm
2. Disconnect the electrical connector from the B 20
sensor.
Figure 369.
A Electrical connector
3. Remove the sensor from the cylinder head.
Figure 370.
B Coolant temperature sensor

4. Put a cap on the open port to prevent loss of fluid
and ingress of dirt.
The coolant temperature sensor unit is a non-

it must be replaced.
15 - 270 9823/0300-1 15 - 270

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

Introduction .................................................. 15-271 The engine oil temperature sensor is mounted in a
Operation ..................................................... 15-272 port on the oil cooler housing adjacent to the engine
Check (Operation) ....................................... 15-272 oil dipstick.
Figure 373. Engine oil tem-
perature sensor location
A Engine oil temperature sensor
15 - 271 9823/0300-1 15 - 271

15 - Engine
84 - Sensor
The oil temperature sensor informs the ECM (Engine 1. For the full inspection and testing procedure,
Control Module) of the engine oil temperature. The refer to the help files in ServiceMaster.
ECM processes the signal to determine the oil
temperature. The ECM adjusts the fuel delivery.
15 - 272 9823/0300-1 15 - 272

15 - Engine
84 - Sensor
Remove and Install Table 134. Torque Values

Item Nm
Special Tools
Description Part No. Qty. 1 21
Before Removal
Figure 374.
B
A Sealing washer
B Engine oil temperature sensor
Remove
2. Disconnect the electrical connector at the engine
oil temperature sensor.
the oil cooler housing.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The engine oil temperature sensor is a non-

it must be renewed.
Install
steps.
3. Use the special tool to tighten the engine oil
temperature sensor to the correct torque value.
15 - 273 9823/0300-1 15 - 273

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

Introduction .................................................. 15-274 The intercooler outlet sensor is located in the air
Operation ..................................................... 15-275 intake on the inlet manifold.
Check (Operation) ....................................... 15-275
P Intercooler outlet sensor
15 - 274 9823/0300-1 15 - 274

15 - Engine
84 - Sensor
The intercooler outlet sensor measures the 1. For the full inspection and testing procedure,
temperature of the air coming from the intercooler refer to the help files in ServiceMaster.
into the inlet manifold. The sensor sends an
analogue voltage signal to the ECM (Engine Control
Module).
15 - 275 9823/0300-1 15 - 275

15 - Engine
84 - Sensor
Remove and Install
Before Removal
Figure 376.
A Intercooler outlet temperature sensor
Remove
2. Disconnect the electrical connector at the sensor.
3. Remove the sensor from the air intake.
4. Cap the open port with a blanking cap to prevent
dirt ingress.
Install
step.
2. Tighten the sensor to the correct torque value.

Item Nm
A 8.5
15 - 276 9823/0300-1 15 - 276

15 - Engine
86 - Solenoid
86 - Solenoid
Contents Page No.
15-86-00 General ......................................................................................................................... 15-279

15-86-03 Engine Shut-off Solenoid (ESOS) ................................................................................ 15-280
15-86-09 Cold Start Advance ...................................................................................................... 15-284
15 - 277 9823/0300-1 15 - 277

Notes:
15 - 278 9823/0300-1 15 - 278

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

that convert energy into linear motion. The term also
refers to a solenoid valve, which is an integrated
device containing an electromechanical solenoid
which actuates a hydraulic valve, or a solenoid
switch.
15 - 279 9823/0300-1 15 - 279

15 - Engine
86 - Solenoid
03 - Engine Shut-off Solenoid (ESOS)
03 - Engine Shut-off Solenoid Introduction

(ESOS)
The ESOS (Engine Shut-Off Solenoid) is attached to
Introduction .................................................. 15-280 the engine fuel injection pump.
Check (Condition) ........................................ 15-281
The ESOS is a solenoid operated fuel valve.
When the solenoid energises, by means of an engine
run / stop switch for example, the fuel supply is
connected to the fuel injection pump and the engine
can run.
When the solenoid de-energises the fuel supply to

the engine fuel injection pump is isolated. If the
engine is running it will stop, it cannot re-start until
the solenoid energises again.
15 - 280 9823/0300-1 15 - 280

15 - Engine
86 - Solenoid
Check (Condition)
If a faulty solenoid is suspected, perform tests to

confirm its serviceability.
15 - 281 9823/0300-1 15 - 281

15 - Engine
86 - Solenoid
Remove and Install
Before Removal
Figure 377.
2
1 ESOS (Engine Shut-Off Solenoid) cartridge 2 Fuel injection pump

3 O-ring
15 - 282 9823/0300-1 15 - 282

15 - Engine
86 - Solenoid
Remove
2. Disconnect the electrical connector at the ESOS.
3. Loosen the ESOS cartridge from the fuel
injection pump body.
4. Discard the O-ring. Cap the open ports to prevent
ingress of dirt.
The ESOS is a non-serviceable component. If the

ESOS is faulty or damaged it must be replaced.
It is essential that the correct solenoid is installed,
as there are types available which operate in
the reverse sense or require additional wiring and
resistors.
Install
procedure.
2. Install a new O-ring.
3. Tighten the ESOS cartridge to the correct torque
value.
4. Start the engine and check for fuel leaks.

Item Nm
1 15
15 - 283 9823/0300-1 15 - 283

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

Introduction .................................................. 15-284 The cold start advance solenoid consists of an
Check (Condition) ........................................ 15-285 electrical solenoid and a valve which allows extra
Remove and Install ..................................... 15-286 fuel to spray into the inlet manifold at specific
temperatures for starting purposes. The fuel is
supplied to this valve by the electric fuel pump.
Under cold starting conditions, the solenoid is

energised that opens the fuel valve allowing jets of
fuel to spray into the inlet manifold and mix with the
incoming air, thus richening the air/fuel mixture to
help in cold starting conditions.
15 - 284 9823/0300-1 15 - 284

15 - Engine
86 - Solenoid
Check (Condition)
1. If a faulty solenoid is suspected, perform tests to
confirm its serviceability.
15 - 285 9823/0300-1 15 - 285

15 - Engine
86 - Solenoid
Remove and Install
Before Removal 2. Get access to the engine.

Figure 378.
2
1 Cold start advance solenoid 2 Fuel injection pump

3 O-ring - cold start advance solenoid
Removal Install
1. Disconnect the electrical connector at the cold 1. Replacement is the reversal of the removal
start advance solenoid. procedure.
2. Remove the solenoid cartridge from the fuel 2. Install a new O-ring seal.
injection pump body.
3. Discard the O-ring seal. Cap all open ports to
prevent ingress of dirt and debris. 4. Start the engine and check for fuel leaks.
The cold start advance solenoid is a non-serviceable Table 137. Torque Values
item. If the solenoid is faulty or damaged it must be Item Nm
renewed. It is essential that the correct solenoid is
1 15
installed.
15 - 286 9823/0300-1 15 - 286

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-00 General ......................................................................................................................... 15-289
15 - 287 9823/0300-1 15 - 287

Notes:
15 - 288 9823/0300-1 15 - 288

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

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

from knocks, dampness and any high temperature
sources. The switches are not serviceable, therefore
they must be replaced in the event of damage.
15 - 289 9823/0300-1 15 - 289

15 - Engine
88 - Cold Start Heater
Contents Page No.
15-88-00 General ......................................................................................................................... 15-291
15 - 290 9823/0300-1 15 - 290

15 - Engine
00 - General
Introduction .................................................. 15-291
Operation ..................................................... 15-292
Introduction
Diagram ....................................................... 15-294 The cold starting device has a resistance, operated
Remove and Install ..................................... 15-295 by the ECM (Engine Control Module).
The cold starting device operates when the ambient

temperature is ≤ 15°C (59.0°F). The intake air is
heated through the resistance and helps in starting
the machine.
Figure 379.
A Cold starting device
15 - 291 9823/0300-1 15 - 291

15 - Engine
00 - General
Operation
The system aids engine starting by heating the air The relay is energised by a feed from the engine
in the induction manifold through an electrical grid compartment fusebox, with the engine ECU proving
heater. Operation of the system is fully automatic and an earth for the relay.
is controlled by the engine ECU (Electronic Control
Unit). The heating sequence is as follows:
The power to the grid heater is supplied by a primary 1. Ignition key set to the on position.
fuse through the link harness to relay. The relay when
energised supplies power to the heater through the 2. Warning light illuminated (grid heater on)- engine
power lead. not ready to start.
The relay is located at the side of the coolant

expansion tank.
Figure 380.
B
A
G
C D
E
F
A Coolant expansion tank B Warning light- grid heater on

C Relay D Primary fuse
E Induction manifold F Grid heater
G Heater H Harness
3. After a preset pre-heat time the warning light will 4. Turn the ignition key to engage the starter motor
off- engine ready to start. and start the engine- grid heater on.
3.1. The pre-heat stage can not be repeated 5. Engine started and starter motor disengaged-
unless the ignition key is first set to the off grid heater off.
position.
15 - 292 9823/0300-1 15 - 292

15 - Engine
00 - General
5.1. If the engine stalls and is restarted without

turning the ignition key to off, the grid heater
will come on while the starter motor is
engaged.
The 'pre-heat' stage can not be repeated unless the

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

ignition key to off position, the grid heater will come
on while the starter motor is engaged.
15 - 293 9823/0300-1 15 - 293

15 - Engine
00 - General
Diagram
Figure 381.
FUSE
A C
D
FUSE
F
G
A Primary fuse link B Engine compartment fuse

C Cold start relay D Grid heater element
E Engine ECU (Electronic Control Unit) F +VE
G -VE
15 - 294 9823/0300-1 15 - 294

15 - Engine
00 - General
Remove and Install
Remove 2.4. Remove the earth cable.
1. Make sure that the engine is safe to work on. If 3. Remove the remaining three screws and
the engine has been running, wait for a minimum washers that attach the flange to the heater.
of one hour before you start work.
4. Remove the flange and the manifold.
2. Remove the earth cable as follows:
5. Remove the heater and the two gaskets from the
2.1. Remove the nut and washer that attaches inlet manifold.
the earth cable to the heater.
6. Put a protective cover on the open port of the inlet
2.2. Release the earth cable from the heater. manifold to prevent contamination.
2.3. Remove the screw that attaches the earth
cable to the flange.
Figure 382.
A
A
C
B
D
K F E
B
G
A Screw B Washer
C Manifold D Flange
E Gasket F Heater
G Inlet manifold H Nut
J Washer K Earth cable
15 - 295 9823/0300-1 15 - 295

15 - Engine
00 - General
Install
1. Put the two gaskets and the heater in position
against the inlet manifold.
2. The heater should be installed between the two
gaskets.
3. Put the flange and manifold in position against
the heater.
4. First attach the flange with three screws and
washers.
5. Do not tighten the screws at this stage.
6. Put the fourth washer and earth cable in position
on the flange.
7. Install the fourth screw on the earth cable.
9. Install the other end of the earth cable on the
heater with the washer and nut.

Item Nm
A 25
15 - 296 9823/0300-1 15 - 296

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-299
15 - 297 9823/0300-1 15 - 297

Notes:
15 - 298 9823/0300-1 15 - 298

15 - Engine
90 - Air Intake
00 - General
00 - General Component Identification

Component Identification ............................. 15-299 Refer to Fuel System- Exhaust, General, Component
Check (Condition) ........................................ 15-300 Identification. Refer to (PIL 18-24).
15 - 299 9823/0300-1 15 - 299

15 - Engine
90 - Air Intake
00 - General
Check (Condition)
15 - 300 9823/0300-1 15 - 300

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-00-30 Throttle Control System ................................................................................................. 18-14
18-03 Tank
18-03-00 General ........................................................................................................................... 18-17
18-09 Filter
18-09-00 General ........................................................................................................................... 18-21
18-09-03 Filter Element ................................................................................................................. 18-27
18-09-06 Sediment Bowl ............................................................................................................... 18-28
18-09-09 Pre-Filter Element .......................................................................................................... 18-29
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-33
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-35
18-18 Injection
18-18-00 General ........................................................................................................................... 18-39
18-18-03 Injector ............................................................................................................................ 18-47
18-18-06 Injector Sleeve ............................................................................................................... 18-53
18-18-12 Rail ................................................................................................................................. 18-54
18-18-15 Pump .............................................................................................................................. 18-58
18-18-27 High Pressure Rail Valve ............................................................................................... 18-67
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-69
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-73
18-24-03 Inlet Manifold .................................................................................................................. 18-78
18-24-04 Outlet Manifold ............................................................................................................... 18-83
18-24-18 Catalyst .......................................................................................................................... 18-87
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-93
18-27-03 Actuator ........................................................................................................................ 18-101
18-27-06 Valve ............................................................................................................................. 18-103
18-27-09 Cooler ........................................................................................................................... 18-106
18-35 Turbocharger
18-35-00 General ......................................................................................................................... 18-111
18-35-05 Compressor .................................................................................................................. 18-122
18-35-06 Wastegate Valve .......................................................................................................... 18-124
18-36 Variable Geometry Turbocharger (VGT)
18-36-00 General ......................................................................................................................... 18-129
18-36-06 Wastegate Valve .......................................................................................................... 18-140
18-39 Fuel Cooler
18-39-00 General ......................................................................................................................... 18-145
18-96 Fuel Pipe
9823/0300-1
2017-11-22
18-96-00 General ......................................................................................................................... 18-149
18-96-03 High Pressure Pipe ...................................................................................................... 18-153
18-96-06 Low Pressure Pipe ....................................................................................................... 18-156
9823/0300-1
2017-11-22
Acronyms Glossary
DEF Diesel Exhaust Fluid

DTI Dial Test Indicator
HPV High Pressure Valve
IMV Inlet Metering Valve
NOx Nitrogen Oxide
9823/0300-1
2017-11-22
Notes:
9823/0300-1
2017-11-22
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3

18-00-30 Throttle Control System ................................................................................................. 18-14
18 - 1 9823/0300-1 18 - 1
Notes:
18 - 2 9823/0300-1 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for
Health and Safety ........................................... 18-4 engine damage due to the use of incorrect or
Technical Data ................................................. 18-4 contaminated fuel is much greater with common
Component Identification ................................. 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Operation ......................................................... 18-6 and cleanliness requirements, refer to Consumable
Discharge and Pressurise ............................... 18-9 Products Refer to: PIL 75-00-00. Technical Data,
Clean ............................................................... 18-9 Fuel, Acceptable and Unacceptable Fuels and
Check (Pressure) .......................................... 18-11 Cleanliness Requirements.
Bleed ............................................................. 18-13 For information about the fuel injection system. Refer
to: PIL 18-18.
Common Rail Fuel Injection

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

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

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

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

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

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9823/0300-1 18 - 3
00 - General

Fuel Table 139.
Primary filter
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or Degree of filtration 5μm
working on the fuel system. Do not refuel with the Secondary filter
engine running. Completely wipe off any spilt fuel Degree of filtration 5μm
which could cause a fire. There could be a fire and Fuel lift pump
injury if you do not follow these precautions.
Maximum Pressure 4bar (58.0psi)
Fluid Under Pressure Flow rate 2L/min
Fine jets of fluid at high pressure can penetrate the Fuel Cooler
skin. Keep face and hands well clear of fluid under Maximum operating 10bar (144.9psi)
pressure and wear personal protective equipment. pressure
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of Maximum burst pressure 25bar (362.3psi)
fluid. If fluid penetrates your skin, get medical help
immediately.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the system
could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
18 - 4 9823/0300-1 18 - 4
00 - General
Figure 383.
M
L
C D
G
F
H
B
E
K
A Fuel tank B Fuel level sender

C Primary filter D Fuel lift pump
E Secondary filter F Fuel cooler
G Hose - Tank to primary filter H Hose - Fuel lift pump to secondary filter
J Hose - Secondary filter to engine fuel system K Hose - From engine fuel system outlet
inlet
L Hose - Engine fuel system to fuel cooler M Hose - Fuel cooler to tank
18 - 5 9823/0300-1 18 - 5
00 - General
Operation
Some fuel flows through the pump at all times to

The fuel system is central to the performance and provide internal lubrication and cooling. This fuel
efficiency of the engine, distributing an accurate bleeds back to tank via the bleed-off fuel lines.
amount of fuel to each cylinder at exactly the right
time. Pressurised fuel from the high pressure pump
passes into the common fuel rail. The high pressure
Fuel is drawn from the fuel tank by the electric pump is capable of pressurising the fuel in the rail
lift pump integral via the 5 micron pre-filter/water up to 2000 bar. The ECM controlled IMV is used to
separator. (The fuel lift pump is integral with the pre- control the amount, and therefore pressure of the fuel
filter/water separator assembly.) in the common rail.
Fuel is pressurised at low pressure by the electric In some operating conditions the inlet metering valve
lift pump and passes through an engine mounted 2 is not able to reduce the rail pressure quickly enough
micron fuel filter on its way to the inlet on the high (if the operator goes from full throttle to no throttle
pressure pump. suddenly for example). In these circumstances the
rail pressure is dumped to the bleed off line using the
Important: Use of the correct fuel grade, together ECM controlled electric HPV (High Pressure Valve).
with effective filtration and decontamination of the
fuel is essential. The high pressure pump, injectors High pressure fuel pipes connect the injectors to
and engine can be damaged beyond repair by the common fuel rail. The injectors are electrically
contaminated fuel or use of incorrect fuel. controlled and incorporate a small solenoid valve.
The high pressure fuel injection pump is a rotary type Injection timing is determined by the ECM. Electrical
and is gear driven by the engine. The pump consists data from several sensors is continually monitored
of two sections, the transfer pump and high pressure and processed by the ECM to determine when, how
pump. Fuel is first pressurised to about 6 bar by the much and to which cylinder fuel must be injected.
transfer pump. A constant pressure is maintained
regardless of engine speed by the regulating valve. The injectors inject fuel in response to a supply
of electrical current from the ECM. So precise is
Fuel is transferred to the high pressure pump via the control that several injections of fuel occur
the IMV (Inlet Metering Valve). The metering valve during each firing stroke for maximum efficiency and
controls the amount of fuel transferred depending on minimum emissions. During fuel injection some fuel
the engine operating parameters (throttle position, bleeds off the injectors and back to tank via bleed off
coolant temperature etc.). The metering valve is lines.
controlled by the ECM (Engine Control Module).
18 - 6 9823/0300-1 18 - 6
00 - General
Figure 384.
2b
2e 2
2c 2d
3b
3
5 4
15
6 6 6 6
14
16
13
1 ECM 2 Fuel high pressure pump

2b IMV 2c Fuel high pressure pump (transfer section)
18 - 7 9823/0300-1 18 - 7
00 - General
2d Fuel high pressure pump (high pressure 2e Pressure regulating valve (transfer section)
section)
3 Common fuel rail 3b HPV
4 High pressure fuel lines 5 Bleed off fuel lines
6 Fuel injectors 13 Fuel filter
14 Pre-filter/water separator 15 Electric fuel lift pump
16 Fuel tank
Table 140. Colour code key

Colour Component
Green Tank pressure
Blue Transfer pressure
Red Injection rail pressure
Yellow Electrical connections
-ECM - injectors
Light Green Pump internal pressure,
injector bleed-off
18 - 8 9823/0300-1 18 - 8
00 - General
Discharge and Pressurise Clean

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

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 9 9823/0300-1 18 - 9
00 - General
• Gases - Air, sulphur dioxide etc. which can Maintenance Environment, Common Rail
create corrosive compounds if dissolved in the Fuel Injection
fluid.
Depending on circumstances engine maintenance
These contaminants can appear during may be required in various working environments.
manufacture, assembly, operation and maintenance. Obviously procedures are best carried out in a
dedicated workshop equipped with a suitable clean
The fuel filter is rated at 5 micron = 0.005mm room, but in practice this is not always possible.
(0.0002in). Listed are a few typical comparisons of
micron size: Maintenance procedures requiring removal or
replacement of fuel system components, particularly
Figure 385. high pressure components, require special
precautions to make the working environment
suitable, reducing the risk of contamination to an
absolute minimum.
Use the following guidelines to make sure you reduce

the chances of fuel system contamination when
C working in different environments:
B
Worksite - Open to weather
This repair site is not an acceptable location. Only

A in extreme circumstances should a machine be
repaired on an open site. Use the guidelines below:
A 8 microns • Clean the engine. If the machine is on hard

B 70 microns standing, clean away the material washed from
C 100 microns the engine.
• Place suitable clean boards on the ground
• Red Blood Cell = 8 microns (0.008mm, around the machine.
0.000315in). • Erect clean plastic sheeting to shelter the
• Human Hair = 70 microns (0.07mm, 0.00275in). engine from wind and rain.
• Grain of Salt = 100 microns (0.1mm, • Wear a new disposable environmental type suit
0.00394in). when working on the fuel system. If the suit
• The smallest particle visible to the naked eye is becomes contaminated with mud, move away
40 microns (0.00157in) approximately. from the engine and change into a new suit.
• Use clean latex gloves (non-powdered).
The fuel filter must be changed in accordance with • Before you start work make sure that all the
the applicable service schedule and procedures. The required replacement parts and tools are on
water in fuel sensor must be maintained to make sure site. Make sure that the replacement parts are
of correct operation at all times. still sealed inside their packaging.
• Put caps on all exposed ports and orifices
The potential for engine damage due to fuel immediately. Do not leave them open.
contamination is much greater when using common • High pressure fuel pipes MUST BE RENEWED
rail injection technology than with mechanical if any pipe joint is loosened or disconnected. DO
injection systems. This is because common rail NOT re-use the original pipe.
requires components with smaller manufacturing
tolerances, especially the fuel injectors. In addition, Worksite - Closed to weather from above
common rail operates at much higher fuel pressures,
over five times that of mechanical systems. This repair site is the least acceptable condition,
if possible move the machine to a more suitable
Similar pressures are used by commercial water environment. Use the guidelines below:
jet cutting machines to cut metal. Fortunately clean
diesel fuel has lubricating qualities that prevents • Clean the engine. Clean the floor of all material
erosion of components but it is obvious that washed from the engine.
contaminated fuel will cause serious damage at such • Place suitable clean boards on the ground
high pressures. around the machine.
• Erect clean plastic sheeting to shelter the
engine from the wind and the possibility of
debris such as dirt and dust falling from above.
18 - 10 9823/0300-1 18 - 10
00 - General
• Wear a new disposable environmental type suit Check (Pressure)

when working on the fuel system. If it becomes
contaminated with mud, move away from the
engine and change into a new suit. When it is necessary to check the fuel rail pressure
• Use clean latex gloves (non-powdered). function on a faulty vehicle, it is often difficult to
• Before you start work make sure that all the decide which component of the system has failed.
required replacement parts and tools are on It is essential to keep in mind the principles of the
site. Make sure that the replacement parts are function of the Common Rail Fuel system:
still sealed inside their packaging.
• Put caps on all exposed ports and orifices Table 141.
immediately. Do not leave them open. Principle Function
• High pressure fuel pipes MUST BE RENEWED
if any pipe joint is loosened or disconnected. DO Pressure production The pump compresses
NOT re-use the original pipe. the fuel at high pressure
Pressure regulation The pressure thus pro-
Vehicle Maintenance Workshop duced is accumulated in
a rail and measured and
Unless the workshop has a dedicated `sealable regulated (the rail pres-
clean room' work bay, precautions must still be taken. sure sensor, the ECU
(Electronic Control Unit)
• Clean the engine. Clean the engine in the and the IMV (Inlet Me-
dedicated area and then move it to the tering Valve) function in
workshop. a closed loop, excess
• Clean the floor area around the machine. pressure is drained to
• Erect clean plastic sheeting to shelter the tank by the HPV (High
engine from any wind and the possibility of Pressure Valve)
debris such as dirt and dust falling from above. Pressure consumption This pressure is finally
• Make sure that workshop doors to the outside consumed by the injec-
are kept closed. A gust of wind through an open tors (injection into the
door will easily blow sand particles into the air. engine cylinders and in-
• Make sure your work wear is clean, non-flocking jector management)
and lint free. If in doubt wear a new disposable
environmental type suit. This means that a pressure fault may come from
• Use clean latex gloves (non-powdered). the producer, the regulator or the consumers. Simply
• Before you start work make sure that all the studying the physical parameters of the rail pressure
required replacement parts and tools are on does not allow the disassociation of the producer and
site. Make sure that the replacement parts are the consumer.
still sealed inside their packaging.
• Put caps on all exposed ports and orifices
immediately. Do not leave them open. Symptoms
• High pressure fuel pipes MUST BE RENEWED • The engine won’t start or is difficult to start.
if any pipe joint is loosened or disconnected. DO • The engine stalls while running.
NOT re-use the original pipe. • Lack of power and dashboard warning lamps
light: the recovery mode may lead to engine
stop.
Hydraulic System Status Analysis

Hydraulic flow balance is established as follows:
Injected flow + Back leaks flow (Flow consumed)

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

• The Injector back leak flow increases sharply,
exceeding the pump capacity.
• This can happen when particles disturb the
internal injector sealing, increasing the back
leak flow from one/several injectors or HPV
18 - 11 9823/0300-1 18 - 11
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 387. Reduction in HP Pump Capacity
• Mechanical wear in the injector.
• HPV stuck open.
100 100
The capacity of the pump to supply the required
pressure is reduced due to internal pump wear,
pressure is reduced due to internal pump wear or a
fuel feed problem.
Figure 386. Increased Back Leak Flow
C
F
C
100 100
E D
0 0
B A
A Production
B Consumption
C Reduction in HP pump capacity
D Pressure deficit
E Pump capacity
E F Injected flow
G Back Leak flow
0 0
B A
A Production
B Consumption
C Increased back leak flow
D Pressure deficit
E Pump capacity
F Injected flow
Example
• Presence of air in the low pressure circuit.
18 - 12 9823/0300-1 18 - 12
00 - General
Bleed
Notice: Running the engine with air in the
system could damage the fuel injection pump.
After maintenance, the system must be bled to
remove any air.
The machine is installed with an electric priming

pump. If the fuel system has been disturbed, the
system must be primed:
1. Make sure that there is enough fuel in the fuel

tank.
2. Turn the starter switch to 'IGN' for the specified
duration before starting engine, to prime the fuel
system.
Duration: 3min
2.1. Do not operate the electric priming pump for
prolonged periods without fuel.
After starting, do not race the engine for at least 2min

to make sure that any pockets of trapped air in the
pump are allowed to escape.
18 - 13 9823/0300-1 18 - 13
30 - Throttle Control System
30 - Throttle Control System Operation

Operation ....................................................... 18-14 With the ignition on 12V is supplied to the engine
Diagram ......................................................... 18-15 ECU, connector J1 at pin 9 from the fuse B7.
The desired engine RPM’s are sent to the chassis

ECU by the foot pedal or the hand throttle dial. The
chassis ECU will react to the highest input.
With the engine running the magnetic pick up sensor

located in the bell housing of the engine sends a
signal to the engine ECU, connector J2 at pins 1,10.
The engine ECU also receives the throttle signal from
the chassis ECU via CAN Bus.
The engine ECU uses the magnetic pick up signal

and chassis ECU signal to adjust the PWM signal
sent to the throttle solenoid via pins 5,8 to maintain
the desired RPM’s setting of the throttle dial / foot
throttle.
Depending on the duty cycle of the PWM signal this

will increase or decrease the engine RPM’s.
There is no calibration procedure for the engine ECU

or the throttle solenoid. The only calibration setup
required is for the magnetic pick-up sensor.
For details of the throttle pedal sensor procedures

refer to (PIL 09-27-36).
18 - 14 9823/0300-1 18 - 14
30 - Throttle Control System
Diagram
Figure 388.
A B
C
44
A Engine ECU B ECU J1 connector

C ECU J2 connector D Hand throttle
E Foot throttle
18 - 15 9823/0300-1 18 - 15
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-17
18 - 16 9823/0300-1 18 - 16
03 - Tank
00 - General
Introduction .................................................... 18-17 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-18 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel

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

tank at the recommended service intervals.
18 - 17 9823/0300-1 18 - 17
03 - Tank
00 - General
Clean
The diesel tank must be drained if there is a chance

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

2. Drain the diesel tank.
3. Drain the fuel from the low pressure fuel pipes.
4. Replace the fuel filters.
5. Refill the tank to the specified level with clean
diesel.
Percentage: 25%
6. Start the engine and leave it to run for the
specified time period.
Duration: 10min
7. Stop the engine.
8. Drain the water separator and the main fuel filter.
9. If there was any water or other liquid in the water
separator, repeat 6 to 8.
18 - 18 9823/0300-1 18 - 18
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-21

18-09-03 Filter Element ................................................................................................................. 18-27
18-09-06 Sediment Bowl ............................................................................................................... 18-28
18-09-09 Pre-Filter Element .......................................................................................................... 18-29
18 - 19 9823/0300-1 18 - 19
Notes:
18 - 20 9823/0300-1 18 - 20
09 - Filter
00 - General
Introduction .................................................... 18-21 The fuel filter consists of a paper element folded in
Technical Data ............................................... 18-22 such a way as to give a very large surface area. It is
Operation ....................................................... 18-23 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-24 in accordance with the machine service schedule.
Use only the correct specification filters.
Check (Leaks) ............................................... 18-24
Bleed ............................................................. 18-25
18 - 21 9823/0300-1 18 - 21
09 - Filter
00 - General
Technical Data
Table 142. Technical Data

Description Value
Filtering surface 0.23m²
Degree of filtration 5μm
Max operating pressure 2bar (29.0psi)
Maximum pressure at in- 0.2bar (2.9psi)
jection pump inlet
Max flow rate 3.17L/min
18 - 22 9823/0300-1 18 - 22
09 - Filter
00 - General
Operation
An integral sediment bowl at the bottom of the filter

Fuel enters the filter and passes through the paper enables water to be drained off by means of a drain
element where any dirt particles or water droplets are screw.
retained.
The system shown is for illustration purposes. The
From the fuel filter low pressure fuel is supplied to the system installed on your machine may be different.
high pressure fuel pump.
Figure 389.
C A
A Fuel tank B Fuel filter

C High pressure fuel pump
18 - 23 9823/0300-1 18 - 23
09 - Filter
00 - General
Drain and Fill Check (Leaks)

1. Obey all fuel system health and safety 1. Make the machine safe.
information.
2. Get access to the engine compartment (if
Refer to: PIL 18-00-00. applicable).
2. Drain off any water in the fuel filter element and 3. Check the engine compartment (if applicable),
the water separator by turning the tap. fuel lines and the area below for leaks.
Figure 390. 4. If necessary, contact your JCB dealer.
A
B
A Fuel filter
B Wing nut
18 - 24 9823/0300-1 18 - 24
09 - Filter
00 - General
Bleed Remove and Install

Notice: Do not allow dirt to enter the system.
Before disconnecting any part of the system, Obey all fuel system health and safety information.
thoroughly clean around the connection. When a Refer to: PIL 01-03-27.
component has been disconnected, always install
protective caps and plugs to prevent dirt ingress. Make sure that you keep a suitable container to
collect the fuel from the cartridge, when you remove
Failure to follow these instructions will lead to the water in fuel sensor from the cartridge.
dirt entering the system. Dirt in the system will
seriously damage the systems components and
could be expensive to repair. Remove
1. Make the machine safe. the engine has been running, let it cool before
2. Get access to the fuel filter.
2. Thoroughly clean the outside of the filter housing
3. Make sure there is sufficient fuel in the tank. and around the filter head.
4. Loosen the bleed screw on the fuel filter. 3. Loosen the drain nut and allow the water/fuel to
5. Turn on the ignition until fuel with no air flows drain into a suitable container
freely from the valve, then close the bleed screw. 4. Loosen the clamps and pull the fuel pipes out of
6. Check the engine for smooth running. the fuel filter support.
7. If the engine continues to run roughly, check Figure 392.

again the bleeding procedure. C
Figure 391. B
A
A Callout
B Fuel pipe
C Support
5. Put caps on the fuel pipes to prevent
contamination.
6. If required, remove the water in fuel sensor.
7. With a strap wrench remove the cartridge and the
gasket from the support.
A Bleed screw
18 - 25 9823/0300-1 18 - 25
09 - Filter
00 - General
Figure 393. Table 143. Torque Values

Item Nm
A 25
D 17
C Support
D Cartridge
Install
1. Attach the fuel pipes to the support with clamps.
2. Tighten the clamps to the correct torque value.
3. Use new gaskets and a new filter element.
4. Lubricate the gasket with clean fuel before
installation.
5. Install the gasket and cartridge to the support.
Figure 394.
C Support
D Cartridge
E Gasket
6. Tighten the cartridge to the correct torque value.
7. If removed, install the water in fuel sensor.
8. Bleed the fuel system.
18 - 26 9823/0300-1 18 - 26
09 - Filter
03 - Filter Element
03 - Filter Element
Remove and Install

2. Get access to the engine compartment
3. Remove the sensor housing.
4. Unscrew and remove the filter element.
5. Fit a new element. Lubricate the gasket of the
new cartridge. Do not fill the new cartridge with
fuel.
6. Refit the sensor housing.
7. Bleed the fuel system.
8. Close the engine cover.
Figure 395.
A Filter element
B Sensor housing
18 - 27 9823/0300-1 18 - 27
09 - Filter
06 - Sediment Bowl
06 - Sediment Bowl
Clean
Draining the Water Separator

2. Get access to the engine compartment
3. If there is water but no sediment, open the tap
to drain the water. If there is any sediment in the
bowl replace the fuel filter element.
4. Close the engine cover.
Figure 396.
A
A Tap
B Bowl
18 - 28 9823/0300-1 18 - 28
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-29 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-30 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 29 9823/0300-1 18 - 29
09 - Filter
09 - Pre-Filter Element

Remove removal procedure. Additionally do the following
steps.
2. Install a new filter element and secure in position
2. Get access to the filter. with the locking ring.
3. On machines with a fuel shut off valve, set the 3. Make sure that the water in fuel electrical
valve to isolate the fuel supply. connector is correctly installed.
4. Drain the water separator bowl. 4. On machines with a fuel shut-off valve, set the
valve to connect the fuel supply.
5. Disconnect the water in fuel sensor.
6. Release the locking ring and remove water
separator bowl. Any fuel and water mix drained
must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
7. Release the locking ring and remove the filter
element, discard the element.
Figure 397.
E
A Filter Element
B Filter element locking ring
C Water separator bowl locking ring
D Water separator bowl
E Water in fuel electrical connector
18 - 30 9823/0300-1 18 - 30
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-33

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-35
18 - 31 9823/0300-1 18 - 31
Notes:
18 - 32 9823/0300-1 18 - 32
00 - General
Introduction .................................................... 18-33 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-34 lift pump is a sealed integral electrical unit. The
Remove and Install ....................................... 18-34 assembly is a non-serviceable component. If any
part is defective, replace the complete pump, filter
and separator assembly.
Figure 398.
A Fuel lift pump

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

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

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

identification, (PIL 18-09).
18 - 33 9823/0300-1 18 - 33
00 - General
Drain and Fill Remove and Install

1. Obey all fuel system health and safety Refer to Fuel and Exhaust system - Filter - Pre-Filter
information. Element. Refer to: PIL 18-09.
3. Drain off any water in the filter element by turning
the tap.
4. Drain off any water in the water separator bowl
by turning the tap. Do not disconnect the water
in fuel electrical connector (if installed).
5. If there is sediment in the bowl after draining,
support the bowl and release the locking ring.
6. Wash the bowl in clean fuel.
7. Install the bowl, secure in position with the
locking ring.
8. Make sure that the water in fuel electrical
connector is correctly installed.
Figure 399. Typical Engine
A
A Fuel filter
B Drain tap
18 - 34 9823/0300-1 18 - 34
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-35
Introduction
The water in fuel sensor operates to indicate the
presence of water in the fuel.
If water is present in the fuel due to its higher specific

weight it will separate from the fuel and will settle
down in the lower part of the filter. The water in
fuel sensor is located at the bottom part of the
filter and will send a signal to the ECM (Engine
Control Module) to activate an alarm signal on the
dashboard. The wheel at the bottom of the filter will
release the water and restores the correct operating
condition.
Figure 400.
A Water in fuel sensor
18 - 35 9823/0300-1 18 - 35
04 - Water in Fuel Sensor
Remove and Install 4. Tighten the sensor to the correct torque value.

Remove Item Nm
A 5
1. Obey all fuel system health and safety
information.
3. Thoroughly clean the outside of the filter housing
and around the filter head.
4. Loosen the drain nut and allow the water/fuel to
drain into a suitable container.
5. Remove the water in fuel sensor and the gasket.
Figure 401.
A Water in fuel sensor

B Gasket
C Fuel filter cartridge
Install
1. Replace the fuel filter element.
2. Lubricate the gasket with clean fuel.
3. Install the gasket and the water in fuel sensor on
to the cartridge.
18 - 36 9823/0300-1 18 - 36
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-39

18-18-03 Injector ............................................................................................................................ 18-47
18-18-06 Injector Sleeve ............................................................................................................... 18-53
18-18-12 Rail ................................................................................................................................. 18-54
18-18-15 Pump .............................................................................................................................. 18-58
18-18-27 High Pressure Rail Valve ............................................................................................... 18-67
18 - 37 9823/0300-1 18 - 37
Notes:
18 - 38 9823/0300-1 18 - 38
18 - Injection
00 - General
Introduction .................................................... 18-39 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-40 injectors via high pressure fuel pipes.
Operation ....................................................... 18-42
Calibrate ........................................................ 18-45 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
the tubes are formed with conical nipples for sealing
in the sealing cones on the common rail and on
the injector at port. It is essential that the tubes
are maintained and installed correctly for safe and
effective engine operation.
Important: If the high pressure fuel pipes are

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

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

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

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

initiates several separate injections of fuel during the
compression stroke. The timing of the fuel injections
is also varied by the ECM depending on engine
operating parameters.
18 - 39 9823/0300-1 18 - 39
18 - Injection
00 - General
Figure 402.
B
C
A Fuel tank B Fuel pipe under low pressure from the tank to
the fuel filter
C Fuel filter D Fuel pipe under low pressure from the fuel filter
to the high pressure pump
E High-pressure pump F Fuel pipe under high pressure from the high
pressure pump to the rail
G Rail H Fuel pipes under high pressure from the rail to
the electronic injectors
J Electronic injectors
18 - 40 9823/0300-1 18 - 40
18 - Injection
00 - General
Figure 403.
J
L
A Fuel tank E High-pressure pump

G Rail J Electronic injectors
K Fuel return pipe under low pressure from the rail L Fuel return pipe under low pressure from the
to the fuel distributor electronic injectors to the fuel distributor
M Fuel return pipe under low pressure from the N Fuel return pipe under low pressure from the
distributor to the fuel tank injection pump to the fuel distributor
P Fuel distributor under low pressure
18 - 41 9823/0300-1 18 - 41
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 404.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM (Engine Control Module) 2 Camshaft position sensor

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
A Camshaft sensor signal - Signal is B Crank position sensor signal - Signal is
generated by camshaft target disc 3 and generated by crankshaft mounted target
sensor 2. Processed by the ECM 1 to disc 5 and sensor 4. Processed by the
determine which cylinder to inject. ECM 1 to determine timing of injection.
C1-C2 Current pulse - injector solenoid coil - D1-D2 Fuel Injection - Start and duration of
Sent to the injector (6) solenoid coil by actual injection. It can be seen that
the ECM 1 to initiate injection. Time of there is a time shift between the current
pulse calculated by the ECM to control pulse and actual injection. This is
the amount of fuel injected. Pulse C1 due to electrical resistance and the
controls pilot injection. Pulse C2 controls individual characteristics on the fuel
the main injection. injector assembly 6. D1 indicates the
pilot injection and D2 the main injection.
Total fuel injected for one cycle = D1 +
D2.
TDC Top dead centre - Shows when piston
is at top dead centre in relation to the
injection sequence.
18 - 42 9823/0300-1 18 - 42
18 - Injection
00 - General
Injection Cycle to bleed from the control chamber and ultimately

back to the fuel tank via the bleed off lines.
It is important to remember that the injector solenoid
coil does not directly lift the injector needle. Instead Although the control chamber is still connected to the
it operates a tiny valve which causes a fuel pressure rail pressure different sized metering orifices K and
imbalance inside the injector. In this way the needle L cause the pressure in the chamber to fall below
is lifted hydraulically. The method of operation is as the rail pressure. The metering orifice ensures full rail
follows: pressure is maintained in the chamber around the
needle.
State 1 - No fuel injection
When the pressure imbalance in the chambers is
The solenoid coil is not energised. Fuel at rail sufficient to overcome spring the needle lifts and
pressure fills the small chamber around the needle. injection begins.
Fuel at rail pressure also fills the control chamber.
Since the surface area of the needle inside the Figure 406.
control chamber is greater than the area inside
chamber the needle is held on its seat by hydraulic
(fuel) pressure. Spring holds the needle on its seat
when the engine is stopped (when the rail pressure
is low or zero).
Figure 405. F
E
L R
K
F
J
M
J
Q
B
B Needle
E Spool valve
Q F Solenoid coil
J Spring
B K Metering orifice
L Metering orifice
M Metering orifice
B Needle Q Small chamber
F Solenoid coil R Control chamber
J Spring
Q Small chamber State 3 - Fuel injection
R Control chamber
When the flow of fuel to the injection nozzle is
State 2 - Fuel injection start established the metering orifice causes a pressure
drop in the small chamber. Since the needle is now
At the commencement of fuel injection the solenoid lifted its surface area subjected to the pressure in the
coil is energised by the ECM.The solenoid coil lifts small chamber is increased. The force is sufficient to
spool valve off its seat. Fuel at rail pressure is allowed keep the needle lifted.
18 - 43 9823/0300-1 18 - 43
18 - Injection
00 - General
H
G
M M
Q Q
B B
B Needle B Needle
M Metering orifice E Spool valve
Q Small chamber F Solenoid coil
G Spring
State 4 - Fuel injection stop H Calibration dowel
J Spring
To stop fuel injection the ECM de-energises the M Metering orifice
solenoid coil. The spool valve is pushed on to its seat Q Small chamber
by the force of the spring. Fuel no longer bleeds from R Control chamber
the control chamber.
A calibration dowel, selected during manufacture, is

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

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

to reduce the fuel pressure in the small chamber.
This is achieved by the metering orifice. As fuel flows
through the metering orifice a pressure drop in the
small chamber is produced. The needle is forced on
to its seat by pressure in the control chamber. Fuel
injection stops.
18 - 44 9823/0300-1 18 - 44
18 - Injection
00 - General
Calibrate
The codes for each injector installed to the engine are

Since the injector operating components are very programmed into the ECM (Engine Control Module)
small, even the most advanced manufacturing using Servicemaster. The operating software in the
techniques do not ensure consistent injection cycle ECM uses the data to adjust the control of the injector
characteristics between injectors. solenoid coil accordingly. The injector is therefore
effectively re-calibrated by the ECM.
For example, small variations in the metering orifice
sizes will alter the time durations for the start and stop It follows that if injectors are removed they must
of injection. The small dimensions involved mean always be installed in their original positions. If
that only a tiny variation will alter the orifice area by new injectors are installed, the ECM must be
a relatively large percentage. reprogrammed with the new injector codes. This
process must also be completed when installing a
For this reason it is necessary to individually test and new engine.
record the operating characteristics of each injector
assembly at the factory. The results of the test are Note: The position of cylinder 1 is at the flywheel end
recorded in code (C2I codes) form and are printed on of the engine.
the injectors. Manually add the injector calibrations
which can be found printed on top of the injector.
Figure 409.
A B
A Calibration code (Visual reading)

B Calibration code (Electronic reading)
18 - 45 9823/0300-1 18 - 45
18 - Injection
00 - General
Figure 410.
Note: Greyed out injector code cells are always set

to zero.
18 - 46 9823/0300-1 18 - 46
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-47 The fuel Injectors are electronically controlled and
Component Identification ............................... 18-48 incorporate a small solenoid valve as an integral
Calibrate ........................................................ 18-48 part. The injectors are supplied with pressurised fuel
Remove and Install ....................................... 18-49 by the high pressure fuel injection pump and when
energised, the injector atomizes the fuel into a fine
Store and Recommission .............................. 18-52 mist so that it can burn easily by the vehicle’s engine.
The fuel injectors are mounted in the inlet manifold

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

chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by an O-ring.
If the electronic fuel injectors are disassembled (not

necessarily replaced) their position with respect to
individual cylinders must not be changed when re-
assembled. Refer to the reference between each
injector and respective cylinder number, refer to Fuel
Injection, Injector-Calibrate PIL 18-18-00 .
Note: The injectors calibration code are located on

the top of the injectors.
Figure 411.
A B
A Calibration code (Visual reading)

B Calibration code (Electronic reading)
18 - 47 9823/0300-1 18 - 47
18 - Injection
03 - Injector
Component Identification Calibrate

Special Tools
Figure 412. Description Part No. Qty.
Tool for protrusion of 892/12467 1
A pistons, injectors and
B glow plugs
C
Injector Projection
1. Measure the injector projection.
D
Figure 413.
E
E J
F
H
A Electronic connector
B Solenoid and valve closure ring A F
C High pressure pipe inlet G
D Electronic injector body
E O-ring
F Sleeve
A Cylinder head
E Injector
F Sleeve
G Rocker arm screw
H Injector bracket
J Injector bracket screw
Figure 414.
E Injector
K Washer
1.1. Put the injector inside the sleeve.
1.2. Put the rocker arm screw up to the stop.
1.3. Attach the injector bracket with the screw,
without doing the calibration.
1.4. Measure the projection of the injector from
the cylinder head with a dial gauge.
18 - 48 9823/0300-1 18 - 48
18 - Injection
03 - Injector
Special Tool: Tool for protrusion of pistons, Remove and Install

injectors and glow plugs (Qty.: 1)
Special Tools
1.5. The projection must be in the
range between 1.68mm (0.066in)-2.42mm Description Part No. Qty.
(0.095in). Tool for protrusion of 892/12467 1
pistons, injectors and
1.6. If the injector projection is not within the glow plugs
specified range, then replace the washer
and do steps 1.1 to 1.5 again. The following procedure is for one injector, the
procedures are identical for all injectors.
Before Removal
3. Remove the high pressure fuel pipes.
5. Make sure that the new high pressure pipes are
available.
Note: If a fuel injector is defective, it must be

replaced.
Remove
1. Disconnect the electrical connector.
Figure 415.
2. Remove the clip that attaches the fuel return pipe
to the injector head.
3. Disconnect the fuel return pipe fitting from the
injector head.
18 - 49 9823/0300-1 18 - 49
18 - Injection
03 - Injector
Figure 416. 12. Put a clean protective cap over the nozzle of the
injector.
D
13. Make sure that the gasket remains in the correct
position on the injector sleeve.
14. Make sure that you hold the electronic injector
only from the body.
Figure 418.
E
F
D Clip
E Return fuel pipe fitting
F Return fuel pipe
4. Make sure that the clip must automatically return M
to their initial position, if not it must be replaced.
5. Seal the return pipe inlet with the relevant plug to N
prevent from impurities.
M Injector sleeve
6. Remove the screw with the washer on the N Gasket
bracket, that attach the injector with the rocker
cover. Install
7. Remove the bracket. Important: The fuel injectors are not interchangeable
Figure 417. between cylinders or other engines. Make sure you
install the injectors in the same positions. If a new or
different injector is installed, the new calibration data
must be re-entered into the ECM (Engine Control
Module) via Servicemaster (Refer to PIL 33-57).
J
procedure.
G
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
L damage the surface of the bore. Any damage
H or surface contamination will cause the injector
K sealing gasket to fail.
3. Install new gaskets on the base and on the seat
G Electronic injector of the injector sleeve.
H Bracket
J Screw 4. Make sure that you lubricate the new gaskets
K Washer with the fuel.
L Gasket
5. Make sure that the injector sleeve is pushed fully
8. Take care when you pull out the electronic into the cylinder head.
injector.
9. If there is a difficulty to pull out the injector use a
34mm diameter key at the injector body to assist
in removal.
10. Make sure that the gaskets are not damaged.
11. Label the injector to make sure it is installed in its
original cylinder at the time of installation.
18 - 50 9823/0300-1 18 - 50
18 - Injection
03 - Injector
Figure 419. 11. Position the electronic injector fixing bracket and
secure it with a screw and washer.
C
Figure 421.
Q
J
P
G
H
K
N
M
G Electronic injector
M Injector sleeve
N Gasket H Bracket
P Gasket J Screw
Q High pressure pipe inlet K Washer
6. Make sure that you clamp the sleeve to the 12. Tighten the injector fixing bracket screw to the
correct torque value. correct torque value.
7. Make sure that you put the injector into the 13. Attach the fuel return pipe fitting to the injector
sleeve. head.
8. Make sure that the injector is installed in the 14. Connect the electrical connector.
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the Note: If the injector projection does not fall into the
engine. specified range then replace the gasket, on the base
of the injector sleeve and repeat the inspection.
9. Make sure that you use a dial gauge to check that
the projection of the electronic injector sleeve After Installation
must be in the specified range.
1. Replace the rocker cover.
Length/Dimension/Distance: 1.68–2.42mm
Special Tool: Tool for protrusion of pistons, Refer to: PIL 15-42-06.
injectors and glow plugs (Qty.: 1)
2. Renew the high pressure fuel pipes.
Figure 420. Refer to: PIL 18-96-03.
M
R 3. Start the engine and check for fuel leaks.

Item Nm
M 30
J 20
M Injector sleeve
N Gasket
R Dial gauge
10. Install the rocker arm pin fixing screw.
18 - 51 9823/0300-1 18 - 51
18 - Injection
03 - Injector
Store and Recommission Figure 423.
Special Tools
Electronic Injector 892/12416 1
Return Line Plugs
Electronic Injector 892/12417 1 B
Plugs
Electronic Injector Fuel 892/12418 1
Spray Plugs C
D
Storage
1. All the openings of the injector must be E
protected by attaching protective caps and it B Connector
must be positioned as shown in figure during the C Pipe fitting
component storage. D Body
Special Tool: Electronic Injector Fuel Spray Plugs E Nozzle
(Qty.: 1)
Special Tool: Electronic Injector Return Line
Plugs (Qty.: 1)
Special Tool: Electronic Injector Plugs (Qty.: 1)
Figure 422.
A
A
A Protective cap
Handling
1. Make sure you hold the injector only from the
body.
2. Do not hold the injector from connector, nozzle
and from the pipe fitting.
18 - 52 9823/0300-1 18 - 52
18 - Injection
06 - Injector Sleeve
06 - Injector Sleeve Figure 425.
Remove and Install A

E
D
B C
Before removal
the engine has been running, let it cool before D
3. Remove the cylinder head assembly.
Refer to: PIL 15-06-00. A Injector sleeve
4. Remove the rocker shaft. B Cylinder head
C Seal 1
Refer to: PIL 15-42-00. D Seal 2
E Injector sleeve seat
Removal
4. Lubricate and install the seal 1 in the seats of the
1. Loosen and remove the sleeves from the cylinder sleeve.
head.
5. Install the seal 2 with the convex side facing
Figure 424. upward at the base of the sleeve.
B 6. Carefully attach the sleeve into the seat of the
cylinder head.
A C 7. Make sure that the injector sleeve is pushed fully
into the cylinder head.
8. Make sure that you clamp the sleeve to the
D A correct torque value.
After Installation
A Injector sleeve
B Cylinder head 1. Install the rocker shaft.
C Seal 1
D Seal 2
2. Install the cylinder head.
2. Remove both of the gaskets from the sleeves.
Install 3. Start the engine and check for fuel leaks.
procedure. Table 146. Torque Values
Item Nm
2. Clean off any sludge or oil from the inner bore of
A 30
the injector sleeve.
3. Make sure you do not damage the surface of the
bore. Any damage or surface contamination will
cause the injector sealing gasket to fail.
18 - 53 9823/0300-1 18 - 53
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-54 The fuel rail also known as a common rail, is a
Component Identification ............................... 18-55 pipe resembling a rail that is used to deliver fuel
Operation ....................................................... 18-55 to individual fuel injectors on internal combustion
Remove and Install ....................................... 18-56 engines. It is designed to have a seat for each
injector as well as an inlet for a fuel supply.
Store and Recommission .............................. 18-57
The fuel rail also incorporates an attached fuel
pressure sensor and a safety valve. The fuel
pressure sensor measures the pressure of the fuel in
the rail and the safety valve operates only if the rail
internal pressure exceeds 2400 bar.
NOTE: DO NOT remove the fuel pressure sensor

from the rail as it is an integral part of the rail
unit. If the sensor is defective replace the complete
common rail assembly.
18 - 54 9823/0300-1 18 - 54
18 - Injection
12 - Rail
Component Identification Operation

Figure 426. Fuel is injected under pressure into the rail from the
C high pressure fuel injection pump.
D
The internal volume of the rail is mostly used for
obtaining the constant high pressure pump flow. The
rail stores the fuel and distributes it to the individual
injectors. It also damps any pressure vibrations
caused by the high pressure pump and injection
B process.
A
E Pressurised fuel from the high pressure pump
passes into the common fuel rail. The high pressure
A Rail assembly pump is capable of pressurising the fuel in the rail up
B Safety valve to 2,400bar (34,782.5psi). The ECM (Engine Control
C Pipe inlet from high pressure pump Module) controlled fuel pressure sensor is used to
D Pipe outlet to electronic injector control the amount and therefore pressure of the fuel
E Fuel pressure sensor in the common fuel rail.
18 - 55 9823/0300-1 18 - 55
18 - Injection
12 - Rail

1. Make sure you align the rail on the crankcase
Before Removal head with the screws.
1. Obey all fuel system health and safety 2. Tighten the screws to the correct torque value.
information.
Note: When the rail assembly is changed YOU
Refer to: PIL 18-00-00. MUST replace all of the high pressure fuel pipes.
the engine has been running, let it cool before Figure 428.
you start the service work. B
4. Remove the high pressure fuel pipes. A
5. Remove the fuel bleed off pipe at the rail.
Remove
Figure 427.
A Fuel rail assembly

B Screws
B B
E Table 147. Torque Values
C D
Item Nm
B 10
F
A
A Fuel rail assembly

B Screws
C Fuel pressure sensor
D Safety valve
E Outlet fittings to electronic injectors
F Inlet fitting from high pressure pump
1. Disconnect the connector at the high pressure
fuel safety valve.
2. Disconnect the electrical connector at the fuel
pressure sensor.
3. Protect the fuel pressure sensor from outside
moisture, knocks and high temperature.
4. Remove the screws and lift off the common rail
assembly.
5. Put protective caps on all open ports.
Important: Seal the common rail assembly inside

a clean plastic bag until it is ready for use. If the
assembly is defective discard it and get a new one.
18 - 56 9823/0300-1 18 - 56
18 - Injection
12 - Rail
Store and Recommission
Storage
All the openings of the rail must be protected by
attaching protective caps and it must be positioned
as shown in figure during the component storage.
Figure 429.
A A
A Protective cap
Handling
1. Make sure you hold the fuel rail only from the
body.
2. Do not hold the fuel rail from the safety valve side.
Figure 430.
D E
C
F
B Body
C Pressure sensor
D Outlet pipe fitting
E Inlet pipe fitting
F Safety valve
3. Do not hold the rail from the pressure sensor
side.
4. Do not hold the rail from the inlet and outlet pipe
fitting.
18 - 57 9823/0300-1 18 - 57
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-58 The high pressure fuel injection pump is a rotary
Technical Data ............................................... 18-59 type device that pumps fuel into the cylinders of the
Component Identification ............................... 18-59 engine. The high pressure pump is operated via the
Operation ....................................................... 18-60 pump control gear. Refer to: PIL 15-51-00.
Store and Recommission .............................. 18-65
18 - 58 9823/0300-1 18 - 58
18 - Injection
15 - Pump
Refer to Fuel System- Technical Data PIL 18-00-00 . Important: Do not use the connection pipe plunger
housing (item D) to carry the fuel injection pump as
this will cause damage resulting in fuel leakage.
The high pressure fuel injection pump is non-

serviceable, if any part is defective replace the
complete pump.
Figure 431. Fuel injection pump
E
F
G
H
D J
K
C A B
A Identification plate with QR code

B Mounting screw
C Fuel inlet fitting
D Connection pipe plunger housing
E Fuel temperature sensor (refer to PIL 15-84)
F Fitting for high pressure outlet to rail
G Fuel return fitting
H Nut
J Fuel pressure sensor (refer to PIL 15-84)
Figure 432.
L
M
K Gasket
L Key for positioning shaft
M Pump control shaft
18 - 59 9823/0300-1 18 - 59
18 - Injection
15 - Pump
Operation Module) controlled IMV determines the amount of

fuel transferred to the high pressure pump. The
plunger actuator block is located on the engine driven
The high pressure fuel injection pump is driven via a eccentric shaft. When the shaft rotates the actuator
gear on the engine and rotates at half engine speed. block operates the two plungers. As one plunger is
The pump comprises of two sections, the transfer pushed up its chamber the other is pushed down by
pump and the high pressure pump. its spring.
Although the pump does not control fuel injection State 1 - Charging
timing, it is still timed in relation to engine phasing.
By timing the pump pressure pulses, the load on the Note: The description is for one plunger. The
engine timing gears is reduced together with reduced opposite plunger operates in an identical way. The
mechanical noise. inlet and delivery ports from each plunger are
connected by internal galleries.
Transfer Pump Operation
When the eccentric shaft is in the position shown
The integral transfer pump is a vane type. An force from spring moves the plunger down its
engine driven rotor houses four vanes in slots. chamber. Pressure in the chamber falls below the
The rotor rotates inside an eccentric liner. The rail pressure and the delivery valve closes. Transfer
vanes are held in contact with the liner by springs. pressure is now sufficient to force inlet valve off its
Fuel is drawn into the pump chamber at port X, seat and allow the fuel to fill the chamber.
pressurised by the decreasing volume inside the
chamber and expelled at port Y. Fuel pressure Figure 434.
generated by the transfer pump is limited to a
specified pressure by an integral pressure regulating E
valve. This pressure is maintained regardless of
engine speed.6bar (87.0psi)
Figure 433.
D
C
E
A
B F
D
A
X Y
A Eccentric shaft
C B Actuator block
C Plunger
A Rotor D Inlet valve
B Vanes (x4) E Delivery valve
C Eccentric liner F Spring
D Springs
E Regulating valve State 2 - Pumping
X Port X
Y Port Y Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
High Pressure Pump Operation connected by internal galleries.
Fuel passes to the high pressure pump via the IMV
When the eccentric shaft is in the position shown the
(Inlet Metering Valve). The ECM (Engine Control
actuator block moves the plunger up its chamber.
18 - 60 9823/0300-1 18 - 60
18 - Injection
15 - Pump
Fuel pressure in the chamber rises and forces the Remove and Install
inlet valve on to its seat. As the plunger is pushed
further up its chamber the fuel pressure exceeds that Special Tools
of the rail pressure and the delivery valve is forced off Description Part No. Qty.
its seat. Fuel is forced into the rail at high pressure. Flywheel locking tool 892/12407 1
Figure 435. High pressure pump 892/12468 1
gear puller
E This part is a non-serviceable component. If
damaged, replace the pump.
Important
D 1. Obey all fuel system health and safety
information.
C Refer to: PIL 18-00-00.
2. Make sure that the fuel rail is not under pressure.
3. Always replace the high pressure pipes after
each disassembly.
B 4. Make sure that you have the new high pressure
pipes before you remove the high pressure fuel
pump.
A
5. Make sure that you do not use the connection
pipe as a handle to prevent the pipe from damage
and fuel leakage.
A Eccentric shaft
B Actuator block 6. Make sure that you hold the pump from the
C Plunger bottom side.
D Inlet valve
E Delivery valve Before Removal
3. Remove the starter motor.
4. Put the flywheel crown mounting tool in the seat
of the starter motor and secure with the starter
motor mounting bolts.
Special Tool: Flywheel locking tool (Qty.: 1)
18 - 61 9823/0300-1 18 - 61
18 - Injection
15 - Pump

C
B H
J
F
G
A
C High pressure fuel pipe
A Starter motor mount F High pressure fuel pipe top nut
B Flywheel crown mounting tool G Fuel rail
H Clamp
Remove J Screw
1. Loosen the nuts to disconnect the high pressure 3. Remove the high pressure fuel pipe and discard.
fuel pipe from the fuel pump and the fuel rail.
4. Immediately put caps on the open ports of the
Figure 437. high pressure pump and the rail.
E 5. Remove the side oil filling flange with its related

gasket.
C
6. Remove the nut that attaches the high pressure
pump control gear.
Figure 439.
D P

D High pressure pump
E High pressure fuel pipe bottom nut
2. Remove the screw that attaches the clamp to the
inlet manifold.
N Nut
P Pump gear
7. Make sure that the nut does not fall into the timing
gear cover.
18 - 62 9823/0300-1 18 - 62
18 - Injection
15 - Pump
8. Put the puller tool on the pump gear. 13. Press the safety retainer to disconnect the fuel
pressure sensor connector.
Special Tool: High pressure pump gear puller
(Qty.: 1) 14. Press the safety retainer to disconnect the fuel
temperature sensor connector.
Figure 440.
15. Loosen the screws that attach the pump to the
crankcase.
16. Tighten the screw of the puller tool to remove the
high pressure pump from the pump timing gear.
Q
17. Remove the screws that attach the pump.
18. Remove the high pressure pump with the gasket.
Figure 442.
P
Y
P Pump gear
Q Puller tool
9. Important: Do not use the cylinder connection
pipe as a handle, to prevent damage or fuel D
leaks.
10. Remove the clamps on the fuel inlet and return
pipe. D High pressure pump
Y Gasket
11. Disconnect the fuel inlet and return pipe from the
high pressure pump. 19. Remove the puller tool.
12. Immediately put caps on the open ports of the Important: When removing components dirt and
high pressure pump. debris may become exposed or dislodged. Stop the
removal procedures and clean away the exposed
Figure 441. deposits.
T
W S Install
1. Make sure that the pump mount surfaces on the
V crankcase are clean.
2. Make sure that the taper surfaces on the injection
pump drive shaft and gear are clean and free
U from oil and damage.
S X 3. Install the high pressure pump as follows:

R 3.1. Put the new gasket on the injection pump.
D The gasket can only be installed in one
direction.
R Cylinder connection pipe 3.2. Put the high pressure pump in position
S Clamp against the crankcase.
T Fuel return pipe
3.3. Make sure that the reference key on the
U Fuel inlet pipe
pump shaft is aligned with the slot in the
V Fuel temperature sensor
pump gear.
W Fuel pressure sensor
X Screw 3.4. Install the nut on the pump shaft.
18 - 63 9823/0300-1 18 - 63
18 - Injection
15 - Pump
3.5. Tighten the pump shaft nut by hand at this Figure 445.
stage.
3.6. Attach the pump to the crankcase with the E
screws. C
3.7. Make sure you use new screws or apply
a few drops of Loctite270 to use the old
screws again.
3.8. Tighten the screws to the correct torque
value. D
Figure 443.
Y
Z E High pressure fuel pipe bottom nut
8. Tighten the nuts by hand at both ends of the high
pressure pipe.
D Figure 446.
X
C

X Screw
Y Gasket
H
Z Pump shaft reference key
3.9. Tighten the pump shaft nut to the correct J
torque value. F
G
Figure 444.

F High pressure fuel pipe top nut
G Fuel rail
H Clamp
J Screw
9. Install the clamp on the intake manifold with the
D N screw.
10. Tighten the high pressure nuts to the correct
D High pressure pump torque value. Tighten the fuel pipe top nut first.
N Nut 11. Attach the fuel inlet and return pipes to the high
4. Install the fuel temperature sensor connector. pressure pump.
5. Install the fuel pressure sensor connector. 12. Install the clamps on the fuel inlet and return
pipes.
6. Remove the protective caps from the ports of the
pump. 13. Attach the side oil filler flange on the crankcase
with the screws.
7. Put a new high pressure fuel pipe in position
against the high pressure pump and the fuel rail. 14. Tighten the screws to the correct torque value.
After Installation
1. Remove the flywheel crown mounting tool from
the seat of the starter motor.
18 - 64 9823/0300-1 18 - 64
18 - Injection
15 - Pump
2. Install the starter motor. Store and Recommission

Special Tools
3. Start the engine and check for any fuel leaks. Description Part No. Qty.
High Pressure Pump 892/12421 1
4. If any leakage is found in the high pressure fuel Plugs (High pressure
circuit, do not intervene with the engine running. line)
Stop the engine and wait for the specified
duration before you check the leak. High Pressure Pump 892/12422 1
Plugs (Low pressure
Duration: 5–10min line)
Storage
Item Description Nm
E High pressure fuel pipe 25 1. All the openings of the pump must be protected
bottom nut by attaching protective caps and it must be
positioned as shown in figure during the
F High pressure fuel pipe top 30
component storage.
nut
N High pressure pump shaft nut 70 Special Tool: High Pressure Pump Plugs (High
pressure line) (Qty.: 1)
X High pressure pump screw 25
Special Tool: High Pressure Pump Plugs (Low
Figure 447.
A Protective cap
Handling
1. Make sure you hold the pump only from the
bottom side.
18 - 65 9823/0300-1 18 - 65
18 - Injection
15 - Pump
Figure 448.
C C
B Bottom side
C Connection pipe.
2. Do not use the connection pipe to hold the pump.
18 - 66 9823/0300-1 18 - 66
18 - Injection
27 - High Pressure Rail Valve
27 - High Pressure Rail Valve
Remove and Install
This is a non-serviceable part if it fails replace the

complete fuel rail. Refer to: PIL 18-18-12.
18 - 67 9823/0300-1 18 - 67
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-69
18 - 68 9823/0300-1 18 - 68
21 - Fuel Pump
00 - General
Operation ....................................................... 18-69 The pump draws fuel from the tank, through the water
Check (Operation) ......................................... 18-70 separator, pumping it through the fuel filter and into
the fuel injection pump. The pump has a built in
protection against running dry and will shut down
after 2min if no fuel is present.
18 - 69 9823/0300-1 18 - 69
21 - Fuel Pump
00 - General
Check (Operation)
If the fuel lift pump is suspect, measure the delivery

flow rate.
Flow Test
2. Disconnect the fuel hose from the outlet of the
pump/ filter assembly.
3. Connect a length of fuel hose from the pump
outlet to a suitable fuel container.
Volume: 5L
4. Activate the fuel pump. Do not attempt to start
the engine.
5. Run the pump. The fuel flow must be equal to or
greater than the value shown.
Duration: 1min
Flowrate: 2.5L/min
Machines with Electronic Control Fuel

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

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5s delay the pump runs for a
period of 24s.
18 - 70 9823/0300-1 18 - 70
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-73

18-24-03 Inlet Manifold .................................................................................................................. 18-78
18-24-04 Outlet Manifold ............................................................................................................... 18-83
18-24-18 Catalyst .......................................................................................................................... 18-87
18 - 71 9823/0300-1 18 - 71
Notes:
18 - 72 9823/0300-1 18 - 72
24 - Exhaust
00 - General
Introduction .................................................... 18-73 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-74 away from the controlled combustion inside the
Component Identification ............................... 18-75 engine by means of an exhaust pipe. Depending
Check (Condition) .......................................... 18-77 on the machine design, the exhaust gas may flow
through the following components:
• Cylinder head and exhaust manifold.

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

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 73 9823/0300-1 18 - 73
24 - Exhaust
00 - General
Health and Safety

Exhaust Gases
Machine exhaust gases can harm and possibly kill
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
Sparks
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
18 - 74 9823/0300-1 18 - 74
24 - Exhaust
00 - General
Table 149. Intake and exhaust circuit

Air in intake.
Gas in recycle.
Gas in exhaust.
Figure 449. Typical circuit
5 2
1
10
11
F
B
4 6
8
C
7
D
1 Air in intake from air filter 2 Air in compression

3 Air in inter cooler flow 4 Air cooling
5 Air in intake manifold flow 6 Air in head intake
7 Air in cylinder intake 8 Gas in cylinder outlet
10 Gas in outlet towards catalyst 11 Gas in oxidation
B Exhaust manifold C Upper crankcase
18 - 75 9823/0300-1 18 - 75
24 - Exhaust
00 - General
D Lower crankcase E Oil sump

F Catalyst
Figure 450. Typical circuit
9
6
11
15
A
12
14
13
6 Air in head intake 9 Gas in head outlet

11 Gas in oxidation 12 Gas in recycle towards EGR valve
13 Gas in EGR valve outlet 14 Gas cooling (in EGR cooler)
15 Exhaust gas recirculation into intake manifold A Intake manifold
G Radiator
18 - 76 9823/0300-1 18 - 76
24 - Exhaust
00 - General
Check (Condition)
Excessive smoke from the exhaust stack combined

with a complaint of low power could be as a result of:
• Dirt or dust (unfiltered air) ingested directly into

the engine, resulting in damage to the cylinder
bores, there will also be a possible increase in
oil consumption.
• Air leaks from the air hose connections.
• Exhaust manifold leaks.
18 - 77 9823/0300-1 18 - 77
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-78 On compression ignition (diesel) engines, the inlet
Component Identification ............................... 18-79 manifold (also called the intake manifold) is the
Check (Condition) .......................................... 18-79 part of the air intake system that distributes air for
Remove and Install ....................................... 18-80 combustion to the cylinders via each inlet port in
the cylinder head. The design of the manifold is
important to make sure that air is distributed as
evenly as possible under all engine speed and load
conditions.
18 - 78 9823/0300-1 18 - 78
24 - Exhaust
03 - Inlet Manifold
The inlet manifold shown may differ from that 1. Check the manifold mating faces for signs of
installed on your engine. damage and distortion.
Figure 451. 2. Check the manifold casting for signs of cracks.
C D 3. Renew the manifold if there are any signs of

B defect.
F
G H
E
A
A EGR (Exhaust Gas Recirculation) valve

B EGR gas inlet pipe
C Water inlet pipe
D EGR water/gas heat exchanger
E Air release manifold
F Water outlet manifold
G EGR gas outlet manifold
H Intake manifold
18 - 79 9823/0300-1 18 - 79
24 - Exhaust
03 - Inlet Manifold
H
NOTE: The illustrations shown are for a 4 cylinder
engine however, the 3 cylinder engine also has a
similar configuration.
Before Removal A
before you start, refer to Parts Catalogue. G
F
the engine has been running, let it cool before A Front intake manifold
you start the service work. G Gasket (x2)
H Separation plate
3. Remove the EGR (Exhaust Gas Recirculation)
cooler. Rear Intake Manifold
4. Remove the TMAP (Temperature Manifold Air 1. Remove the screw that attaches the holder to the
Pressure) sensor. rear intake manifold.
Figure 454.
Remove
Front Intake Manifold
1. Remove the screw to loosen the clamp that
secures the coolant hose between the oil cooler
and water pump. J
Figure 452.
E K
C
J Screw
K Holder
A
2. Remove the screws to loosen the clamp of the
B high pressure fuel pipe.
D 3. Remove the screws that attach the rear intake
manifold to the cylinder head.
A Front Intake manifold
B Screw 4. Remove the rear intake manifold with its gasket.
C Clamp
D Coolant hose
E Water pump
2. Remove the screws to open the front intake
manifold.
3. Remove the two gaskets and the separation
plate from the front intake manifold.
18 - 80 9823/0300-1 18 - 80
24 - Exhaust
03 - Inlet Manifold

R
Q P
M
P
N Q
R
N
L Screw N Screw
M Clamp P Rear intake manifold
N Screw Q Gasket
P Rear intake manifold R Mounting stud
Q Gasket
5. Put protective covers on the open ports of the
cylinder head. 6. Install the screws to attach the holder to the rear
intake manifold.
6. Inspect the intake manifolds for any damage.
Replace if damaged. 7. Tighten the screws to the correct torque value.
Refer to: PIL 18-24-03. 8. Install the screws to attach the clamp of the high
pressure fuel pipe.
Install
Figure 457.
Rear Intake Manifold M
1. Remove the protective cover from the open ports L

of the cylinder head.
2. Install the intake manifold mounting studs to align
the holes on the cylinder head with the rear intake
manifold. J
3. Put the rear intake manifold and the gasket in

position against the cylinder head.
K
4. Install the screws to attach the rear intake
manifold to the cylinder head.
J Screw
K Holder
L Screw
M Clamp
Front Intake Manifold

1. Put the two gaskets and the separation sheet in
position on the intake manifold mounting studs.
2. Make sure you install the separation plate
between the two gaskets.
3. Put the front intake manifold in position against
the mounting studs.
18 - 81 9823/0300-1 18 - 81
24 - Exhaust
03 - Inlet Manifold
4. Put the screws into the front intake manifold. After Installation
Figure 458. 1. Install the TMAP sensor.
R
2. Install the EGR cooler.

G Item Nm
G H
F F 23
J 6
L 6
N 23
A Front intake manifold

G Gasket
H Separation plate
R Mounting stud
5. Make sure that you leave the holes shown open
for the EGRcooler and the coolant hose clamp.
Figure 459.
S Screw holes for EGR cooler and coolant hose

clamp
7. Install the screw on the clamp that secures the
hose between the oil cooler and water pump.
Figure 460.
E
C
B
D
A Front Intake manifold

B Screw
C Clamp
D Coolant hose
E Water pump
18 - 82 9823/0300-1 18 - 82
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-83 The exhaust manifold collects the exhaust gases
Check (Condition) .......................................... 18-84 from the multiple cylinders and deliver it to the
Remove and Install ....................................... 18-85 exhaust pipe.
Figure 461.
A Outlet manifold B Fixing bolts

C Manifold gasket
18 - 83 9823/0300-1 18 - 83
24 - Exhaust
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
18 - 84 9823/0300-1 18 - 84
24 - Exhaust
Remove and Install
3. Remove the turbocharger.

NOTE: The illustrations shown are for a 4 cylinder
engine however, the 3 cylinder engine also have a 4. Remove the nuts that attach the exhaust
similar configuration. manifold to the cylinder head. Discard the nuts.
5. Remove the exhaust manifold and its metal
Remove gaskets.
1. Make sure that the engine is safe to work on. If 6. Discard the gaskets.
you start the service work. 7. Put protective covers on the cylinder
head openings and manifolds to prevent
2. Get access to the exhaust manifold. contamination.
Figure 462.
A Exhaust manifold B Self locking nut (x10)

C Gasket (x5)
18 - 85 9823/0300-1 18 - 85
24 - Exhaust
Install
Important: Replace the metal gaskets between the
manifold and the cylinder head every time they are
removed.
1. Remove the protective covers from the cylinder

head and manifolds.
2. Make sure that the contact surfaces of the
cylinder head and manifolds are clean.
3. Put the metal gaskets on the cylinder head studs.
4. Put the exhaust manifold on the studs.
5. Apply Loctite 242 on the studs.
6. Install the self locking nuts to secure the exhaust
manifold.
7. Tighten the nuts to the correct torque value.
8. Install the turbocharger.

Item Nm
B 25
18 - 86 9823/0300-1 18 - 86
24 - Exhaust
18 - Catalyst
18 - Catalyst Introduction
Introduction .................................................... 18-87 The catalytic converter also called a catalyst is a
Component Identification ............................... 18-88 vehicle emissions control device that converts toxic
Operation ....................................................... 18-89 pollutants in exhaust gas to less toxic pollutants by
Check (Condition) .......................................... 18-90 catalyzing a reaction (oxidation or reduction).
18 - 87 9823/0300-1 18 - 87
24 - Exhaust
18 - Catalyst
Figure 463.
A Turbine housing with Wastegate valve B Catalyst support flange

C Gasket D Catalyst
18 - 88 9823/0300-1 18 - 88
24 - Exhaust
18 - Catalyst
Operation
The catalytic converter consists of a monolith catalyst, several exhaust pollutants are converted
honeycomb substrate coated with platinum group into harmless substances.
metal catalyst. This honeycomb structure is then
covered in a stainless steel container. The diesel oxidation catalyst is designed to oxidize
carbon monoxide, gas phase hydrocarbons, and the
The honeycomb structure with many small parallel Soluble Organic Fraction (SOF) of diesel particulate
channels presents a high catalytic contact area matter to CO2 and H2O:
to exhaust gases. As the hot gases contact the
Figure 464.
Diesel exhaust contains sufficient amounts of

oxygen, necessary for the above chemical reactions.
The concentration of O2 in the exhaust gases from
diesel engine varies between 3–17%, depending on
the engine load.
The catalyst activity increases with temperature.

A minimum exhaust temperature of about 200°C
(391.7°F) is necessary for the catalyst to "light off".
At higher temperatures, conversions depend on the
catalyst size and design and can be higher than 90%.
The catalytic oxidation of SOF results in reduction

of diesel particulate matter emission. The particulate
matter conversion efficiency can range widely,
depending on the SOF contents of the particulates
and sulphur level in the fuel.
18 - 89 9823/0300-1 18 - 89
24 - Exhaust
18 - Catalyst
A catalyst converter may reach the end of its life Remove

prematurely if on the receiving end of a badly
performing engine. Catalytic converters are free 1. Make sure that the engine is safe to work on. If
from moving components and require little to no the engine has been running, let it cool before
maintenance. Therefore, what wears out or damages you start the service work.
a catalytic converter is external and not an issue
caused by the unit itself. 2. The catalyst can be hot even after the engine has
cooled. Let the catalytic converter cool even if the
What damages a catalytic converter can vary, but engine has cooled.
here's a few examples:
3. Remove the nuts and bolt that attach the catalyst
• Out-of-tune engine - Catalytic converters are to the front exhaust pipe.
designed to work when the engine is running
optimally. This could be due to incorrect fuel Figure 465.
mixture, incorrect engine timing etc. Including
potential damage to the catalytic converter,
such issues may cause damage to the engine
itself.
• Excessive fuel - If your vehicle is using B
excessive fuel, it won't get burnt and make your A C
machine go faster. It's simply unused and re-
routed through the exhaust. As a result, this
unused fuel will enter the catalytic converter.
The converters operate at high temperatures
and can ignite the fuel as it enters, this E D
renders the catalytic converter at super-hot F
temperatures, even causing it to melt down.
• Oil - Oil entering the exhaust will ultimately G
travel though the catalytic converter, clogging
the internals of the catalytic converter and A Strap
preventing it from working efficiently. This can B Nut (x3)
cause excessive heat to accumulate within the C Gasket
converter and other engine components. D Front exhaust pipe
• Physical damage - The catalytic converter E Bolt
being located where it is, can receive damage F Catalyst
from road debris such as rocks. Although the G Mounting bracket
catalytic converter is protected, a strike from
a heavy piece of debris may damage the 4. Remove the gasket between the catalyst and the
internals. front exhaust pipe.
5. Only loosen the strap of the catalyst from the
Important catalyst mounting bracket at this stage.
• Use only the specified fuel. Low S.A.P.S.
technology (fuel with low Sulphate, 6. Remove the nuts that attach the catalyst to the
Phosphorous, Sulphur content) keeps catalyst turbocharger support flange.
in working conditions. The presence of sulfate,
phosphorus and sulfur ashes causes with
time the catalyst clogging and its consequent
inefficiency.
• Do not run the engine at idle for more than
10min.
18 - 90 9823/0300-1 18 - 90
24 - Exhaust
18 - Catalyst
Figure 466. Table 152. Torque Values

Item Nm
A 10
B 24
H 24
K
J
F H
F Catalyst
H Nut (x3)
J Gasket
K Turbocharger support flange
7. Remove the gasket between the catalyst and the
support flange.
8. Release the strap completely from the catalyst.
9. Carefully remove the catalyst from the engine
with a soft mallet.
10. Remove the thermal blanket from the catalyst.
Install
1. Make sure that the catalyst is clean and not
damaged.
2. Make sure you always use new gaskets.
3. Put the thermal blanket on the catalyst.
4. Put the catalyst in position against the mounting
bracket.
5. Attach the strap. Do not tighten it at this stage.
6. Put the gasket on the support flange studs.
7. Put the catalyst mounting flange on the
turbocharger support flange.
8. Install the nuts to attach the catalyst to the
turbocharger support flange.
9. Put the gasket between the catalyst and the front
exhaust pipe.
10. Attach the front exhaust pipe to the catalyst with
the bolts and nuts.
11. Tighten all of the nuts to the correct torque value.
12. Tighten the strap to the correct torque value.
18 - 91 9823/0300-1 18 - 91
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-93

18-27-03 Actuator ........................................................................................................................ 18-101
18-27-06 Valve ............................................................................................................................. 18-103
18-27-09 Cooler ........................................................................................................................... 18-106
18 - 92 9823/0300-1 18 - 92
00 - General
Introduction .................................................... 18-93 The EGR (Exhaust Gas Recirculation) system is
Technical Data ............................................... 18-94 a technique that re-circulates a portion of the
Component Identification ............................... 18-95 exhaust gases back into the combustion chamber.
Operation ....................................................... 18-96 The system cools and controls the quantity of re-
circulated exhaust gas.
Check (Condition) .......................................... 18-97
Remove and Install ....................................... 18-97 The EGR valve is controlled by the CANBUS system,
Store and Recommission ............................ 18-100 which opens and closes to allow the exhaust gases
to flow back into the intake system through the EGR
cooler. This lowers the combustion temperature and
reduces the formation of nitrogen oxide (NOx).
In order to ensure full power is always available when

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

a feedback position sensor, linkage and a valve
mechanism. The valve actuator, which is controlled
by the CANBUS system, position sensor and linkage,
operates the valve to the demanded position.
18 - 93 9823/0300-1 18 - 93
00 - General
Technical Data
Table 153.
Type Dell'Orto (EGV A16)
18 - 94 9823/0300-1 18 - 94
00 - General
Figure 467.
F
E
D
C
B
H
A
A EGR (Exhaust Gas Recirculation) valve B EGR gas inlet pipe

C Water inlet pipe D EGR water/gas heat exchanger
E Air release manifold F Water outlet manifold
G EGR gas outlet manifold H Intake manifold
18 - 95 9823/0300-1 18 - 95
00 - General
Operation Figure 470.
1. Exhaust gases enter the exhaust manifold.

Figure 468.
4. Exhaust gases enter the mixer tube.

Figure 471.
2. The exhaust gases travel through the
intermediate EGR (Exhaust Gas Recirculation)
cooler.
Figure 469.
5. The exhaust gases are mixed with new air and

re-enter the engine.
Figure 472.
3. The exhaust gases enter the main cooler which
reduces the heat.
18 - 96 9823/0300-1 18 - 96
00 - General

1. Check that the EGR (Exhaust Gas Recirculation) The EGR (Exhaust Gas Recirculation) valve can
for excessive carbon build up. Visually inspect for be removed separately without removal of the
leaks at the EGR. Make sure all gaskets are in complete EGR system. After replacement, the EGR
good condition, replace as required. system must go through a complete actuator learn
procedure.
Remove
2. Get access to the EGR system.
3. Remove the EGR gas outlet pipe as follows:
Figure 473.
D F E
C
A
A Inlet manifold
B EGR cooler
C Gas outlet pipe
D Gasket
E Screw
F Screw
3.1. Remove the screws that attach the gas
outlet pipe to the intake manifold.
3.2. Remove the screws that attach the gas
outlet pipe to the EGR cooler.
3.3. Remove the EGR gas outlet pipe and its
related gaskets.
4. Remove the EGR gas inlet pipe as follows:
18 - 97 9823/0300-1 18 - 97
00 - General

H G K
B
K
L R
B EGR cooler
B EGR cooler R Protective cap
G Screw
H Screw 9. Disconnect the electrical connector from the
J Gas inlet pipe EGR valve.
K Gasket
Figure 477.
L EGR valve unit
4.1. Remove the screws that attach the gas inlet
pipe to the EGR valve unit.
4.2. Remove the screws that attach the gas inlet S
pipe to the EGR cooler. V
4.3. Remove the EGR gas inlet pipe and its
related gaskets.
5. Loosen the clamps and remove the water inlet
and outlet hoses from the EGR cooler.
U
Figure 475. T
S Electrical connector
N P
N T EGR valve
M U Screw
V Clamp
10. Remove the screw to release the clamp attached
to the EGR valve.
B 11. Remove the screws that attach the EGR valve to

the EGR valve holder.
Q
B EGR cooler
M Water inlet hose
N Clamp
P Water outlet hose
Q Screw
6. Remove the screws that attach the EGR cooler
to the inlet manifold.
7. Remove the EGR cooler.
8. Put protective caps on all open ports of the EGR
cooler and inlet manifold.
18 - 98 9823/0300-1 18 - 98
00 - General
Figure 478. 3. Put a new gasket on the EGR valve holder.

4. Attach the EGR valve holder to the cylinder head
X with the screws.
W 5. Tighten the screws to the correct torque value.

T
6. Put a new gasket on the EGR valve.
7. Attach the EGR valve and gasket to the EGR
holder with the screws.
8. Tighten the screws to the correct torque valve.
Y
9. Install the electrical connector on the EGR valve.
10. Attach the clamp to the EGR valve unit with the
T EGR valve screw.
W Gasket
X EGR valve holder 11. Install the EGR cooler and the pipes as follows:
Y Screw
11.1. Put the water inlet hose on the EGR cooler.
12. Remove the EGR valve and its gasket. Discard
the gasket. Figure 480.
13. Remove the screws that attach the EGR valve N

holder to the cylinder head. B
Figure 479.
AA
B EGR cooler
X M Water inlet hose
Z
N Clamp
Q Screw
X EGR valve holder 11.2. Put the EGR cooler in position against the
Z Screw inlet manifold.
AA Gasket
11.3. Attach the EGR cooler with the screws.
14. Remove the EGR valve holder and its gasket. 11.4. Do not tighten the screws at this stage.
Discard the gasket.
11.5. Attach the water inlet hose with the clamp.
15. Put protective covers on the open ports of the
cylinder head and valve holder. 11.6. Put the gas inlet pipe in position against
the EGR valve unit.
The EGR valve is a non-serviceable item. If the valve 11.7. Attach the gas inlet pipe to the EGR valve
is defective it must be replaced. with the screws.
Install 11.8. Tighten the screws to the correct torque

value.
1. Remove the protective caps from the cylinder 11.9. Attach the gas inlet pipe to the EGR cooler
head and EGR valve holder. with the screws.
2. Make sure that the contact surfaces between the 11.10. Tighten the screws to the correct torque
EGR valve holder and the cylinder head are free value.
from impurities.
18 - 99 9823/0300-1 18 - 99
00 - General
11.11. Put the gas outlet pipe in position against Store and Recommission
the inlet manifold.
11.12. Attach the gas outlet pipe to the inlet Put protective caps on all open ports of the EGR
manifold with the screws. cooler.
value. Figure 481.
11.14. Attach the gas outlet pipe to the EGR
cooler with the screws.
value.
11.16. Tighten the EGR cooler installation B
screws to the correct torque value.
11.17. Attach the water outlet hose to the EGR
cooler with the clamp. R
After Installation
1. Complete the actuator learn procedure. Use
B EGR cooler
Servicemaster.
R Protective cap
2. Start the engine and check for exhaust leaks.
3. The EGR valve is a CAN operated device
and can only be evaluated with the use of
Servicemaster.
4. All conditions of the EGR are reported by the fault
codes. Test the turbocharger boost pressure.

Item Nm
E-G 25
H 10
Q 25
Y-Z 10
18 - 100 9823/0300-1 18 - 100

03 - Actuator
03 - Actuator Introduction
Introduction .................................................. 18-101 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ..................................... 18-102 smart electronic CAN driven device and can only be
evaluated with the use of Servicemaster.
The device does a self check on the operating range

to check the adaption window every time the ignition
is switched off and on. The unit is extremely sensitive
and constantly monitors the conditions it is operating
under. If it detects over voltage, under voltage, high
or low current, movement, temperature etc, if it is
working outside of it's desired limits in any way at all,
it will shut down until the fault is rectified.
18 - 101 9823/0300-1 18 - 101

03 - Actuator
Remove and Install
The EGR (Exhaust Gas Recirculation) electronic

actuator is not a serviceable component, if it fails
replace the EGR valve assembly.
18 - 102 9823/0300-1 18 - 102

06 - Valve
06 - Valve Introduction
Introduction .................................................. 18-103 The EGR valve controls a small passageway
Remove and Install ..................................... 18-104 between the intake and exhaust manifolds.
When the valve opens, intake vacuum draws

exhaust through the valve. This dilutes the incoming
air/fuel mixture and has a quenching effect
on combustion temperatures which keeps NOx
(Nitrogen Oxide) within acceptable limits. As
an added benefit, it also reduces the engine's
octane requirements which lessens the danger of
detonation.
18 - 103 9823/0300-1 18 - 103

06 - Valve
The EGR (Exhaust Gas Recirculation) valve is not

a serviceable item, and if damaged, it should be
replaced with a new one.
Before Removal
K
L
3. Drain the engine cooling system. K Screw
Refer to: PIL 21-00-00. L Flange
5. Remove the flange with the relative gasket.
Removal
1. Remove the connector from the EGR valve. Install
2. Make sure you remove the screws that attach the Check that the contact surfaces between the EGR
EGR valve with the flange. valve unit and the structure are free from impurities.
Figure 482. 1. Put the new gasket on the flange.
2. Make sure that you attach the flange with the
screws on the structure.
H
Figure 484.
G K
J
G Connector
H EGR valve
J Screw M L
3. Remove the EGR valve with the relevant gasket.
K Screw
4. Remove the screws from the flange.
L Flange
M Gasket
4. Put the screws on the EGR valve.
5. Make sure that you attach the gasket on the EGR
valve with reference to the screws.
18 - 104 9823/0300-1 18 - 104

06 - Valve
Figure 485.
N H
H EGR valve
J Screw
L Flange
N Gasket
6. Install the EGR valve on the flange with the
screws.
8. Connect the connector on the EGR valve.
After install
1. Start the engine and check for any leaks.

Item Nm
K 10
J 10
18 - 105 9823/0300-1 18 - 105

09 - Cooler
09 - Cooler Introduction
Introduction .................................................. 18-106 The EGR cooler is installed to return part of the
Remove and Install ..................................... 18-107 exhaust gases to the air intake section, and acts to
feed cooled exhaust to the engine.
18 - 106 9823/0300-1 18 - 106

09 - Cooler

H G K
Consumables
Description Part No. Size J
Antifreeze HP/ 4006/1101 5L
Coolant ASTM D6210 4006/1120 20L
Concentrate 4006/1103 200L K
Before Removal
L
the engine has been running, let it cool before B
2. Drain the coolant from the engine.
Refer to: PIL 21-00-00. B EGR cooler
G Screw
H Screw
Remove J Gas inlet pipe
K Gasket
1. Get access to the EGR (Exhaust Gas
L EGR valve unit
Recirculation) system.
3.1. Remove the screws that attach the gas inlet
2. Remove the EGR gas outlet pipe as follows:
pipe to the EGR valve unit.
Figure 486. 3.2. Remove the screws that attach the gas inlet
D F E pipe to the EGR cooler.
C
3.3. Remove the EGR gas inlet pipe and its
related gaskets.
D
4. Loosen the clamps and remove the water inlet
B and outlet hoses from the EGR cooler.
Figure 488.
N P
M N
A
A Inlet manifold
B EGR cooler
C Gas outlet pipe B
D Gasket Q
E Screw
F Screw
2.1. Remove the screws that attach the gas B EGR cooler
outlet pipe to the intake manifold. M Water inlet hose
2.2. Remove the screws that attach the gas N Clamp
outlet pipe to the EGR cooler. P Water outlet hose
Q Screw
2.3. Remove the EGR gas outlet pipe and its
related gaskets. 5. Remove the screws that attach the EGR cooler
to the inlet manifold.
3. Remove the EGR gas inlet pipe as follows:
6. Remove the EGR cooler.
7. Put protective caps on all open ports of the EGR
cooler and inlet manifold.
18 - 107 9823/0300-1 18 - 107

09 - Cooler
Figure 489. 1.10. Tighten the screws to the correct torque

value.
1.11. Put the gas outlet pipe in position against
the inlet manifold.
1.12. Attach the gas outlet pipe to the inlet
B manifold with the screws.
value.
R 1.14. Attach the gas outlet pipe to the EGR
cooler with the screws.
value.
B EGR cooler 1.16. Tighten the EGR cooler installation screws
R Protective cap to the correct torque value.
Install 1.17. Attach the water outlet hose to the EGR

cooler with the clamp.
1. Install the EGR cooler and the pipes as follows:
After Installation
1.1. Put the water inlet hose on the EGR cooler.
1. Fill the engine with coolant.
Figure 490.
Consumable: Antifreeze HP/Coolant ASTM
N D6210 Concentrate
B
2. Start the engine and do a test for leaks in the
exhaust system.

Item Nm
E-G 25
H 10
M Q 25
Q
B EGR cooler
M Water inlet hose
N Clamp
Q Screw
1.2. Put the EGR cooler in position against the
inlet manifold.
1.3. Attach the EGR cooler with the screws.
1.4. Do not tighten the screws at this stage.
1.5. Attach the water inlet hose with the clamp.
1.6. Put the gas inlet pipe in position against the
EGR valve unit.
1.7. Attach the gas inlet pipe to the EGR valve
with the screws.
value.
1.9. Attach the gas inlet pipe to the EGR cooler
with the screws.
18 - 108 9823/0300-1 18 - 108

35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ......................................................................................................................... 18-111

18-35-05 Compressor .................................................................................................................. 18-122
18-35-06 Wastegate Valve .......................................................................................................... 18-124
18 - 109 9823/0300-1 18 - 109

Notes:
18 - 110 9823/0300-1 18 - 110

35 - Turbocharger
00 - General
Introduction .................................................. 18-111 The turbocharger uses variable vanes to control
Component Identification ............................. 18-113 exhaust flow and to introduce EGR (Exhaust Gas
Check (Condition) ........................................ 18-114 Recirculation) to reduce emission in diesel engines.
Check (Operation) ....................................... 18-114
The turbo uses heat energy from the waste exhaust
Remove and Install ..................................... 18-115 gases to drive a turbine which in turn drives the
Store and Recommission ............................ 18-117 compressor to pull new air at high pressure into the
cylinders. The extra volume of air allows more fuel to
be injected increasing the engine power output.
This lowers the combustion temperature and

reduces formation of NOx (Nitrogen Oxide) gases.
The turbocharger is installed on the outlet port of the

exhaust manifold.
The air is compressed to a minimum pressure of

1bar (14.5psi) depending upon engine speed and
load. The turbocharger spins at up to 100,000
rpm and reaches temperatures approaching 700°C
(1,291.0°F).
It is essential, therefore, that a good supply of oil

reaches the turbocharger at all times. The oil not only
lubricates the turbocharger but also carries away
excess heat.
An external oil feed pipe connected to a port on

the cylinder block supplies oil to the turbocharger
bearing. Oil returns to the engine oil sump through
an external drain pipe. Integral oil seals prevent oil
escaping to the compressor and turbine ends of the
turbocharger.
18 - 111 9823/0300-1 18 - 111

35 - Turbocharger
00 - General
Figure 491.
2 4
12
6
7
8
11
9
10
1 Air intake hose 2 Wastegate control valve hose

3 Wastegate control valve device 4 Wastegate control valve linkage
5 Turbine housing with Wastegate valve 6 Turbocharger central body
7 Catalyst support flange 8 Turbocharger lubrication pipe
9 Oil drain pipe 10 Compressed air flow hose to intercooler
11 Engine crankcase breather 12 Turbocharger housing
18 - 112 9823/0300-1 18 - 112

35 - Turbocharger
00 - General
Figure 492.
F G
A
D
H E
D E
J
L
K M
A Air intake hose B Turbocharger housing

C Turbocharger central body D Turbine housing with Wastegate valve
E Catalyst support flange F Wastegate control valve hose
G Wastegate control valve device H Wastegate control valve linkage
J Engine crankcase breather K Air compressed flow hose to intercooler
L Oil drain pipe M Turbocharger lubrication pipe
N Catalyst
18 - 113 9823/0300-1 18 - 113

35 - Turbocharger
00 - General
Check (Condition) Check (Operation)

1. Inspect the compressor and turbine for damage. To maximise the duration of the turbocharger follow
the rules described below.
2. Make sure that the compressor blades do not rub
on the housing and rotate freely. It is normal to
detect a bit of play on the blades. Start-up
3. Make sure that the shaft rotates freely. Start the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached within
4. Before you install the turbocharger, make sure a few seconds, but it is useful to allow the moving
that the code of the component is correct for parts to warm up in good lubrication conditions.
the type of engine, as installation of the wrong Immediately increasing the engine speed after start
turbocharger can damage the turbo and engine up will result in the turbocharger running at high rpm
and void the warranty. with less than optimal lubrication. This may lead to
premature failure of the turbocharger.
After maintenance
When carrying out maintenance on the engine
or turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it is
completely full. After pre-lubrication, let the engine
run via the starter motor without firing (engine /
fuel pump stop out) to allow the oil to circulate
through the complete system under pressure. Upon
engine start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to work
satisfactorily.
Low temperature air or engine inactivity

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 114 9823/0300-1 18 - 114

35 - Turbocharger
00 - General

D
Before Removal
1. Make sure you refer to the special instructions
on handling, operation and installation of the E
turbocharger. Refer to Store and Recommission. F
D
Remove
Refer to: PIL 01-03-27. E
D Bolt
2. Get access to the engine. E Gasket
F Oil inlet pipe
3. Remove the following components from the
turbocharger. 7.1. Remove the bolts that attach the
turbocharger oil inlet pipe.
3.1. Hose between the air cleaner and
turbocharger sleeve. 7.2. Disconnect the oil inlet pipe and gaskets
from the crankcase and the turbocharger.
3.2. Charge air cooler inlet hose.
7.3. Discard the gaskets.
3.3. Diesel oxidation catalyst.
7.4. Put caps on the turbocharger oil inlet port
4. Loosen the clamps that attach the sleeve to the and the crankcase.
turbocharger and the crankcase ventilation filter
hose. 8. Remove the turbocharger oil drain pipe as
follows:
Figure 493.
Figure 495.
C
H
A Sleeve G
B Clamps
C Crankcase ventilation filter hose G Clamp
H Screw
5. Remove the sleeve and the clamps. J Oil drain pipe
6. Put a cap on the inlet side of the turbocharger to 8.1. Remove the clamp that attaches the oil
prevent contamination. drain pipe to the crankcase ventilation filter
7. Remove the turbocharger oil inlet pipe as follows: bracket.
8.2. Remove the screws that attach the drain
pipe to the turbocharger.
8.3. Remove the oil drain pipe and gasket.
8.4. Discard the gasket.
18 - 115 9823/0300-1 18 - 115

35 - Turbocharger
00 - General
9. Remove the nuts that attach the turbocharger to 3. Make sure that the seat of the turbocharger on
the exhaust manifold. the exhaust manifold is free from contamination.
Figure 496. 4. Remove the caps from the ports of the
turbocharger.
L
5. Make sure you always hold the turbocharger
from the housing or centre housing side.
6. Put the turbocharger in position on to the studs
of the exhaust manifold.
Figure 498.
M
K
K K
L
K Bolt
L Turbocharger M
M Exhaust manifold
10. Remove the turbocharger from the exhaust
manifold.
11. Make sure you put caps on all the open ports of J
H
the turbocharger and the exhaust manifold.
H Screw
12. Inspect the turbocharger for any damage. J Oil drain pipe
Replace if damaged. K Nut
L Turbocharger
Refer to: PIL 18-35-00. M Exhaust manifold
Install 7. Install the nuts to secure the turbocharger to the

exhaust manifold.
1. Attach the turbocharger oil drain pipe to the
crankcase ventilation filter bracket with the 8. Tighten the nuts to the correct torque value.
clamp.
9. Attach the oil drain pipe to the turbocharger with
Figure 497. the screws.
10. Attach the oil inlet pipe to the turbocharger and
P the crankcase with the bolts.
Figure 499.
D
J
E
F
D
G N
G Clamp
J Oil drain pipe E
N Crankcase ventilation filter bracket
D Bolt
P Gasket
E Gasket
2. Lubricate and put a new gasket into the seat of F Oil inlet pipe
the turbocharger oil drain pipe.
18 - 116 9823/0300-1 18 - 116

35 - Turbocharger
00 - General
11. Make sure you install the oil inlet pipe gaskets Store and Recommission
between the:
11.1. Pipe and bolt
What to do
11.2. Pipe and crankcase
• Before assembling the turbocharger, make sure
11.3. Pipe and turbocharger. that the protection caps are installed on all
openings of the turbocharger.
12. Tighten the bolts to the correct torque value. • Make sure that the packaging is correct before
storing the turbocharger to be assembled.
13. Attach the sleeve to the turbocharger inlet with
• Make sure the turbocharger is pre-lubricated.
the clamp.
• Periodically check that the joints are sealed
Figure 500. against oil and air.
• Use only the specified lubricating oil.
• Check the engine oil level.
• Before switching the engine off after use, let it
A run at idle speed for around 1 minute.
• Check the condition of the air and oil filter
regularly as per the service schedule given in
the Maintenance Schedules.
• Make sure that the engine maintenance
intervals are observed.
• Make sure that the engine and equipment are
B used in a way that is not harmful to the life of
the turbocharger.
C
What not to do
A Sleeve
B Clamps • Do not store the turbochargers in stacks.
C Crankcase ventilation filter hose • Do not store the turbochargers in damp or wet
conditions.
14. Attach the crankcase ventilation filter hose to the • Do not expose the turbochargers to dust and
sleeve with the clamps. dirt.
• Do not lift the turbocharger by holding the
15. Test the turbocharger is working correctly. actuator rod.
Refer to: PIL 18-35-00. • Do not increase the engine speed immediately
after start-up.
Table 157. Torque Values • Do not run the engine at idle speed for more
than 20-30 minutes at a time.
Item Description Nm • Do not change the actuator settings.
D Bolts 30
K Nut 25 Practical operating rules
1. Start-up: Start the engine and keep it at idle
speed for about a minute. The oil operating
pressure is reached within a few seconds, but
it is useful to allow the moving parts to warm
up in good lubrication conditions. Immediately
increasing the engine speed after start up will
result in the turbocharger running at high RPM
(Revolutions Per Minute) with less than optimal
lubrication. This may lead to premature failure of
the turbocharger.
2. After maintenance: When carrying out
maintenance on the engine or on the
turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it
is completely full. After pre-lubrication, let the
engine run via the starter motor without firing,
to allow the oil to circulate through the complete
system under pressure. Upon engine start-up,
18 - 117 9823/0300-1 18 - 117

35 - Turbocharger
00 - General
make it run at idle speed for a few minutes, Figure 502.

allowing the oil and bearings system to work
satisfactorily.
3. Low temperature air or engine inactivity: If the A
engine has been inactive for a certain period of
time or the air temperature is very low, start the
engine and then let it run at idle speed. This
before applying high loads and speeds to the
engine and turbocharger.
4. Engine shutdown: Before switching off the
engine after intense use allow the turbocharger
to cool down. Therefore run the engine at idle
speed for at least 2 minutes that allow the
turbocharger to cool down.
A Turbocharger compressor side
5. Engine at idle speed: Do not run the engine at
idle speed for more than 20-30 minutes at a time. 3. Do not hold the turbocharger from the points
It may cause oil leaks from the seals at the end of shown in figure.
the engine shaft or it can cause blue smoke from
the exhaust when the engine speed and load are Figure 503.
increasing.
N N
Handling instructions
1. Always lift the turbocharger with both hands from
the box.
N
Figure 501. N
Y
N N
Y
N
N Restricted area
Y Acceptable handling area
4. Always handle the turbocharger from the housing
A or from the centre housing side.
Figure 504.

2. Do not lift the turbocharger from the compressor
side.
C Turbocharger housing side
18 - 118 9823/0300-1 18 - 118

35 - Turbocharger
00 - General
5. Make sure you DO NOT hold the turbocharger 10. Check for any visible scoring marks on the wheel
from any of the hoses of the turbocharger. or on the housing.
6. Always make sure that the turbocharger Figure 508.
compressor inlet cap is in place until the hose is
installed.
Figure 505.
F Bolt
B 11. Check for any oil leaks on the complete housing.
12. Check for any loose bolts and marks in paint.
B Turbocharger compressor inlet cap
Replacement or installation instructions
7. Remove the turbocharger protective caps
carefully and smoothly. 1. Always make sure that the cause of damage
to the original turbocharger is examined and
Figure 506. corrected before replacing it.
2. Do not modify the calibration of the turbocharger
it can cause damage to the turbocharger and
void the warranty.
D
3. Always use the correct gaskets to avoid blocking
holes when mounting.
4. Make sure that dirt does not enter the
turbocharger during installation.
5. Before mounting the turbocharger check that the
code of the component is correct for the type of
engine.
D Turbocharger protective cap
6. Mounting the wrong turbocharger can damage
8. Move the shaft with finger and look for excessive the turbocharger or the engine and void the
and radial play. warranty.
Figure 507. 7. Use only the specified lubricating oil during
installation of the turbocharger.
Turbocharger installation
E 1. Clean both manifolds before connecting to the
turbocharger.
2. Clean the air filter and the housing.
E Shaft
9. Make sure that your hands and the gloves are
not contaminated.
18 - 119 9823/0300-1 18 - 119

35 - Turbocharger
00 - General
G Air filter K
3. Clean the engine breather system.

K Compressor impeller
4. Check the breather system is working properly.
8. Install the turbocharger on the manifold and
5. Replace the gasket and pipe of the exhaust connect the exhaust pipe, secure with clamping
manifold. bolts.
H L
F
F Bolt
L Flange
9. Check the condition of the bosses and the flange
which must be intact.
H Gasket 10. Make sure that you clean the oil supply and drain
pipes.
6. Carefully remove the plastic or foam caps from
the turbocharger before mounting it.
7. Fill the turbocharger with new oil and make it
turn a few times by hand as shown in figure,
the compressor impeller should turn freely. It is
normal to detect a bit of play on the impellers.
18 - 120 9823/0300-1 18 - 120

35 - Turbocharger
00 - General
Figure 513. 18. Switch off the engine and check the oil level
again.
Figure 515.
M
M M
M Oil
M 19. Make sure that the oil level is not above the inlet
of the oil returning pipe to the crankcase.
20. Check the pressure of the engine housing, if the
engine housing pressure is high it can be caused
by a blocked bypass valve or by a clogged
breather system.
Figure 516.
M Oil
11. Make sure that the pipes are not damaged and
kinked.
12. If the oil level is correct, but the drain pipe is
clogged, there will be an outflow of pressurised
oil from the turbocharger.
M
13. Install the air pipes and clamp them.
14. Make sure you use new air, oil and fuel filters.
M Oil
Figure 514.
21. Follow the turbocharger 'Check Condition'
guidelines.
G Air filter
15. Fill the engine with new clean engine oil.
16. Start the engine at idle speed for 3-4 minutes,
then increase the speed.
17. Check for any oil, gas or air leaks.
18 - 121 9823/0300-1 18 - 121

35 - Turbocharger
05 - Compressor
05 - Compressor Introduction
Introduction .................................................. 18-122 The compressor increases the mass of intake air
Remove and Install ..................................... 18-123 entering the combustion chamber. The compressor
is made up of an impeller, a diffuser and a volute
housing.
18 - 122 9823/0300-1 18 - 122

35 - Turbocharger
05 - Compressor
Remove and Install
This part is not serviceable. If damaged replace the

complete turbocharger assembly.
18 - 123 9823/0300-1 18 - 123

35 - Turbocharger
06 - Wastegate Valve
06 - Wastegate Valve Introduction

Introduction .................................................. 18-124 The wastegate is a valve that diverts exhaust gases
Technical Data ............................................. 18-125 away from the turbine in the turbocharged engine.
Check (Pressure) ........................................ 18-126 Diversion of exhaust gases regulates the turbine
Adjust .......................................................... 18-127 speed, which in turn regulates the rotating speed of
the compressor.
The primary function of the wastegate is to regulate

the maximum boost pressure in turbocharger
systems, to protect the engine and the turbocharger.
18 - 124 9823/0300-1 18 - 124

35 - Turbocharger
Technical Data
Table 158.
Wastegate control valve 1.25bar (18.1psi)
hose pressure
18 - 125 9823/0300-1 18 - 125

35 - Turbocharger
Check (Pressure)
in position with the probe on the wastegate

Important: The pressure check must be done when linkage terminal.
the engine is switched off.
Pressure: 2bar (29.0psi)
1. Disconnect the wastegate valve hose from the 5. Turn the pressure regulator to supply air to the
turbocharger, then connect it to the pressure wastegate valve in order to move the actuator rod
gauge. by 1mm.
2. Connect the pressure gauge to a pressure 6. The pressure reading on the pressure regulator
regulator unit with a suitable length of hose. gauge and the pressure gauge must be
3. Connect the pressure regulator unit to a suitable 1250mbar.
source of compressed air. 7. If the pressure value is less or more than the
4. Set the air pressure from the compressed air specified value, then adjust the wastegate valve.
source to the specified value. Put a dial indicator Refer to: PIL 18-35-06.
Figure 517.
A
B C
D
H
F
J
A Wastegate control valve B Nut

C Rod D Terminal
E Pressure regulator F Wastegate control valve hose
G Pressure gauge H Probe
J DTI (Dial Test Indicator)
18 - 126 9823/0300-1 18 - 126

35 - Turbocharger
Adjust
The adjustment must be done when the engine is

switched off.
1. Check the pressure.

2. If the pressure is less or greater than the stated
value, adjustment must be done, as follows.
3. Unscrew the nut.
4. Remove the split pin on the terminal and
disconnect the rod.
5. Hold the rod, screw to increase / or unscrew to
decrease the pressure, the ring until the pressure
reaches the corrected calibration.
6. Tighten the nut.
7. Reconnect the rod and replace the cotter pin
on the terminal. The rod should not turn during
adjustment.
Figure 518.
A
B C
D
A Wastegate control valve

B Nut
C Rod
D Terminal
18 - 127 9823/0300-1 18 - 127

36 - Variable Geometry Turbocharger (VGT)
Contents Page No.
18-36-00 General ......................................................................................................................... 18-129

18-36-06 Wastegate Valve .......................................................................................................... 18-140
18 - 128 9823/0300-1 18 - 128

00 - General
Introduction .................................................. 18-129 The turbocharger uses variable vanes to control
Component Identification ............................. 18-131 exhaust flow and to introduce EGR to reduce
Check (Condition) ........................................ 18-132 emission in diesel engines.
Check (Operation) ....................................... 18-132
The turbo uses heat energy from the waste exhaust
Remove and Install ..................................... 18-133 gases to drive a turbine which in turn drives the
Store and Recommission ............................ 18-135 compressor to pull new air at high pressure into the
cylinders. The extra volume of air allows more fuel to
be injected increasing the engine power output.
This lowers the combustion temperature and

reduces formation of NOx gases.
The turbocharger is installed on the outlet port of the

exhaust manifold.
The air is compressed to a minimum pressure of

1bar (14.5psi) depending upon engine speed and
load. The turbocharger spins at up to 100,000
rpm and reaches temperatures approaching 700°C
(1,291.0°F).
It is essential, therefore, that a good supply of oil

reaches the turbocharger at all times. The oil not only
lubricates the turbocharger but also carries away
excess heat.
An external oil feed pipe connected to a port on

the cylinder block supplies oil to the turbocharger
bearing. Oil returns to the engine oil sump through
an external drain pipe. Integral oil seals prevent oil
escaping to the compressor and turbine ends of the
turbocharger.
18 - 129 9823/0300-1 18 - 129

00 - General
Figure 519.
2 4
12
6
7
8
11
9
10
1 Air intake hose 2 Wastegate control valve hose

3 Wastegate control valve device 4 Wastegate control valve linkage
5 Turbine housing with Wastegate valve 6 Turbocharger central body
7 Catalyst support flange 8 Turbocharger lubrication pipe
9 Oil drain pipe 10 Compressed air flow hose to intercooler
11 Engine crankcase breather 12 Turbocharger housing
18 - 130 9823/0300-1 18 - 130

00 - General
Figure 520.
F G
A
D
H E
D E
J
L
K M
A Air intake hose B Turbocharger housing

C Turbocharger central body D Turbine housing with Wastegate valve
E Catalyst support flange F Wastegate control valve hose
G Wastegate control valve device H Wastegate control valve linkage
J Engine crankcase breather K Air compressed flow hose to intercooler
L Oil drain pipe M Turbocharger lubrication pipe
N Catalyst
18 - 131 9823/0300-1 18 - 131

00 - General

1. Inspect the compressor and turbine for damage. To maximise the duration of the turbocharger follow
the rules described below.
2. Make sure that the compressor blades do not rub
on the housing and rotate freely. It is normal to
detect a bit of play on the blades. Start-up
3. Make sure that the shaft rotates freely. Start the engine and keep it at idle speed for about a
minute. The oil operating pressure is reached within
4. Before you install the turbocharger, make sure a few seconds, but it is useful to allow the moving
that the code of the component is correct for parts to warm up in good lubrication conditions.
the type of engine, as installation of the wrong Immediately increasing the engine speed after start
turbocharger can damage the turbo and engine up will result in the turbocharger running at high rpm
and void the warranty. with less than optimal lubrication. This may lead to
premature failure of the turbocharger.
After maintenance
When carrying out maintenance on the engine
or turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it is
completely full. After pre-lubrication, let the engine
run via the starter motor without firing (engine /
fuel pump stop out) to allow the oil to circulate
through the complete system under pressure. Upon
engine start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to work
satisfactorily.
Low temperature air or engine inactivity

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 132 9823/0300-1 18 - 132

00 - General

D
Before Removal
1. Make sure you refer to the special instructions
on handling, operation and installation of the E
turbocharger. Refer to Store and Recommission. F
D
Remove
Refer to: PIL 01-03-27. E
D Bolt
2. Get access to the engine. E Gasket
F Oil inlet pipe
3. Remove the following components from the
turbocharger. 7.1. Remove the bolts that attach the
turbocharger oil inlet pipe.
3.1. Hose between the air cleaner and
turbocharger sleeve. 7.2. Disconnect the oil inlet pipe and gaskets
from the crankcase and the turbocharger.
3.2. Charge air cooler inlet hose.
7.3. Discard the gaskets.
3.3. Diesel oxidation catalyst.
7.4. Put caps on the turbocharger oil inlet port
4. Loosen the clamps that attach the sleeve to the and the crankcase.
turbocharger and the crankcase ventilation filter
hose. 8. Remove the turbocharger oil drain pipe as
follows:
Figure 521.
Figure 523.
C
H
A Sleeve G
B Clamps
C Crankcase ventilation filter hose G Clamp
H Screw
5. Remove the sleeve and the clamps. J Oil drain pipe
6. Put a cap on the inlet side of the turbocharger to 8.1. Remove the clamp that attaches the oil
prevent contamination. drain pipe to the crankcase ventilation filter
7. Remove the turbocharger oil inlet pipe as follows: bracket.
8.2. Remove the screws that attach the drain
pipe to the turbocharger.
8.3. Remove the oil drain pipe and gasket.
8.4. Discard the gasket.
18 - 133 9823/0300-1 18 - 133

00 - General
9. Remove the nuts that attach the turbocharger to 3. Make sure that the seat of the turbocharger on
the exhaust manifold. the exhaust manifold is free from contamination.
Figure 524. 4. Remove the caps from the ports of the
turbocharger.
L
5. Make sure you always hold the turbocharger
from the housing or centre housing side.
6. Put the turbocharger in position on to the studs
of the exhaust manifold.
Figure 526.
M
K
K K
L
K Bolt
L Turbocharger M
M Exhaust manifold
10. Remove the turbocharger from the exhaust
manifold.
11. Make sure you put caps on all the open ports of J
H
the turbocharger and the exhaust manifold.
H Screw
12. Inspect the turbocharger for any damage. J Oil drain pipe
Replace if damaged. K Nut
L Turbocharger
Refer to: PIL 18-35-00. M Exhaust manifold
Install 7. Install the nuts to secure the turbocharger to the

exhaust manifold.
1. Attach the turbocharger oil drain pipe to the
crankcase ventilation filter bracket with the 8. Tighten the nuts to the correct torque value.
clamp.
9. Attach the oil drain pipe to the turbocharger with
Figure 525. the screws.
10. Attach the oil inlet pipe to the turbocharger and
P the crankcase with the bolts.
Figure 527.
D
J
E
F
D
G N
G Clamp
J Oil drain pipe E
N Crankcase ventilation filter bracket
D Bolt
P Gasket
E Gasket
2. Lubricate and put a new gasket into the seat of F Oil inlet pipe
the turbocharger oil drain pipe.
18 - 134 9823/0300-1 18 - 134

00 - General
11. Make sure you install the oil inlet pipe gaskets Store and Recommission
between the:
11.1. Pipe and bolt
What to do
11.2. Pipe and crankcase
• Before assembling the turbocharger, make sure
11.3. Pipe and turbocharger. that the protection caps are installed on all
openings of the turbocharger.
12. Tighten the bolts to the correct torque value. • Make sure that the packaging is correct before
storing the turbocharger to be assembled.
13. Attach the sleeve to the turbocharger inlet with
• Make sure the turbocharger is pre-lubricated.
the clamp.
• Periodically check that the joints are sealed
Figure 528. against oil and air.
• Use only the specified lubricating oil.
• Check the engine oil level.
• Before switching the engine off after use, let it
A run at idle speed for around 1 minute.
• Check the condition of the air and oil filter
regularly as per the service schedule given in
the Maintenance Schedules.
• Make sure that the engine maintenance
intervals are observed.
• Make sure that the engine and equipment are
B used in a way that is not harmful to the life of
the turbocharger.
C
What not to do
A Sleeve
B Clamps • Do not store the turbochargers in stacks.
C Crankcase ventilation filter hose • Do not store the turbochargers in damp or wet
conditions.
14. Attach the crankcase ventilation filter hose to the • Do not expose the turbochargers to dust and
sleeve with the clamps. dirt.
• Do not lift the turbocharger by holding the
15. Test the turbocharger is working correctly. actuator rod.
Refer to: PIL 18-35-00. • Do not increase the engine speed immediately
after start-up.
Table 159. Torque Values • Do not run the engine at idle speed for more
than 20-30 minutes at a time.
Item Description Nm • Do not change the actuator settings.
D Bolts 30
K Nut 25 Practical operating rules
1. Start-up: Start the engine and keep it at idle
speed for about a minute. The oil operating
pressure is reached within a few seconds, but
it is useful to allow the moving parts to warm
up in good lubrication conditions. Immediately
increasing the engine speed after start up will
result in the turbocharger running at high RPM
with less than optimal lubrication. This may lead
to premature failure of the turbocharger.
2. After maintenance: When carrying out
maintenance on the engine or on the
turbocharger, pre-lubricate the oil inlet of the
turbocharger by adding clean lubricant until it
is completely full. After pre-lubrication, let the
engine run via the starter motor without firing,
to allow the oil to circulate through the complete
system under pressure. Upon engine start-up,
make it run at idle speed for a few minutes,
18 - 135 9823/0300-1 18 - 135

00 - General
allowing the oil and bearings system to work Figure 530.

satisfactorily.
3. Low temperature air or engine inactivity: If the
engine has been inactive for a certain period of A
time or the air temperature is very low, start the
engine and then let it run at idle speed. This
before applying high loads and speeds to the
engine and turbocharger.
4. Engine shutdown: Before switching off the
engine after intense use allow the turbocharger
to cool down. Therefore run the engine at idle
speed for at least 2 minutes that allow the
turbocharger to cool down.
5. Engine at idle speed: Do not run the engine at
idle speed for more than 20-30 minutes at a time.
It may cause oil leaks from the seals at the end of 3. Do not hold the turbocharger from the points
the engine shaft or it can cause blue smoke from shown in figure.
the exhaust when the engine speed and load are
increasing. Figure 531.
Handling instructions N N
1. Always lift the turbocharger with both hands from
the box.
Figure 529. N
N
Y
N N
Y
N
N Restricted area
Y Acceptable handling area
A 4. Always handle the turbocharger from the housing

or from the centre housing side.
Figure 532.

2. Do not lift the turbocharger from the compressor
side.
C Turbocharger housing side
18 - 136 9823/0300-1 18 - 136

00 - General
5. Make sure you DO NOT hold the turbocharger 10. Check for any visible scoring marks on the wheel
from any of the hoses of the turbocharger. or on the housing.
6. Always make sure that the turbocharger Figure 536.
compressor inlet cap is in place until the hose is
installed.
Figure 533.
F Bolt
B 11. Check for any oil leaks on the complete housing.
12. Check for any loose bolts and marks in paint.
B Turbocharger compressor inlet cap
Replacement or installation instructions
7. Remove the turbocharger protective caps
carefully and smoothly. 1. Always make sure that the cause of damage
to the original turbocharger is examined and
Figure 534. corrected before replacing it.
2. Do not modify the calibration of the turbocharger
it can cause damage to the turbocharger and
void the warranty.
D
3. Always use the correct gaskets to avoid blocking
holes when mounting.
4. Make sure that dirt does not enter the
turbocharger during installation.
5. Before mounting the turbocharger check that the
code of the component is correct for the type of
engine.
D Turbocharger protective cap
6. Mounting the wrong turbocharger can damage
8. Move the shaft with finger and look for excessive the turbocharger or the engine and void the
and radial play. warranty.
Figure 535. 7. Use only the specified lubricating oil during
installation of the turbocharger.
Turbocharger installation
E 1. Clean both manifolds before connecting to the
turbocharger.
2. Clean the air filter and the housing.
E Shaft
9. Make sure that your hands and the gloves are
not contaminated.
18 - 137 9823/0300-1 18 - 137

00 - General
G Air filter K
3. Clean the engine breather system.

K Compressor impeller
4. Check the breather system is working properly.
8. Install the turbocharger on the manifold and
5. Replace the gasket and pipe of the exhaust connect the exhaust pipe, secure with clamping
manifold. bolts.
H L
F
F Bolt
L Flange
9. Check the condition of the bosses and the flange
which must be intact.
H Gasket 10. Make sure that you clean the oil supply and drain
pipes.
6. Carefully remove the plastic or foam caps from
the turbocharger before mounting it.
7. Fill the turbocharger with new oil and make it
turn a few times by hand as shown in figure,
the compressor impeller should turn freely. It is
normal to detect a bit of play on the impellers.
18 - 138 9823/0300-1 18 - 138

00 - General
Figure 541. 18. Switch off the engine and check the oil level
again.
Figure 543.
M
M M
M Oil
M 19. Make sure that the oil level is not above the inlet
of the oil returning pipe to the crankcase.
20. Check the pressure of the engine housing, if the
engine housing pressure is high it can be caused
by a blocked bypass valve or by a clogged
breather system.
Figure 544.
M Oil
11. Make sure that the pipes are not damaged and
kinked.
12. If the oil level is correct, but the drain pipe is
clogged, there will be an outflow of pressurised
oil from the turbocharger.
M
13. Install the air pipes and clamp them.
14. Make sure you use new air, oil and fuel filters.
M Oil
Figure 542.
21. Follow the turbocharger 'Check Condition'
guidelines.
G Air filter
15. Fill the engine with new clean engine oil.
16. Start the engine at idle speed for 3-4 minutes,
then increase the speed.
17. Check for any oil, gas or air leaks.
18 - 139 9823/0300-1 18 - 139

06 - Wastegate Valve Introduction

Introduction .................................................. 18-140 The wastegate is a valve that diverts exhaust gases
Technical Data ............................................. 18-141 away from the turbine in the turbocharged engine.
Check (Pressure) ........................................ 18-142 Diversion of exhaust gases regulates the turbine
Adjust .......................................................... 18-143 speed, which in turn regulates the rotating speed of
the compressor.
The primary function of the wastegate is to regulate

the maximum boost pressure in turbocharger
systems, to protect the engine and the turbocharger.
18 - 140 9823/0300-1 18 - 140

Technical Data
Table 160.
Wastegate control valve 1.25bar (18.1psi)
hose pressure
18 - 141 9823/0300-1 18 - 141

Check (Pressure)
in position with the probe on the wastegate

Important: The pressure check must be done when linkage terminal.
the engine is switched off.
1. Disconnect the wastegate valve hose from the 5. Turn the pressure regulator to supply air to the
turbocharger, then connect it to the pressure wastegate valve in order to move the actuator rod
gauge. by 1mm.
2. Connect the pressure gauge to a pressure 6. The pressure reading on the pressure regulator
regulator unit with a suitable length of hose. gauge and the pressure gauge must be
3. Connect the pressure regulator unit to a suitable 1250mbar.
source of compressed air. 7. If the pressure value is less or more than the
4. Set the air pressure from the compressed air specified value, then adjust the wastegate valve.
source to the specified value. Put a dial indicator Refer to: PIL 18-35-06.
Figure 545.
A
B C
D
H
F
J
A Wastegate control valve B Nut

C Rod D Terminal
E Pressure regulator F Wastegate control valve hose
G Pressure gauge H Probe
J DTI
18 - 142 9823/0300-1 18 - 142

Adjust
The adjustment must be done when the engine is

switched off.
1. Check the pressure.

2. If the pressure is less or greater than the stated
value, adjustment must be done, as follows.
3. Unscrew the nut.
4. Remove the split pin on the terminal and
disconnect the rod.
5. Hold the rod, screw to increase / or unscrew to
decrease the pressure, the ring until the pressure
reaches the corrected calibration.
6. Tighten the nut.
7. Reconnect the rod and replace the cotter pin
on the terminal. The rod should not turn during
adjustment.
Figure 546.
A
B C
D
A Wastegate control valve

B Nut
C Rod
D Terminal
18 - 143 9823/0300-1 18 - 143

39 - Fuel Cooler
39 - Fuel Cooler
Contents Page No.
18-39-00 General ......................................................................................................................... 18-145
18 - 144 9823/0300-1 18 - 144

39 - Fuel Cooler
00 - General
00 - General
Remove and Install
Remove 5. Open the engine compartment cover. Refer to

(PIL 06-06).
6. Disconnect the fuel hoses from the matrix at the
2. Follow the general health and safety procedures. quick release couplings.
7. Support the matrix.
3. Switch off the engine before working in the
engine compartment. Remove ignition key or 8. Remove the nuts.
isolate battery to prevent the engine from being
started. Refer to (PIL 33-03). 9. Remove the fuel cooler matrix from the machine.
4. If the engine is hot let it cool for one hour.
Figure 547.
B
B C
A Quick release couplings B Nuts

C Matrix
18 - 145 9823/0300-1 18 - 145

39 - Fuel Cooler
00 - General
Install
steps also.
1.1. Bleed the fuel system. Refer to fuel system-
general, refer to (PIL 18-00).
1.2. After installation, start the engine and check
for fuel leaks.
18 - 146 9823/0300-1 18 - 146

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-149

18-96-03 High Pressure Pipe ...................................................................................................... 18-153
18-96-06 Low Pressure Pipe ....................................................................................................... 18-156
18 - 147 9823/0300-1 18 - 147

Notes:
18 - 148 9823/0300-1 18 - 148

96 - Fuel Pipe
00 - General
Introduction .................................................. 18-149 Important: The high pressure fuel pipes must be
Health and Safety ........................................ 18-150 replaced every time they are removed. If you install
Component Identification ............................. 18-150 the original pipes, it will cause leaks at the fuel pipe
Preparation .................................................. 18-151 connections.
High Pressure Pipe
The high pressure pipes are thick walled and
seamless tubes made of steel. The high pressure
fuel pipes supply pressurised fuel from the high
pressure fuel pump to the fuel rail. From the rail, fuel
is supplied to the electronic injectors through the high
pressure pipes.
The ends of the tubes are formed with conical nipples

for proper installation in the sealing cones on the fuel
rail and on the injector port.
Low Pressure Pipe

During fuel injection some fuel bleeds off the
electronic injectors and is sent back to the tank
through the low pressure pipes. The return fuel
from the high pressure fuel pump is also transferred
through the low pressure pipe.
All the low pressure return fuel is collected at a

common fuel distributor and is sent to the tank
through the low pressure pipes.
The low pressure fuel pipe also supplies low

pressure fuel from the tank to the high pressure pump
through the fuel filter.
18 - 149 9823/0300-1 18 - 149

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

WARNING Do not open the high pressure fuel
system with the engine running. Engine operation Refer to Fuel System - Component Identification.
causes high fuel pressure. High pressure fuel Refer to (PIL 18-00).
spray can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously
damage the fuel injection equipment and could be
expensive to repair.
18 - 150 9823/0300-1 18 - 150

96 - Fuel Pipe
00 - General
Preparation
1. Make sure that the engine is safe to work on. The

Important: Before you disconnect or remove fuel engine must cool and pressure in the fuel system
pipes make sure that you have the correct new parts. must decay before you start work. If the engine
The high pressure fuel pipes MUST BE REPLACED has been running, wait at least one hour before
with new ones. The new fuel pipes must remain you start work.
sealed inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one. 2. Clean the engine.
Obey all fuel system health and safety information.
Refer to: PIL 18-00-00. 3. Remove any dirt or debris that is exposed.
Figure 548.
A
B
D
E
A High pressure pipe from pump B High pressure pipe from rail (x4)
C Low pressure pipe D Rocker cover
E Injector (x4)
18 - 151 9823/0300-1 18 - 151

96 - Fuel Pipe
00 - General
Remove and Install
Refer to the separate fuel pipe procedures:
• High pressure pipes - refer to PIL 18-96-03 .

• Low pressure pipes - refer to Refer to: PIL
18-96-06.
18 - 152 9823/0300-1 18 - 152

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe Figure 549.
Remove and Install

Special Tools
Description Part No. Qty. E
Fuel Rail Plugs 892/12419 1
Plugs (High pressure
line)
D C A
B
NOTE: The illustrations shown are for a 4 cylinder A Common rail
engine however, the 3 cylinder engine also have a B Fuel pipe rail nut
similar configuration. C High pressure fuel pipe
D Fuel pipe injector nut
Before Removal E Electronic injector
1. Make sure that the engine is safe to work on. 1.1. Remove the fuel pipes one at a time.
2. The engine must cool and pressure in the fuel 1.2. Loosen the fuel pipe nut on the rail. Do not
system must decrease before you start work. If remove the nut at this stage.
the engine has been running, wait for a minimum 1.3. Loosen the fuel pipe nut on the electronic
of one hour before you start work. injector. Do not remove the nut at this stage.
3. Clean the engine. 1.4. Push the fuel pipe against the rail cone and
remove the nut.
1.5. Push the fuel pipe against the injector cone
4. Always replace the high pressure pipes after and remove the nut.
each disassembly.
1.6. Remove the fuel pipe.
5. Before you disassemble the high pressure pipes, 1.7. Seal all the open ports, use the correct parts
make sure the new high pressure pipes are from the service kit.
available.
Special Tool: Fuel Rail Plugs (Qty.: 1)
electronic injectors. 2. Do steps 1.1 through 1.7 again for remaining fuel
pipes.
Injector to Rail Fuel Pipes 3. Remove the screw that attaches the electronic
injector bracket to the rocker cover.
Remove
Figure 550.
1. The procedure given below is for one fuel pipe.
G
F Screw
G Washer
H Injector bracket
18 - 153 9823/0300-1 18 - 153

96 - Fuel Pipe
4. Remove the washer and the electronic injector 11. Tighten the bracket screws to the correct torque
bracket. value.
Install Pump to Rail Fuel Pipes

Important: The high pressure fuel pipes must be Remove
replaced every time they are removed. The new fuel
pipes must remain sealed inside their bags before 1. Loosen the nuts to disconnect the high pressure
use. If a bag is open do not use the fuel pipe, get a fuel pipe from the fuel pump and the fuel rail.
new one. Do not open the bag until you are ready to
assemble the fuel pipe. Figure 552.
1. Put the correct end of the fuel pipe against the K

correct injector cone. L
2. Tighten the nut with your hand.
3. Put the other end of the fuel pipe against the
correct rail cone.
4. Tighten the nut with your hand. M
5. Put the electronic injector bracket in position
against the injector.
6. Tighten the fuel pipe nut on the injector to the
correct torque value. K High pressure fuel pipe bottom nut
L High pressure fuel pipe
7. Tighten the fuel pipe nut on the common rail to M High pressure pump
the correct torque value.
2. Remove the screw that attaches the clamp to the
8. Replace the fuel pipes if the electronic injector intake manifold.
bracket screws do not rotate freely.
Figure 553.
9. Make sure that the electronic injector brackets
are positioned correctly on the: L
Figure 551.
F Q
H
G R
N
P
J
E
L High pressure fuel pipe
N High pressure fuel pipe top nut
P Fuel rail
Q Clamp
E Electronic Injector R Screw
F Screw
G Washer 3. Remove the high pressure fuel pipe and discard.
H Injector bracket 4. Immediately put caps on the open ports of the
J Rocker arm screw. high pressure pump and the rail.
9.1. Electronic injectors Special Tool: Fuel Rail Plugs (Qty.: 1)
9.2. Screws of the rocker arm assembly. Special Tool: High Pressure Pump Plugs (High
10. Attach the electronic injector bracket with the
washer and screw.
18 - 154 9823/0300-1 18 - 154

96 - Fuel Pipe
Install
Important: The high pressure fuel pipes must be
replaced every time they are removed. The new fuel
pipes must remain sealed inside their bags before
use. If a bag is open do not use the fuel pipe, get a
new one. Do not open the bag until you are ready to
assemble the fuel pipe.
1. Put a new high pressure fuel pipe in position

against the high pressure pump and the fuel rail.
2. Tighten the nuts by hand at both ends of the high
pressure pipe.
3. Install the clamp on the intake manifold with the
screw.
4. Tighten the high pressure pipe nuts to the correct
torque value. Tighten the fuel pipe top nut first.
After Installation
1. Start the engine and test for leaks in the fuel
system.
2. If any leakage is found in the high pressure fuel
circuit, do not intervene with the engine running.
Stop the engine and wait for the specified
duration before you check the leak.
Duration: 5–10min

Item Nm
B 25
D 30
F 20
K 25
N 30
18 - 155 9823/0300-1 18 - 155

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 555.
Remove and Install

Special Tools E
Plugs (Low pressure D
line)
Obey all fuel system health and safety information. C
Before Removal
C Screw
1. Make sure that the engine is safe to work on. D Distributor
E Cylinder head
4. Release the clamp that attaches the low pressure
2. The engine must be cool and pressure in the fuel fuel pipe to the high pressure fuel pump.
system must decrease before you start work. If
the engine has been running, wait for a minimum Figure 556.
of one hour before you start work. M K
3. Clean the engine. L
Remove J
1. Pull the clips out and remove them from the low
pressure pipe fitting. F
Figure 554.
B H
G
A
F Clamp
G High pressure pump
H Low pressure pipe (pump)
J Screw
K Rail pressure relief valve
L Low pressure pipe (rail relief valve)
M Low pressure pipe fitting
5. Disconnect the low pressure fuel pipe from the
high pressure pump.
A Clip 6. Put a cap on the open port of the fuel pump.

B Injector low pressure pipe Special Tool: High Pressure Pump Plugs (Low
2. Make sure that the clips return to the initial
position after removal. Replace the clip if it does 7. Remove the screw that attaches the low pressure
not return to the initial position. fuel pipe to the pressure relief valve of the
common rail.
3. Remove the screw that attaches the fuel
distributor to the cylinder head. 8. Remove the two O-rings and the low pressure
fuel pipe from the rail relief valve.
9. Put a cap on the relief valve of the common rail.
Special Tool: Fuel Rail Plugs (Qty.: 1)
18 - 156 9823/0300-1 18 - 156

96 - Fuel Pipe
06 - Low Pressure Pipe
10. Disconnect the low pressure pipe fittings from the 12. Remove the cap from the fuel return port of the
electronic injectors. high pressure pump.
11. Put caps on the open ports of the injectors. 13. Install the low pressure pipe on the fuel return
port of the high pressure pump.
12. Remove the fuel pipes with the distributor. Do not
disconnect the fuel pipes from the distributor until 14. Attach the low pressure pipe to the pump with the
required. clamp.
Install After Installation

1. Inspect the O-rings installed on the low pressure 1. Test for leaks in the fuel system.
pipe fitting. Replace the O-rings if they are
damaged. Table 162. Torque Values
Figure 557. Item Nm

M C 10
D Distributor
M Low pressure pipe fitting
N O-ring
2. Make sure that you do not disconnect the pipes
from the distributor.
3. Put the low pressure pipes in position and install
the fuel distributor to the cylinder head with the
screw.
5. Remove the caps from the fuel injectors.
6. Install the low pressure pipe fittings on the fuel
injectors.
7. Lock the low pressure pipe fittings with the clips,
when you attach the clip make sure that you hear
a click.
8. Remove the cap from the pressure relief valve of
the common rail.
9. Put the screw and the two O-rings on the low
pressure fuel pipe to be installed on the rail relief
valve.
10. Install the low pressure fuel pipe between the two
O-rings.
11. Install the low pressure fuel pipe to the pressure
relief valve of the common rail with the screw.
18 - 157 9823/0300-1 18 - 157

Notes:
18 - 158 9823/0300-1 18 - 158

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

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-15
21-03-09 Transmission Oil Cooler ................................................................................................. 21-23
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-27
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-39
21-09 Pump
21-09-00 General ........................................................................................................................... 21-43
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-49
21-21 Inlet
21-21-00 General ........................................................................................................................... 21-57
21-93 Hose
21-93-00 General ........................................................................................................................... 21-61
9823/0300-1
2018-01-15
Acronyms Glossary

9823/0300-1
2018-01-15
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9823/0300-1 21 - 1
Notes:
21 - 2 9823/0300-1 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Component Identification ................................. 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Fault-Finding .................................................... 21-7 quickly and then maintain it.
Drain and Fill ................................................... 21-9
Check (Condition) .......................................... 21-11
Check (Leaks) ............................................... 21-11
Check (Level) ................................................ 21-12
21 - 3 9823/0300-1 21 - 3
21 - Cooling System
00 - Cooling System
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 163.
cap, hot coolant can spray out and burn you. Thermostat Wax element with by-
Make sure that the engine is cool before you work pass blanking
on the cooling system.
Thermostat operating 79°C (174.1°F)
CAUTION Antifreeze can be harmful. Obey the temperature:
manufacturer's instructions when handling full Stroke at 91°C (195.7°F) 7.5mm
strength or diluted antifreeze.
Liquid recirculation (from 0.15L/min
0.3bar (4.3psi)
Water pump flow rate 75L/min
21 - 4 9823/0300-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 558.
M
J G
F
H
K
B
C
A Water pump B Coolant intake

C Return from expansion tank D Coolant cylinder
E Coolant cylinder head F EGR cooler coolant
G Expansion tank H Vent line to expansion tank
J Coolant to radiator K Thermostatic valve
L Vent line from radiator to expansion tank M Coolant into radiator
21 - 5 9823/0300-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
Figure 559.
H L
G
F N
F
E
C D
P
C Return from expansion tank D Coolant cylinder

E Coolant cylinder head F EGR cooler coolant
G Expansion tank H Vent line to expansion tank
L Vent line from radiator to expansion tank N EGR gas coolant (EGR valve flange)
P Oil radiator coolant inlet manifold Q Oil coolant
R Oil radiator coolant outlet manifold
21 - 6 9823/0300-1 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 165. Page 21-7
Coolant - Over Temperature. Table 166. Page 21-7
Coolant - Under Temperature. Table 167. Page 21-8
Coolant - Contaminated. Table 168. Page 21-8
Table 165. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting See Also: Table 166. Coolant - Over Temperature.
in loss through the radiator overflow.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
EGR (Exhaust Gas Recirculation) cooler leak (if Check/replace the EGR cooler. Check for signs of
applicable). coolant leaking into combustion chamber.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
Table 166. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 165. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level overfilled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of anti-freeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
Coolant pump faulty. Check/replace the coolant pump.
21 - 7 9823/0300-1 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
Leak between the top tank and the auxiliary tank Check for coolant leakage between radiator auxiliary
(sudden overheating). tank and radiator top tank.
Cooling passages in radiator, cylinder head, head Flush the system and fill with clean coolant.
gasket or crankcase blocked.
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault (if applicable). connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
Table 167. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, (open - not sealing). Check/replace the thermostat.
Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss
may result in the gauge showing low temperature
initially. In which case, check the level.
Table 168. Coolant - Contaminated.

Cause Remedy
Coolant rusty, operation without correct mixture of Drain and flush the cooling system. Fill with correct
antifreeze and water. mixture of antifreeze and water. Review the coolant
change interval.
Engine oil cooler, or cooler housing allowing cross Remove the oil cooler assembly and check relevant
contamination of coolant with engine oil. sealing elements for damage.
Transmission lubricating oil cooler leaking (if Check/replace lubricating oil cooler. Refer to
applicable). equipment manufacturer's procedures.
Lubricating oil leaks from lubricating oil cooler, head See Also: Table 165. Coolant - Loss.
gasket, head and crankcase.
21 - 8 9823/0300-1 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Figure 561.
Consumables
Antifreeze HP/ 4006/1101 5L
Coolant ASTM D6210 4006/1120 20L
Concentrate 4006/1103 200L

Refer to: PIL 01-03-27. A
C
2. Stop the engine and let it cool down.
3. Open the rear access cover to get access to the
engine. D
E
4. Carefully loosen the cap just enough to let any
pressure escape. Remove the cap when all A Radiator
pressure is released. C Exhaust pipe
Figure 560. D Clamp
E Sealing plug
6. Remove the sealing plug from the exhaust pipe.
B
A
7. Drain the coolant into an suitable container from
the radiator.
8. Remove the cap from the manifold.
9. Drain the coolant from the manifold.
10. Put the cap on the manifold along with a new
copper gasket.
Figure 562.
A Radiator
B Radiator cap
CAUTION! The cooling system is pressurised

when the coolant is hot. When you remove the
cap, hot coolant can spray out and burn you.
Make sure that the engine is cool before you work
5. Loosen the clamp that attaches the sealing plug

on to the exhaust pipe.
F
G
F Cap
G Gasket
11. Tighten the cap to the correct torque value.
12. Connect the sealing plug or expansion tank pipe
to the exhaust pipe with a strap.
21 - 9 9823/0300-1 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Figure 563. 19. Stop the engine and let it cool down.
20. When the engine is cooled, check the coolant
level again, and if necessary top up with the
coolant.

Item Nm
F 50
A E
A Radiator
E Sealing plug
13. Use the correct coolant to fill the radiator.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
14. Fill the coolant in the radiator,until the pipes
inside the radiator are covered by about 5mm.
15. Fill the coolant into the expansion tank up to the
MAX level mark.
Figure 564.
H
J
K
H Expansion tank cap

J MAX level
K Expansion tank
16. Bleed the cooling circuit.
17. Start the engine without the radiator cap or the
expansion tank cap installed.
18. Make sure that the engine is running at idle
speed until the coolant level goes down and
become stable in the system.
21 - 10 9823/0300-1 21 - 10
21 - Cooling System
00 - Cooling System
00 - General
Check (Condition) Check (Leaks)

1. Visually inspect the engine and related cooling Before you start the machine, inspect the system for
components for: leaks:
1.1. Leaks. 1. Make the machine safe.
1.2. Cracked, burnt or perished hoses. Refer to: PIL 01-03-27.
1.3. Hose clips are in good condition and
2. Get access to the cooling pack.
torqued to the correct value.
3. Check under the cooling pack and cooling hoses
for signs of leaks.
4. Repair or replace any damaged components
before starting the machine.
21 - 11 9823/0300-1 21 - 11
21 - Cooling System
00 - Cooling System
00 - General
Check (Level)
2. Get access to the coolant expansion tank.
3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
cap and top up to the level indicated.
4. Install the filler cap and make sure it is tight.
5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
21 - 12 9823/0300-1 21 - 12
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-15

21-03-09 Transmission Oil Cooler ................................................................................................. 21-23
21 - 13 9823/0300-1 21 - 13
Notes:
21 - 14 9823/0300-1 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-15 The engine cooling pack is designed as a sub
Component Identification ............................... 21-16 assembly which can consist of the following
Clean ............................................................. 21-18 components depending on machine variant/
Check (Condition) .......................................... 21-18 specification.
Remove and Install ....................................... 21-19 • Transmission oil cooler. Refer to (PIL 21-03-09).
Disassemble and Assemble .......................... 21-22 • Hydraulic oil cooler. Refer to (PIL 21-03-12).
• Fuel cooler Refer to (PIL 18-39).
• Air conditioning condenser. Refer to (PIL
12-15).
• Engine air intercooler. Refer to (PIL 18-39).
21 - 15 9823/0300-1 21 - 15
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 565.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
21 - 16 9823/0300-1 21 - 16
21 - Cooling System
03 - Cooling Pack
00 - General
Table 170.
Item Description
A Air cleaner / fuse box
support bolts
B Fuel sedimentor and
pump
C Air to air inter cooler ma-
trix
D Hydraulic oil cooler ma-
trix (if installed)
E Fixing points
F Hydraulic hoses- Fan
Motor/Oil Cooler
G Solenoid valve- re-
versible fan (if installed)
H Fan speed sensor
J Proportional fan speed
control solenoid
K Engine coolant radiator
matrix
L Radiator top hose con-
nection
M Inter cooler inlet hose
connection
N Fixed Speed Cooling fan
and hydraulic motor as-
sembly (55KW engines)
P Variable Speed Cooling
fan and hydraulic motor
assembly (81, 93 and
108 KW engines)
Q Inter cooler outlet hose
connection
R Radiator bottom hose
connection
21 - 17 9823/0300-1 21 - 17
21 - Cooling System
03 - Cooling Pack
00 - General
Clean Check (Condition)
If the radiator tubes/fins get clogged the radiator will 1. Make the machine safe. Refer to (PIL 01-03).
be less efficient.
2. Let the engine cool.
3. Get access to the cooling pack. Refer to (PIL
2. Open the engine cover. Refer to (PIL 06-06-06). 21-03)
3. Remove the undershield. Refer to (PIL 4. Check the hoses, radiator and fan for:
06-06-30).
4.1. Condition.
4. Use a soft bristle brush to remove all unwanted 4.2. Damage.
material from the rear of the radiator.
4.3. Security.
5. Release the fastener and pull the condenser
away from the radiator. 5. If necessary, Replace the system hoses/radiator.
6. Use the soft bristle brush to remove all unwanted

material from both sides of condenser and
the front of the radiator. Then push back the
condenser and lock in position with the fastener.
7. Make sure that the loosened material is removed
out of the engine compartment.
21 - 18 9823/0300-1 21 - 18
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install
Although it is possible to remove individual 11. Plug all the open ports and hoses to prevent
components it is quicker and easier to remove contamination.
the complete sub assembly, particularly if access
is necessary for engine overhaul or removal and 12. Disconnect the hydraulic hoses from the chassis.
replacement for example.
13. Plug all the open ports and hoses to prevent
contamination.
Disassembly
14. On 527-56 machines, the fan motor hydraulic
1. Make the machine safe. Refer to (PIL 01-03). hoses are connected to the bulkhead plate.
2. Make sure that the engine and hydraulic system Figure 566.
are cool before you start the removal procedure.
3. Remove the engine cover and side console
assembly. Refer to (PIL 06-06).
4. Put a label on the fuel lines, hoses and electrical
connectors to help installation.
5. Disconnect the fuel lines and electrical connector
from the fuel separator or remove the fuel
separator bolts, the fuel line clips and tie the
assembly safely out of the way.
6. Disconnect the radiator bottom hose and drain S T
the coolant.
7. Disconnect the radiator top hose. S Bulkhead plate
T Fan motor hydraulic hoses
8. Disconnect the fan motor electrical connections
(if installed). 15. Disconnect the intercooler inlet and outlet hoses.
9. For 81 kW, 93 kW and 108 kW Machines. 16. Support the cooling pack assembly, remove the
fusebox bolts and the fixing bolts.
9.1. Disconnect the electrical connectors from
the fan motor direction control valve (if 17. Carefully lift and move the assembly away from
installed), control solenoid and the speed the machine.
sensor.
10. Disconnect the transmission cooler hoses from
the chassis.
21 - 19 9823/0300-1 21 - 19
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 567.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
Table 171.
Item Description
A Fusebox support bolts
B Fuel separator and pump
C Air to air intercooler matrix
(1)
D Hydraulic oil cooler matrix (if installed)

(1)
E Fixing points
21 - 20 9823/0300-1 21 - 20
21 - Cooling System
03 - Cooling Pack
00 - General
Item Description
F Hydraulic hoses- Fan Motor/Oil Cooler
G Solenoid valve- reversible fan (if installed)
H Fan speed sensor
J Proportional fan speed control solenoid
K Engine coolant radiator matrix
(1)
L Radiator top hose connection

M Intercooler inlet hose connection
N Fixed Speed Cooling fan and hydraulic motor assem-
bly (55KW engines)
P Variable Speed Cooling fan and hydraulic motor as-
sembly (81, 93 and 108 KW engines)
Q Intercooler outlet hose connection
R Radiator bottom hose connection
(1) The engine coolant radiator, transmission oil cooler and air to air inter cooler matrix are all integral part. If
any part of the assembly has failed the complete unit must be replaced.
Install 1.1. Tighten the clamps to the correct torque

value.
steps.
Figure 568.
U
U
U Clamp
1.2. Fill the engine cooling system with the Table 172. Torque Values
correct type of coolant. Refer to (PIL 21-00).
Item Description Nm
1.3. Operate the engine and check the fan motor U Clamp 5.5
speed.
1.4. Check the hydraulic fluid level. Refer to (PIL
30-00-00).
1.5. Check the transmission oil level and top up
as necessary.
21 - 21 9823/0300-1 21 - 21
21 - Cooling System
03 - Cooling Pack
00 - General
With the cooling pack removed from the machine

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

(PIL 21-03-09).
• Remove the cooling fan motor. Refer to (PIL
21-05).
• Remove the hydraulic oil cooler. Refer to (PIL
21-03-12).
• Remove the fuel cooler. Refer to (PIL 18-39-00).
• Remove the air conditioning condenser. Refer
to (PIL 12-15-00).
21 - 22 9823/0300-1 21 - 22
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Check (Condition)

Check (Condition) .......................................... 21-23 The liquid to liquid cooler is a possible source of
Remove and Install ....................................... 21-24 water contamination. It should be tested for possible
failure as follows:
1. Drain any remaining oil/water from the cooler.

2. Install a blanking plug to the outlet of the cooler.
3. Connect an air supply to the transmission oil inlet.
4. The air test pressure must not exceed the
specified value.
5. Submerge the cooler in a tank of water and apply
air pressure to test for leakage. If bubbles are
visible there is a breakdown between the water
and hydraulic circuits.
6. Replace the cooler. Refer to cooling system-
cooling pack.
7. If the cooler is not damaged, clean and make it
dry before you assemble it to the machine.
21 - 23 9823/0300-1 21 - 23
21 - Cooling System
03 - Cooling Pack
Remove and Install
Remove 4. Drain the engine coolant. Refer to (PIL 21-00).
1. Make the machine safe. Refer to (PIL 01-03). 5. Disconnect the electrical oil temperature sensor.
2. Follow the general health and safety procedures. 6. Carefully disconnect the oil feed and return
Refer to (PIL 01-03). hoses. The oil may be hot.
3. Remove the engine cover base for easy access 7. Remove the water hose clips and the retaining
to the transmission oil cooler. Refer to (PIL clips. Take out the cooler.
06-06).
Figure 569.
A
C D C C C
A Electrical oil temperature sensor B Oil feed and return hoses

C Retaining clips D Cooler
21 - 24 9823/0300-1 21 - 24
21 - Cooling System
03 - Cooling Pack
Install
steps.
1.1. Check the transmission oil level. Refer to
(PIL 27-00).
1.2. Fill the cooling system. Refer to (PIL 21-00).
1.3. Operate the machine, stop the engine and
check for water/oil leaks at the cooler hose
connections.
1.4. Check the transmission oil level. Refer to
(PIL 27-00).
1.5. Check the coolant level.
If a faulty oil cooler has been replaced with a new

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

oil and check for signs of water contamination. There
should be no contamination. Refill the transmission
with fresh oil.
21 - 25 9823/0300-1 21 - 25
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-27
21 - 26 9823/0300-1 21 - 26
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-27 The product is equipped with a hydraulically driven
Operation ....................................................... 21-28 fan motor to provide air flow though the cooling pack.
Disassemble and Assemble .......................... 21-36 Some products may have either a fixed speed fan or
a variable speed hydraulic fan.
On some products, the fan may be reversible to

assist with the removal of debris from the cooling
pack.
21 - 27 9823/0300-1 21 - 27
21 - Cooling System
05 - Fan Motor
00 - General
Operation
Fixed speed Schematic diagram
The schematic diagram shows an general overview Figure 570.

of the system. Your machine may have a triple pump D F
installed but the system will be similar.
C
The cooling fan motor is hydraulically driven. The
motor turns the cooling fan and air is drawn through
E
the radiators in the machine cooling pack.
Hydraulic oil from the pump supplies the fan motor

and pilot pressure supply valve.
The pressure relief valve prevents component

damage.
A Main pump
B Hydraulic tank
C Pump pressure supply
D Fan motor case drain line
E Fan motor pressure relief valve
F Fan motor
21 - 28 9823/0300-1 21 - 28
21 - Cooling System
05 - Fan Motor
00 - General
Table 173. Colour key-Oil flow and pressure to inform the right hand instrument ECU of the
ambient air temperature.
Full pressure
The ECU varies the speed of the fan motor according
Exhaust to the temperature signals, the fan will be at a higher
speed in high temperatures and a lower speed in low
temperatures.
Neutral
The ECU generates the correct PWM (Pulse Width
Modulation) signal for operation of the fan speed
proportional solenoid.
Variable speed
The proportional solenoid operates as a pressure
The engine cooling pack is cooled by a hydraulically reducing valve. The supply to the fan motor is at a
powered cooling fan motor. pressure in relation to the ambient temperature.
The fan speed is controlled by the right hand The fan speed sensor sends a signal to the ECU to
instrument ECU (Electronic Control Unit). record current fan speed.
The engine air temperature sensor sends a signal A reversible fan option is provided where an operator
over the machine CAN (Controller Area Network)bus switch energises the fan direction solenoid to reverse
the direction of the fan.
21 - 29 9823/0300-1 21 - 29
21 - Cooling System
05 - Fan Motor
00 - General
Schematic diagram
Figure 571.
G H
B
C
A Hydraulic tank B Hydraulic variflow pump assembly

C Hydraulic gear pump (Fan supply) D Oil cooler
E Fan speed proportional solenoid F Fan direction solenoid (if installed)
G Fan motor housing H Fan motor
21 - 30 9823/0300-1 21 - 30
21 - Cooling System
05 - Fan Motor
00 - General
Table 174. Colour key-Oil flow and pressure

Full pressure
Exhaust
Neutral
21 - 31 9823/0300-1 21 - 31
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Fixed Speed Fan (If Installed) If the performance is below that specified, the
motor should be renewed. Renewal of individual
Your machine may be installed with a fixed or components such as gears, bearings and housings
variable speed fan. Removal and installation of both will not result in a permanent cure. If the motor
types of fan are shown. performance is satisfactory, but there is external
leakage, it should be dismantled for re-sealing
Before you remove the fan motor, check its purposes only.
performance.
Figure 572.
21 - 32 9823/0300-1 21 - 32
21 - Cooling System
05 - Fan Motor
00 - General
A Fan retaining nut B Motor retaining bolts

C Fan bracket securing bolts D Feed and return hoses
E Case drain hose
Remove If the performance is below that specified, the motor

should be renewed.
1. Make the machine safe. Refer to (PIL 01-06)
Remove
2. Install the safety strut. Refer to (PIL 06-69).
30-00). 2. Follow the general health and safety procedures.
4. Mark the hydraulic feed and return hoses to help
identification when you install. 3. Install the safety strut. Refer to (PIL 06-69).
5. Disconnect and plug the feed and return hoses. 4. Discharge the hydraulic pressure. Refer to (PIL
30-00).
6. Disconnect and plug the case drain hose.
5. Mark the electrical connectors to help in
7. Remove the fan guard. identification when you install.
8. Undo the fan bracket securing bolts (x4) and lift 6. Disconnect the harness from the solenoid
the fan and motor assembly from the machine. electrical connector.
9. Prevent the fan from turning, release the tab 7. Disconnect the harness from the speed sensor
washer and then undo the fan retaining nut. electrical connector.
10. Withdraw the fan from the motor shaft. Retain the 8. If installed, disconnect the harness from the
drive key (not shown). direction solenoid.
11. Undo the motor retaining bolts and remove the 9. Mark the hydraulic hoses to help in identification
motor. when you install.
Install 10. Disconnect and plug the feed hose and return
hose.
removal procedure. Additionally do the following 11. If installed, disconnect and plug the case drain
steps. hose.
1.1. Tighten all the fastening nuts and bolts to 12. Support the motor and the fan.
1.2. Make sure all hoses are attached to the
correct ports. The case drain hose (if 14. Remove the fan bracket, the fan and then the
installed) must be fed in to a tank line motor from the machine.
otherwise damage to the motor will occur.
15. Stop the fan from turning.
1.3. Check and adjust the hydraulic fluid level.
16. Remove the tab washer and then remove the nut.
Table 175. Torque Settings 17. Remove the fan from the motor shaft. Keep the
Item Value drive key.
A 36N·m 18. Remove the motor/ control pack retaining nuts.
B 28N·m
19. Remove the motor from the bracket.
C 47N·m
Variable Speed Fan (If Installed)

Before you remove the fan motor, check its
performance.
21 - 33 9823/0300-1 21 - 33
21 - Cooling System
05 - Fan Motor
00 - General
Figure 573.
A
A
J H
E
B G
K
A D F
A
A Bolts B Case drain hose

C Feed hose D Return hose
E Motor retaining nuts F Solenoid electrical connector
G Speed sensor electrical connector H Bracket
J Direction solenoid K Fan nut
21 - 34 9823/0300-1 21 - 34
21 - Cooling System
05 - Fan Motor
00 - General
Install 1.2. The case drain hose (if installed) must be

fed into a tank line otherwise the motor can
1. The installation procedure is the opposite of the be damaged.
steps. 1.3. Replace the tab washer located on the fan
nut.
1.1. Make sure all hoses are attached to the 1.4. Check the hydraulic fluid level. Refer to (PIL
correct ports. 30-00).
Table 176. Torque settings

Item Value
B 27N·m
C 48N·m
D 48N·m
K 36N·m
21 - 35 9823/0300-1 21 - 35
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 36 9823/0300-1 21 - 36
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-39
21 - 37 9823/0300-1 21 - 37
Notes:
21 - 38 9823/0300-1 21 - 38
21 - Cooling System
06 - Expansion Tank
00 - General
00 - General
Remove and Install
Consumables 5. Open the engine compartment cover. Refer to

Description Part No. Size (PIL 06-06).
JCB Threadlocker 4101/0250 0.01L 6. Drain the engine coolant. Refer to (PIL 21-00).
Strength) 7. Remove the bolts.
Remove 8. Remove the expansion tank cover.
1. Make the machine safe. Refer to (PIL 01-03). 9. Disconnect the coolant level sensor electrical
connector (if installed).
Refer to (PIL 01-03). 10. Loosen the hose clips and disconnect the hoses
from the expansion tank.
3. Switch off the engine before working in the
engine compartment. Remove the ignition key or 11. Support the expansion tank.
isolate battery to prevent the engine from being 12. Remove the expansion tank from the bracket.
started. Refer to (PIL 33-03).
4. If the engine is hot, let it cool for one hour.
21 - 39 9823/0300-1 21 - 39
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 574.
D A
E F E E
A Hose clips B Hoses

C Tank cover D Expansion tank
E Bolts F Bracket
21 - 40 9823/0300-1 21 - 40
21 - Cooling System
06 - Expansion Tank
00 - General
Install
steps.
1.1. Apply sealant to the bolts.
(Medium Strength)
1.2. Tighten the bolts to the specified torque
value.
1.3. Fill the engine cooling system with the
correct type of coolant. Refer to (PIL 21-00).
1.4. When the installation procedure is
complete, start the engine and check for
coolant leaks.

Item Description Nm
E Bolts 5
21 - 41 9823/0300-1 21 - 41
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-43
21 - 42 9823/0300-1 21 - 42
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-43 The coolant pump is a centrifugal type located in the
Technical Data ............................................... 21-44 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-46 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
Remove and Install ....................................... 21-46 are not renewable.
21 - 43 9823/0300-1 21 - 43
21 - Cooling System
09 - Pump
00 - General
Technical Data
Table 178. Technical Data

Flow rate 75L/min
RPM (Revolutions Per 2600
Minute)
Transmission ratio 1.3
(pumpRPM/engineRPM)
Max operating tempera- 130°C (265.8°F)
ture
No. of pump revolutions 3.380
21 - 44 9823/0300-1 21 - 44
21 - Cooling System
09 - Pump
00 - General
Figure 575.
A Water pump control pulley B Water intake fitting

C Water return manifold from the water/oil heat
exchanger
21 - 45 9823/0300-1 21 - 45
21 - Cooling System
09 - Pump
00 - General
The coolant pump is driven via a pulley and front end This part is a non-serviceable component. If
accessory drive belt, the pump draws coolant from damaged, replace the pump.
the pump cavity. The coolant is pumped through the
outlet gallery to the oil cooler cavity in the left side Before Removal
of the crankcase. As the coolant flows past the oil
cooler matrix, heat is exchanged from the oil to the 1. Make sure that the engine is safe to work on. If
coolant. This enables the oil to function as a coolant the engine has been running, let it cool before
as well as a lubricant. you start the service work.
For cooling system operation. 2. Drain the coolant from the engine.
3. Remove the drive belt according to the belt
configuration used.
Remove
1. Remove the clamp and remove the coolant pipe.
Figure 576.
G
H
G Clamp
H Coolant pipe
2. Release the electrical harness clamp from the
water pump.
Figure 577.
K
J Electrical harness clamp
K Water pump
21 - 46 9823/0300-1 21 - 46
21 - Cooling System
09 - Pump
00 - General
3. Remove the screws that attach the pump to the

timing gear case.
4. Remove the pump and the gasket.
Figure 578.
L
M
K Water pump
L Screw
M Gasket
Install
1. Always replace the gasket after each removal.
2. Put the gasket and water pump on the timing
gear case.
3. Attach the water pump with the screws.
5. Attach the coolant pipe to the water pump with
the clamp.
6. Install the electrical harness clamp on the pump.
After Installation

Item Nm
L 25
21 - 47 9823/0300-1 21 - 47
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-49
21 - 48 9823/0300-1 21 - 48
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-49 The thermostat is installed on the cylinder head. It is
Component Identification ............................... 21-50 located between the engine and the radiator in the
Operation ....................................................... 21-51 cooling circuit.
Check (Condition) .......................................... 21-52
The function of the thermostat is to block the flow of
Check (Operation) ......................................... 21-52 coolant to the radiator until the engine has warmed
Remove and Install ....................................... 21-53 up to a sufficient temperature.
When the engine is cold, no coolant flows through

the engine. Once the engine reaches its operating
temperature, refer to Cooling System - Technical
Data, the thermostat opens. By letting the engine
warm up as quickly as possible, the thermostat
reduces engine wear, deposits and emissions. Refer
to: PIL 21-00-00.
21 - 49 9823/0300-1 21 - 49
21 - Cooling System
12 - Thermostat
00 - General
Figure 579. Thermostat
A Cylinder head B Water outlet cover

C Thermostat D Gasket
E Air bleeding hole
21 - 50 9823/0300-1 21 - 50
21 - Cooling System
12 - Thermostat
00 - General
Operation diameter orifice allows trapped air to be expelled

from the system.
The thermostat is a wax element type and is Figure 581.

configured for by-pass blanking. The thermostat 7 3
functions as follows:
8 11
State A - Closed (Engine Cold)
When the engine is cold the wax pellet has
contracted into its housing. This allows the spring to
act against the thermostat body and move the valve
plate up against its seat, closing the outlet port to the 9
radiator. Since the bottom valve plate is connected
to the top valve plate it also moves up, opening the
bypass port. The coolant flows from the thermostat 1
housing inlet port into the bypass gallery.
Figure 580. 2
7 3
6
8 10
11 5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
9 5 Wax pellet
1 6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
2 9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
6
10
5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1mm
21 - 51 9823/0300-1 21 - 51
21 - Cooling System
12 - Thermostat
00 - General

1. If the thermostat is suspected of being faulty, A period of 3–5min before the thermostat valve starts
perform a thermostat test, to confirm its to operate is normal because of the time required to
serviceability. heat soak the thermostat.
2. Note that the thermostat is a non-serviceable 1. Make sure that the engine is safe to work on. If
item. If the thermostat is faulty or damaged it the engine has been running, let it cool before
must be renewed. you start the service work.
3. Inspect the seal for damage or splits. If necessary 2. Remove the thermostat housing and the
replace the seal. Make sure that the seal is thermostat.Refer to Figure 582.
correctly installed.
Figure 582.
A Thermostat housing
B Thermostat
3. Suspend the thermostat in a suitable container
of coolant. Use an external heat source to
gradually increase the temperature of the
coolant. Note: When working with boiling water,
all the necessary safety precautions must be
taken. Refer to Figure 583.
21 - 52 9823/0300-1 21 - 52
21 - Cooling System
12 - Thermostat
00 - General
The thermostat is a non-serviceable item. If the

thermostat is faulty or damaged it must be renewed.
Before Removal
3. Drain the coolant.
4. Use a thermometer to measure the temperature
of the coolant.
Remove
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the 1. Disconnect the radiator hose at the thermostat
movement of the valve plate should be evident. housing.
6. Record the starts to open temperature, the fully Figure 584.

open temperature and the amount of valve lift
when fully open.
A Radiator hose
2. Remove the bolts that attach the housing.
3. Remove the housing.
4. Lift out the thermostat.
21 - 53 9823/0300-1 21 - 53
21 - Cooling System
12 - Thermostat
00 - General
Figure 585. 5. Make sure you install the thermostat the right way
up.
B
6. Make sure the seal is located correctly.
C 7. Install the housing with the bolts.
9. Connect the radiator hose to the housing.
D After Installation
1. Fill the cooling system with the recommended
coolant mixture.
B Screw Refer to: PIL 21-12-00.

C Housing 2. Start the engine and check for coolant leaks.
D Thermostat
5. If the thermostat is suspected of being faulty,
perform tests to confirm its serviceability. Item Nm
Refer to: PIL 21-12-00. B 10
Install
procedure.
2. Inspect the seal for damage or splits. Always
replace the seal after each removal.
3. Put the seal on the thermostatic valve.
4. Install the thermostatic valve in the seat.
Figure 586.
E
D
D Thermostat
E Seal
21 - 54 9823/0300-1 21 - 54
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-57
21 - 55 9823/0300-1 21 - 55
Notes:
21 - 56 9823/0300-1 21 - 56
21 - Cooling System
21 - Inlet
00 - General
00 - General Figure 587.
Remove and Install

1
Before Removal
the engine has been running, let it cool before 1
1
3. Drain the cooling system. 2
The housing may be orientated differently to that

shown in the illustration, depending on the engine
installation.
Remove
1. Disconnect the radiator hose at the inlet housing.
2. Undo the bolts and lift off the housing.
X 6.8
1 Inlet housing
2 Fixing bolts
6 Sealing Ring
X Locating tab - sealing ring
Install
steps.
2. Make sure that the sealing ring is undamaged.
If necessary install a new seal. Make sure that
the seal is correctly located in its groove on the
housing. Note the locating tab.
4. Reconnect the radiator hose at the housing.
After Installation
1. Refill the engine with the recommended coolant
mixture.
2. Start the engine and check for coolant leaks.
21 - 57 9823/0300-1 21 - 57
21 - Cooling System
21 - Inlet
00 - General

Item Nm
2 24
21 - 58 9823/0300-1 21 - 58
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-61
21 - 59 9823/0300-1 21 - 59
Notes:
21 - 60 9823/0300-1 21 - 60
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-61 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-62 the cooling system. They carry the liquid coolant
Component Identification ............................... 21-63 between the engine and the radiator/cooling pack.
Check (Condition) .......................................... 21-65
21 - 61 9823/0300-1 21 - 61
21 - Cooling System
93 - Hose
00 - General
Health and Safety

when the coolant is hot. When you remove the
cap, hot coolant can spray out and burn you.
21 - 62 9823/0300-1 21 - 62
21 - Cooling System
93 - Hose
00 - General
Figure 588. Typical Cooling System
A Coolant outlet hose B Coolant inlet hose
21 - 63 9823/0300-1 21 - 63
21 - Cooling System
93 - Hose
00 - General
Figure 589.
C Oil cooler inlet hose D Oil cooler outlet hose
21 - 64 9823/0300-1 21 - 64
21 - Cooling System
93 - Hose
00 - General

1. Visually inspect the engine and related cooling when the coolant is hot. When you remove the
components for: cap, hot coolant can spray out and burn you.
1.1. Leaks. on the cooling system.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and Before Removal
tightened to the correct torque value.
3. Drain the coolant from the engine.
Remove
2. Remove the supporting screw and remove the
clamp 1.
Figure 590.
F
B
D
A
E
G
D
C
A Heat exchanger
B Inlet hose
C Outlet hose
D Clamp
E Clamp 1
F Screw
G Water pump
3. Remove the inlet hose from the structure.
4. Remove the clamp 2 and then remove the outlet
hose.
21 - 65 9823/0300-1 21 - 65
21 - Cooling System
93 - Hose
00 - General
C
F
B E
G D
G
C Outlet hose A Heat exchanger

G Water pump B Inlet hose
H Clamp 2 D Clamp
E Clamp 1
Install F Screw
G Water pump
1. Assemble the outlet hose behind the high
pressure pump. 5. Tighten the clamp 1 with the screws.
Figure 592. After Installation

A 2. Start the engine and check for any leaks.
C
D C
H
A Heat exchanger
C Outlet hose
D Clamp
H Clamp 2
2. Attach the outlet hose with the clamp 2 and then
connect to the heat exchanger.
3. Connect the inlet hose to the heat exchanger and
to the water pump with the clamps.
4. Attach the inlet hose with the clamp 1.
21 - 66 9823/0300-1 21 - 66
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ............................................................................................................................. 24-9
24-03-01 Master Cylinder .............................................................................................................. 24-32
24-03-03 Tank ................................................................................................................................ 24-35
24-03-39 Piston ............................................................................................................................. 24-36
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-39
24-03-46 Vacuum Pump ................................................................................................................ 24-40
24-03-50 Light Switch .................................................................................................................... 24-44
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-49
24-18-12 Control Valve .................................................................................................................. 24-56
24-18-21 Disc ................................................................................................................................ 24-57
9823/0300-1
2018-01-21
Acronyms Glossary

9823/0300-1
2018-01-21
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9823/0300-1 24 - 1
Notes:
24 - 2 9823/0300-1 24 - 2
24 - Brake System
00 - Brake System
00 - General

Health and Safety ........................................... 24-3 Brake Fluid
Fault-Finding .................................................... 24-5 Use of incorrect brake fluid will cause serious
damage to the seals of the braking system. This will
result in brake failure.
Accumulators
The accumulators contain hydraulic fluid and gas at
high pressure. Prior to any work being carried out
on systems incorporating accumulators, the system
pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
cause serious injury or death.
Service Brake Bleeding
Before bleeding the service brake system, park on
level ground and set the park brake to on. Put blocks
on both sides of the wheels on one axle to prevent
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If
you do not take these precautions the machine could
run over you.
Park Brake Maintenance
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the
machine could run over you.
Make sure that any attachments on the machine are
movement.
Brake Dust
Brake pads generate dust, which if inhaled may
endanger health. Wash off the caliper assemblies
before commencing work. Clean hands thoroughly
after completing the work.
Brake Dust
Brake shoes generate dust, which if inhaled
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
24 - 3 9823/0300-1 24 - 3
24 - Brake System
00 - Brake System
00 - General
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Put blocks on all wheels to prevent the machine
rolling.
WARNING! Do not use the machine with any part of
its brake system disconnected or inoperative. When
the test has been completed, make sure all brake
system components are installed and the system is
operating correctly.
WARNING! Before testing the park brake make sure
the area around the machine is clear of people.
WARNING! If the machine starts to move during the
park brake test, immediately apply the foot brake and
reduce the engine speed.
WARNING! If the machine starts to move during the
service brake test, immediately reduce the engine
speed and apply the park brake.
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
WARNING! Oil on the brake disc will reduce brake
effectiveness. Keep oil away from the brake disc.
Remove any oil from the disc with a suitable solvent.
Read and understand the solvent manufacturer's
safety instructions. If the pads are oily, install with the
new pads.
WARNING! Faulty brakes can kill. If you have to
top up the brake reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
WARNING! The park brake must not be used to
slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will
be reduced. Whenever the park brake has been used
in an emergency the brake friction components must
be renewed and the other components inspected.
Notice: Over adjustment or failure to disengage the
park brake properly will cause excessive wear of the
park brake mechanism.
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24 - Brake System
00 - Brake System
00 - General
Fault-Finding
Fault
One or more brakes do not apply. (Brake travel not excessive, brakes not Table 182. Page 24-5
pulling to one side)
Pedal travel excessive (but not touching floor) Table 183. Page 24-5
Pedal hard to operate Table 184. Page 24-5
Pedal touches floor under constant pressure- no fluid loss Table 185. Page 24-6
Pedal touches floor under constant pressure and fluid loss Table 186. Page 24-6
Poor braking (not pulling to one side) Table 187. Page 24-6
Brakes not releasing Table 188. Page 24-6
Poor braking when hot Table 189. Page 24-7
Excessive brake noise in operation (Due to the metal to metal contact of oil Table 190. Page 24-7
immersed brakes, limited noise can be heard which is consistent and normal
with this type of design).
Fluid loss when machine standing (for example- overnight). (Conform that Table 191. Page 24-7
the fault is as indicated by checking that the brake pedal does not touch the
floor when it is operated under constant pressure).
Table 182. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side)
Cause Remedy
Master cylinder fault. Check master cylinder to identify fault area, service
as necessary. Refer to (PIL 24-03-01).
Friction/counter plate distortion. Replace friction/counter plates- both sides of relevant
axle.
Table 183. Pedal travel excessive (but not touching floor)

Cause Remedy
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03).
Bleed the brake system. Refer to (PIL 24-00-00).
Leak in hydraulic system. Check for fluid loss at master cylinder and brake
piston, all pipes and fittings for loose connections.
correct as necessary. Refer to (PIL 24-03-39).
Check fluid reservoir level. Check for fluid/air leaks,
axle.
Table 184. Pedal hard to operate

Cause Remedy
Tightness at pedal pivot. Check the pedal pivot. Free-off/lubricate.
Fluid contamination/seal damage. Flush system and renew all hydraulic seals. Bleed
the brake system. Refer to (PIL 24-00-00).
Misaligned push rod/pedal. Check and correct as necessary.
Kinked or crushed brake pipes. Check/replace brake pipework.
Vacuum failure due to low vacuum at source. Check/service engine mounted exhauster unit as
(Machines fitted with servo assisted brakes only). necessary.
Blocked/leaking vacuum pipe. (Machines fitted with Check/renew vacuum pipe. Refer to (PIL 24-03-96).
servo assisted brakes only).
Servo defect. (Machines fitted with servo assisted Replace the servo unit.
brakes only).
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24 - Brake System
00 - Brake System
00 - General
Table 185. Pedal touches floor under constant pressure- no fluid loss
Cause Remedy
axle.
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
Table 186. Pedal touches floor under constant pressure and fluid loss
Cause Remedy
External fluid leaks. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03)
Internal fluid leaks. Bleed the brake system. Refer to (PIL 24-00-00).
Table 187. Poor braking (not pulling to one side)

Cause Remedy
Friction plates worn beyond limits or distorted. Replace friction/counter plates- both sides of relevant
axle.
Annular piston fault. See table 'Brakes not releasing', item 'Annular brake
piston(s) binding in axle'.
Incorrect/low axle oil. Fill the axle with correct type of oil.
Vacuum failure Check vacuum source/pipes, service as necessary.
Table 188. Brakes not releasing

Cause Remedy
Brake pedal spring fault. Install a new spring.
Master cylinder fault (plunger stuck in bore). Check master cylinder to identify fault area, service
Blocked hole in master cylinder reservoir cap Install a new reservoir cap.
Brake pedal free travel incorrect. Adjust pedal free travel.
Fluid contamination/seal damage. Flush system and replace hydraulic seals. Refill with
clean fluid.
Annular brake piston(s) binding in axle. Check that correct brake fluid has been used
(incorrect fluid could swell the annular brake piston
seals).
Check if annular brake piston seals are in good
condition.
Check that annular brake piston rotates freely in its
housing with no seals installed.
Check that the annular brake piston seal retracts the
piston approximately to the specified value.
Length: 0.5mm
Kinked or crushed brake pipes. Check and replace pipes as necessary.
Friction/counter plates not free on splines and/or Check friction/counter plates for free movement,
dowels. replace if necessary- both sides of relevant axle.
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24 - Brake System
00 - Brake System
00 - General
Table 189. Poor braking when hot

Cause Remedy
Moisture in system vaporising when axle is hot. Strip axle and clean annular piston to remove
moisture.
Remove master cylinder and check for corrosion,
service as necessary.
Flush system and replace hydraulic seals. Refill with
clean fluid.
Table 190. Excessive brake noise in operation (Due to the metal to metal contact of oil immersed brakes,
limited noise can be heard which is consistent and normal with this type of design).
Cause Remedy
Deterioration of axle oil or wrong type of axle oil Change axle oil. Refer to check level (PIL 20-00)
Axle oil loss. Refill axle with correct oil and check for leaks. Refer
to (PIL 20-00).
Friction plates worn beyond limits. Renew friction/counter plates on both sides of
relevant axle.
Friction/counter plates in poor condition. Check for distortion or surface pitting and/or
roughness of the plates. (Annular grooving of counter
plates is acceptable).
Table 191. Fluid loss when machine standing (for example- overnight). (Conform that the fault is as
indicated by checking that the brake pedal does not touch the floor when it is operated under constant
pressure).
Cause Remedy
Severe damage or slight cut/nick in the brake piston Test the brake piston seals for leakage. If necessary,
seal. strip axle and renew seal(s).
External leakage through brake pipe connections etc. Check for and repair leaking connections.
24 - 7 9823/0300-1 24 - 7
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ............................................................................................................................. 24-9

24-03-01 Master Cylinder .............................................................................................................. 24-32
24-03-03 Tank ................................................................................................................................ 24-35
24-03-39 Piston ............................................................................................................................. 24-36
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-39
24-03-46 Vacuum Pump ................................................................................................................ 24-40
24-03-50 Light Switch .................................................................................................................... 24-44
24 - 8 9823/0300-1 24 - 8
24 - Brake System
03 - Service Brake
00 - General
00 - General Technical Data

Technical Data ................................................. 24-9 Table 192. Service Brakes
Type Single circuit, oil im-
Operation ....................................................... 24-11 mersed multi-plate disc
Check (Leaks) ............................................... 24-14 Actuation Hydraulic
Bleed ............................................................. 24-15 Location Front axle, centre
Disassemble and Assemble .......................... 24-17 mounted (2 brake
packs)
Table 193. Master Cylinder

Type Master cylinder- single
No of cylinders 1
Stroke 36mm
24 - 9 9823/0300-1 24 - 9
24 - Brake System
03 - Service Brake
00 - General
Figure 594. Exploded View

19 2
3
1 4
19
5
6
21 7
8
20
20 18
20 22 9
17 10
20 14
22 25 17
26 16
24 27 15
13 35
12
34
33
28
28
29
30
31 32
1 Friction disc 2 Intermediate brake disc

3 Coupling 4 Fixing ball
5 Spacer 6 Shim
7 Intermediate disc 8 Alignment pins
9 Service brake piston 10 O-ring
11 Plug 12 Breather nipple
13 Plug 14 Back-up ring
15 O-ring 16 Back-up ring
17 Circlip 18 Spring (42)
19 Back-up ring 20 O-ring
21 Dowel 22 Piston assembly module
23 O-ring 24 Pin
25 O-ring 26 O-ring
27 Negative brake piston 28 Disc springs
29 Slotted nut 30 Negative brake locking screws
31 O-ring 32 Spacer
33 Grub screw 34 Seal
35 Bolt
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24 - Brake System
03 - Service Brake
00 - General
Operation
For: 505-20 [T4F] ...................... Page 24-11

For: Dana 211 Series, Dana 211 Series LSD
................................................... Page 24-12
(For: 505-20 [T4F])
Figure 595. Service Brake
A Brake pack B Brake cylinder reservoir

C Master cylinder D Pedal
The service brake acts on the brake pack on the The brake cylinder reservoir is situated outside of the
front axle half shafts of the machine. The brakes are cab, below the front windscreen.
oil immersed, multi-disc types which are operated
hydraulically by a single pedal and master cylinder
arrangement.
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24 - Brake System
03 - Service Brake
00 - General
(For: Dana 211 Series, Dana 211 Series LSD)
Service Brake Applied
Figure 596.
A P2 P3 P1
B
A Service brake discs compressed B Moving components colour code

C Oil filling colour code D Disc washer compressed
E Differential discs locked P1 Park brake release pressure
15–30bar (217.4–434.8psi)
P2 Service brake release pressure - maximum P3 No pressure
80bar (1,159.4psi)
24 - 12 9823/0300-1 24 - 12
24 - Brake System
03 - Service Brake
00 - General
Differential Lock Applied
Figure 597.
A
P2 P3 P1
B
A Service brake discs free B Moving components colour code

E Differential discs locked P1 Park brake release pressure
15–30bar (217.4–434.8psi)
P2 No pressure P3 100% differential lock pressure
15–25bar (217.4–362.3psi)
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24 - Brake System
03 - Service Brake
00 - General
Check (Leaks)
Refer to bleed, (PIL 24-03).
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24 - Brake System
03 - Service Brake
00 - General
Bleed
WARNING Before proceeding with the bleed 6.1. If pressure drops there are leaks in the
procedure it is important to make sure that the system which must be rectified before trying
park brake is engaged and that one pair of wheels to bleed the system.
is chocked on both sides.
7. Unscrew the bleed nipple on the front axle a few
WARNING Use of incorrect fluid will cause turns until fluid flows. When the fluid is free from
serious damage to the seals which could in turn bubbles tighten the nipple and replace protective
cause brake failure. cap.
CAUTION It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or 7.1. Use a suitable container to catch the fluid
lubricants. escaping from the nipple and dispose of
in the correct manner according to local
Used fluids and/or lubricants, filters and regulations.
accordance with local regulations. Use authorised 8. If the machine has trailer brakes, unscrew the
waste disposal sites. bleed nipple on the trailer brake valve a few
turns until fluid flows. When the fluid is free
1. Make the machine safe. Refer to (PIL 01-03). from bubbles tighten the nipple and replace the
protective cap.
2. Fill the brake fluid reservoir with the correct fluid.
Refer to technical data, (PIL 75-00-00). 9. Release the pressure from brake bleeder by
pressing down on the release button.
2.1. Make sure the level does not fall below the
minimum mark on the reservoir during this 10. Remove cap on the brake bleeder from reservoir
procedure. on machine and install the original cap.
3. Install a brake bleeding unit to the reservoir. 11. Before driving the machine test the brake pedal.
The first pedal press should stop the specified
4. Make sure that all brake bleed nipples are distance from the floor (dimension X). The
closed. specified distance is
5. Pressurise the brake system to the specified Length/Dimension/Distance: 50mm

pressure using the pump on the bleeding unit. 11.1. If the pedal travel is further than this, the
Pressure: 0.69bar (10.0psi) brakes should be re-bled.
6. Using the gauge on the brake bleeding unit 12. Make sure the brake reservoir is topped up to the
make sure that the pressure is maintained in the maximum level mark when the system has been
system for a few minutes. bled correctly.
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24 - Brake System
03 - Service Brake
00 - General
Figure 598.
1 Brake fluid reservoir 2 Brake bleeding unit

3 Pressure gauge 4 Bleed nipple (front axle)
5 Front axle 6 Trailer brake valve
7 Bleed nipple (trailer brake valve) 8 Pressure release button (brake bleeding unit)
9 Brake pedal X Dimension X (distance from the floor)
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24 - Brake System
03 - Service Brake
00 - General
For details of Dana special tools, refer to after sales,

(For: Dana 211 Series) non JCB tools, Dana axle, (PIL 78-94-60).
Special Tools Disassemble

Hand Pump Pressure 892/00223 1 1. Make the machine safe. Refer to (PIL 01-03).
Test
2. Remove the axle from the machine. Refer to (PIL
Pressure Gauge (0-70 892/00346 1 27-20).
Bar)
3. Drain the oil from the drive head.
Consumables
Description Part No. Size 3.1. Before draining oil make sure to loosen
JCB Threadlocker 4101/0250 0.01L the oil filling plug or the breather (if
and Sealer (Medium present), and wait until the internal pressure
4101/0251 0.05L is completely released. Remove the oil
Strength)
draining plug and drain oil only when the
WARNING When removing the piston, make sure pressure is completely released.
you use low air pressure as the piston may 4. Connect a pump and pressure gauge to port P1
suddenly eject. Take care not to injure yourself or of the negative brake system on the axle. Using
damage the piston. the pump increase the pressure to the specified
WARNING Fine jets of fluid at high pressure can value to release the pressure on the braking
penetrate the skin. Keep face and hands well system.
clear of pressurised fluid and wear protective Pressure: 15 ± 30bar (217.4 ± 434.8psi)
glasses. If fluid penetrates your skin, get medical Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
help immediately. Special Tool: Hand Pump Pressure Test (Qty.: 1)
Do not attempt any maintenance if the axle is hot. Hot 5. Loosen the negative brake locking screws and
oil and components can cause personal injury. Avoid remove the spacers.
skin contact. Wear protective gloves and glasses.
24 - 17 9823/0300-1 24 - 17
24 - Brake System
03 - Service Brake
00 - General
Figure 599.
A Spacers B Negative brake locking screws
6. Release the pressure from the pump to port P1 7. Install the negative brake locking screws without
gradually until no pressure remains. the spacers.
24 - 18 9823/0300-1 24 - 18
24 - Brake System
03 - Service Brake
00 - General
Figure 600.
8. Remove the pressure gauge and pump from the Figure 601.
axle.
9. Remove the axle driveshaft. Refer to (PIL 27-51).
10. Mark the installation position of the axle arm with
respect to the drive head case.
11. Using suitable lifting equipment support the
weight of the axle arm.
12. Remove the axle arm securing bolts and remove
the arm from the drive head case.
24 - 19 9823/0300-1 24 - 19
24 - Brake System
03 - Service Brake
00 - General
13. To keep the disc springs of the negative brake 16. Using a suitable M12 puller remove the brake
compressed, install screws and washers of the piston assembly module.
specified size and tighten until the screw reaches
the end stop. Screw size: M12 x Figure 605.
Figure 602.
Figure 606.
14. Remove the negative brake locking screws.

Always replace the O-ring.
Figure 603.
17. Make sure the locking screw is present.
B Figure 607.
A Negative brake locking screws

B O-ring
15. Remove the spring compression screws A
previously installed.
Figure 604.
A Locking screw
18. Put a mark on the intermediate disc and
the piston assembly module to aid correct
positioning during assembly.
19. Remove the intermediate disc.
24 - 20 9823/0300-1 24 - 20
24 - Brake System
03 - Service Brake
00 - General
A Intermediate disc
20. Using compressed air into the hole shown 23. Put a mark on the slotted nut and brake module
remove the service brake piston from the to aid correct positioning during assembly.
module.
Figure 612.
Figure 609.
A Piston assembly module 24. Remove the slotted nut.

B Service brake piston
Figure 613.
21. Using compressed air into the hole shown
remove the three pins from the module.
Figure 610.
A
A
A Slotted nut
B 25. Remove the disc springs.

A Pin
B Third hole from the top
22. Using a punch remove the roll pin securing the
slotted nut on the underside of the brake module.
24 - 21 9823/0300-1 24 - 21
24 - Brake System
03 - Service Brake
00 - General
A
B
J K
G H
C D E F
A Disc springs
26. Using compressed air into the hole shown M
remove the negative brake piston from the
module.
Figure 615.
A M
L
A Hydraulic block piston (If installed)
C Back-up ring
D O-ring
B E Back-up ring
A Negative brake piston F O-ring
B Hole G O-ring
H Back-up ring
27. Make a note of the correct positions of the O- J Back-up ring
rings and back-up rings. Remove and discard. K O-ring
L Negative brake piston
M O-rings
28. Remove the circlip from the intermediate disc.
Figure 617.
A Circlip
B Intermediate disc
24 - 22 9823/0300-1 24 - 22
24 - Brake System
03 - Service Brake
00 - General
29. Remove the coupling and washers from the Figure 620.
intermediate disc.
30. Measure and make a note of the height of the
washers when built up together.
A
Figure 618.
C
B
A Intermediate disc
B Washers
C Coupling
31. Using a suitable puller compress the spring.
Figure 619.
A Circlip
B Fixing ball
33. Slowly release the pressure on the spring by
unscrewing the puller.
A 34. Remove the spring and washer.

Figure 621.
A Spring
32. With the spring safely compressed remove the
circlip and fixing ball.
B
A Washer
B Spring
35. Remove the circlip from the brake pack.
24 - 23 9823/0300-1 24 - 23
24 - Brake System
03 - Service Brake
00 - General
36. Remove the brake discs one by one. Make sure

to record the sequence of the brake discs to aid
assembly.
Figure 623. B
A Circlip
B Fixing ball
B 3. Rotate the circlip until the gap is aligned with the

centre of the fixing ball.
A Friction disc Figure 626.
B Intermediate brake disc
Assemble
1. Install the spring and washer onto the coupling.
Figure 624.
B A
A
A Circlip
B B Fixing ball
4. Install new O-rings and back-up rings.
A Washer
B Spring
2. Using a suitable puller compress the spring and
install the circlip and fixing ball.
24 - 24 9823/0300-1 24 - 24
24 - Brake System
03 - Service Brake
00 - General
A Pin
B O-ring
Figure 628.
6. Using a soft faced hammer, install the service
A brake piston.
B
Figure 630.
J K
G H
C D E F A
A Service brake piston

7. Install the intermediate disc making sure to align
the alignment pins and the marks made during
disassembly.
Figure 631.
M
L A
A Hydraulic block piston
C Back-up ring
D O-ring
E Back-up ring
F O-ring
G O-ring
H Back-up ring
J Back-up ring
K O-ring
A Intermediate disc
L Negative brake piston
M O-rings 8. Install the negative brake piston to the underside
of the piston assembly module.
5. Install new O-rings onto the pins and install the
pins into the piston assembly module.
24 - 25 9823/0300-1 24 - 25
24 - Brake System
03 - Service Brake
00 - General
Figure 632. 10.4. Measure the height difference between

the top of the brake pack discs and
the top of the negative brake disc. This
should be the same as value "A". The disc
A springs must not be installed to check this
measurement.
Figure 635.
A Negative brake piston

9. Install the slotted nut and rotate to tighten for 5
whole turns.
Figure 633.
X5
10.5. To calculate the adjustment value (A) use

A
the formula: 141 - (minus) D + (plus) G = A
10.6. Example : D (44.7) + (plus) G (1.4) = 46.1.
10.7. If the measurement is incorrect turn
the slotted nut to get the correct
measurement.
11. Before removing the slotted nut to install the
springs measure and record the dimension of "Z"
to make sure the slotted nut is replaced in the
A Slotted nut correct position.
10. Measure the height of the brake pack discs Figure 636.
(intermediate brake discs and friction discs
combined).
10.1. This measurement is to be recorded as
Z
"D".
10.2. Add value D to value "G" (brake
clearance).
10.3. Example : D (44.7) + (plus) G (1.4) = 46.1.
Figure 634.
12. Get access to the base of the piston assembly

module and install the intermediate disc.
Make sure to align the marks made during
disassembly.
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24 - Brake System
03 - Service Brake
00 - General
A Intermediate disc
13. Select a pack of washers of the specified total 16. Install the brake discs in the correct sequence.
thickness.
16.1. The first disc installed will be a friction disc.
Dimension: 1.5mm
16.2. The final disc to be installed will be an
Figure 638. intermediate disc.
Figure 641.
A
B
A Washers
14. Install the washers and coupling in to the piston A Friction disc
assembly module. B Intermediate brake disc
Figure 639. 17. Set the depth gauge to zero when aligned with
the surface of the brake discs and the top face
of the coupling.
17.1. Press the disc pack several times to make
sure the discs are correctly seated.
A
17.2. Measure the distance "M" between the
B brake disc surface and the thrust bearing.
17.3. Calculate the clearance required using the
formula R = M + (plus) G - (minus) L.
17.4. Example : M (36.4) + (plus) G (1.4) - L
(37.5) = R
C Length/Dimension/Distance: 0.3mm
17.5. Using the value "R" calculate the thickness
15. Measure and record the dimension "L". of the shims required.
17.6. Measure the dimension "M" and replace
shims until the correct value of "R" is as
specified.
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24 - Brake System
03 - Service Brake
00 - General
17.7. When dimension "R" is correct install the Figure 643.

retaining ring.
Figure 642.
A
A Intermediate disc
19. Get access to the top of the piston assembly
module and remove the slotted nut.
20. Install the disc springs in the correct position.
21. Install the slotted nut to the correct position as
M = 36.4 mm determined in measurement "Z".
22. Install the slotted nut roll pin.
Figure 644.
A
A Roll pin
B 23. Install two M12 screws to aid assembly of piston

module into casing.
A Shims
B Retaining ring Figure 645.
18. Install the assembled intermediate disc.
24 - 28 9823/0300-1 24 - 28
24 - Brake System
03 - Service Brake
00 - General
24. Check the locking screw is present in the piston Figure 648.
module.
Figure 646.
27. Install two screws of the specified size. M12 x

A Locking screw Length/Dimension/Distance: 45mm
25. Install the piston module into the casing. 28. Tighten the screws alternately to the correct
torque.
25.1. Make sure that the groove in the module
is aligned with the locking screw in the Torque: 45N·m
casing.
Figure 649.
25.2. Make sure that the input holes are to be
facing the top of the casing when the axle
is in position. 45 Nm
Figure 647.
29. Install the negative brake locking screws. Always

replace the O-ring.
Figure 650.
A
A
B
A Piston module assembly
A Negative brake locking screws
26. Using a soft faced hammer on the M12 screws B O-ring
alternately, install the piston module fully in the
casing and remove the screws. 30. Remove the assembly screws.
24 - 29 9823/0300-1 24 - 29
24 - Brake System
03 - Service Brake
00 - General
Figure 651. Consumable: JCB Threadlocker and Sealer

(Medium Strength)
35. Install the axle arm screws.
36. Tighten the screws alternately to the correct
torque.
Torque: 128N·m
Figure 653.
128 Nm
31. Lubricate and install new O-ring.

Figure 652.
37. Connect a pump and pressure gauge to port P1

of the negative brake system on the axle. Using
the pump increase the pressure to the specified
value to release the pressure on the braking
system. Maximum
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
Special Tool: Hand Pump Pressure Test (Qty.: 1)
32. Using suitable lifting equipment support the 38. Loosen the negative brake locking screws and
weight of the axle arm. install the spacers.
33. Install the axle arm to the drive head casing. 39. Tighten the negative brake locking screws to the
correct torque.
34. Apply threadlocker to the axle arm screws.
Torque: 95–115N·m
24 - 30 9823/0300-1 24 - 30
24 - Brake System
03 - Service Brake
00 - General
Figure 654.
40. Release the pressure from the pump to port P1

gradually until no pressure remains.
41. Remove the pressure gauge and pump from the
axle.
41.1. Make sure that the hydraulic pressure is
discharged completely before removing
the external pump sleeve connected to the
brake.
24 - 31 9823/0300-1 24 - 31
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Remove and Install

Disassemble and Assemble .......................... 24-34
Remove
01-06).
2. Remove the instrument panel.
3. Remove the clip and clevis pin to disconnect
the master cylinder operating rod clevis from the
brake pedal mechanism.
4. Disconnect the plastic feed pipe from the brake
fluid reservoir and either blank off the pipe or
drain the reservoir.
5. Disconnect the master cylinder output pipe. Plug
the cylinder port and blank off the hose (or pipe)
to prevent ingress of dirt.
6. Remove nuts and bolts and lift the master
cylinder clear of the machine.
Install
procedure and additionally follow the step(s)
below:
1.1. Once the master cylinder is installed and
the pipework connected, check the brake
fluid reservoir and then bleed the brake
system. Refer to (PIL 24).
1.2. Tighten the nuts and bolts to the specified
torque. The specified torque is
Torque: 43N·m
1.3. Check the operation of the brake light
switch. Adjust if necessary, refer to (PIL
24-03-50).
24 - 32 9823/0300-1 24 - 32
24 - Brake System
03 - Service Brake
Figure 655. Master Cylinder
A C
D
A Master cylinder operating rod clevis B Nuts and bolts

C Plastic feed pipe D Master cylinder output pipe
E Master cylinder F Clip
24 - 33 9823/0300-1 24 - 33
24 - Brake System
03 - Service Brake
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 34 9823/0300-1 24 - 34
24 - Brake System
03 - Service Brake
03 - Tank
03 - Tank Figure 656.
Remove and Install
Remove A
1. Make the machine safe, refer to (PIL 01-03).
2. Remove the ignition key so the machine cannot
be started.
3. Seal the tube using the correct hose clamp.
4. Remove tube from the tank. Put a cap on the pipe B
on the bottom of the tank.
4.1. Use a suitable container to catch any
leakage.
5. Support the tank and remove the bolts.
6. Remove the tank. Make sure you keep the tank
vertical.
Install
procedure and additionally follow the steps
below.
C
1.1. Examine the tube. If it is defective replace
it with a new one.
1.2. Torque tighten the bolts to the specified
torque. The specified torque is A Tank
B Bolts
Torque: 9N·m C Tube
1.3. Bleed the brakes. Refer to (PIL 24-03-00).
24 - 35 9823/0300-1 24 - 35
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-36
Technical Data ............................................... 24-37
Brake Piston Seal Leakage
Check (Condition) .......................................... 24-37 The most common reason for internal piston seal
Disassemble and Assemble .......................... 24-38 leakage is a build-up of axle contamination. It is
caused as a result of excessive brake wear caused
by extended service periods.
Two types of internal leakage can occur within the

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

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

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

without disassembling the axle. Refer to brakes-
service brake, refer to (PIL 24-03).
Make sure that you do the leak test only when the
axle is cold.
24 - 36 9823/0300-1 24 - 36
24 - Brake System
03 - Service Brake
39 - Piston
Technical Data Check (Condition)

Special Tools
Refer to brakes- general, refer to (PIL 24-00). Description Part No. Qty.
Hand Pump Pressure 892/00223 1
Test
Pressure Gauge (0-70 892/00346 1
Bar)
Brake Piston Gap Check

1. Remove negative brake locking screws.
2. Install the special tool (910.07.0001) into the seat
of the manual release where the screws were
installed. For tool details refer to (PIL 78-94-60).
Figure 657.
T1 Special tool - Dana part number - 910.07.0001

3. Install a DTI (Dial Test Indicator) into the special
tool and set it to the specified distance.
Dimension: 1mm
4. Using a hand pump and pressure gauge
introduce the specified pressure to the following
ports: maximum
Special Tool: Hand Pump Pressure Test (Qty.: 1)
4.1. Port P1 - parking brake port. Check the
reading on the DTI, the needle must not
move more than the specified dimension
when the pressure is applied.
Dimension: 0.1mm
4.2. Port P2 - service brake port. Check the
reading on the DTI, the needle must not
move more than the specified dimension
when the pressure is applied.
Dimension: 0.1mm
24 - 37 9823/0300-1 24 - 37
24 - Brake System
03 - Service Brake
39 - Piston
Figure 658. Disassemble and Assemble
Refer to driveline- front axle, refer to (PIL 27-20).
P2 P1
B2 B1
P3
4.3. Make sure to check for any leaks of

hydraulic fluid. Fine jets of fluid under
pressure can be dangerous.
24 - 38 9823/0300-1 24 - 38
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit
Check (Leaks)
Refer to (PIL 24-03-46).
24 - 39 9823/0300-1 24 - 39
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump Check (Leaks)

Check (Leaks) ............................................... 24-40 The procedure explains how to determine if the brake
Remove and Install ....................................... 24-42 servo vacuum system is functioning correctly.
The following test equipment is used to carry out this

test:
• Vacuum gauge (range up to 1 bar).

• T-adaptor.
• Vacuum hose- 2 lengths x 75 mm (3 inch) long.
• Clips- worm drive.
Brake Vacuum Test (if applicable)

2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Disconnect the brake vacuum line at the brake
vacuum pump and connect a vacuum gauge
directly to the pump.
3.1. The location of the vacuum pump may
differ depending on the specification of your
machine.
4. Run the engine at 1500 RPM (Revolutions Per
Minute) and note the reading on the vacuum
gauge:
4.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
4.2. If there is little or no vacuum, renew the
vacuum pump.
5. Remove the vacuum gauge from the pump port
and connect it again into the brake vacuum line
using a T-adaptor.
6. Run the engine at 1500 RPM and note the
reading on the vacuum gauge:
6.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
6.2. If there is little or no vacuum, check the
vacuum hose connections for leaks.
6.3. Check the security of the clips and then do
step 7.
7. Switch OFF the engine and monitor the vacuum
gauge reading:
7.1. Make sure that the mercury (Hg) level stays
above the specified value after 60 seconds.
24 - 40 9823/0300-1 24 - 40
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
7.2. Check that the vacuum is sufficient for 3 or 4

pedal operations. The vacuum must decay
slowly with each pedal operation.
8. The brake vacuum pump and brake servo unit
are non-serviceable parts. If they are suspected
as being faulty, install new parts.
Figure 659. Typical Vacuum Pump Installation
A Brake vacuum line

B T-adaptor
24 - 41 9823/0300-1 24 - 41
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Remove and Install
If the brake performance is poor and the brake servo 8. Install a cap on the open ends of the hoses to
vacuum is suspected, do the brake vacuum test prevent the ingress of dirt. Tie the hoses out of
before you install a new servo exhauster unit. Refer the way.
to brakes- service brake. Refer to (PIL 24-03).
9. Remove the screws and carefully take out the
servo exhauster unit from the engine. Discard the
Remove gasket.
1. Make the machine safe. Refer to (PIL 01-03)
Install
Refer to (PIL 01-03). The servo exhauster unit is a non-serviceable part. If
it is suspected as being faulty it must be renewed as
3. Disconnect the battery. Refer to (PIL 33-03). a complete assembly.
4. Open the engine compartment cover. Refer to
The special adaptor is installed with an oil feed
(PIL 06-06).
restrictor orifice (3 mm diameter). Check to make
5. Access to the servo exhauster unit is limited. If sure that the orifice is not blocked before installing
necessary remove the machine cooling pack to the servo exhauster unit.
gain sufficient access. Refer to (PIL 21-03).
6. Remove the clip and release the brake vacuum removal procedure. Additionally do the following
hose from the pipe stub. steps.
7. Disconnect the oil feed hose.
24 - 42 9823/0300-1 24 - 42
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Figure 660.
A
B
A Vacuum hose B Pipe stub

C Oil feed hose D Screw
E Gasket F Adaptor
G Gear
1.1. Make sure that the servo exhauster unit

flange and the engine mating face is clean.
Install a new gasket.
1.2. Carefully align the gear so that the gear
teeth engages with the drive gear in the
engine.
1.3. Tighten the screws to the specified torque
value.
1.4. On completion, test the brakes.

Item Nm
D 47
24 - 43 9823/0300-1 24 - 43
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-44 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-45 harness.
Figure 661.
3 2 1 3 2 1
24 - 44 9823/0300-1 24 - 44
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 663.
Brake Light Switch- Proximity Type
Figure 662.
D
E F
F
C
B
D Brake light switch
E Metal vane
F Switch faces
1. This type of switch is not adjustable.
2. If a switch failure is suspected, check all
associated wing and connectors for damage.
3. Make sure the vane moves between the switch
faces when the brake pedal is pressed.
4. If the switch does not work, it must be renewed.

Item Nm
A Proximity sensor C 20
B Brake lever
C Locknut
1. Set the ignition switch to the on position, do not
start the engine.
2. Adjust the proximity sensor to the correct
clearance between the sensor face and the edge
of the brake lever.
Length/Dimension/Distance: 2–3mm
3. Tighten the locknut to the correct torque.
4. Press the brake pedal and check that the sensor
operates (brake light illuminates) when the brake
pedal has travelled the correct distance. Check
that the sensor remains on throughout the rest of
the travel.
Length/Dimension/Distance: 10–15mm
5. Check that the brake lights illuminate when the
brake pedal is pressed.
24 - 45 9823/0300-1 24 - 45
24 - Brake System
03 - Service Brake
50 - Light Switch
Remove and Install
Remove 4. Disconnect the electrical connector from the

panel harness.
5. Hold the switch and remove the screw.
Refer to (PIL 01-03). 6. Remove the switch from the bracket.
3. Press the brake pedal.
Figure 664.
A Electrical connector B Bracket

C Screw D Switch
24 - 46 9823/0300-1 24 - 46
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 47 9823/0300-1 24 - 47
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-49

24-18-12 Control Valve .................................................................................................................. 24-56
24-18-21 Disc ................................................................................................................................ 24-57
24 - 48 9823/0300-1 24 - 48
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-49 The park brake also called the hand brake is a
Technical Data ............................................... 24-50 latching brake usually used to keep the vehicle
Component Identification ............................... 24-51 stationary. It is also used to prevent a vehicle from
Operation ....................................................... 24-52 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Check (Operation) ......................................... 24-54
Bleed ............................................................. 24-55 The park brake usually consists of a cable directly
connected to the brake mechanism on one end, and
to a hand-operated lever, on the floor at the side of
the driver.
24 - 49 9823/0300-1 24 - 49
24 - Brake System
18 - Park Brake
00 - General
Technical Data
Table 196.
Type Wet disc brake on front axle (6 disc wellman), (Spring
applied, hydraulic release).
Free play 1.4mm
Release pressure 25bar (362.3psi)
24 - 50 9823/0300-1 24 - 50
24 - Brake System
18 - Park Brake
00 - General
Figure 665.
1
C
32
3
D
1
B
2
A Parkbrake lever B Front axle

C Parkbrake solenoid D Parkbrake valve
24 - 51 9823/0300-1 24 - 51
24 - Brake System
18 - Park Brake
00 - General
Operation
brake valve to supply pressure to the parkbrake on

The park brake system is a SAHR (Spring applied the axle.
Hydraulic Release) type.
The hand brake lever is modular i.e. in the forward
The brake pack in the front axle is always applied via position the hand brake is fully off and in the rear
spring pressure. Hydraulic pressure supplied from position the hand brake is fully on and the whole
the park brake valve overcomes the spring pressure lever movement in between progressively applies /
to release the parkbrake. releases the hand brake. The two notched positions
are to hold the lever in the off and on position but are
A lever in the cab sends a PWM (Pulse Width soft enough that in the case on an emergency and
Modulation) signal to the ECU (Electronic Control the hand brake is to be used to stop the machine it
Unit) to operate the proportional solenoid on the park can be applied smoothly to prevent a sudden sharp
deceleration of the machine.
Park Brake Applied
Figure 666.
A
P2 P3 P1
A Service brake discs locked B Disc washer extended

C Differential discs locked P1 No pressure
P2 No pressure P3 No pressure
24 - 52 9823/0300-1 24 - 52
24 - Brake System
18 - Park Brake
00 - General
Park Brake Released
Figure 667.
A
P2 P3 P1
B
A Service brake discs free B Moving components colour code

E Differential discs lightly compressed P1 Park brake release pressure
15–30bar (217.4–434.8psi)
P2 No pressure P3 No pressure
24 - 53 9823/0300-1 24 - 53
24 - Brake System
18 - Park Brake
00 - General
Check (Operation)
Lever Output
Solenoid Test
1. Remove the lever from the cab trim and measure
1. Using the applicable test equipment test the mA the cross track voltage- the reading should be in
supplied to the parkbrake valve solenoid on the the specified range. The specified range is
parkbrake valve with the parkbrake lever in the Voltage: 0.5–4.5V
released position.
1.1. If not within this range check the supply to
2. The reading should be within the range shown in the lever. If the lever is faulty, install a new
the table. Refer to Table 197. one.
2.1. A different reading indicates a faulty supply
to the solenoid. Hydraulic Pressure Test
1. Install a pressure gauge into the port on the
parkbrake valve.
Table 197. Test Values

Parkbrake Status Engine Speed Measured Pressure Measured Current
Parkbrake Engaged Idle Tank Pressure 0
Flight Tank Pressure 0
Parkbrake Disengaged Idle 22.5 ± 2.5 (326.1 ± 36.2) 1.125A
Flight 22.5 ± 2.5 (326.1 ± 36.2) 1.125A
Figure 668.
2
1
4
1 Parkbrake lever 2 Parkbrake valve solenoid

3 Parkbrake valve 4 Port (pressure gauge)
24 - 54 9823/0300-1 24 - 54
24 - Brake System
18 - Park Brake
00 - General
Bleed
WARNING Before proceeding with the bleed 2.1. Make sure the level does not fall below the
procedure it is important to make sure that the minimum mark on the reservoir during this
park brake is engaged and that one pair of wheels procedure.
is chocked on both sides.
3. Switch on the engine.
WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn 4. Release the park brake lever.
cause brake failure.
5. Close and lock the cab door.
CAUTION It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or 6. Unscrew the bleed nipple on front axle a few
lubricants. turns until fluid flows. Catch the escaping fluid in
Used fluids and/or lubricants, filters and a suitable container. When the fluid is free from
contaminated materials must be disposed of in bubbles, tighten the nipple and replace protective
accordance with local regulations. Use authorised cap.
7. Top up the brake fluid reservoir to the maximum
mark.
2. Fill the brake fluid reservoir with the correct fluid.
Refer to technical data, (PIL 75-00-00).
Figure 669.
A Parkbrake lever B Front axle

C Bleed nipple
24 - 55 9823/0300-1 24 - 55
24 - Brake System
18 - Park Brake
12 - Control Valve
12 - Control Valve
Remove and Install
5. Remove the bolts and lift the valve from the

Remove machine.
1. Make the machine safe with the lift arm lowered. Install
2. Disconnect the harness from the solenoid procedure and additionally follow the step(s)
electrical connector. below:
3. Label the hydraulic hoses to help identification 1.1. Check the brake fluid reservoir level.
when re-installing the hoses.
1.2. Bleed the service and park brake system.
4. Disconnect the hydraulic hoses. Plug the cylinder Refer to (PIL 24).
port and blank off the hose (or pipe) to prevent
the ingress of dirt.
Figure 670.
1
1 Electrical connector- solenoid 2 Lift valve

3 Bolts 4 Hydraulic hoses
24 - 56 9823/0300-1 24 - 56
24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc
Introduction
A disc brake is a wheel brake that slows the rotation

of the wheel by the friction caused by pushing brake
pads against a brake disc with a set of calipers.
24 - 57 9823/0300-1 24 - 57
Notes:
24 - 58 9823/0300-1 24 - 58
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-00-03 Manual Steer Mode System .......................................................................................... 25-17
25-00-06 Auto Steer Mode System ............................................................................................... 25-28
25-01 Pump
25-01-00 General ........................................................................................................................... 25-37
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-39
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-41
25-09 Mode Valve
25-09-06 Auto Mode Valve ............................................................................................................ 25-47
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-53
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-55
25-33 Link Arm
25-33-00 General ........................................................................................................................... 25-57
9823/0300-1
2017-11-13
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
9823/0300-1
2017-11-13
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3

25-00-03 Manual Steer Mode System .......................................................................................... 25-17
25-00-06 Auto Steer Mode System ............................................................................................... 25-28
25 - 1 9823/0300-1 25 - 1
Notes:
25 - 2 9823/0300-1 25 - 2
00 - General

Health and Safety ........................................... 25-3 Engine/Steering Failure
Technical Data ................................................. 25-4 If the engine or steering fails, stop the machine as
Component Identification ................................. 25-5 quickly as possible. Do not operate the machine until
Operation ......................................................... 25-6 the fault has been corrected.
Diagram ........................................................... 25-8 Working Under the Machine
Fault-Finding .................................................... 25-9 Make the machine safe before getting beneath it.
Check (Leaks) ............................................... 25-12 Make sure that any attachments on the machine are
Check (Pressure) .......................................... 25-13 correctly attached. Engage the park brake, remove
Adjust ............................................................ 25-14 has wheels use blocks to prevent unintentional
Bleed ............................................................. 25-15 movement.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help
immediately.
Hydraulic Pressure
Before connecting or removing any hydraulic hose,
removing hoses. Make sure the engine cannot be
started while the hoses are open.
WARNING! When getting access for maintenance
work, make sure no-one is in a position to be caught
and/or crushed by the wheels when the steering
wheel is turned.
25 - 3 9823/0300-1 25 - 3
00 - General
Technical Data
Table 198.
Description Data
Maximum system pres- 190 -0/+7bar
sure (2,753.6 -0.0/+101.4psi)
Maximum back pressure 21bar (304.3psi)
Rated flow 23L/min
Temperature range -20–93°C (-4.0–199.3°F)
Load sense relief valve 165 -0/+7bar
pressure P-T (2,391.3 -0.0/+101.4psi)
at 23L/min
Cylinder relief valve 225 -0/+7bar
pressure R/L- T (3,260.9 -0.0/+101.4psi)
at 23L/min
Displacement 100 cc
Input torque (powered) 1.3–2.2N·m
Input torque (non-pow- 136N·m
ered)
25 - 4 9823/0300-1 25 - 4
00 - General
Figure 671. Basic Steering System
332/ G6412
G G
F G G
A Steer Unit B Steer Isolation Valve

C Priority Valve D Hydraulic Pump
E Steering Wheel F Steering Column
G Power Track Rods
25 - 5 9823/0300-1 25 - 5
00 - General
Operation
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 675. Gear pump type valve shown
LS P EF
LS
A
B
P EF
orifice 2, onto the end of the priority valve spool. This

creates a large pressure difference across the spool,
Table 199. causing it to move up against the force of the spring.
Item Description This allows the full pump flow to be directed through
port (EF) back to the tank or join with the main flow
A Pump outlet
to the control valve.
B Orifice 1
C Priority valve spool Turning
D Orifice 2
E Steering unit When the steering wheel is turned, a pressure signal
is generated in the load sense line from the steering
P Pressure line
unit.
LS Load sense line
EF Port Pressure is then applied to the spring end of
the priority valve spool. This reduces the pressure
When the steering is not being operated, flow to the difference across the spool, causing it to move down
steering circuit is dead ended by the closed centre under spring force. This allows some of the pump
steering unit, and no pressure signal (demand) is outlet flow to be directed through the pressure port
generated in the load sense line. Pressure from the to the steering unit, which in turn directs the flow to
pump outlet is directed through the orifice 1 and the corresponding steer rams to turn the wheels.
25 - 6 9823/0300-1 25 - 6
00 - General
Figure 676. Gear pump type valve shown
LS P EF
LS
A
B
P EF
Table 200.
Item Description
A Pump outlet
B Orifice 1
C Priority valve spool
D Orifice 2
E Steering unit
P Pressure line
LS Load sense line
EF Port
The excess flow goes through the port (EF) back to

the tank or joins with the main flow to the control.
When the steering reaches the required position,

the pressure signal in the load sense line from
the steering unit ceases and restore the pressure
difference across the spool. The spool moves back
up and allow the pump full flow to be directed through
port (EF) back to the tank or joins with the main flow
to the control valve.
The maximum steering system pressure is set by a

relief valve located inside the steering unit.
25 - 7 9823/0300-1 25 - 7
00 - General
Diagram
Figure 677. Permanent 4WS Circuit

3
4 5
2a
1a
1 Hydraulic Pump 1a Priority Valve

2 Steer Unit 2a Steering System Relief Valve
3 Steer Isolation Valve 4 Power Track Rod- Front Axle
5 Power Track Rod- Rear Axle 6 Hydraulic Tank
25 - 8 9823/0300-1 25 - 8
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 201. Page 25-9
Steering wheel turns on its own. Table 202. Page 25-9
Machine will not turn when the steering wheel turned. Table 203. Page 25-9
Steering 'drifts' out of phase during operation. Table 204. Page 25-10
Steering fails to respond to selected mode (solenoid operated mode valve Table 205. Page 25-10
only).
Table 201. Steering wheel difficult to turn

Cause Remedy
Tyres not inflated to correct pressure. Inflate tyres to correct pressure.
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
required. Refer to (PIL 30-00).
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00 ).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 30-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. Check if the priority valve is sticking (contamination)
rectify as required. Check the load sense line from
the steer unit to the priority valve for signs of leaking
or poor connection. Refer to (PIL 25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Refer
to the Steer Mode Valve topic. Check if solenoids
operating, replace solenoids as required. Refer to
(PIL 25-00).
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00).
Table 202. Steering wheel turns on its own.

Cause Remedy
Dirt in the steer control unit (causing sleeves to stick Clean and inspect unit. Refer to (PIL 25-06).
open).
Steer control valve centring springs damaged, Check steer unit. Refer to (PIL 25-06).
broken or missing.
Steer control valve- position of rotor to shaft slot Correct as required. Refer to (PIL 25-06).
incorrect.
Table 203. Machine will not turn when the steering wheel turned.
Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
required. Refer to (PIL 30-00)
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 25-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
25 - 9 9823/0300-1 25 - 9
00 - General
Cause Remedy
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. – Check if the priority valve is sticking
(contamination) rectify as required. Check the load
sense line from the steer unit to the priority valve for
signs of leaking or poor connection. Refer to (PIL
25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Check if
solenoids operating, replace solenoids as required.
Refer to (PIL 25-00)
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00)
Steer column splined shaft not fully engaged in steer Check shaft engagement. Refer to (PIL 25-12)
valve.
Power track rod/Steer Ram failure. Check power track rod/Steer Ram for signs of
damage, leaks etc. Refer to (PIL 30-15).
Table 204. Steering 'drifts' out of phase during operation.

Cause Remedy
(1) Does steering go out of phase in less than four YES = go to (2), NO = Ensure system is rephased
hours of continuous use? after four hours of continuous use (see Operator's
Handbook).
(2) Does steering go out of phase by a small amount YES = go to 3, NO = go to 4.
and drift no further when changing steer modes?
(3) Ensure operator changes steer mode at low YES = done, NO = Ensure power track-rod piston
engine speed and observes 5 second delay between is centralised and wheel tracking is correct. Adjust
modes (see Operator's Handbook), is it OK now? alignment of steer proximity switches to optimise
accuracy.
(4) Bleed steering system to remove air. Is it OK YES = done, NO = go to 5.
now?
(5) Possible leakage through anti-cavitation valve (if YES = done, NO = go to 6.
fitted). Replace Steer Unit. Refer to (PIL 25-06).
(6) Check both front and rear power track rods YES = done, NO = go to 7.
for internal leakage. Check the seal installation is
correct, check the seal damage, scoring or bore
ovality. Re-seal or renew faulty unit(s). Refer to (PIL
30-15). Is it OK now?
(7) Strip steer mode valve and inspect spool for YES = done, NO = go to 8.
scoring or damage. Renew valve if required. Refer to
(PIL 25-06). Is it OK now?
(8) Check for contamination in the hydraulic system. YES = Filter the hydraulic system. Refer to (PIL
30-00), NO = It is likely that one of the preceding
tests was not conclusive. Go to (1).
Table 205. Steering fails to respond to selected mode (solenoid operated mode valve only).
Cause Remedy
Electrical failure. (The steer mode ECU will generate Check relevant electrical connectors, if problem still
a blink code for some fault conditions). Refer to (PIL persists, do a wiring continuity check on relevant
57-90). circuits.
Selector switch faulty. Check selector switch, replace as required.
Proximity switches not operating correctly. Check operation of proximity switches, adjust or
replace switches as required. Refer to (PIL 25-15).
Steer mode relay not operating correctly. Renew relay. Refer to (PIL 33-09).
25 - 10 9823/0300-1 25 - 10
00 - General
Cause Remedy
Steer mode valve not operating correctly. – Check if spools sticking, rectify as required. Refer
to (PIL 25-06). Check if solenoids operating in
accordance with the mode selected. Refer to (PIL
25-06).
Leaks in the relevant hoses or component Check hoses and connections for leaks.
connections.
ECU failure. The ECU is normally a reliable component and
failure is unlikely. Before renewing the ECU make
sure that all relevant electrical connections and
components are functioning correctly. (Make sure
you do not connect a test meter directly to the pins
on the ECU).
25 - 11 9823/0300-1 25 - 11
00 - General
Check (Leaks) 4. Select the machine in 2WS mode and then close
the ball valves. Measure the length of one side of
the track rod and record the value.
Internal hydraulic leakage check 5. Drive the machine, in a circle, in one direction,
several times. Stop the machine and again
If hydraulic leaks at the steer mode valve or power
measure the track rod length. Compare the
track rods, the steering system will go progressively
measurements.
out of phase, the more the steering is operated the
further the front and rear wheels will drift out of phase. 5.1. If the track rod has moved then it can
be assumed that there is internal leakage
Some drifting out of phase is normal over time and across the piston seals in the power track
the system must be routinely re-phased. Refer to rod. This may be due to defective or
(PIL 25-00). incorrectly installed seals, or a defective
cylinder bore. Disassemble and inspect the
If the system goes out of phase over short periods
power track rod.
of time it is probable that there is hydraulic leakage.
External leakage is obvious and may occur at 5.2. If the track rod has not moved it can be
track rod seals, relevant hoses, pipes and adaptors. assumed there is internal leakage at the
Internal leakage can occur across power track rod steer mode valve.
piston seals or within the steer mode valve.
To check the internal leakage follow the below steps.
• 4WS (Four Wheel Steer) mode faults: Both

front and rear track rods and the steer mode
valve must be checked individually for possible
leakage.
• 2WS (Two Wheel Steer) mode faults: It is
possible to identify fault, if internal leakage is
at the rear power track rod, or steer mode
valve without first removing and dismantling
components. Follow the steps below.
2. Disconnect the hydraulic hoses from the rear
power track rod and Install isolating ball valves
at each port on the track rod and then reconnect
the hoses.
3. Open the ball valves. Start the engine and bleed
the system. Refer to (PIL 25-00).
Figure 678.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 12 9823/0300-1 25 - 12
00 - General
Check (Pressure) 5. If the hydraulic pump flow and pressure tests

are satisfactory, then the priority valve must be
Special Tools renewed.
Digital Pressure Gauge 892/01268 1 Steering Pressure
0-400 bar
Figure 680.
WARNING When getting access for maintenance
work, make sure no-one is in a position to be
caught and/or crushed by the wheels when the
steering wheel is turned.
Standby Pressure
Figure 679.
B C
A
B C
A
E
A Hose 1
B Steer valve port
C Steer valve
2. Turn the steering wheel to the left and to the right
several times to discharge the system pressure.
D
3. Disconnect the hose 1 from the steer valve and
install the specified pressure test gauge and T-
A Hose 1
piece between the hose 1 and the steer valve
B Steer valve port
port B.
C Steer valve
Special Tool: Digital Pressure Gauge 0-400 bar D Plug
(Qty.: 1) E Allen key
4. Set the steering to neutral, i.e. do not turn the 1. Make the machine safe. Refer to (PIL 01-03).
steering wheel, and start the engine.
4.1. The pressure should be as stated. Refer to several times to discharge the pressure.
Technical Data (PIL 25-00-00).
3. Disconnect the hose 1 from the steer valve and
4.2. If the pressure is outside the limits try install the specified pressure test gauge and T-
cleaning the priority valve. piece between the hose 1 and the steer valve
4.3. If cleaning the valve does not rectify the port B.
fault, check the steering pump section flow Special Tool: Digital Pressure Gauge 0-400 bar
rate and pressure. Refer to Technical Data (Qty.: 1)
(PIL 25-00-00).
25 - 13 9823/0300-1 25 - 13
00 - General
4. Run the engine at the specified speed. The Adjust

specified speed is 1500 RPM (Revolutions Per
Minute).
To change the steer mode:
4.1. Turn the steering wheel to full lock. Hold
the wheel on full lock and check the gauge 1. Stop the machine. Select the neutral position on
reading. This should be equal to the relief the forward/reverse lever.
valve operating pressure. Refer to (PIL
25-00-00). 2. Turn the steering wheel until all the wheels are
pointing in the straight ahead position.
4.2. If necessary, adjust the pressure setting by
removing the plug on the hydraulic steer 3. Use the steer mode selector lever to select the
unit. steer mode required.
4.3. Use an Allen key to adjust the valve screw Figure 681.
until the correct pressure is shown on the
gauge. The pressure adjusting screw can
be accessed through a cut-out at the base
of the steering column after you remove the
panels. It may be necessary to remove the
hydraulic steer unit if access is restricted.
4.4. Install the plug. A
A Steer mode selector lever

B 4-wheel steer
C 2-wheel steer
D Crab steer
To align the wheels:
1. Stop the machine. Select the neutral position on

the forward/reverse lever.
2. Use the steer mode selector lever to select 4-
wheel steer.
3. Turn the steering wheel until the rear wheels are
4. Use the steer mode selector lever to select 2-
wheel steer.
5. Turn the steering wheel until the front wheels are
6. All wheels are now pointing straight ahead, select
the steer mode required and continue in the
normal manner.
25 - 14 9823/0300-1 25 - 14
00 - General
Bleed 8. Disconnect the hydraulic hose from the rod side

of the rear steer ram, draining the hydraulic fluid
into a suitable container.
Machines with Permanent Four Wheel 9. Start the engine.
Steer
10. Turn the steering wheel to full right lock.
Figure 682.
11. Stop the engine.
12. Reconnect the rear steer ram rod side hose
332/ G6412
13. Start the engine.

14. Turn the steering wheel to full right lock.
15. Move setting lever to the LOCK position as
shown.
16. Repeat steps 1 to 16 if necessary.
17. Lower the front wheels to the ground and stop
the engine.
18. Top up the hydraulic fluid level as required.
Machines with Manual Steer Mode

System
Whenever any hydraulic steering component is
disconnected or removed the system must be bled
as follows:
With the engine running, the following procedure

must be carried out in the correct order that is laid
down. You must not change the order of selections
and operations.
A Setting lever 1. Select 2 wheel steer.

L Lock position
1.1. Turn the steering wheel to left, until both the
U Unlocked position
front wheels are fully locked to the left.
If a steering system component has been replaced, 1.2. Turn the steering wheel to right, until both
e.g., a steer ram, or after a steering hose burst the the front wheels are fully locked to the right.
following procedure must be followed:
1.3. Turn the steering wheel to left, until both
1. Start the engine. the front wheels are in the straight ahead
position.
2. Carefully raise the front wheels just clear of the
ground. 2. Select 4 wheel steer.
3. Stop the engine 2.1. Turn the steering wheel to left, until the front
wheels are fully locked to the left.
4. Move the setting lever to the Unlocked position
2.2. Turn the steering wheel to the right, until
as shown.
both the front wheels are in the straight
5. Start the engine. ahead position.
6. Turn the steering wheel to full left lock (only the 3. Select 2 wheel steer.
rear wheels will move).
3.1. Turn the steering wheel to full right lock.
7. Stop the engine. 3.2. Turn the steering wheel to full left lock.
25 - 15 9823/0300-1 25 - 15
00 - General
3.4. Turn the steering wheel to left, until both 2.1. Turn the steering wheel to left, until front
the front wheels are in the straight ahead wheels are fully locked to the left.
position.
2.2. Turn the steering wheel to right, until front
4. Select 4 wheel steer. wheels are fully locked to the right.
4.1. Turn the steering wheel to left, until the front 3. Select 4 wheel steer.
wheels are fully locked to the left.
3.1. Turn the steering wheel to left, until front
4.2. Turn the steering wheel to right, until both wheels are fully locked to the left.
the front wheels are in the straight ahead
position. 4. Select 2 wheel steer.
5. Select 2 Wheel Steer. 4.1. Turn the steering wheel to full right lock.
4.2. Turn the steering wheel to full left lock.
5.3. Turn the steering wheel to full right lock. 5. Select 4 wheel steer.
5.4. Turn the steering wheel to left, until both 5.1. Turn the steering wheel to left, until the front
the front wheels are in the straight ahead wheels are fully locked to the left.
position.
6. Select 2 wheel steer.
wheels are fully locked to the left. 6.2. Turn the steering wheel to full left lock.
6.2. Turn the steering wheel to right, until both 6.3. Turn the steering wheel to full right lock.
the front wheels are in the straight ahead 7. Select 4 wheel steer.
position.
7. Select 2 wheel steer. wheels are fully locked to the left.
7.1. Turn the steering wheel to full right lock. 8. Select 2 wheel steer.
7.4. Turn the steering wheel to left, until both
the front wheels are in the straight ahead 8.3. Turn the steering wheel to full right lock.
position. 9. Select 4 wheel steer.
8. Select 4 wheel steer. 9.1. Turn the steering wheel to left, until the front
8.1. Turn the steering wheel to left, until the front and rear wheels are fully locked.
and rear wheels are fully locked. 10. Stop the engine and fill up the hydraulic tank as
9. Stop the engine and fill up the hydraulic tank as necessary.
necessary.
Machines with Manual Steer Mode Valve

(Optional)
Whenever any hydraulic steering component is
disconnected or removed the system must be bled
as follows:
This procedure must be carried out in the correct

order that is laid down. You must not change the
order of selections and operations.

25 - 16 9823/0300-1 25 - 16
03 - Manual Steer Mode System
03 - Manual Steer Mode System Introduction

Introduction .................................................... 25-17 In a manual steer system, there are three steering
Operation ....................................................... 25-18 modes available:
Operation (Electrical) ..................................... 25-24
Diagram ......................................................... 25-26 • 2-wheel steer (front axle only) - only the front
wheels are steered
• 4-wheel steer - both axles are steered, giving a
smaller turning circle
• Crab steer - allows the machine to be driven
diagonally
25 - 17 9823/0300-1 25 - 17
Operation
Figure 683. Right turn shown

Manual Steer Mode System
Machines with power track rods A
2-wheel steer selected
With the spool of the steer mode control valve in the

2-wheel steer position there is a hydraulic connection L R
between the steer unit and the front power track
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track
rod is blocked by the spool assembly and the axle is
held in the straight ahead position by the locked-up
hydraulic oil in the track rod ram.
When the steering wheel is turned, the steering P

system only operates the front power track rod.
B
E
If the steering wheel is turned to the left, the oil flow T
is reversed and the machine will turn in the opposite
direction. D
V
Table 206.
Item Description
A Front power track rod
B Steer unit
C Rear axle power track rod
D Steer mode control valve port
E Steer mode control valve port
L Left side
P Steer mode control valve port
R Right side
T Steer mode control valve port
V Steer mode control valve
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 18 9823/0300-1 25 - 18
4-wheel steer selected Figure 684. Right turn shown
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection A
between the steer unit and the front and rear axle
power track rods. Steer mode control valve ports
are internally connected. When the steering wheel is
turned to the right, oil is fed to the rear power track rod
and the displaced oil is fed to the front power track L R
rod through the valve spool. The front power track
rod turns the wheels in the opposite direction to the
rear wheels and displaced oil returns to tank.
If the steering wheel is turned to the left, the oil flow

direction. P
E
B
D T
Table 207.
Item Description
B Steer unit
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
Crab steer selected axle power track rods. Steer mode valve ports are
internally connected. When the steering wheel is
With the spool of the steer mode valve in the turned to the right, oil is fed to the rear power track
crab steer position there is a hydraulic connection rod and the displaced oil is fed to the front power
between the steer unit and the front and rear
25 - 19 9823/0300-1 25 - 19
track rod through the valve spool. The front power Figure 685. Right turn shown
track rod turns the wheels in the same direction as
the rear wheels, causing the machine to crab to the
right. Displaced oil returns to tank. A

is reversed and the machine will crab in the opposite
direction.
L R
P
B
E
D V T
Table 208.
Item Description
B Steer unit
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 20 9823/0300-1 25 - 20
Machines with steer rams Figure 686.
2-wheel steer selected
With the spool of the steer mode control valve in the

2-wheel steer position there is a hydraulic connection
between the steer unit and the front steer rams. Steer
mode control valve ports are internally connected.
The oil feed to the rear axle steer rams is blocked by
the spool assembly and the axle is held in the straight L R
ahead position by the locked-up hydraulic oil in the F G
rams.
When the steering wheel is turned, only the front axle

rams are operated by the steering unit.
If the steering wheel is turned to the left, the oil flow P

direction. B
E
D T
H J
Table 209.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 21 9823/0300-1 25 - 21
4-wheel steer selected Figure 687.
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection
steer rams. Steer mode control valve ports are
internally connected. When the steering wheel is
turned to the right, oil is fed to the rear rams and
the displaced oil is fed to the front rams through the
spool assembly. The front rams turn the wheels in the L
opposite direction to the rear wheels and displaced F R
G
oil returns to tank.

direction. P
E T
B
D
H J
Table 210.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
25 - 22 9823/0300-1 25 - 22
Crab steer selected Figure 688.
With the spool of the steer mode valve in the

crab steer position there is a hydraulic connection
steer rams. Steer mode valve ports are internally
connected. When the steering wheel is turned to the
right, oil is fed to the rear rams through the spool
assembly. The front rams turn the wheels in the same
direction as the rear wheels, causing the machine to L R
crab to the right. Displaced oil returns to tank. F G

direction.
P
B
E
T
D
V
H J
Table 211.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 23 9823/0300-1 25 - 23
Figure 690. Symbol 1 Show-

The axle proximity switches inform the ECU ing "No Wheels Aligned"
(Electronic Control Unit) of the position of the
steering trackrods. The ECU supplies a signal to the
right hand cluster display to illuminate the symbol 1.
Figure 689.
ing "Front Wheels Aligned"

ing "Rear Wheels Aligned"
X Symbol 1
Indicated Manual Steer Mode (if Figure 693. Symbol 1 Show-

installed) Frame ing "All Wheels Aligned"
Displays when the wheels are aligned to the straight

ahead position, if there is a fault an icon will flash on
and off rapidly, and a notification will be displayed.
25 - 24 9823/0300-1 25 - 24
Figure 694.
2
1
3
5 J5-14
4
6
J5-11
J5-6 ECU
1 J5-3
J4-7
2
1 3
3
5
4
6
2
1
3
5 J5-14
4
6
J5-11
J5-6 ECU
1 J5-3
J4-7
2
1 3
3
5
4
6
2
1
3
5 J5-14
4
6
J5-11
J5-6 ECU
1 J5-3
J4-7
2
1 3
3
5
4
6
1 Front Steer Proximity Switch 2 Rear Steer Proximity Switch

3 Hydraulic Control ECU
25 - 25 9823/0300-1 25 - 25
Diagram
Figure 695. Manual Steer Mode System

5
3
4
2a
1a
1 Hydraulic Pump 1a Priority Valve

2 Steer Unit 2a Steering System Relief Valve
3 Steer Mode Valve 4 Power Track Rod - Front Axle
5 Power Track Rod - Rear Axle 6 Hydraulic Tank
25 - 26 9823/0300-1 25 - 26
Figure 696. Hose and Pipework

L
T
LS
P
3
R
A
P
1 4
T
B
1 Rear Power Track Rod 2 Steer Mode Valve

3 Steer Unit 4 Front Power Track Rod
25 - 27 9823/0300-1 25 - 27
06 - Auto Steer Mode System
06 - Auto Steer Mode System Operation

Operation ....................................................... 25-28
Operation (Electrical) ..................................... 25-34
Auto Steer Mode System
There are 3 steering modes available:
• 2- wheel steer (front axle only)

• 4- wheel steer
• Crab steer
In the 2-wheel steer mode, only the front wheels

are steered. In 4-wheel steer mode, both the axles
are steered, giving a smaller turning circle. The
crab steer mode allows the machine to be driven
diagonally.
The system is prevented from changing mode until

all the wheels are in the straight ahead position. This
is detected by proximity sensors on the front and rear
axles. If the system is set in 4-wheel steer and 2-
wheel steer is selected, the system will stay in 4-
wheel steer until the rear wheels are turned to the
straight ahead position. The rear wheels are then
hydraulically locked in the straight ahead position.
The operation of the steer mode switch, solenoids

and proximity switches is controlled by the hydraulic
control ECU (Electronic Control Unit) and the
transmission control ECU. Refer to steering system-
general, refer to (PIL 25-00).
540-170 machines use a separate steer mode ECU.

Refer to electrical system- electronic diagnostic, refer
to (PIL 33-57).
Hydraulic Operation and Schematics
Machines with power track rods

Operation- 2-wheel steer selected
The illustrations shown are for the purpose of circuit

explanation only. Actual installations may not be as
shown.
With the spools of steer mode control valve in the 2-

wheel steer position (solenoid energised), there is a
hydraulic connection between the steer unit and the
front power track rod. The oil feed to the rear axle
power track rod is blocked by the spool assembly and
the axle is held in the straight ahead position by the
locked-up hydraulic oil in the track rod ram.
When the steering wheel is turned, the steering unit

operates only the front power track rod.

direction.
25 - 28 9823/0300-1 25 - 28
Figure 697. The front power track rod turns the wheels in the
opposite direction to the rear wheels and displaced
oil returns to tank.

F is reversed and the machine will turn in the opposite
direction.
Figure 698.
L R
F
E.C.U.
L R
V E.C.U.
T
A S
C
D T
A Solenoid Energised
B Rear power track rod
F Front power track rod
L Left B
R Right
S Steer unit
V Control valve
B Rear track rod
Operation- 4-wheel steer selected C Solenoid1
D Solenoid2
The illustrations shown are for the purpose of circuit F Front track rod
explanation only. Actual installations may not be as L Left
shown. R Right
S Steer unit
With the spools of steer mode valve in the 4-wheel T Tank
steer position (solenoid1 and solenoid2 energised), V Steer mode valve
there is a hydraulic connection between the steer unit
and the front and rear axle power track rods. When
the steering wheel is turned (right turn shown), oil is
fed to the rear power track rod and the displaced oil is
fed to the front power track rod via the valve spools.
25 - 29 9823/0300-1 25 - 29
Operation- Crab Steer Selected Figure 699.
The illustrations shown are for the purpose of circuit

explanation only. Actual installations may not be as
shown. F
With the spools of steer mode valve in the crab
steer position (solenoid1 and solenoid2 energised),
there is a hydraulic connection between the steer unit
and the front and rear power track rods. When the
steering wheel is turned (right turn shown), oil is fed L R
to the rear power track rod and the displaced oil is fed
to the front power track rod via the valve spools. The
front power track rod turns the wheels in the same
direction as the rear wheels, causing the machine to
E.C.U.
crab to the right. Displaced oil returns to tank.

direction.
S
C
D
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
R Right
S Steer unit
V Steer mode valve
Schematics
The steer mode valve spools have mechanical

detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer mode
suddenly.
25 - 30 9823/0300-1 25 - 30
2- wheel steer
Figure 700.
V
C B
F2
R2
F1
R1 A
D
C D
F1 R1
A B
F2 R2
S
R L
R Oil flow direction- right

turn
Table 212. 2- wheel steer
L Oil flow direction- left
Steer Mode 2- wheel steer turn
Ports internally connect- F2 - F1 V Steer mode valve
(1)
ed FR Front axle
Ports internally blocked R1 - R2
(1) Refer to component location for variation of valve
Solenoids energised A orientation.
Key
S Steer unit
25 - 31 9823/0300-1 25 - 31
4- wheel steer
Figure 701.
V
C B
F2
R2
F1
R1 A
D
C D
F1 R1
B
A
F
F2 R2
S
R L
S Steer unit
Table 213. 4- wheel steer
turn
Steer Mode 4- Wheel Steer L Oil flow direction- left
Ports internally connect- F1 - R2 turn
ed F2 - R1 V Steer mode valve
(1)
Ports internally blocked - FR Front axle

Solenoids energised B, D (1) Refer to component location for variation of valve
Key orientation.
25 - 32 9823/0300-1 25 - 32
Crab steer
Figure 702.
V
C B
F2
R2
F1
R1 A
D
C D
F1 R1
B
A
F
F2 R2
S
R L
Table 214. crab steer

Steer Mode Crab Steer
Ports internally connect- F1 - R1
ed F2 - R2
Ports internally blocked -
Solenoids energised B, C
Key
S Steer unit
turn
L Oil flow direction- left
turn
V Steer mode valve
(1)
FR Front axle
(1) Refer to component location for variation of valve
orientation.
25 - 33 9823/0300-1 25 - 33
Two signals are output from the unit, a track 1 signal

Steer Mode Switch Operation and a track 2 signal. One signal varies the voltage
by the angle between 0 and -45º. The other signal
A variable resistor within the unit changes the voltage varies the voltage by the angle between 0 and 45º.
output in relation to the position of the steer mode Both signals will always add up to 4.5v.
switch dial.
Figure 703.
-45º +45º
V
5.0
4.5 S1
4.0
3.5
3.0
2.5
2.0 S2
1.5
1.0
0.5
0 X
-50 -40 -30 -20 -10 0 10 20 30 40 50
V Sensor Output (Volts) X Displacement Angle (º)

S1 Signal Output 1 S2 Signal Output 2
25 - 34 9823/0300-1 25 - 34
System Operation Figure 707. Crab Steer Mode Enabled
The axle proximity switches 1 and 2 inform the

ECU (Electronic Control Unit) of the position of the
steering trackrods. The ECU supplies a signal to the
right hand cluster display to illuminate the symbol.
Refer to steering system, mode valve, auto mode
When the operator selects a steer mode using the
valve, check operation (PIL 25-09-06).
cab mounted selector switch, the ECU energises the
relevant solenoids A, B, C or D on the steer mode
valve.
The steer mode valve spools have mechanical

detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer mode
suddenly. However,faulty electrical connections to
the solenoid coils (energising the coil) could cause
the steer mode to change suddenly with no operator
input.
Figure 704.
X Auto Steer Mode (if installed) Frame
The Auto Steer Mode Frame displays the steer

mode that is enabled (in solid grey). When changing
between modes the (amber) icons will flash on and
off at the specified intervals. The specified interval is
1s
If there is a fault detected, an icon will flash on and

off rapidly, and a notification will be displayed.
Figure 705. 2 Wheel Steer
Figure 706. 4 Wheel Steer
25 - 35 9823/0300-1 25 - 35
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-37
25 - 36 9823/0300-1 25 - 36
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 37 9823/0300-1 25 - 37
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-39
25 - 38 9823/0300-1 25 - 38
03 - Priority Valve
00 - General
00 - General
Operation
There are four types of steering system which can be

installed on this machine:
1. Permanent 4WS (Four Wheel Steer)

2. Manual steer mode system (option)
3. Manual (indicated) steer mode system (option)
4. Auto steer mode system (option)
This topic describes the main steering system

without steer mode options. This system is common
to all machines. Permanent 4WS4 wheel steer
machines use this system alone. Machines with steer
mode options include additional components which
are detailed in later topics:
Basic Steering System

The main components of the permanent 4WS system
are the priority valve, load sensing steer unit,
steer isolation valve, and double acting power track
rod rams. Refer to component identification (PIL
25-00-00).
When the steering wheel is turned, the movement is

transferred to the steer unit via the steering column.
At the steer unit a pressure signal (demand) is
generated in the load sense line from the steer unit
to the priority valve. The priority valve then directs oil
from the hydraulic pump to the steer unit, which in
turn directs the flow to the power track rods on the
axles.
When the steering lock is achieved, the pressure

signal in the load sense line ceases. The priority
valve then directs the oil from the hydraulic pump
into the main hydraulic system for operation of the
hydraulic services.
The maximum steering system pressure is set by a

relief valve housed inside the steer unit.
An isolation valve is installed to isolate the rear

wheels during the wheel alignment procedure. This
valve is not used on machines with selectable steer
modes.
25 - 39 9823/0300-1 25 - 39
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-41
25 - 40 9823/0300-1 25 - 40
00 - General
Introduction .................................................... 25-41 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-42 fluid flow in the steering system.
25 - 41 9823/0300-1 25 - 41
00 - General
Figure 708.
L R
D
C
T LS P
M
T L
LS
P R
Item Description
Table 215.
K Steer vale
Item Description L Left feed / return port
C Hydraulic steer unit LS Load sense port
D Shock Valves (if in- M Steering System Relief
stalled) Valve
E Check valve
25 - 42 9823/0300-1 25 - 42
00 - General
Item Description
P Valve inlet
R Right Feed/Return Port
T Return Line
25 - 43 9823/0300-1 25 - 43
00 - General
Remove and Install
Consumables 5. Get access to the steer unit. Remove the front

Description Part No. Size panel from the cab.
JCB Threadlocker 4101/0250 0.01L 6. Mark and disconnect the hydraulic hoses from
and Sealer (Medium 4101/0251 0.05L the steering unit.
Strength)
7. Install caps on all the open hoses and ports to
Remove prevent contamination.
1. Make the machine safe. Follow all the general 8. Mark the orientation of steering unit to the splined
safety procedure. Refer to (PIL 01-03). shaft.
2. Discharge the hydraulic pressure. Refer to (PIL 9. Remove the bolts from inside the cab. At the
30-00). same time have an assistant to support the
steering unit from under the machine.
several times to discharge the system pressure. 10. Remove the steering unit.
4. Make sure that the steering wheel is in the

straight ahead position.
Figure 709.
A Steering unit B Splined shaft

C Bolts (X4)
Install 2. Tighten the bolts in the numerical order shown to

Installation is the opposite of the removal procedure.
During the installation procedure also do the steps 3. Make sure that the hoses are installed in the
below. correct positions.
4. If the hydraulic adaptors are removed make sure
1. Apply JCB threadlocker to the fasteners.
that they are tightened to the correct torque
Consumable: JCB Threadlocker and Sealer value.
(Medium Strength)
25 - 44 9823/0300-1 25 - 44
00 - General
Figure 710.
E
D
D
D Hydraulic adaptor 1 E Hydraulic adaptor 2
5. The steering unit is spring loaded to the neutral

position. Make sure the steering wheel is in the
straight ahead position when you connect the
splined shaft.
6. Before you drive the machine, bleed the system.
7. If a new steering unit is installed then the system
relief valve must be tested for correct pressure
setting.
8. Check the hydraulic fluid level. Refer to (PIL
30-00).

Item Nm
C 30
D 77
E 22
25 - 45 9823/0300-1 25 - 45
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-06 Auto Mode Valve ............................................................................................................ 25-47
25 - 46 9823/0300-1 25 - 46
09 - Mode Valve
06 - Auto Mode Valve
06 - Auto Mode Valve Check (Operation)

Check (Operation) ......................................... 25-47 Machines may be installed with different types of
Remove and Install ....................................... 25-48 steer mode solenoid valve.
The solenoids operate according to the selected
steer mode.
Figure 711.
A D
C
B
Table 217.
Mode Solenoid(s) energised
2 Wheel Steer C
4 Wheel Steer B, D
Crab Steer A, D
Operation (energisation) of a solenoid can be easily

identified by placing a steel object (e.g. screwdriver
blade) close to the outer case. magnetic attraction
of the steel object towards the solenoid indicates
energisation.
If a solenoid is not energising do the following

checks:
1. Make the machine safe. Refer to (01-03).

2. Check the appropriate fuse. If it has blown, make
sure the wiring is not damaged and then renew
the fuse. Check that all steer mode solenoid
combinations function correctly.
3. If the fuse is ok then, remove the electrical
connector from the malfunctioning solenoid(s)
and check that the 12V supply is available across
the connector pins. If not, check the supply
circuit.
4. Check the solenoid coil resistance which should
measure a few ohms (if you are not sure about
the value compare with a known good solenoid).
25 - 47 9823/0300-1 25 - 47
09 - Mode Valve
4.1. Replace the solenoid, if the reading Remove and Install

indicates a short circuit (zero ohms) or open
circuit (infinite resistance). If a reading is WARNING Make the machine safe before getting
somewhere between the zero and infinite, beneath it. Make sure that any attachments on
then reverse the two instrument probes and the machine are correctly attached. Engage the
repeat for a valid check. park brake, remove the ignition key, disconnect
the battery.
The electrical connectors at the steer mode valve
solenoids are identical. Before you remove any of the WARNING Hydraulic fluid at system pressure
connectors, make sure you label them A, B, C or D can injure you. Before connecting or removing
as applicable. If you think that the connectors have any hydraulic hose, residual hydraulic pressure
been made to the wrong solenoids see the electrical trapped in the service hose line must be vented.
connection data for wire number identification. Make sure the hose service line has been vented
before connecting or removing hoses. Do not start
the engine with loose or open hose connections.
WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
clear of fluid under pressure and wear personal
protective equipment. Hold a piece of cardboard
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Remove
30-00).
several times to discharge the system pressure.
Make sure that the steering wheel is in the
straight ahead position.
5. Disconnect the electrical solenoid connections.
6. Put a label on each connector before you remove
to help installation. Identify the wires as shown in
the figure. Refer to Figure 712.
7. Put a label on the hoses to help installation.
8. Disconnect all the hydraulic hoses from the steer
mode valve assembly.
contamination.
10. Support the steer mode valve assembly and
remove the screws. Remove the steer mode
valve from the machine.
11. Make sure to keep two washers to the rear of the
valve block which may fall out when you remove
the screws.
25 - 48 9823/0300-1 25 - 48
09 - Mode Valve
Figure 712. 1.1. Make sure that the electrical solenoid

connections are installed in the correct
position.
1.2. Make sure that the hoses are correctly
installed.
1.3. Make sure that the two washers are
installed between the valve block and the
chassis side plate.
value.
1.5. Bleed the steering system. Refer to (PIL
25-00).

Item Description Nm
E Screw 40
B A
C D
A-D Electrical solenoid connector wires

E Screw
Figure 713.
G H
E Screw
F Chassis side plate
G Washer
H Valve block
Install
steps.
25 - 49 9823/0300-1 25 - 49
09 - Mode Valve
The solenoid valves are non-serviceable parts. Disassemble

Replace the faulty valves. The following procedure
explains the removal and installation of a valve 1. Loosen and remove the knurled cap and pull off
installed at the manifold block. The procedure is the solenoid coil.
identical for all the valves (2 or 4 valve assemblies
depending on machine variant). The procedure 2. Remove the O-ring 1 and the O-ring 2.
assumes that the complete valve and manifold block
3. Using the correct open ended spanner, loosen
assembly has been removed from the machine.
the valve stem from the manifold block.
4. Remove the O-ring 3.
Figure 714.
F
E
C
B
A Manifold block B Knurled cap

C O-ring 1 D Solenoid coil
E O-ring 2 F Valve stem
G O-ring 3
25 - 50 9823/0300-1 25 - 50
09 - Mode Valve
Assemble
1. Make sure that all components are perfectly
clean. If contamination is suspected, make sure
that all the oilways in the manifold block are clear
of debris.
2. Install new O-rings.
3. Lubricate the parts with JCB special hydraulic
fluid before assembling.
25 - 51 9823/0300-1 25 - 51
Contents Page No.
25-15-00 General ........................................................................................................................... 25-53
25 - 52 9823/0300-1 25 - 52
00 - General
00 - General
Introduction
These are installed on machines with auto steer

mode system or manual (indicated) mode system.
25 - 53 9823/0300-1 25 - 53
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-55
25 - 54 9823/0300-1 25 - 54
00 - General
00 - General 5. To prevent damage to the seals, clamp the

cylinder in a vertical position and lower the piston
rod assembly into the cylinder during installation.
Check (Condition)
6. Install new wiper seals (not shown).
Check Energiser Seals 7. Install the power track rod assembly again.
8. Check the tracking. Refer to Driveline - Front
If there is difficulty in steering the machine and
Wheel. Refer to (PIL 27-29).
routine fault finding indicates power track rod
leakage, it is possible that the rectangular section 9. Check for correct operation and steer phasing.
piston head seal on the power track rod piston head
is installed incorrectly i.e. twisted. 10. Check the hydraulic oil level and top up as
Check the front and rear power track rods as follows:
Figure 717.
1. Disassemble the ram. Refer to Steering System-
Track Rod. Refer to (PIL 25-18).
2. Remove the piston seal and check to see if
the energiser seal has been installed twisted or
rolled.
3. Inspect the cylinder bore and piston rod for
scoring, nicks and burrs.
Figure 715.
A
B
A Piston seal
B Energiser seal
4. Assemble the ram with new seals. Make sure that
the energiser seal is not twisted or rolled. Check
the white installation marks.
Figure 716.
B
B Energiser seal
25 - 55 9823/0300-1 25 - 55
33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ........................................................................................................................... 25-57
25 - 56 9823/0300-1 25 - 56
33 - Link Arm
00 - General
00 - General
Remove and Install
Consumables Figure 718.

JCB Threadlocker 4101/0250 0.01L
Strength)
Remove
If you have to dismantle the power track rod or
replace the link arms, do the following steps:
Remove
1. Fix the assembly on a locally made strip/rebuild 2. Use two suitable open ended spanners at point1
bench. Refer to Figure 718. and point2 and turn against each other until one
ball joint unscrews as shown. Refer to Figure
719.
3. For this explanation, assume the ball joint at
point1 is now loose, do as follows:
25 - 57 9823/0300-1 25 - 57
33 - Link Arm
00 - General
Figure 719.
A
B
A Point1 B Point2
25 - 58 9823/0300-1 25 - 58
33 - Link Arm
00 - General
C Point3 D Point4
3.1. Unscrew the ball joint until you can fit an Install
open ended spanner on the rod at point3.
Turn the ball joint towards the spanner to If the you have to dismantle the power track rod
secure it and to prevent damage to the rod. ram, carry out the procedure before you remove and
install the link arms. Refer to (PIL 30-15).
3.2. The piston rod operates at full length. Any
damage to the surface will cause fluid leaks. 1. The installation procedure is the opposite of the
Make sure you do not damage it or attempt removal procedure.
to grip the rod diameter with pipe grips etc.
3.3. Hold the spanner at point3 and remove the 2. When you install, also do the following steps:
ball joint at point4 by moving it against the 2.1. Install the target disc (where applicable).
spanner at point3.
2.2. Apply threadlocker and sealer on the first
4. Remove the target disc where applicable. three threads of the inner ball joint where it
screws into the end of the track rod.
5. If you replace the inner or outer ball joints, make
sure you install a replacement link arm assembly. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Figure 720.
2.3. If the link arms have been renewed, make
sure you check the wheel alignment.
2.4. Bring the wheels to straight ahead position.
J 2.5. Measure the distance1 and distance2

between the outer edges of the wheel hub
as shown.
2.6. Make sure that the difference between
the distance1 and the distance2 is of the
specified value for correct alignment.
E F G H 2.7. To adjust the wheel alignment, remove
the lock nuts. Turn the threaded adjusters
equally to get the correct alignment. Tighten
E Lock nut the lock nuts.
F Threaded adjuster 2.8. Check the target disc and proximity switch
G Spanner flat on ball joint setting (where applicable). Refer to steering
H Spanner flat on the rod system- track rod, refer to (PIL 25-18).
J Target disc
25 - 59 9823/0300-1 25 - 59
33 - Link Arm
00 - General
Figure 721.
X Distance1 Y Distance2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 60 9823/0300-1 25 - 60
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-20 Axle
27-20-00 General ............................................................................................................................. 27-7
27-20-81 Mount ............................................................................................................................. 27-18
27-22 Drivehead
27-22-00 General ........................................................................................................................... 27-21
27-22-06 Crownwheel .................................................................................................................... 27-22
27-22-09 Pinion Gear .................................................................................................................... 27-24
27-24 Differential
27-24-00 General ........................................................................................................................... 27-43
27-27 Hub
27-27-00 General ........................................................................................................................... 27-69
27-27-66 Wheel Stud .................................................................................................................... 27-85
27-29 Wheel
27-29-00 General ........................................................................................................................... 27-87
27-31 Wheel Drive Pump
27-31-00 General ........................................................................................................................... 27-93
27-32 Wheel Drive Motor
27-32-00 General ......................................................................................................................... 27-121
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-127
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-131
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-135
9823/0300-1
2018-01-12
Acronyms Glossary
4WD Four Wheel Drive

LMI Load Moment Indicator
LSD Limited Slip Differential
9823/0300-1
2018-01-12
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9823/0300-1 27 - 1
Notes:
27 - 2 9823/0300-1 27 - 2
27 - Driveline
00 - Driveline
00 - General
Introduction ...................................................... 27-3 This section contains information on machine
Health and Safety ........................................... 27-4 driveline system. The machine driveline system
Check (Condition) ............................................ 27-4 consists of the following parts.
• Axle. Refer to: PIL 27-20-00.

• Wheel drive pump. Refer to: PIL 27-31-00.
• Wheel drive motor. Refer to: PIL 27-32-00.
• Wheels. Refer to: PIL 27-29-00.
27 - 3 9823/0300-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Health and Safety Check (Condition)

Working Under the Machine 1. Make the machine safe. Refer to (PIL 01-03).
Make sure that any attachments on the machine are 2. Get access to the mounting(s).
correctly attached. Engage the park brake, remove 3. Make sure that the entire mounting(s) system is
the ignition key, disconnect the battery. If the machine in good condition.
movement. 3.1. Inspect brackets and casings for cracks,
WARNING! A raised and badly supported machine damage and security.
can fall on you. Position the machine on a firm, level 3.2. Inspect rubber mountings (if installed) for
surface before raising one end. Ensure the other wear and tears and too much movement.
end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine 3.3. Make sure that all fastenings are there and
when working under it. Disconnect the battery, to they are tightened to the correct torque.
prevent the machine being started while you are Refer to (PIL 72).
beneath it.
4. Install new components if any are defective.
WARNING! Before disconnecting any propshaft, Refer to the correct section in the service manual
make sure you block both sides of all wheels to as necessary.
prevent machine movement. The park brake will
become ineffective or may only operate on 2 wheels
(depending on machine specification).
WARNING! If a 4 wheel drive machine is to be
raised and the engine/transmission run, make sure
all four wheels are raised off the ground. Make sure
the machine is correctly supported by the correct
axle stands. If only one pair of wheels is raised, the
machine could move and fall off the stands.
WARNING! Under no circumstances must the
engine be run with the transmission in gear and only
one driving wheel jacked clear of the ground, since
the wheel on the ground will move the machine.
27 - 4 9823/0300-1 27 - 4
27 - Driveline
20 - Axle
20 - Axle
Contents Page No.
27-20-00 General ............................................................................................................................. 27-7

27-20-81 Mount ............................................................................................................................. 27-18
27 - 5 9823/0300-1 27 - 5
Notes:
27 - 6 9823/0300-1 27 - 6
27 - Driveline
20 - Axle
00 - General
Introduction ...................................................... 27-7 Axles are an integral component of a wheeled
Technical Data ................................................. 27-8 vehicle. The axle transmits a driving torque to the
Component Identification ................................. 27-9 wheel, as well as maintaining the position of the
Check (Level) ................................................ 27-11 wheels relative to each other and to the vehicle body.
Remove and Install ....................................... 27-12 The front axle is mounted rigidly to the machine using
Disassemble and Assemble .......................... 27-17 bolts and pads.
The rear axle is mounted to the machine using a pin.

This enables oscillation of the axle when the machine
travels over uneven ground.
Front and rear axles are steer drive axles allowing

4WS (Four Wheel Steer) and 4WD (Four Wheel
Drive) functions.
27 - 7 9823/0300-1 27 - 7
27 - Driveline
20 - Axle
00 - General
Technical Data
For: Front .................................... Page 27-8

For: Rear ..................................... Page 27-8
(For: Front)
Table 220. 211 Steer drive front axle
Mounting Pad mount
Type Spiral bevel input with epicyclic hub reduction
Brakes Oil immersed multi-plate discs, located in centre sec-
tion
Steering Power track rod
(For: Rear)
Table 221. 211 Rear Axle
Item Description
Mounting Pivot mount
Type Spiral bevel input with epicyclic hub reduction
Steering Powered track rod
Total axle ratio -
Wheel nut torque 500N·m
27 - 8 9823/0300-1 27 - 8
27 - Driveline
20 - Axle
00 - General
For: Front .................................... Page 27-9

For: Rear ................................... Page 27-10
(For: Front)
Figure 722.
A Reduction gear hub B Steer track rod

C Steer swivel trunnion bearings D Drivehead
E Axle arms
27 - 9 9823/0300-1 27 - 9
27 - Driveline
20 - Axle
00 - General
(For: Rear)
Figure 723.
F
D
A Reduction gear hub B Steer track rod

C Steer swivel trunnion bearings D Drivehead
E Pivot F Axle arms
27 - 10 9823/0300-1 27 - 10
27 - Driveline
20 - Axle
00 - General
Check (Level)
For: Front .................................. Page 27-11 (For: Front)

For: Rear ................................... Page 27-11
Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
Figure 724.
B A B
A Axle fill / level plug B Axle drain plug

2. Get access to the axle fill / level plug.
3. Clean the area around the fill / level plug.
4. Remove the plug with its sealing washer.
5. Make sure the oil is level with the bottom of the
hole.
6. If necessary add oil.
7. Clean the fill/level plug.
8. Install the plug with its sealing washer.
(For: Rear)
Refer to Check (Level) (For: Front) PIL (27-20-00).
27 - 11 9823/0300-1 27 - 11
27 - Driveline
20 - Axle
00 - General
Remove and Install
For: Front .................................. Page 27-12 5. Remove the roadwheels. Refer to (PIL 27-29).
For: Rear ................................... Page 27-14
6. Disconnect the propshaft coupling from the axle
by unscrewing bolts 2 and removing the straps.
(For: Front)
7. Disconnect and plug the hydraulic hoses to the
WARNING A raised and badly supported power track rod.
machine can fall on you. Position the machine
on a firm, level surface before raising one end. 8. Disconnect the axle breather pipe from the axle.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks 9. Disconnect the brake pipes at the axle
to support the machine when working under it. connectors. (if installed)
Disconnect the battery, to prevent the machine
being started while you are beneath it. 10. Blank off the exposed connections.
11. Support the axle on a trolley jack.
Remove 12. Remove the axle mounting nuts, bolts 1 and the
1. Make the machine safe. Refer to (PIL 01-03). washers.
2. Follow the care and safety procedures. Refer to 12.1. If installed, retain the spacer plates.
(PIL 01-03). 13. Lower the axle down from the machine.
3. Remove the front mud guards. Refer to (PIL 14. Remove the axle from the machine.
06-54).
4. Remove the front chassis cover. Refer to (PIL
06-03).
27 - 12 9823/0300-1 27 - 12
27 - Driveline
20 - Axle
00 - General
Figure 725.
A
A
B C D E
A Hydraulic hoses B Axle mounting bolts 1

C Axle mounting nuts D Connectors
E Axle F Bolts 2
G Straps H Coupling
27 - 13 9823/0300-1 27 - 13
27 - Driveline
20 - Axle
00 - General
Install 2. Install the maintenance strut. Refer to (PIL

06-69).
removal procedure. Additionally do the following 3. Remove the rear mudguards. Refer to (PIL
steps. 06-54).
1.1. Install the roadwheels and do the tightness 4. Remove the roadwheels. Refer to (PIL 27-29).
check. Refer to (PIL 27-29).
5. Remove the bolts 2 and the straps.
1.2. The front propshaft retaining straps stretch
with use. Install new straps. 6. Disconnect the propshaft coupling from the axle.
1.3. Bleed the brake system. Refer to (PIL 7. Disconnect the LMI (Load Moment Indicator)
24-03). transducer electrical connector.
1.4. Bleed the steering system. Refer to (PIL 8. Discharge the hydraulic pressure. Refer to (PIL
25-00). 30-00).
1.5. Re-phase the steering system. Refer to (PIL
25-00). 9. Put a label on the hoses to help installation.
10. Disconnect the hydraulic hoses.
(For: Rear) 11. Disconnect the axle breather pipe from the axle.
WARNING A raised and badly supported
machine can fall on you. Position the machine 12. Plug all the open ports and hoses to prevent
on a firm, level surface before raising one end. contamination.
Ensure the other end is securely chocked. Do 13. Disconnect the steer proximity switch electrical
not rely solely on the machine hydraulics or jacks connector (if installed).
to support the machine when working under it.
Disconnect the battery, to prevent the machine 14. Support the axle on a trolley jack.
being started while you are beneath it.
15. Remove the bolt 1 securing the axle pivot pin.
Remove 16. Remove the pivot pin towards the rear of the
machine.
17. Carefully remove the axle from the machine.
27 - 14 9823/0300-1 27 - 14
27 - Driveline
20 - Axle
00 - General
Figure 726.
B
A
E D
F
G
A Bolt 1 B Axle pivot pin

C Axle D Hydraulic hoses
E Propshaft coupling F Bolts 2
G Straps
27 - 15 9823/0300-1 27 - 15
27 - Driveline
20 - Axle
00 - General
Install
steps.
1.1. Install the roadwheels and do the tightness
check. Refer to (PIL 29-00).
1.2. The propshaft retaining straps stretch with
use. Replace with new straps.
1.3. Bleed the steering system. Refer to (PIL
25-00).
1.4. Re-phase the steering system. Refer to (PIL
25-00).
1.5. Grease the axle pivot trunnions. Refer to
(PIL 75-06).
1.6. Calibrate the LMI. Refer to (PIL 33-66).
27 - 16 9823/0300-1 27 - 16
27 - Driveline
20 - Axle
00 - General
(For: Dana 211 Series, Rear)

Refer to (PIL 24-03, 27-25, 27-28, 27-52 and 78-94).
27 - 17 9823/0300-1 27 - 17
27 - Driveline
20 - Axle
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
27 - 18 9823/0300-1 27 - 18
27 - Driveline
22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-00 General ........................................................................................................................... 27-21

27-22-06 Crownwheel .................................................................................................................... 27-22
27-22-09 Pinion Gear .................................................................................................................... 27-24
27 - 19 9823/0300-1 27 - 19
Notes:
27 - 20 9823/0300-1 27 - 20
27 - Driveline
22 - Drivehead
00 - General
Introduction .................................................... 27-21 The axle drivehead transmits drive from the input
Component Identification .......................... 27- coupling yoke to the driveshafts through the
Disassemble and Assemble ..................... 27- differential unit.
27 - 21 9823/0300-1 27 - 21
27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................... 27-22 A crown wheel is a rotating gear wheel with teeth set
Check (Operation) ......................................... 27-23 at right angles to its plane, it is usually matched with a
pinion gear that meshes with the crown wheel. They
are mainly used in vehicles to maintain a forward
movement.
27 - 22 9823/0300-1 27 - 22
27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Operation) Figure 729.
Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking
three of the pinion teeth with engineers marking
compound and rotating the pinion. The marking will
then be transferred to the crown wheel teeth.
1. Correct tooth marking.

Figure 727.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 728.
3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.
27 - 23 9823/0300-1 27 - 23
27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear Introduction

Introduction .................................................... 27-24 A pinion gear is a small gear that meshes with a
Calibrate ........................................................ 27-25 larger crownwheel. They are mainly used in vehicles
Disassemble and Assemble .......................... 27-28 to maintain a forward movement.
27 - 24 9823/0300-1 27 - 24
27 - Driveline
22 - Drivehead
09 - Pinion Gear
Calibrate Figure 733.
1. Insert the thrust block of the bearing opposite

side of the ring gear shims of an initial thickness
of the specified value.
Figure 730.
5. Insert the complete differential.

Figure 734.
2. Insert the thrust block and the shims into the left
arm. Verify at the end of stroke.
Figure 731.
5.1. Take care not to damage the seat of the O-

ring with the planetary gear.
6. Insert the thrust block of the bearing shims with
an initial thickness of the specified value.
Figure 735.
3. Check the O-ring and apply grease.

Figure 732.
7. Insert the thrust block and the shims into the right
arm. Verify at the end of stroke.
4. Insert the screws of the arm temporarily.
27 - 25 9823/0300-1 27 - 25
27 - Driveline
22 - Drivehead
09 - Pinion Gear
8. Insert the ring gear side arm without half axle. 10.1. For example, consider pinion torque of the
specified value.
Figure 737. Torque: 0.8–1.2N·m
10.2. The torque meter reading will be pinion +
differential torque value.
Torque: 1.2–1.8N·m
11. Insert a depth gauge with rotary key through the
rear cap hole.
12. Position depth gauge on the centre of one of the
crown teeth, preset it to the specified value and
reset it to zero.
13. Manually move the crown in both directions to
check the existing clearance between pinion and
8.1. To check the torque of the differential, do not
crown. Make sure that the gap is of the specified
install both half axles.
value.
9. Temporarily insert all screws of the arm. Length/Dimension/Distance: 0.13–0.2mm
Figure 738. 14. In order to increase the gap while keeping the
load on the bearing unchanged, take off shims
from the ring gear side and insert them on the
opposite side.
15. In order to decrease the gap, do the opposite.
Figure 740.
10. Insert a torque meter to the pinion nut and

check the torque. The torque will increase to
the specified value as a result of the differential
bearing pre-load.
27 - 26 9823/0300-1 27 - 26
27 - Driveline
22 - Drivehead
09 - Pinion Gear
16. Tighten the nuts in the criss cross method to the

Torque: 130N·m
Figure 741.
17. Use a driver to install the cap and secure with the
snap ring.
Figure 742.
27 - 27 9823/0300-1 27 - 27
27 - Driveline
22 - Drivehead
09 - Pinion Gear
Consumables WARNING Before draining the oil make sure

Description Part No. Size you loosen the oil filler plug or the breather (if
Cleaner/Degreaser 4104/1557 0.4L installed), and wait until the internal pressure
- General purpose is completely released. Remove the oil draining
solvent based parts plug and drain oil only when the pressure is
cleaner completely released.
JCB High Strength 4102/0551 0.05L
Threadlocker Bevel Pinion
CAUTION To avoid burning, wear personal The annotations in the procedure refer to the
protective equipment when handling hot exploded view. Refer to Figure 743.
components. To protect your eyes, wear goggles
when using a brush to clean components.
Figure 743. Exploded view
F K P
H
E
L
C
J
A G
A Nut B O-ring
C Flange D Guard
E Sealing ring F Ring nut
G Spacer H Inner bearing
J Spacer 1 K Spacer 2
L Shims M External bearing
N Housing P Pinion
27 - 28 9823/0300-1 27 - 28
27 - Driveline
22 - Drivehead
09 - Pinion Gear
Disassemble Figure 746.
1. Make the machine safe. Refer to (PIL 01-03). D

27-20).
4. Put a mark on the nut, flange and end of pinion
to aid assembly.
C
Figure 744.
A
C Flange
D Guard
P 8. Loosen and remove the sealing ring complete
with spacer.
8.1. The sealing ring must be discarded and
replaced with a new ring.
Figure 747.
A Nut
P Pinion E
5. Using special tool (910.99.0002) lock the pinion

in position. Refer to Special Tools (PIL 78-94).
6. Remove the nut.
Figure 745.
G
Q Special tool E
6.1. If necessary heat the nut to aid removal and
dissolve thread retaining fluid. E Sealing ring
6.2. If heating is required parts must not be G Spacer
subjected to direct flame. Ideally use a hot
9. Remove the pinion, shims and spacer.
plate, a rod heater or a heating oven.
Temperature: 90–100°C (193.9–211.9°F)
7. Using a suitable puller remove the flange and
guard.
27 - 29 9823/0300-1 27 - 29
27 - Driveline
22 - Drivehead
09 - Pinion Gear
12. Using a suitable drift and a hammer remove the

thrust block of the internal bearing and shim
washers.
K H
Figure 751.
M J H
P
H Inner bearing
J Spacer 1
K Spacer 2 H
M External bearing
P Pinion
10. Using a suitable press remove the inner bearing
from the pinion.
Figure 749.
L
H
H
H Inner bearing
L Shims
H Inner bearing 13. Remove the circlip and cap.

P Pinion
11. Using a suitable puller remove the external
bearing thrust block.
27 - 30 9823/0300-1 27 - 30
27 - Driveline
22 - Drivehead
09 - Pinion Gear
Figure 752. 10.1. Using a flat plate and a DTI (Dial Test
Indicator) set the DTI to zero at the
specified thickness.
Dimension: 30mm
10.2. Pre-load the DTI to the specified
dimension.
Dimension: 3mm
10.3. Place the inner bearing and thrust block
below the DTI.
R 10.4. Press the thrust block onto the bearing and

take several measurements at different
positions.
R Circlip
10.5. The movement on the DTI is to be
recorded as dimension "D".
Assemble
Figure 753.
1. All components must be thoroughly cleaned, with
particular attention being paid to the corners,
cavities and recesses of housings and covers.
Use JCB Cleaner/Degreaser to clean all the
parts.
Consumable: Cleaner/Degreaser - General
2. Old sealing compound must be carefully
removed.
30mm
3. Use a carborundum paper to remove scratches.
4. Let all the parts dry.
5. Check lubricating holes, grooves and pipes for
obstruction by residues, foreign materials and
protective coatings. The latter applies especially
to new parts.
6. Bearings, bushes, thrust washers etc. subjected
to normal wear during operation must be
checked by skilled service personnel before
being re-used. If in doubt, renew suspect parts.
7. When heating is required prior to assembly, parts D H
must not be subjected to direct flame. Ideally
use a hot plate, a rod heater or a heating
oven. Bearing races, covers, flanges and other H Inner bearing
parts requiring heat, should be pre-heated to the
specified temperature. Hot mounted parts should 10.6. Make a note of the nominal dimension "i"
be re-checked for proper contact after cooling. which is marked on the pinion.
Temperature: 90–100°C (193.9–211.9°F) 10.7. The dimension "y" is the dimension
marked on the pinion - either + or -.
8. Some parts may be cooled to
10.8. Subtract or add dimension "y" from / to
Temperature: 0°C (32.0°F) dimension "i" as required. This value is
dimension "I" - the centre distance.
9. Before pressing components into place, both the
component and housing must be lubricated. 10.9. Example - i (98) - y (0.1) = I
10. To calculate the pinion centre distance : Dimension: 97.9mm
27 - 31 9823/0300-1 27 - 31
27 - Driveline
22 - Drivehead
09 - Pinion Gear
i = 98mm y = -0.1mm
T
L S
H
H Inner bearing
L Shims
11. To calculate the shims required below the thrust S Specified shim thickness
block of the inner bearing : T Special tool
11.1. Shims (S) = X - (I + D). 13. Using a tension rod and suitable press move
11.2. X is fixed dimension. the thrust block of the bearings into the seats.
When thrust block is fully installed into the seat
11.3. I is piston centre distance. disconnect and remove the tension rod and
11.4. D is total bearing thickness. press.
11.5. Example - S = 128 - (97.9+29.45) = Figure 757.
Dimension: 0.65mm
11.6. Therefore in the above example the shims
required would be
Dimension: 0.65mm
Figure 755.
14. Calculate the pinion bearings rolling torque:

14.1. Using special tool (910.04.2389) install the
bearings into the housing. Refer to Special
Tools (PIL 78-94).
14.2. Tighten the tool by hand until a rolling
torque is able to be observed.
12. Using special tool (910.06.4069) partially install
the thrust block of the bearings and shims. Refer 14.3. Install a DTI into the hole either side of the
to Special Tools (PIL 78-94). special tool. Set the DTI to a pre load of
the specified dimension.
Dimension: 3mm
27 - 32 9823/0300-1 27 - 32
27 - Driveline
22 - Drivehead
09 - Pinion Gear
N
U
U
H
U M
M
H
H Inner bearing
M External bearing
U
N Housing
U Special tool
15. Remove the DTI, bearings and special tool from
the housing.
16. Install a spacer between the two bearings and J K
install the special tool with bearings and DTI.
17. Tighten the tool by hand.
18. Make note of the reading on the DTI this is
measurement "A". H Inner bearing
J Spacer 1
19. Remove the DTI, bearings and special tool from K Spacer 2
the housing. M External bearing
U Special tool
20. Remove the bearings from the tool.
24. Use the measurements to calculate the shim (S2)
21. Install the two bearings plus shim and the largest
required.
calibrated shim in between the bearings onto the
tool. 24.1. S2 = H + X.
22. Make note of the reading on the DTI this is
measurement "B".
23. Subtract measurement "B" from measurement
"A" to get dimension "H".
27 - 33 9823/0300-1 27 - 33
27 - Driveline
22 - Drivehead
09 - Pinion Gear
100 o
P
M
M External bearing
P Pinion
25. Heat the bearing and install on to the pinion.
26. Install the pinion, Shims (S) and spacers 1 and 2 Standard Drive Yoke Flange
into the housing.
1. Install the spacer and washers (if installed).
Figure 761.
2. Install the flange and guard on to the pinion
without the sealing ring.
100 o
Figure 763.
P
G
K J
H Inner bearing
J Spacer 1
K Spacer 2
L Shims C Flange
P Pinion D Guard
G Spacer
27. Heat the external bearing and install on to pinion.
3. Install the nut without thread locking fluid.
28. Lubricate the bearing.
27 - 34 9823/0300-1 27 - 34
27 - Driveline
22 - Drivehead
09 - Pinion Gear
Figure 764. bearing, spacer 1 and spacer 2. Install a

thinner shim.
7.4. Increasing or decreasing the thickness of
the shim by the specified amount - will alter
the rolling torque by the specified amount.
Torque: 60N·m
8. Put a mark on the nut, flange and end of pinion
A and remove nut and flange.
Figure 766.
A Nut A

in position. Refer to Special Tools (PIL 78-94). P
5. Tighten the nut to the correct torque value.
Torque: 260N·m
Figure 765.
A Nut
P Pinion
Q 9. Apply rubber cement to the outer surface of the

new sealing ring.
10. Using special tool (910.04.4214) install the new
sealing ring into the housing. Refer to Special
Tools (PIL 78-94).
Figure 767.
Q Special tool
6. Measure the rolling torque of the pinion. The
correct torque is as specified. E
7. If the rolling torque exceeds the limits perform the
following adjustments.
7.1. If the rolling torque is greater than specified V
limits - replace the shim S which is installed
between the inner bearing, spacer 1 and
spacer 2. Install a thicker shim.
7.2. If the rolling torque is less than the specified E Sealing ring
limits, the pinion nut can be tightened in V Special tool
gradual stages to the maximum torque 11. Lubricate the sealing ring and install the flange.
specified. Check the rolling torque after
each tightening. 12. Install O-ring.
Torque: 300N·m
13. Apply thread locking fluid to the threads on the
7.3. If after tightening the nut to the maximum pinion.
torque the rolling torque figure is still below
Consumable: JCB High Strength Threadlocker
the specified limits - replace the shim
S which is installed between the inner
27 - 35 9823/0300-1 27 - 35
27 - Driveline
22 - Drivehead
09 - Pinion Gear
14. Using special tool (910.99.0002) lock the pinion correct torque is as specified. Refer to Special
in position. Refer to Special Tools (PIL 78-94). Tools (PIL 78-94).
15. Tighten the nut until the marks are aligned. Torque: 400N·m
B
4. If the rolling torque exceeds the limits perform the
following adjustments.
4.1. If the rolling torque is greater than specified
limits - replace the shim S which is installed
between the inner bearing, spacer 1 and
spacer 2. Install a thicker shim.
A
4.2. If the rolling torque is less than the specified
limits, the ring nut can be tightened in
gradual stages to the maximum torque
A Nut
specified. Check the rolling torque after
B O-ring
each tightening.
Q Special tool
Torque: 500N·m
Counter Revolution Yoke Flange 4.3. If after tightening the nut to the maximum
1. Apply thread locking fluid to the threads on the torque the rolling torque figure is still below
ring nut. the specified limits - replace the shim
S which is installed between the inner
Consumable: JCB High Strength Threadlocker bearing, spacer 1 and spacer 2. Install a
thinner shim.
2. Install the ring nut on to the pinion.
4.4. Increasing or decreasing the thickness of
Figure 769. the shim by the specified amount - will alter
the rolling torque by the specified amount.
Torque: 60N·m
5. Remove the special tool.
6. Using a torque meter measure the rolling torque
of the pinion. The correct torque is as specified.
F Ring nut
3. Using special tool (910.04.4066) and torque
wrench measure the torque of the pinion. The
27 - 36 9823/0300-1 27 - 36
27 - Driveline
22 - Drivehead
09 - Pinion Gear
7. Apply rubber cement to the outer surface of the

new sealing ring.
8. Using special tool (910.04.4214) install the new
sealing ring into the housing. Refer to Special
Tools (PIL 78-94).
Q
Figure 772.
A Nut
E B O-ring
C Flange
Q Special tool
Crownwheel and Pinion Installation and

Adjustment
V
1. Install the bearing thrust block and shims. Initial
shim thickness is as specified.
Dimension: 0.55mm
E Sealing ring
V Special tool 1.1. Make sure that the thrust block and shims
are fully seated in position.
9. Lubricate the sealing ring and install the flange.
10. Install O-ring.
11. Apply thread locking fluid to the threads on the
pinion.
Consumable: JCB High Strength Threadlocker
in position. Refer to Special Tools (PIL 78-94).
13. Tighten the nut to the correct torque value.
27 - 37 9823/0300-1 27 - 37
27 - Driveline
22 - Drivehead
09 - Pinion Gear
4. Install the differential assembly making sure not

to damage the O-ring.
Figure 777.
2. Lubricate and install the O-ring.

Figure 775.
5. Install the bearing thrust block and shims. Initial

shim thickness is as specified.
Dimension: 0.75mm
3. Install the axle arm without driveshaft and secure

with screws.
27 - 38 9823/0300-1 27 - 38
27 - Driveline
22 - Drivehead
09 - Pinion Gear
5.1. Make sure that the thrust block and shims 7. Using a torque meter attached to the pinion nut
are fully seated in position. check the torque of the pinion.
6. Install the opposite side axle arm without drive 8. The torque should be greater than the rolling
shaft and secure with screws. torque without the differential installed by the
specified amount.
Torque: 40–60N·m
8.1. The pinion torque without differential is
within the specified limits.
8.2. Therefore the torque with the differential
installed is within the specified limits.
9. Install a DTI into the rear cover cap hole.
9.1. Position the DTI tip on the centre of one of
the crown teeth and preset to the specified
value.
9.2. Set the DTI to zero.
9.3. Move the crownwheel in both directions
and note the movement on the DTI. This
movement is the clearance between the
crownwheel and pinion. The clearance
must be within the specified limits.
27 - 39 9823/0300-1 27 - 39
27 - Driveline
22 - Drivehead
09 - Pinion Gear
9.4. If the clearance is greater than the specified Figure 781.

limits remove shims from the ring gear side
thrust block and install removed shims on
the opposite side thrust block.
9.5. If the clearance is less than the specified
limits remove shims from the non ring gear
side thrust block and install removed shims
on the ring gear side thrust block.
Figure 780.
10. Tighten the axle arm screws to the correct torque

value.
Torque: 130N·m
10.1. Make sure to tighten screws in a diagonal
pattern.
11. Install the cover cap and secure with circlip.
27 - 40 9823/0300-1 27 - 40
27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ........................................................................................................................... 27-43
27 - 41 9823/0300-1 27 - 41
Notes:
27 - 42 9823/0300-1 27 - 42
27 - Driveline
24 - Differential
00 - General
Introduction .................................................... 27-43 A differential is a particular type of simple planetary
Operation .................................................. 27- gear train.
The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational

velocity of the input shaft is the average of the
rotational velocity of the output shafts under normal
traction conditions. Therefore, increasing the speed
of one output shaft will decrease the speed of the
other output shaft.
The problem is an open differential always tries to

balance the torque. It means that if the spider gears
are pushing on both drive gears and one of them
offers lots of resistance and the other side offers no
resistance then it will try to find a balance where both
sides are receiving almost no torque at all. All the
rotational energy is guided to the side with the least
resistance. In the end, that side spins very fast and
the pressure on each drive gear is the same. Almost
no torque is needed to spin one wheel, and since
the open differential always sends the same amount
of torque to both output shafts, almost no torque is
going to the other side as well.
Limited Slip Differential (LSD)

In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
27 - 43 9823/0300-1 27 - 43
27 - Driveline
24 - Differential
00 - General
2. More predictable handling at the limits of grip.
This type behaves as an open differential unless one

wheel begins to spin and exceeds that threshold.
The LSD will remain open unless enough torque is
applied to cause one wheel to lose traction and spin,
at which point it will engage.
An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.
27 - 44 9823/0300-1 27 - 44
27 - Driveline
24 - Differential
00 - General
For: Dana 211 Series ................ Page 27-45 Consumables

For: Dana 211 Series LSD ......... Page 27-60 Description Part No. Size
JCB Threadlocker and 4101/0550 0.01L
(For: Dana 211 Series) Sealer (High Strength) 4101/0552 0.2L
Special Tools Do not attempt any maintenance if the axle is hot. Hot
Description Part No. Qty. oil and components can cause personal injury. Avoid
Hand Pump Pressure 892/00223 1 skin contact. Wear protective gloves and glasses.
Test
Pressure Gauge (0-70 892/00346 1 Standard Pre-Loaded Differential
Bar)
The annotations in the procedure refer to the
exploded view. Refer to Figure 782.

A C
F G
H F G
D
E
J
B
J
K
F L M
N
G
P
J
H Q
F Q
Q
G
R
R
S
T
V
W
A Crownwheel bearing B Crownwheel

C Crownwheel securing screws D Shim washer
27 - 45 9823/0300-1 27 - 45
27 - Driveline
24 - Differential
00 - General
E Planetary gear F Satellite gears

G Spherical washers H Half shafts
J Shaft securing pins K Planetary gear shaft
L Planetary gear cross shaft M Planetary gear
N Washer P Carrier
Q Differential lock intermediate discs R Differential lock friction discs
S Thrust block assembly T Disc retaining ring
U Differential carrier bearing V Ring
W Carrier bearing retaining ring
Disassemble Figure 784.

27-20).
3.1. Before draining the oil make sure to
loosen the oil filler plug or the breather
(if installed), and wait until the internal
pressure is completely released. Remove U
the oil draining plug and drain oil only when
the pressure is completely released.
4. If replacing the crownwheel bearing: U Carrier bearing
4.1. Remove two of the crownwheel securing 6. Remove the disc retaining ring.
screws. Discard the crownwheel securing Figure 785.
screws.
4.2. Using a suitable puller remove the
crownwheel bearing. T
Figure 783.
T Disc retaining ring

7. Remove the thrust block assembly.
B
C Figure 786.
B Crownwheel
C Crownwheel securing screws
5. If replacing the carrier bearing:
5.1. Using a suitable puller remove the carrier
bearing.
S Thrust block assembly
27 - 46 9823/0300-1 27 - 46
27 - Driveline
24 - Differential
00 - General
8. Remove the differential lock friction and Figure 790.

intermediate discs.
Figure 787.
Q R
J Shaft securing pins

12. Remove the planetary gear shaft.
Q Intermediate discs
R Friction discs Figure 791.
9. Remove the crownwheel securing screws and

crownwheel from the carrier. Discard the
crownwheel securing screws.
Figure 788.
K Planetary gear shaft

C
13. Remove the half shafts, spherical washers and
satellite gears.
Figure 792.
B Crownwheel
10. Remove the shim washer and planetary gear.
Figure 789.
H Half shafts
14. Remove the planetary gear cross shaft.
D
D Shim washer
E Planetary gear
11. Remove the shaft securing pins and half shafts.
27 - 47 9823/0300-1 27 - 47
27 - Driveline
24 - Differential
00 - General
H
H
L Planetary gear cross shaft H Half shafts

15. Remove the planetary gear and washer. 3. Partially install the planetary gear shaft and
install the satellite gears and spherical washers.
Figure 794.
Figure 797.
M
N F
G
M Planetary gear
N Washer F Satellite gears
G Spherical washers
Assemble K Planetary gear shaft
1. Lubricate and install the planetary gear and 4. Use a dummy pin to position the satellite gear
washer. and spherical washer inside the carrier.
M Planetary gear
N Washer 5. Install the planetary gear cross shaft in the
correct position.
2. Install the half shafts, spherical washers and
satellite gears.
27 - 48 9823/0300-1 27 - 48
27 - Driveline
24 - Differential
00 - General
Q R
L Planetary gear cross shaft Q Intermediate discs

R Friction discs
6. Secure the satellite gears and spherical washers
by fully inserting the gear shaft. 8.1. The first and last discs to be installed are
intermediate discs.
Figure 800.
8.2. Install the discs in an alternate order -
intermediate, friction, intermediate, friction
and continue.
F
9. Install the thrust block assembly.
Figure 803.
F Satellite gears
K Planetary gear shaft S
7. Align the shaft securing pin holes and install the

pins.
Figure 801.
9.1. Install the block with the largest internal
diameter first.
9.2. Install the bearing.
9.3. Install the block with the smallest internal
J diameter last.
10. Install the disc retaining ring.

8. Install the differential lock friction and
intermediate discs.
27 - 49 9823/0300-1 27 - 49
27 - Driveline
24 - Differential
00 - General
Figure 804. 16. Install the retaining screws and tighten.

Figure 806.
T

11. Install the planetary gear. C Crownwheel securing screws
12. Apply grease to the shim washer. 17. Heat the bearings to the minimum specified
temperature.
13. Install the shim washer on to the crownwheel.
Temperature: 100°C (211.9°F)
Figure 805.
18. Install the bearings.
Figure 807.
E
A
D
D Shim washer
E Planetary gear
14. Install the crownwheel on to the carrier. A Crownwheel bearing
U Differential carrier bearing
15. Install the retaining screws and tighten.
Standard Differential
15.1. Make sure you Install the correct new
retaining screws pre-treated with locking The annotations in the procedure refer to the
adhesive. Do not re-use the old screws. exploded view. Refer to Figure 808.
27 - 50 9823/0300-1 27 - 50
27 - Driveline
24 - Differential
00 - General

F G
A
H
C
F G
J
E
J
K
B E
D
F
M
G L
N
P
J
H
A Crownwheel bearing B Crownwheel securing screws

C Crownwheel D Shim washer
L Planetary gear cross shaft M Carrier
N Carrier bearing P Shims
Disassemble the oil draining plug and drain oil only when
the pressure is completely released.
4. Connect a pump and pressure gauge to port P1
2. Remove the axle from the machine. Refer to (PIL of the negative brake system on the axle. Using
27-20). the pump increase the pressure to the specified
value to release the pressure on the braking
3. Drain the oil from the drive head. system.
3.1. Before draining the oil make sure to Pressure: 15 ± 30bar (217.4 ± 434.8psi)
loosen the oil filler plug or the breather Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
(if installed), and wait until the internal Special Tool: Hand Pump Pressure Test (Qty.: 1)
pressure is completely released. Remove
5. Loosen the negative brake locking screws and
remove the spacers.
27 - 51 9823/0300-1 27 - 51
27 - Driveline
24 - Differential
00 - General
Figure 809.
6. Release the pressure from the pump to port P1 7. Install the negative brake locking screws without
gradually until no pressure remains. the spacers.
27 - 52 9823/0300-1 27 - 52
27 - Driveline
24 - Differential
00 - General
Figure 810.
8. Remove the pressure gauge and pump from the 13. Remove the screws from the centre cover.
axle.
Figure 812.
9. Remove the axle driveshaft. Refer to (PIL 27-51).
10. Mark the installation position of the axle arm with
respect to the drive head case.
11. Using suitable lifting equipment support the
12. Remove the axle arm securing bolts and remove
the arm and brake disc pack from the drive head
case.
Figure 811.
14. Using a lever remove the centre cover making

sure not to damage the mating faces.
27 - 53 9823/0300-1 27 - 53
27 - Driveline
24 - Differential
00 - General
N Carrier bearing
15. If replacing the crownwheel bearing remove 18. Remove the crownwheel securing screws and
the bearing thrust blocks and shims from the crownwheel from the carrier. Discard the old
crownwheel. screws
C
A Crownwheel bearing
P Shims
16. Remove the differential carrier assembly.
Figure 815.
B Crownwheel securing screws

C Crownwheel
M
19. Remove the shim washer.
M Carrier
bearing.
27 - 54 9823/0300-1 27 - 54
27 - Driveline
24 - Differential
00 - General
D Shim washer E Planetary gear
20. Remove the planetary gear. 21. Remove the shaft securing pins and half shafts.
23. Remove the half shafts, spherical washers and
satellite gears.
27 - 55 9823/0300-1 27 - 55
27 - Driveline
24 - Differential
00 - General
Figure 820.
G
F
H
J
J L
F Satellite gears G Spherical washers

H Half shafts J Shaft securing pins
K Planetary gear shaft L Planetary gear cross shaft
25. Remove the planetary gear.
27 - 56 9823/0300-1 27 - 56
27 - Driveline
24 - Differential
00 - General

K
E
F

G Spherical washers
26. Remove the shim washer. K Planetary gear shaft
Figure 822. 3. Install the half shafts, spherical washers and
D satellite gears.
Figure 825.
G
F
H
J
L
D Shim washer
Assemble H
F Satellite gears
1. Lubricate and install the washer and planetary G Spherical washers
gear. H Half shafts
Figure 823. L Planetary gear cross shaft
E
D 4. Install the cross shaft and the gear shaft.
Figure 826.
D Shim washer
E Planetary gear K
2. Partially install the planetary gear shaft, spherical
washer and satellite gear. K Planetary gear shaft
L Planetary gear cross shaft
5. Fully install the half shafts.
27 - 57 9823/0300-1 27 - 57
27 - Driveline
24 - Differential
00 - General
6. Align the shaft securing pin holes and install the Figure 829.
pins.
7. Make sure the satellite gears rotate freely on the
shafts.
Figure 827.
H
D Shim washer
10. Install the crownwheel on to the carrier.
11. Always use new crownwheel securing screws.
12. Standard screws - apply threadlocker to the
securing screws.
(High Strength)
12.1. Tighten the screws using a diagonal
sequence to the correct torque.
13. Driloc screws - tighten the screws using a
J
diagonal sequence to the correct torque.
H Half shafts
8. Lubricate and install the planetary gear.
Figure 828.
E Planetary gear
9. Apply grease to the shim washer and install on
to the crownwheel.
27 - 58 9823/0300-1 27 - 58
27 - Driveline
24 - Differential
00 - General
C
P Shims
17. Install the differential assembly into the centre
cover.
18. Replace the O-ring.
C Figure 833.
B Crownwheel securing screws

C Crownwheel
14. Heat the bearings to the specified temperature.
15. Install the bearings onto the carrier and
crownwheel.
Figure 831.
19. Install the centre cover.
100ºC 19.1. Make sure the centre cover is installed
with the oil discharge in the lowest position
when axle is installed on machine.
A Figure 834.
N
N Carrier bearing
16. If replacing the bearing install the bearing thrust
blocks and shims.
27 - 59 9823/0300-1 27 - 59
27 - Driveline
24 - Differential
00 - General
20. Install the screws in to the centre cover and 23. Secure with axle arm securing screws.
tighten to the correct torque.
Figure 836.
Figure 835.
(For: Dana 211 Series LSD)

21. Using suitable lifting equipment support the Limited Slip Differential
The annotations in the procedure refer to the
22. Install the axle arm and brake disc pack to the
exploded view. Refer to Figure 837.
drive head case.
27 - 60 9823/0300-1 27 - 60
27 - Driveline
24 - Differential
00 - General

A B
D
F G
LS1
LS1 F G
H
LS1
C
E J
LS2 J
LS2
LS3
L K M
F N
G
P
J
H Q
Q
F Q
G
R
R
S
T
U
V
W
A Crownwheel bearing B Crownwheel

C Crownwheel securing screws D Shim washer
L Planetary gear cross shaft LS1 Limited slip intermediate discs
LS2 Limited slip friction discs LS3 Ring
M Planetary gear N Washer
P Carrier Q Differential lock intermediate discs
R Differential lock friction discs S Thrust block assembly
T Disc retaining ring U Differential carrier bearing
V Ring W Carrier bearing retaining ring
Disassemble wait until the internal pressure is completely

released. Remove the oil draining plug
1. Make the machine safe. Refer to (PIL 01-03). and drain oil only when the pressure is
completely released.
27-20). 4. If replacing the crownwheel bearing:
3. Drain the oil from the drive head. 4.1. Remove two of the crownwheel securing
screws. Discard the crownwheel securing
3.1. Before draining oil make sure to loosen the screws.
oil filler plug or the breather (if installed), and
27 - 61 9823/0300-1 27 - 61
27 - Driveline
24 - Differential
00 - General
4.2. Using a suitable puller remove the Figure 841.

crownwheel bearing.
Figure 838.

B
C
8. Remove the differential lock friction and
B Crownwheel intermediate discs.
Figure 842.
Q R
bearing.
Figure 839.
R Friction discs
U
9. Remove the crownwheel securing screws and
crownwheel from the carrier. Discard the
crownwheel securing screws.
U Carrier bearing
Figure 843.
6. Remove the disc retaining ring.
Figure 840. B
B Crownwheel
T Disc retaining ring 10. Remove the shim washer, planetary gear and
limited slip disc pack.
7. Remove the thrust block assembly.
27 - 62 9823/0300-1 27 - 62
27 - Driveline
24 - Differential
00 - General
D
D Shim washer H Half shafts
E Planetary gear
11. Remove the shaft securing pins and half shafts.
Figure 848.
Figure 845.

15. Remove the planetary gear and washer.
Figure 849.
Figure 846.
M
M Planetary gear
K Planetary gear shaft N Washer
13. Remove the half shafts, spherical washers and Assemble
satellite gears.
1. Lubricate and install the planetary gear and
washer.
27 - 63 9823/0300-1 27 - 63
27 - Driveline
24 - Differential
00 - General
M Planetary gear
N Washer
5. Install the planetary gear cross shaft in the
2. Install the half shafts, spherical washers and correct position.
satellite gears.
Figure 854.
Figure 851.
H
H

H Half shafts 6. Secure the satellite gears and spherical washers
3. Partially install the planetary gear shaft and by fully inserting the gear shaft.
install the satellite gears and spherical washers. Figure 855.
Figure 852.
F
G
K
F Satellite gears
F Satellite gears K Planetary gear shaft
G Spherical washers 7. Align the shaft securing pin holes and install the
K Planetary gear shaft pins.
4. Use a dummy pin to position the satellite gear
and spherical washer inside the carrier.
27 - 64 9823/0300-1 27 - 64
27 - Driveline
24 - Differential
00 - General
Figure 856. 9.1. Install the block with the largest internal
diameter first.
9.2. Install the bearing.
9.3. Install the block with the smallest internal
diameter last.
10. Install the disc retaining ring.
J
Figure 859.

8. Install the differential lock friction and
intermediate discs.
Figure 857.
Q R

11. Install the limited slip ring to the planetary gear,
the side with the notches must be on the gear
side.
12. Install the limited slip disc pack.
Figure 860.
LS3
R Friction discs
8.1. The first and last discs to be installed are
intermediate discs.
8.2. Install the discs in an alternate order -
intermediate, friction, intermediate, friction
and continue.
9. Install the thrust block assembly.
Figure 858.
LS1
LS1 Limited slip intermediate discs

S Thrust block assembly LS2 Limited slip friction discs
LS3 Ring
27 - 65 9823/0300-1 27 - 65
27 - Driveline
24 - Differential
00 - General
12.1. Install intermediate disc first, friction disc 17.1. Make sure you Install the correct new
then alternate. retaining screws pre-treated with locking
adhesive. Do not re-use the old screws.
12.2. The last disc will be an intermediate disc.
18. Heat the bearings to the minimum specified
13. Install the planetary gear and limited slip disc
temperature.
pack.
14. Apply grease to the shim washer.
19. Install the bearings.
15. Install the shim washer on to the crownwheel.
Figure 863.
16. Install the crownwheel on to the carrier.
A
Figure 861.
U
E
P
U Differential carrier bearing
B Crownwheel
D Shim washer
E Planetary gear
P Carrier
17. Install the retaining screws and tighten.
Figure 862.
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27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ........................................................................................................................... 27-69

27-27-66 Wheel Stud .................................................................................................................... 27-85
27 - 67 9823/0300-1 27 - 67
Notes:
27 - 68 9823/0300-1 27 - 68
27 - Driveline
27 - Hub
00 - General
Introduction .................................................... 27-69 The hub is the part of the axle where the wheel
Component Identification ............................... 27-70 is mounted and where the axle shaft (if installed)
Remove and Install .................................. 27- passes through.
Some hubs are not driven and rotate due to motion
of the machine and some driven hubs may also have
reduction gearing installed.
The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.
27 - 69 9823/0300-1 27 - 69
27 - Driveline
27 - Hub
00 - General
(For: Dana 211 Series)
Figure 864. Exploded View
13
12
11
2
3 10
9
5 8
6
4 7
14
15
44 42 16 17
40 18
45
39 21
20 19
43 37
36
35 28 27
41 26
33
38
31
30
25
34 29
32 24
22
23
1 Arm casing 2 Arm bushing

3 Arm seal ring 4 Universal joint
5 Sealing ring 6 Bushing
7 Bushings 8 Top articulation pin sealing ring
9 Top articulation pin shims 10 Top articulation pin
11 Grease nipple 12 Grease nipple cap
13 Cap screws 14 Steering hub
27 - 70 9823/0300-1 27 - 70
27 - Driveline
27 - Hub
00 - General
15 Bolts 16 Washers
17 Ball cover 18 Bottom articulation joint sealing ring
19 Cap screws 20 Grease nipple cap
21 Grease nipple 22 Plug
23 Cap screws 24 Sealing washer
25 Hub cover 26 Planetary gear bearing
27 Planetary gears 28 Circlip
29 Spacer 30 Circlip
31 Shim washer 32 Nuts
33 Safety flange 34 Stud
35 Crown flange 36 Ring gear
37 Circlip 38 External bearing
39 O-ring 40 Nuts
41 Hub 42 Bolts
43 Internal bearing 44 Steering case sealing ring
45 Bottom articulation pin

Special Tools
Consumables
JCB Multi-Gasket 4102/1212 0.05L
Strength)
Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
Do not attempt any maintenance if the axle is hot. Hot

oil and components can cause personal injury. Avoid
skin contact. Wear protective gloves and glasses.
Disassemble
2. Drain the oil from the hub.
2.1. Before draining oil make sure to rotate
the hub to position the drain plug in the
drain position. Loosen the drain plug and
wait until the internal pressure is completely
released. Remove the plug and drain
oil only when the pressure is completely
released.
3. Remove the hub cover securing screws and hub
cover. If the hub cover is difficult to remove it can
be levered off making sure not to damage the
cover or the hub flange.
4. Disconnect the steering link arms from the swivel
hub.
27 - 71 9823/0300-1 27 - 71
27 - Driveline
27 - Hub
00 - General

A
B
C
A Hub cover securing screws A Planetary gears
B Hub cover
C Swivel hub 8. Remove the ring gear assembly.
5. Remove the circlips which secure the planetary 8.1. Remove the ring gear retaining ring.
gears to the cover.
Figure 869.
Figure 866.
A
A Retaining ring
A Circlips
Figure 870.
B Planetary gears
6. Make a note of the position and correct location A
of the planetary gears. B
G
Figure 867. C
D
H F E
G
A
A Lower face of gears - hub cover side
7. Using a suitable puller remove the planetary
gears from the hub cover.
27 - 72 9823/0300-1 27 - 72
27 - Driveline
27 - Hub
00 - General
E
A
A Hub
10. Remove the external hub bearing and remove
the hub.
Figure 873.
B
A
A Retaining ring
B Ring gear
C Ring gear flange
D Safety Flange
E Shim Washer B
F Ring gear retaining ring A External hub bearing
G Nuts B Hub
H Studs
11. Using a suitable hammer and drift remove the
8.2. Remove the nuts from the ring gear bearing external thrust blocks. Tap evenly around
assembly. the surface of the thrust blocks to prevent
8.3. Remove the shim washer. damage or deformation.
8.4. Remove the safety flange.
8.5. Using a suitable puller remove the ring gear.
9. Using a soft faced hammer working around the
hub, partially remove the hub.
27 - 73 9823/0300-1 27 - 73
27 - Driveline
27 - Hub
00 - General
A
A
A Thrust blocks
12. Remove the sealing ring from the swivel casing 15. Remove the trunnion bolt securing nut.
making sure not to damage the bearing seat.
16. Using a suitable puller remove the tapered
Figure 875. trunnion bolt.
A Figure 878.
A Sealing ring
13. Measure and record the dimension of the
steering stop screw adjustment position. A
Figure 876.
A Swivel hub
17. Remove the lower trunnion securing screws and
remove the trunnion and sealing ring from the
swivel hub.
14. Loosen the locknut and fully screw in the steering
stop screw to allow access to the link arm end.
27 - 74 9823/0300-1 27 - 74
27 - Driveline
27 - Hub
00 - General
A A
C
B
B C
A
B
A Sealing ring A Upper trunnion

B Lower trunnion B Shims
C Trunnion securing screws C Sealing ring
D Trunnion securing screws
18. Remove the upper trunnion securing screws and
remove the upper trunnion, shims and sealing 19. Remove the steering swivel case.
ring from the swivel hub.
Figure 881.
A Steering swivel case

20. Put a mark on the sealing ring and case to aid
21. Using a suitable puller remove the sealing ring
from the swivel case.
27 - 75 9823/0300-1 27 - 75
27 - Driveline
27 - Hub
00 - General
Figure 882. 25. Using a suitable puller remove the upper and
lower bushings.
Figure 885.
A
A Sealing ring
B Steering swivel case
22. Put a mark on the bushing and case to aid
26. Make a mark on the sealing rings and which
23. Using a suitable press remove the bushing from trunnion they are installed on to aid assembly.
the swivel case.
27. Remove the sealing rings from the trunnions.
Figure 883.
Figure 886.
A Sealing ring
24. Remove the driveshaft and universal joint B Trunnion
assembly.
28. If the trunnion cover requires replacement use a
24.1. If necessary a soft faced hammer or lever suitable press to remove from the trunnion.
may be used but make sure not to damage
the shaft, joint or casing. Figure 887.
Figure 884.
B
A
A Cover
B Trunnion
A Driveshaft and universal joint assembly
27 - 76 9823/0300-1 27 - 76
27 - Driveline
27 - Hub
00 - General
29. Remove the sealing ring and bushing from the Figure 890.
axle arm.
Figure 888.
A
A Special tool
5. Apply multi gasket to the outer surface of the
swivel case sealing ring.
Consumable: JCB Multi-Gasket
Assemble 6. Using special tool (910.06.4203) install the

swivel case sealing ring into the seat. Refer to
1. Lubricate the bushing and the bearing seat in the Special Tools (PIL 78-94).
swivel case.
Figure 891.
2. Using special tool (910.06.4209) install the
bushing into the seat. Refer to Special Tools (PIL
78-94).
Figure 889.
A
B
A Special tool
6.1. Make sure the sealing ring is correctly
positioned.
A Steering swivel case 7. If the trunnion cover was removed use a suitable
B Bushing press to install the cover to the trunnion.
3. Lubricate the outer surface of the sealing ring. Figure 892.
4. Using special tool (910.06.4207) install the

sealing ring into the seat. Refer to Special Tools
(PIL 78-94). A
A Cover
27 - 77 9823/0300-1 27 - 77
27 - Driveline
27 - Hub
00 - General
8. Install the sealing rings on to the trunnions, Figure 895.

make sure to align the marks made during
disassembly.
Figure 893.
A
B A Bushing
B Special tool
12. Lubricate the sealing ring.
A Sealing ring
B Trunnion 13. Using special tool (910.06.4210) install the
sealing rings into the seat. Refer to Special Tools
9. Lubricate the upper and lower bushings and (PIL 78-94).
install into the arm.
Figure 896.
Figure 894.
B B
A
A
A Sealing ring
A Upper bushing B Special tool
B Lower bushing
13.1. Make sure to install the sealing rings in the
10. Lubricate the bushing and the seat in the arm. correct position.
11. Using special tool (910.06.4209) install the 14. Install the driveshaft and universal joint assembly
bushing into the seat. Refer to Special Tools (PIL into the arm casing.
78-94).
Figure 897.
A
A Driveshaft and universal joint assembly
27 - 78 9823/0300-1 27 - 78
27 - Driveline
27 - Hub
00 - General
15. Lubricate the driveshaft splines and install the Figure 900.
steering swivel case.
Consumable: Special HP Grease
15.1. Make sure not to damage the dust cover
rings and sealing rings.
Figure 898.
19. Using Molikote Grease, lubricate the lower

A trunnion assembly and seat in the swivel case.
20. Install the lower trunnion assembly into the swivel
C case and secure with screws.
A Driveshaft splines 21. Tighten the upper and lower trunnion screws in a
B Grease diagonal sequence to the correct torque.
C Steering swivel case
16. Select shims measuring within the specified
thickness limits.
17. Install the shims onto the upper trunnion.
Figure 899.
B
A Upper trunnion
B Shims
18. Using Molikote Grease, lubricate the upper
trunnion assembly and install trunnion into the
swivel case.
27 - 79 9823/0300-1 27 - 79
27 - Driveline
27 - Hub
00 - General
Figure 901. 22.1. If there is movement add extra shims to the

upper trunnion. Refer to assemble - step
17
Figure 902.
23. Using a torque wrench attached to one of the

upper trunnion securing screws, turn the swivel
A hub and record the reading on the torque wrench.
This is the swivel torque.
Figure 903.
23.1. The torque must be between the specified

limits.
Torque: 40–80N·m
23.2. If the torque is greater than the specified
limits add shims to get the correct value.
Refer to assemble - step 17
24. Install the steering link arm into the swivel hub.
A Steering swivel case 24.1. Tighten the nut to the correct torque
B Lower trunnion making sure the notch on the nut is aligned
C Trunnion securing screws with the roll pin hole.
D Upper trunnion Torque: 270–300N·m
22. Using a DTI (Dial Test Indicator) and lever
measure if there is any movement or gap
between the trunnion mountings on the arm and
the swivel case.
27 - 80 9823/0300-1 27 - 80
27 - Driveline
27 - Hub
00 - General
A External bearing thrust block

B Special tool (910.04.4214)
25. Unscrew the steering stop screw until it is at the
correct adjustment position as measured during 28. Lubricate the internal bearing thrust block and
disassembly. Tighten the locknut. seat.
Figure 905. 29. Using special tool (910.06.2385) install the
internal bearing thrust block. Make sure that
the thrust block is correctly positioned. Refer to
Special Tools (PIL 78-94).
Figure 908.
C
A
B
Figure 906.
A Internal bearing thrust block

B Hub
C Special tool (910.06.2385)
30. Install the external hub bearing.
30.1. If necessary use a soft faced hammer to
gently tap the bearing in position. Make
sure to keep the bearing square to the
shaft by tapping around the edge of the
bearing.
31. Install the hub.
26. Position the thrust block of the external hub
bearing on to the special tool (910.04.4214).
Refer to Special Tools (PIL 78-94).
27. Using the special tool install the thrust block
into the hub. Make sure that the thrust block is
correctly positioned.
27 - 81 9823/0300-1 27 - 81
27 - Driveline
27 - Hub
00 - General
A A
B
B
A External hub bearing
B Hub
32. Install the ring gear and flange.
32.1. If necessary use a soft faced hammer to
gently tap the ring gear and flange in to
position. Make sure to keep square to the
shaft by tapping around the edge of the
flange and ring gear.
33. Using Tecno Lube 101 lubricate the ring gear A Ring gear
flange mating surface of the safety flange. B Ring gear flange
34. Install the safety flange. 35. Apply thread locker to the nuts and install on to
hub.
(Medium Strength)
27 - 82 9823/0300-1 27 - 82
27 - Driveline
27 - Hub
00 - General
A Retaining ring
36. Tighten the nuts to the correct torque in two 39. Measure the rolling torque of the hub.
stages using a diagonal sequence.
39.1. The torque should be within the specified
Figure 912. limits.
Torque: 7–20N·m
A Figure 915.
A Nuts
36.1. Stage 1 -
Torque: 90N·m
36.2. Stage 2 - 40. Install the planetary gears in to the cover.
Torque: 100N·m
Figure 916.
37. Install the shim washer.
Figure 913.
A A Lower face of gears - hub cover side

40.1. Make sure to align the marks made during
A Shim washer disassembly.
40.2. If new gears are used the lower face (cover
38. Install the ring gear retaining ring. Make sure the side) is as shown. Refer to Figure 916.
ring is correctly located in the seat.
27 - 83 9823/0300-1 27 - 83
27 - Driveline
27 - Hub
00 - General
41. Install the circlips which secure the planetary

gears to the cover.
Figure 917.
A Circlips
B Planetary gears
42. Install the hub cover to the swivel hub.
Figure 918.
43. Install the hub cover securing screws and tighten

to the correct torque.
Torque: 40–50N·m
Figure 919.
A
B
C
A Hub cover securing screws
B Hub cover
C Swivel hub
27 - 84 9823/0300-1 27 - 84
27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 921.

B
Remove and Install
This remove and install procedure is the same for all

wheel studs.
WARNING! If, for whatever reason, a wheel stud

is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may A
have been damaged.
Remove
C
A Wheel stud
2. Follow the general health and safety procedures. B Wheel stud hole
Refer to (PIL 01-03). C Hub carrier
3. Remove the wheel from the hub. Refer to (PIL 2. Use a nut and washer to pull the stud into the hub
27-29). carrier.
4. Push out the wheel stud. 3. Check the stud and make sure that it is installed
correctly.
Figure 920.
A 4. If the stud is loose replace the whole hub carrier
assembly.
A
A Wheel stud
5. Remove and discard all the wheel studs.
Check the condition of the wheel stud holes in the

hub carrier. If the holes are defective do not use the
hub carrier. Replace the hub carrier with a new one.
Install
1. Install the stud into the hub carrier hole.
27 - 85 9823/0300-1 27 - 85
27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ........................................................................................................................... 27-87
27 - 86 9823/0300-1 27 - 86
27 - Driveline
29 - Wheel
00 - General

WARNING If, for whatever reason, a wheel stud
Health and Safety .......................................... 27-87 is renewed, all the studs for that wheel must be
Remove and Install ....................................... 27-88 changed as a set, since the remaining studs may
have been damaged.
WARNING Wheels and tyres are heavy. Take
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury.
WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/
wheel specialist for all repair work.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Wheels installed with semi-solid tyres
are heavy. Removing and installing them requires
special equipment and training. Have the work
carried out by your JCB dealer or a tyre specialist.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a
trained specialist.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required.
Where run flat inserts have been specified for use,
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
27 - 87 9823/0300-1 27 - 87
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29 - Wheel
00 - General
Remove and Install
For: 505-20 [T4F], Front ............ Page 27-88 Figure 922.

For: 505-20 [T4F], Rear ............. Page 27-88
(For: 505-20 [T4F], Front)

changed as a set, since the remaining studs may
have been damaged.
WARNING Whenever a wheel has been A
changed, check the nut torques every two hours.
When the nuts stay tight for 8h, the interval for
checking can revert to the period stated in the E
servicing schedule.
C
Remove (One Wheel) D
1. Make the machine safe. Follow all safety

precautions. Refer to (PIL 01-03).
B
2. Put blocks 1 under the rear wheels.
A Blocks 1
3. Loosen the five wheel nuts by half a turn. B Wheel nuts
C Jack
4. Put a jack under the axle arm. Use the correct D Front wheel
jack. E Blocks 2
5. Use the jack to lift the machine until the front
wheel is off the ground.
Install
6. Put blocks 2 under the axle arm. Installation is opposite of the removal procedure and
additionally do the below steps.
7. Hold the wheel and remove the wheel nuts.
1. Make sure that the mating surfaces of the wheel
8. Remove the wheel. and axle hub are clean.
2. Tighten the wheel nuts to the correct torque
value.
Table 222. Torque table

Item Torque value
B
(1)
500N·m
(1) 505-20 Machines only
(For: 505-20 [T4F], Rear)

changed as a set, since the remaining studs may
have been damaged.
27 - 88 9823/0300-1 27 - 88
27 - Driveline
29 - Wheel
00 - General
WARNING Whenever a wheel has been 4. Make sure that the engine cannot be started.
changed, check the nut torques every two hours.
When the nuts stay tight for 8h, the interval for 5. Put blocks 1 under the front wheels.
checking can revert to the period stated in the
servicing schedule. 6. Loosen the five wheel nuts by half of one turn.
7. Put a jack under the centre of the rear axle. Use
Remove the correct jack.
1. Make the machine safe with the lift arm raised. 8. Use the jack to lift the machine until both rear
Refer to (PIL 01-03). wheels are off the ground.
2. Install the lift arm safety strut. Refer to (PIL 9. Put blocks 2 under each end of the rear axle.
06-69) 10. Hold the wheel and remove the wheel nuts.
3. Follow the general safety precautions. Refer to 11. Remove the wheel.
(PIL 01-03).
Figure 923.
D
C
A B
A Blocks 1 B Nuts
C Jack D Wheel
E Blocks 2
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29 - Wheel
00 - General
Install 1. Make sure that the mating surfaces of the wheel

and axle hub are clean.
Installation is opposite of the removal procedure and
additionally do the below steps. 2. Tighten the wheel nuts to the correct torque
value.
Table 223. Torque Table

Item Torque Value
B
(1)
500N·m
(1) 505-20 Machines only
27 - 90 9823/0300-1 27 - 90
27 - Driveline
31 - Wheel Drive Pump
Contents Page No.
27-31-00 General ........................................................................................................................... 27-93
27 - 91 9823/0300-1 27 - 91
Notes:
27 - 92 9823/0300-1 27 - 92
27 - Driveline
00 - General
Introduction .................................................... 27-93 There are variants of the transmission system. This
Technical Data ............................................... 27-96 section will help to identify which system is installed
Component Identification ............................... 27-97 on the machine.
Operation ....................................................... 27-98
To identify the applicable hydraulic system refer to
Fault-Finding ................................................ 27-105 (PIL 30-00).
Check (Operation) ....................................... 27-109
Check (Pressure) ........................................ 27-110 Machines With Gearpump Hydraulic
Bleed ........................................................... 27-116 System
Refer to the machine identification plate. Refer to
Figure 924.
The transmission code is shown in the figure. Refer

to Figure 925.
20km/h (12.4mph) = P
25km/h (15.5mph) = R
Machines With Variflow Hydraulic

System
Refer to the machine identification plate. Refer to
Figure 924.
The transmission code is shown in the figure. Refer

to Figure 925.
20km/h (12.4mph) = P
30km/h (18.6mph) = V
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27 - Driveline
00 - General
Figure 924. Identification Plate Location
27 - 94 9823/0300-1 27 - 94
27 - Driveline
00 - General
Figure 925. Identification Plate Digit
P
R
V
A Transmission code
27 - 95 9823/0300-1 27 - 95
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00 - General
Technical Data Charge pump displace- TBA

ment
Relief valve settings
Gearpump Hydraulic System Machines Maximum charge pres- 34bar (492.8psi)
sure
Transmission pump Maximum system pres- 350bar (5,072.4psi)
sure
Table 224.
Model reference A 10 VG 63 Transmission motor
Type Axial piston pump- vari-
able displacement (elec- Table 227. 20 kph and 30 kph Machine
tro proportional solenoid Model reference HMV 165E4
control) Type Variable displacement
Mounting Engine axial piston motor
Direction of rotation Clockwise Mounting Chassis
Maximum displacement 63 cc/rev Maximum displacement 165 cc/rev
Charge pump displace- 14.9 cc Minimum displacement 40 cc/rev
ment Maximum flowrate (A-B) 511
Relief valve settings Maximum loop pressure TBA
Charge pressure- max 25bar (362.3psi) Maximum case pressure 5bar (72.5psi)
Maximum system pres- 350bar (5,072.4psi) Maximum continuous
sure speed
At maximum pivot angle 3100 RPM
Transmission motor
At minimum pivot angle 3500 RPM
Table 225. 20 kph and 25 kph Machine
Model reference HMV 135EF
Type Variable displacement
axial piston motor
Mounting Chassis
Maximum displacement 135 cc/rev
Minimum displacement 35 cc/rev
Maximum flowrate (A-B) 511L/min
Maximum loop pressure TBA
Maximum case pressure 5bar (72.5psi)
Maximum continuous
speed
At maximum pivot angle 3200 RPM (Revolutions
Per Minute)
At minimum pivot angle 3700 RPM
Variflow Hydraulic System Machines

Transmission pump
Table 226.
Model reference A 4VG 65
Type Axial piston pump- vari-
able displacement (elec-
tro proportional solenoid
control)
Mounting Engine
Direction of rotation Clockwise
Maximum displacement 65 cc/rev
27 - 96 9823/0300-1 27 - 96
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00 - General
Figure 926.
F
D E
A Transmission ECU (Electronic Control Unit) B Front axle

C Front propshaft D Transmission motor
E Rear propshaft F Rear axle
G Transmission pump
27 - 97 9823/0300-1 27 - 97
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00 - General
Operation
Hydrostatic Transmission by the transmission pump output and the direction of

flow around the circuit (loop).
The hydrostatic transmission is an infinitely variable-
speed hydraulic drive system which eliminates Thus, to drive the machine forwards, one side of
the need for a conventional gearbox. The the loop feeds the oil to the transmission motor and
system comprises of an engine-driven transmission this side of the circuit becomes the high pressure
hydraulic pump which is connected by hoses to a side. The other side of the loop returns the oil from
transmission hydraulic motor to drive the wheels. the motor and this becomes the low pressure side.
The transmission pump and motor are of a variable To drive the machine in the opposite direction, the
displacement axial piston design and incorporate all direction of flow around the transmission circuit is
the necessary control valves. reversed.
The transmission hydraulic circuit is a bi-directional When the machine is stationary, there is no flow
closed loop which enables the transmission motor to around the transmission circuit. The oil pressure
be driven at various speeds in either direction. The on each side of the circuit is equal. Therefore the
motor speed and direction of rotation is determined transmission motor is prevented from turning by the
effect of a hydraulic lock in the system.
Figure 927.
A B
A Hydraulic motor B Hydraulic pump
27 - 98 9823/0300-1 27 - 98
27 - Driveline
00 - General
Transmission Pump controlled via the swash control piston. The piston
varies the angle of the tilting swashplate, which alters
The transmission hydraulic pump is a variable the displacement (stroke) of the pistons.
displacement axial piston pump, which uses the
swashplate design principle. Integral with the transmission pump is the charge
pump, which generates the control pressure for the
Rotation of the input drive shaft produces linear pump control circuits.
movement of the axial pistons. The pump output is
Figure 928.
D F
C
E
A G
L K J H
A Drive shaft B Retaining valve

C Swash control piston D Controller
E Control plate F Pressure cut of valve
G Charge pump H Suction port
J Cylinder K Piston
L Slipper pad M Swash plate
Proportional (EP) control unit The pump is part of a closed loop which supplies high
pressure to the motor. The pump port 1 and pump
This system uses an ECU (Electronic Control Unit) port 2 are the pressure supply and return lines for the
to control the pump output. motor. The direction of drive required by the operator
27 - 99 9823/0300-1 27 - 99
27 - Driveline
00 - General
dictates which port supplies high pressure and which by a set amount, according to the valve current
is the return. signal.
The proportional solenoid valves alter the pump In this way, the hydraulic power curve of the pump
output (power curve characteristic). The solenoid can be altered electrically by the current signal
valves are controlled by a current signal from the from the transmission ECU. The current signal from
transmission ECU. The solenoid valves work as a the transmission ECU is a PWM (Pulse Width
separate pressure regulating valve and vary the Modulation) signal.
charge pressure acting on the swash control piston
Figure 929.
Xa 4 Xb
3
2 6
7 1
6 5
Charge pump and control pressure

Table 228. The charge pump provides charge pressure and flow
Item Description to the main pump and the motor. Oil from the tank is
drawn through the suction filter and enters the charge
1 Charge pump
pump at port S. Some of the oil is pushed into the low
2 Main pump pressure side of the high pressure loop to make up
3 Swash control piston for leakage losses. Some is used to provide a flow for
4 Direction control valve pump control and the remainder is dumped across
5 Charge pressure relief the charge pressure relief valve into the pump case
valve for cooling and lubrication purposes.
6 High pressure relief and The charge pressure is directed through internal
make up valves drillings to the swash control piston via the
7 Pressure cut off valve proportional solenoid operated direction control
Xa
(1)
Proportional direction valve. Selection of 'forward' or 'reverse' on the
control solenoid 1 forward/neutral/reverse lever (column switch), sends
Proportional direction a signal to the transmission ECU. The ECU
Xb
(2)
control solenoid 2 energises the relevant proportional solenoid 1 or

proportional solenoid 2. The proportional solenoid
(1) Solenoid 1- engages forward direction on agri directs the charge pressure to the corresponding end
machines. of the swash control piston. The charge pressure
(2) Solenoid 2- engages forward direction on moves the swash control piston proportionally
construction machines. against the force of the centring springs and in turn
moves the pump swashplate. A feedback lever on
27 - 100 9823/0300-1 27 - 100

27 - Driveline
00 - General
the pump control piston keeps the transmission ECU transmission when large pressure peaks may occur
informed of the piston position. in the transmission circuit as the pump swashplate
angle changes rapidly.
Figure 930.
Transmission Motor
Xa Xb The transmission hydraulic motor is a bi-directional,
variable displacement axial piston motor.
The linear movement of the axial pistons produces

rotation of the output drive shaft. The motor output
is controlled via the swash control piston. The piston
varies the angle of the swashplate which alters the
displacement (stroke) of the pistons.
The angle of the swashplate swivel is regulated by

the control pressure entering at port. This is supplied
by the transmission pump and varies according to the
pump speed.
When the solenoid is not energised, the control

pressure is directed to move the displacement valve.
The displacement valve supplies oil to the swash
control piston and moves it in the direction of
Xa Proportional direction control solenoid 1 maximum displacement.
Xb Proportional direction control solenoid 2
When the solenoid is energised, the control pressure
High pressures in the transmission circuit and/or moves the displacement valve. This allows oil flow to
simultaneous operation of the machine hydraulic the swash control piston and moves it in the direction
services will load the engine. This causes the engine of minimum displacement.
rpm to decrease slightly (i.e. decreasing the pump
drive speed). Decreasing the pump drive speed During normal operation, the motor displacement
generates a lower charge pressure at the swash varies constantly with changes in pump speed.
control piston. This in turn decreases the pump
swashplate angle and output flow. In this way, there The two main loop connections from the
is full utilisation of the engine power available, and transmission pump to the transmission motor are
automatic power division between the transmission shown at connection 1 and connection 2. It may
and hydraulic services. be assumed that connection 2 is pressurised when
forward drive is selected and the connection 1 is
The maximum charge pressure that can be achieved pressurised when reverse drive is selected.
is set by the charge pressure relief valve.
Table 229.
Two high pressure relief and make-up valves set Swash An- Speed Torque Solenoid
the maximum pressure in the transmission circuit, gle
and protect the transmission pump and transmission Minimum High Low Energised
motor from over pressurisation. The valves also
function as make-up valves, allowing some of the Maximum Low High Not ener-
flow from the charge pump to enter the low pressure gised
side of the transmission circuit to make-up for oil
losses due to normal internal leakage. The start of regulation is determined by the pressure
setting of the starter screw. This adjusts the spool
The high pressure relief valves also provide a bypass of the displacement valve and this value is the
facility to enable towing of a disabled machine. Refer point where the motor begins to swing to maximum
to operators manual. displacement.
When the pressure cut-off valve reaches its The shuttle valve senses which side of the
pressure setting, it operates and vents some of transmission circuit is high pressure. The valve spool
the charge pressure back to tank via the case moves across to connect the low pressure side of the
drain. This decreases the pump swashplate angle transmission circuit to the purge valve.
proportionally. The pressure cut-off valve prevents
the high pressure relief valves from operating The purge valve operates constantly and allows
during normal accelerating or decelerating of the some of the oil in the low pressure side of the
27 - 101 9823/0300-1 27 - 101

27 - Driveline
00 - General
transmission circuit to continually vent back to tank

via the motor case drain port.
Figure 931.
Figure 932.
13
11
9
10 12 13
9
6
13 13
Item Description
Table 230. 3 Piston slipper
Item Description 4 Housing
1 Control 5 Valve plate housing
2 Swash plate 6 Control pistons
27 - 102 9823/0300-1 27 - 102

27 - Driveline
00 - General
Item Description Item Description

7 Rotating group 11 Shuttle spool
8 Through drive option 12 Purge valve
9 Speed select solenoid 13 Drive output
10 Displacement valve
Operation schematics
Figure 933. Motor In Low Speed Range
9 11
12
10
2
6
13 13
High pressure Control pressure
Low pressure Case drain / lubrication pressure
2 Swash Plate 6 Control pistons

9 Speed select solenoid 10 Displacement valve
11 Shuttle spool 12 Purge valve
13 Drive output
27 - 103 9823/0300-1 27 - 103

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00 - General
Figure 934. Motor In High Speed Range
9 11
12
10
6
2
13 13
High pressure Control pressure
Low pressure Case drain / lubrication pressure
2 Swash Plate 6 Control pistons

9 Speed select solenoid 10 Displacement valve
11 Shuttle spool 12 Purge valve
13 Drive output
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00 - General
Fault-Finding
Fault
Lack of pulling power in high range Table 231. Page 27-105
No reverse drive Table 232. Page 27-105
No forward or reverse drive Table 233. Page 27-106
Machine creeping Table 234. Page 27-106
Machine pulls away prematurely Table 235. Page 27-107
Machine movement slow to reach top speed Table 236. Page 27-107
Machine does not achieve maximum road speed Table 237. Page 27-107
Machine will not travel uphill Table 238. Page 27-108
Hydraulic oil temperature high Table 239. Page 27-108
Table 231. Lack of pulling power in high range

Cause Remedy
Check the engine. Do a complete stall test on the If OK, go to 2.
machine. If no, refer to (PIL 15-00).
Check the tyre pressures, hydraulic oil temperature If OK, go to 3.
and hydraulic oil grade. If no, repair the fault on the machine.
Check if parking brake and service brake pads are If OK, go to 4.
not binding or ceased on to the disc. If no, repair the brakes. Refer to (PIL 24-00).
Check the charge pressure. If OK, go to 5.
If no, check the filter for contamination. Check the
charge pressure relief valve. Remove, clean and
replace if necessary.
Check the control pressure X1 and X2. If OK, go to 6.
If no, remove the control valve, clean and replace.
Check the inching valve operation.
Check the Ma and Mb high pressure loop. If OK, go to 7.
If no, remove, clean and replace the pressure cut off
valve.
Check pump current with the machine blocked -
against a wall or other sturdy obstacle. If flow is low, check the electronic data systems.
Table 232. No reverse drive

Cause Remedy
Make sure that the hand brake is released. Also If OK, go to 2.
make sure that the calipers on the hand brake and If no, repair the brakes. Refer to (PIL 24-00).
the service brake are free from the disk.
Check filter for contamination. Check the charge
pressure relief valve, remove, clean and replace. If
charge pressure still low, replace drive coupling.
If X1 and X2 are low, check the control valve or
check the inching valve operation. If both OK, the
pump servo piston is worn. Replace the pump.
Check electrical solenoids on the pump and check If OK, go to 5.
continuity and switch in cab. If electrics are OK, check the control valve or check
the inching valve operation. If both OK, the pump
servo piston is worn. Replace the pump.
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00 - General
Cause Remedy
Check Ma and Mb high pressure loop. -
If no, remove and clean the pressure cut off valve
and relief valve.
If the machine moves slowly go to 6.
Check the pump current with the machine blocked -
Table 233. No forward or reverse drive

Cause Remedy
Make sure that the hand brake is released. Also If OK, go to 2.
make sure that the calipers on the hand brake and If no, repair the brakes. Refer to (PIL 24-00).
the service brake are free from the disk.
Check filter for contamination. Check the charge
pressure relief valve, remove, clean and replace. If
charge pressure still low, replace drive coupling.
If X1 and X2 are low, check the control valve or
check the inching valve operation. If both OK, the
pump servo piston is worn. Replace the pump.
Check electrical solenoids on the pump and check If OK, go to 5.
continuity and switch in cab. If electrics are OK, check the control valve or check
the inching valve operation. If both OK, the pump
servo piston is worn. Replace the pump.
Check Ma and Mb high pressure loop. -
If no, remove and clean the pressure cut off valve
and relief valve.
If the machine moves slowly go to 6.
Table 234. Machine creeping

Cause Remedy
Does machine drive at idle speed with the drive If OK, go to 2.
switch in neutral.
Remove control valve, clean and replace. Check the
inching valve operation.
Check the neutral swash angle adjuster. -
Adjust as necessary.
Check pump current with machine blocked against a -
wall or other sturdy obstacle. If flow is low, check the electronic data systems.
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Table 235. Machine pulls away prematurely

Cause Remedy
Does the machine drive at idle speed with the drive If OK, go to 2.
selected. If no, machine is OK.
Check the eninge idle speed. Refer to (PIL 15-00). If OK, go to 3.
If no, adjust as necessary.
Table 236. Machine movement slow to reach top speed

Cause Remedy
Is machine on level ground. If OK, go to 2.
If no, reposition the machine.
Check the hydraulic oil temperature. If OK, go to 3.
If no, refer to table 9.
Check parking brake and service brake pads are not If OK, go to 4.
binding or ceased on to the disc. If no, repair the brakes. Refer to (PIL 24-00).
If no, check filter for contamination. Check the charge
pressure relief valve, remove clean and replace.
Check control pressure X1 and X2. If OK, go to 6.
If no remove control valve, clean and replace. Check
inching valve operation.
Check DA valve setting. -
Make sure that between 1000 RPM (Revolutions Per
Minute) and 1100 RPM the machine begins to move.
Table 237. Machine does not achieve maximum road speed

Cause Remedy
If no, check the filter for contamination. Check the
charge pressure relief valve. Remove, clean and
replace if necessary.
Check the Ma and Mb high pressure loop. If OK, go to 6.
valve.
Check calibration of the LLMC (Longitudinal Load If OK, go to 7.
Moment Control) chassis angle sensor. If no, refer to (PIL 33-66).
Check X1 pressure (motor). If OK, go to 8.
If no, remove, clean and replace the displacement
valve. If still not OK, go to 8.
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Cause Remedy
Check flushing pressure maintaining valve operation. If OK, go to 9.
Replace if necessary.
Check pump current with machine blocked against a -
wall or other sturdy obstacle. If flow is low, check the electronic data systems.
Table 238. Machine will not travel uphill

Cause Remedy
Check parking brake and service brake pads are not If OK, go to 4.
binding or ceased on to the disc. If no, repair the brakes. Refer to (PIL 24-00).
If no, check filter for contamination. Check the charge
pressure relief valve, remove clean and replace.
Check Ma and Mb high pressure loop. If OK, go to 7.
valve.
Check calibration of the LLMC chassis angle sensor. -
If no, refer to (PIL 33-66).
Table 239. Hydraulic oil temperature high

Cause Remedy
Check tank. Check if the hydraulic oil level too low.
Check if the hydraulic oil has wrong viscosity.
Check cooler/radiator. Check if the cooling fan defective.
Check for oil contamination.
Check if the by-pass valve defective.
Check if the cooler blocked- internal/external.
Check the hose routing.
Check transmission pump. Check for incorrect valve settings.
Check for defective flushing valve.
Check for pump mechanical wear.
Check the drive motor. Check for insufficient cooling.
Check for defective surge valve.
Check for motor mechanical wear.
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Check (Operation) To access the fault codes and diagnostic software,

use servicemaster. Refer to (PIL 33-57).
This section helps you to identify faults on a

faulty unit (valve, actuator, ram, solenoid, proximity
switch, etc). After you identify the fault refer to the
disassembly, inspection and test procedures in the
steering section.
To identify the various components mentioned in the

fault finding procedures, refer to (PIL 33-00) and (PIL
30-00).

2. Do the relevant electrical checks before you do
the hydraulic test procedures.
3. Make sure that the hydraulic fluid is at the
specified working temperature.
4. Check the condition of the hydraulic fluid.
5. Drain and refill if necessary. Refer to (PIL 30-00).
6. Make sure to remove all the contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
7. Install new seals and O-rings before you
assemble the hydraulic components.
Machine ECU (Electronic Control Unit)s will generate

a fault code for some fault conditions. Refer to (PIL
33-57).
Transmission Limp Modes

When applicable the transmission ECU provides
restricted or modified transmission operation if faults
are detected by the ECU. Typical 'limp mode' forms
of operation are given below.
Table 240.
Mode Possible Reason
Limp mode- speed limit Speed sensor error
reduced Transmission tempera-
ture above 95 (202.9)
Electronic Fault Codes

The machine will log some system faults as an
error code. These error codes can be accessed with
the correct diagnostics software tool, using a laptop
computer connected to the machine CAN (Controller
Area Network) system.
For fault code descriptions refer to (PIL 33-57).
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Check (Pressure)
Special Tools WARNING If a 4 wheel drive machine is to be

Description Part No. Qty. raised and the engine/transmission run, make
Pressure Gauge (0-600 892/00280 2 sure all four wheels are raised off the ground.
Bar) Make sure the machine is correctly supported by
the correct axle stands. If only one pair of wheels
Pressure Gauge (0-70 892/00346 2 is raised, the machine could move and fall off the
Bar) stands.
General Precautions Make the machine safe. Refer to (PIL 01-03).

WARNING When working close to the machine
with the machine running, protective clothing Follow all the care and safety procedures. Refer to
must be worn, i.e. Safety glasses, ear protection, (PIL 01-03).
gloves etc.
Make sure that the hydraulic fluid is at the correct
working temperature of 50°C (121.9°F).
Pump Port Identification

Construction 25kph machines
Table 241. Ports

Port Service Adaptor Pressure gauge
Size Part number
MA High pressure 7/16 in- 20 UNF 2B TBA 0–500bar (0.0–
7,246.3psi)
MB High pressure 7/16 in- 20 UNF 2B TBA 0–500bar (0.0–
7,246.3psi)
X1 Actuating pressure 7/16 in- 20 UNF 2B TBA 0–50bar (0.0–
724.6psi)
724.6psi)
Table 242. Ports

Port Service Adaptor Expected Read- Pressure gauge
Size Part number ing
G Charge pressure HSP TBA 25 ± 2bar 0–50bar (0.0–
supply to trans- (362.3 ± 29.0psi) 724.6psi)
mission motor constant
test point
Table 243. Ports

Port Service Adaptor Maximum Pressure gauge
Size Part number Reading
MH Measuring high 7/16 in- 20 UNF TBA Use servicemaster software
pressure test 2B
point
S Suction port 1 5/16 in- 12 UN TBA Positive up to 0–50bar (0.0–
2B 4bar (58.0psi) 724.6psi)
T1/T2 Leakage fluid 7/8 in- 14 UNF TBA TBA TBA
and filling/drain 2B
ports
T3 Hydraulic return 3/4 BSP TBA TBA TBA
line via oil cooler
27 - 110 9823/0300-1 27 - 110

27 - Driveline
00 - General
Figure 935. Pump

G P
FA FE B,A
PS X2
T2 X1
MB
R
S
X1
MA
S T1 X2
Q
MB/MA
G Charge pressure MA High pressure 1

MB High pressure 2 MH High pressure test point
S Suction port T1 Leakage fluid fill / drain port 1
T2 Leakage fluid fill / drain port 2 T3 Hydraulic return line
X1 Actuating pressure 1 X2 Actuating pressure 2
27 - 111 9823/0300-1 27 - 111

27 - Driveline
00 - General
Agri 34kph machines
Table 244. Ports

Port Service Adaptor Pressure gauge
Size Part number
MA High pressure 7/16 in- 20 UNF 2B TBA 0–500bar (0.0–
7,246.3psi)
MB High pressure 7/16 in- 20 UNF 2B TBA 0–500bar (0.0–
7,246.3psi)
724.6psi)
724.6psi)
Table 245. Ports

Port Service Adaptor Expected Read- Pressure gauge
Size Part number ing
G Charge pressure HSP TBA 25 ± 2bar 0–50bar (0.0–
supply to trans- (362.3 ± 29.0psi) 724.6psi)
mission motor constant
test point
Table 246. Ports

Port Service Adaptor Maximum Pressure gauge
Size Part number Reading
MH Measuring high 7/16 in- 20 UNF TBA Use servicemaster software
pressure test 2B
point
S Suction port 1 5/16 in- 12 UN TBA Positive up to 0–50bar (0.0–
2B 4bar (58.0psi) 724.6psi)
T1/T2 Leakage fluid 1 1/16 in- 12 UN TBA TBA TBA
and filling/drain 2B
ports
T3 Hydraulic return 3/4 BSP TBA TBA TBA
line via oil cooler
Table 247.
Solenoid Actuated Test Point for Control Pressure Test Point for Operating Pres-
sure
a (Reverse) X1 MB
b (Forward) X2 MA
27 - 112 9823/0300-1 27 - 112

27 - Driveline
00 - General
Figure 936. Pump

Xa
Xb
A Mb X1 MH
Fa R
X2
Ps
S
B Ma G
T2
G Charge pressure MA High pressure 1

MB High pressure 2 MH High pressure test point
S Suction port T1 Leakage fluid fill / drain port 1
T2 Leakage fluid fill / drain port 2 T3 Hydraulic return line
X1 Actuating pressure 1 X2 Actuating pressure 2
Pressure Tests 6. Using a 3/16 allen key remove the blanking plugs
in the X1 and X2 pump ports.
Charge pressure 6.1. If you need to test the pressure for one
1. Make the machine safe. Refer to (PIL 01-03). travel direction only, connect one gauge and
blank one port.
2. Follow all the care and safety procedures. Refer
to (PIL 01-03). 7. Connect the specified test gauges to the pump
ports X1 and X2 (the port direction depends on
3. Stop the engine. machine model).
4. Connect the specified test gauge to the test point. Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 2)
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1) 8. Select the drive direction using the column
switch.
5. Run engine at maximum speed with the
transmission in neutral and check the pressure is Notice: To prevent oil overheating and machine
as specified. Refer to (PIL 30-00). damage, make sure that the test does not take
longer than the specified time. Make sure you
Pump actuating pressure allow sufficient time between tests for the oil to
cool.
9. Run the engine at full RPM (Revolutions Per
2. Follow all the care and safety procedures. Refer Minute) for the specified time, release the hand
to (PIL 01-03). brake and make sure that there is no wheel slip.
3. Stop the engine. Duration: 10s
4. Make sure the machine will not move in forward 10. Make sure that the pressure is of the specified
or reverse as this test requires the transmission value. Refer to (PIL 30-00).
to be in drive. Block the machine against a wall
or other sturdy obstacle. 11. If the pressure is not as specified, check or
replace the relief valves and test again.
5. Raise the lift arm and install a maintenance strut.
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27 - Driveline
00 - General
Pump high pressure 4. Raise the lift arm and install a maintenance strut.
5. Apply the throttle gradually. The road wheels
2. Follow all the care and safety procedures. Refer should start to turn 1400- 1500 RPM
to (PIL 01-03). (Construction) / 1000- 1100 RPM (Agricultural).
3. Stop the engine. Pump solenoid
4. Make sure the machine will not move in forward 1. Make the machine safe. Refer to (PIL 01-03).
or reverse as this test requires the transmission
to be in drive. Block the machine against a wall 2. Follow all the care and safety procedures. Refer
or other sturdy obstacle. to (PIL 01-03).
5. Raise the lift arm and install a maintenance strut. 3. Make sure the machine will not move in forward
Refer to (PIL 06-69). or reverse as this test requires the transmission
6. Using a 3/16 allen key remove the blanking plugs or other sturdy obstacle.
in the Ma and Mb pump ports.
7. Connect the specified test gauges to the pump Refer to (PIL 06-69).
ports Ma and Mb.
Special Tool: Pressure Gauge (0-600 Bar) (Qty.: 5. Select the drive direction using the column
2) switch.
8. Select drive direction using column switch. 6. Make sure the current at the solenoid are as
follows.
Notice: To prevent oil overheating and machine
damage, make sure that the test does not take 6.1. When the machine is in neutral the mA on
longer than the specified time. Make sure you pump should be 0.
allow sufficient time between tests for the oil to 6.2. When drive selected, the mA should hop on
cool. to the specified value and then increase as
RPM increases.
9. Run the engine at full RPM for the specified time,
release the hand brake and make sure that there Current: 0.33A
is no wheel slip. 6.3. The reading should be of the specified value
Duration: 10s at full throttle.
Current: 0.975A
10. Make sure that the pressure is of the specified
value. Refer to (PIL 30-00). Figure 937.
11. If the pressure is not as specified, check or Xa
replace the relief valves and test again. Xb
Electrical System Tests
Electronic start of drive
WARNING If a 4 wheel drive machine is to be
raised and the engine/transmission run, make
sure all four wheels are raised off the ground.
Make sure the machine is correctly supported by
the correct axle stands. If only one pair of wheels
is raised, the machine could move and fall off the
stands.

Xa Engages forward direction on agri machines
2. Follow all the care and safety procedures. Refer Xb Engages forward direction on construction
to (PIL 01-03). machines
3. Raise all four wheels off the ground and support

the machine with axle stands.
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27 - Driveline
00 - General
Motor Solenoid Testing 5. Select the drive direction using the column
switch.
6. Make sure the current at the solenoid are as
2. Follow all the care and safety procedures. Refer follows.
to (PIL 01-03).
6.1. When the applicable speed is selected, the
3. Make sure the machine will not move in forward current at the solenoid should be as shown
or reverse as this test requires the transmission in table. Refer to Table 248.
or other sturdy obstacle. The higher readings will only be achieved when the
machine is moving and not blocked.
Table 248.
Speed Machine Type Reading
High (hare) 25km/h (15.5mph) and 20km/h 0.35–1A
(12.4mph) construction
30km/h (18.6mph) and 20km/h 0.3–1A
(12.4mph) agri
Low (tortoise) All 0.3A
Figure 938. Construction Motor
A
A Solenoid
Figure 939. Agri Motor
A
A Solenoid
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27 - Driveline
00 - General
Bleed 10. With the forward/reverse switch (in the cab) at

neutral, 'jog' the engine using the starter. The
Special Tools pressure gauge should show a small rise in
Description Part No. Qty. pressure as the engine turns. If so, operate the
Pressure Gauge (0-40 892/00278 1 starter until the engine starts.
Bar) 11. As air leaves the system, the charge pressure
(as indicated on the gauge) should rise to
If a new or rebuilt pump is being installed, always refill the specified value. If charge pressure is not
the pump with filtered oil prior to start up. Disconnect registered on the gauge, shut-down and find the
the hose from the tank port 1 and pour 1.5L of oil into cause.
the pump. Use the correct oil to refill. Refer to (PIL
75-03). Pressure: 25bar (362.3psi)
The following start-up procedure should always be 12. After you get the correct charge pressure,
followed when starting up a new installation or when operate the drive system 10 times in all the
restarting an installation in which either a pump or directions with the engine at idle.
motor has been removed from the system.
13. Slowly increase the engine speed while you
WARNING! It is necessary to disable the continue to operate the system.
machine during this procedure (wheels lifted off 14. Operate the system in all directions several times
the ground, work function disconnected etc). with the engine running at maximum speed.
1. Make the machine safe. Refer to (PIL 01-03). 15. Make sure that the charge pressure at maximum
engine speed is as specified. Refer to (PIL
2. Place the machine safely onto blocks, so that all 15-00).
four wheels are clear of the ground. Make sure
that the machine is stable. 16. Stop the engine and remove the gauge.
WARNING! It is not possible to vent all residual 17. Check the system for leaks and top up the fluid
pressure. Loosen the connection one full turn as necessary.
and allow the pressure to dissipate. Keep all
parts of your body well clear of pressurised
hydraulic oil and wear protective glasses.
WARNING! Fine jets of fluid at high pressure

can penetrate the skin. Keep face and hands
well clear of pressurised fluid and wear protective
glasses. If fluid penetrates your skin, get medical
help immediately.
3. Fill the hydraulic tank with the correct fluid via a

10 micron no by-pass filter. Refer to (PIL 75-03).
4. Install the maintenance strut. Refer to (PIL
06-69).
5. Make sure that the pump inlet line from the
hydraulic filter to the pump unit is filled with fluid,
by slackening the hose connection at the pump.
6. Bleed air from the pump casing by slackening the
case drain hose connections at tank port 1 and
tank port 2 until the oil flows freely.
7. Tighten the connections again.
8. Connect the specified pressure gauge to the
charge pressure test point.
9. Prevent the engine from starting.
27 - 116 9823/0300-1 27 - 116

27 - Driveline
00 - General
Figure 940.
T1
T2
A Charge pressure test point

T1 Tank port 1
T2 Tank port 2
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27 - Driveline
00 - General
Remove and Install
Figure 941.
A
B A
B
K
D
J
E
H F
A Pump securing bolts B Solenoid electrical connectors

C Hose 1 D Flow / return to motor hoses
E Flange bolts F Flange
G Hose 2 H Hose 3
J Electrical connector K Hose 4
Remove 6.2. Plug all the open ports and hoses to prevent
contamination.
7. Remove the flange bolts.
30-00). 8. Remove the flanges and the flow / return hoses
from the pump.
3. Remove the hydraulic pump. Refer to (PIL 30-11)
or (PIL 30-12). 9. Remove the pump securing bolts from the engine
coupling.
4. Attach suitable lifting equipment to the pump.
10. Withdraw the pump assembly horizontally until
5. Disconnect the solenoid connectors and the inner coupling is clear before lifting out.
electrical connector.
5.1. Put a label on the connectors to help
Install
installation. 1. The installation procedure is the opposite of the
6. Disconnect the hoses 1, 2, 3 and 4.
steps.
6.1. Put a label on the hoses to help installation.
27 - 118 9823/0300-1 27 - 118

27 - Driveline
00 - General
2. Use a reduced length Allen key to tighten the

flange bolts.
Figure 942. 8mm modified Allen key
A
A 15mm
3. Check the hydraulic oil level and top up as
4. Follow the pump start-up procedure before
operating the engine or pump. Failure to carry out
the procedure may cause the transmission pump
and drive motor to be damaged. Refer to Bleed
(PIL 27-31).
27 - 119 9823/0300-1 27 - 119

27 - Driveline
32 - Wheel Drive Motor
Contents Page No.
27-32-00 General ......................................................................................................................... 27-121
27 - 120 9823/0300-1 27 - 120

27 - Driveline
00 - General

Component Identification ............................. 27-121 The gearbox has a serial number stamped on a data
Remove and Install ..................................... 27-122 plate as shown.
A Data plate
A Data plate
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27 - Driveline
00 - General
Remove and Install
Remove 7. Remove the flange bolts and disconnect the loop

hoses from the flanges.
8. Disconnect the electrical connections to the
2. Discharge the hydraulic pressure. Refer to (PIL solenoid valves.
30-00).
9. Disconnect the speed sensor electrical
3. If the machine has the trailer brake option, make connector.
sure to release the accumulator pressure. To do
this turn the ignition key to off and apply the brake 10. Attach suitable lifting equipment to the lifting eye
pedal repeatedly until there is no resistance at and support the weight of the motor.
the pedal.
11. Place a suitable trolley below the motor.
4. Remove the undershields.
12. Remove the motor mounting bolts from the three
5. Remove the propshafts. Refer to (PIL 27-47). mounts.
6. Disconnect the motor hydraulic hoses. 13. Lower the motor out of the chassis and onto the
trolley.
6.1. Put a label on the hoses to help installation.
14. Wheel the motor clear of the machine.
6.2. Plug all the open ports and hoses to prevent
contamination. 15. Remove the drive motor securing bolts and
remove the motor from the mounting frame.
6.3. Take care to catch any oil spillage when you
disconnect the hoses to the drive motor.
27 - 122 9823/0300-1 27 - 122

27 - Driveline
00 - General
Figure 945.
B
A
A F
E
K A G H H
A H
A Drive motor securing bolts B Drive motor

C Flange bolts D Loop hoses
E Flange F Solenoid valve
G Drive motor mounting bolts H Drive motor mounts
J Mounting bracket K Speed sensor electrical connector
27 - 123 9823/0300-1 27 - 123

27 - Driveline
00 - General
Install
steps.
1.1. Check condition of motor mounts - replace
if worn or damaged.
1.2. After replacing the transmission motor do
not start the engine until the correct start-
up procedure has been carried out. Failure
to carry out the procedure may cause
the transmission pump and motor to be
damaged. Refer to (PIL 27-31).
1.3. Check the hydraulic oil level and top up as
27 - 124 9823/0300-1 27 - 124

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-127
27 - 125 9823/0300-1 27 - 125

Notes:
27 - 126 9823/0300-1 27 - 126

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-127 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-128 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-128 ground.
Tyre materials are usually synthetic rubber, natural

rubber, fabric and wire, along with other compound
chemicals. They consist of a tread and a body.
The tread provides traction while the body ensures
support.
Make sure that the tyres are kept in good condition.

27 - 127 9823/0300-1 27 - 127

27 - Driveline
33 - Tyre
00 - General
Health and Safety Check (Condition)

DANGER Make sure that all tyres are inflated
to the correct pressure. Refer to the machine Always drive with consideration for the condition
operator manual. of the tyres. Incorrect tyre pressures will affect the
stability of the machine. Check the tyres daily for
WARNING An exploding tyre can kill. Inflated the correct tyre pressure and signs of damage. For
tyres can explode if over-heated or over-inflated. example:
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/ • Signs of distortion (bulges).
wheel specialist for all repair work. • Cuts or wear.
WARNING Wheels and tyres are heavy. Take • Embedded objects (nails, etc.).
to ensure that they cannot fall and cause injury. Install the valve caps firmly to prevent dirt from
entering the valve. Inspect for leaks when you check
WARNING Do not use the machine with the tyre pressures.
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed Inspect the tyre valve for leaks, when you check the
limitation of the tyres installed and do not operate tyre pressures.
at more than their recommended maximum
speed.
Tyre Inflation
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which Always try to maintain the tyre pressure to the
at high speeds may endanger life. recommended settings. Using a machine with under-
WARNING Deflate the tyre you wish to change inflated tyres means:
before removing the wheel from the machine.
• Decreasing the machines stability.
Air pressure in the tyres can cause the tyre and
• Higher tyre temperatures.
rim sections to explode causing serious injury or
• Excessive strain of the tyre fabric.
death. Never loosen the nuts that hold the inner
• Causes bulging of the sidewalls.
and outer wheel halves together when there is air
• Shortens the tyres life.
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a Using the machine with over-inflated tyres is
wheel made for a solid tyre. Do not install a solid dangerous:
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for • It causes excessive tensile loads in the fabric:
your machine, contact your local JCB dealer or a this makes a tyre more susceptible to cuts and
trained specialist. punctures.
WARNING When ordering tyres, you must Do not cut or weld on the rim of an inflated tyre.
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are After checking or amending the tyre pressure always
shown in the Operator's Manual. On no account replace and secure the valve cap.
should you use tyres of other designations
without first gaining approval from the machine Always deflate the tyre before removing foreign
manufacturer. obstacles from the tread.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully Procedure
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode. These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure,
call in a qualified tyre mechanic. The tyre mechanic
should use a tyre inflation cage and the correct
equipment to do the job.
1. Prepare the wheel. Before you add air to the tyre,

make sure it is correctly installed on the machine
or installed in a tyre inflation cage.
27 - 128 9823/0300-1 27 - 128

27 - Driveline
33 - Tyre
00 - General
Figure 946.
2. Prepare the equipment.

2.1. Use only an air supply system which
includes a pressure regulator. Set the
regulator no higher than 1.38 bar (20 psi)
above the recommended tyre pressure.
2.2. Use an air hose fitted with a self-locking air
chuck and remote shut-off valve.
3. Add the air.
3.1. Make sure that the air hose is correctly
connected to the tyre valve. Clear other
people from the area. Stand behind the
tread of the tyre while adding the air.
3.2. Inflate the tyre to the recommended
pressure. Do not over-inflate.
27 - 129 9823/0300-1 27 - 129

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-131
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27 - Driveline
47 - Propshaft
00 - General
00 - General
Remove and Install
Consumables Remove
JCB Threadlocker 4101/0250 0.01L 1. Make the machine safe with the lift arm raised.
and Sealer (Medium Refer to (PIL 01-03).
4101/0251 0.05L
Strength) 2. Remove the central access panels. Refer to (PIL
Special MPL-EP 4003/1501 0.4kg 06-06).
Grease 4003/1506 12.5kg
3. Put marks on both propshaft companion flanges
4003/1510 50kg
and the sliding joints before removal to help
during the installation procedure.
WARNING Before disconnecting any propshaft,
make sure you block both sides of all wheels 4. Remove the front propshaft.
to prevent machine movement. The park brake
will become ineffective or may only operate on 2 4.1. Support the propshaft.
wheels (depending on machine specification).
Figure 947.
E F
G H J
A Straps B Strap retaining bolts

C Front propshaft D Nuts
E Motor F Speed sensor ring
G Bolts H Rear propshaft
J Rear axle
4.2. Remove the nuts and bolts to 5.3. Remove the bolts and straps to disconnect
disconnect the propshaft coupling from the the propshaft from the axles.
transmission.
4.3. Remove the bolts and straps to disconnect Install
the propshaft form the axles.
5. Remove the rear propshaft. removal procedure. Additionally do the following
steps.
5.1. Support the propshaft.
1.1. Tighten the bolts to the correct torque value
5.2. Remove the nuts and the bolts to for the machine.
disconnect the propshaft coupling from the
transmission.
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27 - Driveline
47 - Propshaft
00 - General
1.2. Lubricate the sliding joints with the specified

grease only, then align the shafts against
identification marks previously made or, in
the case of a shaft being replaced use the
manufacturer's alignment markings.
1.3. Apply sealant to the threads of all the flange
bolts.
(Medium Strength)
1.4. New straps must always be installed.
1.5. The propshaft must have both ends exactly
on the same plane as shown below. Refer to
Refer to Figure 948. The yokes must not be
at right angles or at an intermediate angle.
Refer to Refer to Figure 948.
Figure 948.
X Same plane (correct)

Y Right angle (not correct)
Z Intermediate angle (not correct)
1.6. Adjust the speed sensor. Refer to (PIL
33-84-09).

Item Size Nm
B M10 x 20 G8.8 Agri 43
Plus Machine
G M10 x 20 G8.8 Agri 43
Plus Machine
B M10 x 25 G10.9 60
Construction
Machine
G M10 x 25 G10.9 60
Construction
Machine
27 - 132 9823/0300-1 27 - 132

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-135
27 - 133 9823/0300-1 27 - 133

Notes:
27 - 134 9823/0300-1 27 - 134

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-135 The driveshaft is a mechanical component for
Disassemble and Assemble ........................ 27-136 transmitting torque and rotation, usually used to
connect other components of the driveline that
cannot be connected directly because of distance
or the need to allow for relative movement between
them.
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27 - Driveline
51 - Driveshaft
00 - General
For information on driveshaft disassembly and

assembly procedure, Refer to: PIL 27-27-00.
27 - 136 9823/0300-1 27 - 136

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-09 Levelling System .............................................................................................................. 30-8
30-00-12 Load Sense System ....................................................................................................... 30-16
30-00-49 Schematic Symbols ........................................................................................................ 30-17
30-00-50 Schematic Circuit ........................................................................................................... 30-21
30-03 Tank
30-03-00 General ........................................................................................................................... 30-41
30-03-12 Suction Strainer .............................................................................................................. 30-46
30-04 Filter
30-04-00 General ........................................................................................................................... 30-49
30-04-09 Return Line .................................................................................................................... 30-51
30-04-60 Pilot Pressure Supply Main ............................................................................................ 30-53
30-11 Gear Pump
30-11-00 General ........................................................................................................................... 30-57
30-12 Variable Displacement Pump
30-12-00 General ........................................................................................................................... 30-71
30-15 Cylinder / Ram
30-15-00 General ........................................................................................................................... 30-77
30-15-06 Lift Arm ........................................................................................................................... 30-80
30-15-08 Lift Compensating .......................................................................................................... 30-83
30-15-34 Steering .......................................................................................................................... 30-86
30-15-99 Seal Kit ........................................................................................................................... 30-96
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-101
30-51 Lift Arm Control Valve Block
30-51-00 General ......................................................................................................................... 30-107
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-114
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-115
30-51-21 Load Sense Relief Valve .............................................................................................. 30-119
30-51-24 Flow Regulator ............................................................................................................. 30-121
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-125
30-60-15 Joystick ......................................................................................................................... 30-127
30-60-27 Auxiliary Circuit ............................................................................................................ 30-129
30-60-90 Flow Regulator ............................................................................................................. 30-130
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-133
30-93 Hose
30-93-00 General ......................................................................................................................... 30-137
30-93-03 Lift Arm ......................................................................................................................... 30-140
30-97 Connectors
9823/0300-1
2018-01-24
30-97-00 General ......................................................................................................................... 30-145
30-97-03 Quick Release Coupling .............................................................................................. 30-148
30-97-09 Adaptor ......................................................................................................................... 30-150
30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-152
30-97-24 Push Lock Fitting ......................................................................................................... 30-154
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-155
9823/0300-1
2018-01-24
Acronyms Glossary
ARV Auxiliary Relief Valve

HBCV Hose Burst Check Valve
HVCS Hydraulic Variable Control Solenoid
Valve
LS Load Sense
LSD Limited Slip Differential
LSRV Load Sense Relief Valve
ORFS O-Ring Face Seal
QRC Quick Release Coupling
SRS Smooth Ride System
9823/0300-1
2018-01-24
Notes:
9823/0300-1
2018-01-24
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-09 Levelling System .............................................................................................................. 30-8
30-00-12 Load Sense System ....................................................................................................... 30-16
30-00-49 Schematic Symbols ........................................................................................................ 30-17
30-00-50 Schematic Circuit ........................................................................................................... 30-21
30 - 1 9823/0300-1 30 - 1
Notes:
30 - 2 9823/0300-1 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3 The hydraulic system is a power transmission system
Health and Safety ........................................... 30-4 that uses the force of flowing liquids to transmit power
Diagram ........................................................... 30-5 to specific components in a machine.
Clean ............................................................... 30-5
To help you trace specific hydraulic problems to
Check (Condition) ............................................ 30-6 a faulty unit (valve, actuator, ram etc.), refer to
Check (Leaks) ................................................. 30-7 Fault finding (PIL 30-00). Once you have traced the
Check (Level) .................................................. 30-7 faulty unit, refer to the relevant section for removal,
disassembly and checking instructions.
To help identify circuits, valves, rams etc. mentioned

in the fault finding procedures, refer to the hydraulic
schematic diagrams (PIL 30-00).
• Before you begin fault finding, read the Health

and Safety Information (PIL 30-00).
• Make simple checks before you remove or
disassemble a major component.
• Make sure that the hydraulic fluid is at the
correct working temperature (50 °C, 122 °F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure.
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
and leakage and can lead to major problems.The
main contaminants can be classified as follows:
30 - 3 9823/0300-1 30 - 3
00 - General
00 - General
1. Solid Particles - sand, fibres, metallic particles, Health and Safety

welding scale, sealing materials and wear
particles etc.
Hydraulic Pressure
2. Liquid - usually water and incompatible oils and Hydraulic fluid at system pressure can injure you.
greases. Before connecting or removing any hydraulic hose,
3. Gases - Air, sulphur dioxide etc. which can create hose line must be vented. Make sure the hose
corrosive compounds if dissolved in the fluid. service line has been vented before connecting or
removing hoses. Make sure the machine cannot be
These contaminants can appear during
manufacture, assembly and operation.
WARNING! Fine jets of fluid at high pressure can
System Identification penetrate the skin. Keep face and hands well clear of
pressurised fluid and wear protective glasses. If fluid
There are two variants of the hydraulic system. This penetrates your skin, get medical help immediately.
will help to identify which system is installed on the WARNING! Take care when disconnecting hydraulic
machine: Refer to Figure 949. Refer to Figure 950. hoses and fittings as the oil will be hot.
Machines with a gearpump hydraulic system WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
1. Refer to the machine identification plate. the machine if a hose or hose fixture is damaged.
2. If the identification digits are "5A4" = construction
machine gearpump.
Machines with a variflow hydraulic system
Notice: Do not allow dirt to enter the system. Before
1. Refer to the machine identification plate. disconnecting any part of the system, thoroughly
clean around the connection. When a component
2. If the identification digits are "5A5" = agri variflow has been disconnected, always install protective
gearpump. caps and plugs to prevent dirt ingress.Failure to
follow these instructions will lead to dirt entering the
Figure 949. Identification Plate Location
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
Figure 950. Identification Plate Digit
V
T
30 - 4 9823/0300-1 30 - 4
00 - General
00 - General
Diagram Clean
Special Tools
Hydraulic State Colour Codes Description Part No. Qty.
Hydraulic Flushing Rig 892/01255 1
Some diagrams in this section use colours to
represent the different hydraulic system states. Refer
to Figure 951.
Cleaning Operation
The purpose of cleaning oil is to remove
Figure 951.
contaminants of all types and sludge by filtering
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
manual.
1 2 3 4 5 6 7
1 Lock up Procedure
2 Cavitation
1. Connect the Hydraulic flushing rig in place of the
3 Exhaust
hydraulic filter.
4 Neutral
5 Servo Special Tool: Hydraulic Flushing Rig (Qty.: 1)
6 Pressure
7 Maximum pressure 2. Run the system for sufficient time to pump all the
hydraulic fluid through the unit.
3. Disconnect the cleaning unit and reconnect the
filter.
4. Top up the system with clean hydraulic fluid as
required.
Figure 952.
A Hydraulic flushing rig
Contaminant Standards
Dirt that damages your system is in many cases
too small to be seen with the eye. The particle
size is measured in microns (1 micron = 0.001 mm
(0.0000394 in).
Listed below are a few typical comparisons:
30 - 5 9823/0300-1 30 - 5
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Condition)

0.000315 in)
• Human Hair = 70 microns (0.07 mm, 0.00275
in) Hydraulic Hoses
• Grain of Salt = 100 microns (0.1 mm, 0.00394
in) WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
The smallest particle visible to the naked eye is use the machine if a hose or hose fixture is
40 microns (0.00157) approximately. Standards will damaged.
often be quoted to ISO (International Standards WARNING Fine jets of fluid at high pressure can
Organisation) for which literature can be obtained. penetrate the skin. Keep face and hands well
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 6 9823/0300-1 30 - 6
00 - General
00 - General
Check (Leaks) Check (Level)

Notice: If the fluid is cloudy, then water or air
has contaminated the system. This could damage External Sight Gauge
the hydraulic pump. Contact your JCB dealer
immediately. 1. Make the machine safe with the boom lowered.
1. Make the machine safe. 2. Get access to the hydraulic oil level indicator and
hydraulic oil filler cap.
2. Open the access covers.
3. Check the hydraulic oil level indicator. The
3. Check the hydraulic hoses for damage. hydraulic oil level must be visible in the level
indicator.
4. Close the access covers.
4. Top up oil level if necessary:
5. If necessary, contact your JCB dealer.
4.1. Remove the hydraulic oil filler cap.
4.2. Add hydraulic oil.
4.3. Install the filler cap.
30 - 7 9823/0300-1 30 - 7
00 - General
09 - Levelling System
Operation
Table 250. Parallel Lift- Typical Systems

Parallel Lift- System 1 Example of a system with single displacement ram at
the rear of the lift arm pivot
Parallel Lift- System 2 Example of a system with single and twin displace-
ment rams forward of the lift arm pivot
Parallel lift (S1) When the lift arm ram extends or lowers the lift arm,
the displacement ram extends or retracts. The ram
Ram operation displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
The following describes a typical system: with the ground.
The parallel lift system operates when the lift arm

extends or lowers.
Figure 953. Single displacement ram at the rear of the lift arm pivot
N P
P
N
N Displacement ram P lift arm ram

Q Tilt ram R Forks
30 - 8 9823/0300-1 30 - 8
00 - General
Lift Arm Raise Cycle This allows oil to feed back to the rod side of the
displacement ram.
When lift spool is selected, the neutral circuit is
blocked and oil feeds to the lift ram hose-burst check- Displacement/ lift link valve is installed between the
valve. Oil flows through free flow direction of HBCV lift spool and the tilt spool. The function of this valve
(Hose Burst Check Valve) and raises the lift arm. is to allow a restricted flow of oil into the tilt circuit to
increase the lift force.
Oil is forced out of the head side of displacement ram
as the lift arm extends. The oil cannot pass the tilt The ARV (Auxiliary Relief Valve) opens to protect
spool, as the spool is not selected. Instead, it flows the tilt ram from over pressurisation. The anti-
to the head side of tilt ram. Oil displaced from the rod cavitation feature of valve makes sure that the tilt and
side of the tilt ram increases pilot pressure in HBCV. displacement rams will not cavitate.
Figure 954.
A
D
B
T
E F
A
C
B
J
L
K
P
M
G
H
C Lift spool D Tilt spool

E ARV 1 F ARV 2
G Lift ram H HBCV 1
J Displacement ram K Tilt ram
L HBCV 2 M Lift link valve
30 - 9 9823/0300-1 30 - 9
00 - General
Lift Arm Lower Cycle spool, as the spool is not selected. Instead, it flows
through free flow direction of HBCV to the rod side
When the lift spool is selected, the neutral circuit is of the tilt ram.
blocked and oil feeds to the rod side of the lift ram. Oil
displaced from the head side of the lift ram increases Displaced oil from the displacement ram closes the
pilot pressure in HBCV and allows oil out of the lift check valve in displacement/ lift link valve.
ram back to tank, thus lower the lift arm.
The ARV opens to protect the tilt ram from over
As the lift arm lowers, oil is forced from the rod side pressurisation. The anti-cavitation feature of valve
of the displacement ram. The oil cannot flow past tilt makes sure that the tilt and displacement rams will
not cavitate.
Figure 955.
A
D
B
T
E F
A
C
B
J
L
K
P
M

E ARV 1 F ARV 2
G Lift ram H HBCV 1
Parallel lift (S2) When the lift arm ram extends or lowers the lift arm,
the displacement ram extends or retracts. The ram
Ram operation displaces oil, then the oil flows to the tilt ram which
will extend or retract and will keep the forks parallel
The following describes a typical system: with the ground.
The parallel lift system operates when the lift arm Machines have a single or twin displacement rams,
extends or lowers. dependent on the machine variant.
30 - 10 9823/0300-1 30 - 10
00 - General
Figure 956. Displacement ram forward of the lift arm pivot
N P
Q
N P
N Lift arm displacement ram P Lift arm ram

Q Tilt ram R Forks
S Lift arm pivot
30 - 11 9823/0300-1 30 - 11
00 - General
Lift arm raise cycle This allows oil to feed back to the rod side of the
displacement ram.
When the lift spool is selected, the neutral circuit is
blocked and oil feeds to the lift ram HBCV. Oil flows A displacement/ lift link valve is installed between the
through free flow direction of HBCV and lifts the lift lift spool and the tilt spool. The function of this valve
arm. is to allow a restricted flow of oil into the tilt circuit to
increase the lift force.
Oil is forced out of the rod side of displacement ram
as the lift arm extends. The oil cannot flow past the tilt The ARV opens to protect the tilt ram from over
spool, as the spool is not selected. Instead, it flows to pressurisation. The anti-cavitation feature of the
the rod side of tilt ram. Oil displaced from the rod side valve makes sure that the tilt and displacement rams
of the tilt ram increases pilot pressure in the HBCV. will not cavitate.
Figure 957. Lift arm raise cycle (machines with single displacement ram)
A
D
B
T
E F
A L
C
B
J
K
P
M
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 12 9823/0300-1 30 - 12
00 - General
Figure 958. Lift arm raise cycle (machines with two displacement rams)
A
D
B
T
E F
A
C
B
K
J
P
J
L
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 13 9823/0300-1 30 - 13
00 - General
Lift arm lower cycle flows through the free flow direction of the HBCV to
the head side of the tilt ram. Oil displaced from the
When the lift spool is selected, the neutral circuit is rod side of the tilt ram feeds back to the rod side of
blocked and oil feeds to the rod side of the lift ram. Oil the displacement ram.
displaced from the head side of the lift ram increases
pilot pressure in HBCV and allows oil out of the lift Displaced oil from the displacement ram closes the
ram back to tank, lowering the lift arm. check valve in displacement/lift link valve.
As the lift arm lowers, oil is forced from the head side The ARV opens to protect the tilt ram from over
of the displacement ram. The oil flow cannot pass pressurisation. The anti-cavitation feature of the
the tilt spool, as the spool is not selected. Instead, it valve makes sure that the tilt and displacement rams
will not cavitate.
Figure 959. Lift arm lower cycle (machines with single displacement ram)
A
D
B
T
E F
A L
C
B
J
K
P
M
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 14 9823/0300-1 30 - 14
00 - General
Figure 960. Lift arm lower cycle (machines with two displacement rams)
A
D
B
T
E F
A
C
B K
J
P
J
L
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 15 9823/0300-1 30 - 15
00 - General
12 - Load Sense System
12 - Load Sense System pressure of another service. This is not the case with
flowshare.
Operation The pressure compensator valves for each service

react to the differing load pressures. For example,
when a pressure compensator valve is subjected to
The schematic diagrams show a typical system. For a higher load sense pressure from another service,
machine specific schematics, refer to the schematics it reacts to reduce the flow to its service, ensuring
circuits. that the associated ram operates at a constant
speed, regardless of the increase in the main system
Neutral pressure.
Oil from the primary pump flows to the inlet-outlet
section of the control valve. When the main system
Main system pressure relief
pressure reaches a preset limit, the spring tension The maximum main system pressure is controlled by
in the flushing valve is overcome and oil is returned limiting the maximum load sense pressure.
back to the tank.
When a service ram reaches the end of its stroke, or
The secondary pump supplies oil to the steer circuit the service meets resistance and generates pressure
and to the main hydraulic system, via the steer above a preset value in the load sense line, the
priority valve. When the steering is operated, the load sense relief valve opens and load sense oil
priority valve spool moves to divert all the oil flow from is dumped to tank, preventing further pressure rise.
the secondary pump to the steering circuit. The flushing valve operates as normal.
Oil from the pump flows to the pilot pressure supply For figure, refer to Load sense system, Diagram (PIL
valve and the fan motor. The valve supplies pilot 30-00-12).
pressure oil to the servo control lever.
For figure, refer to Load sense system, Diagram (PIL

30-00-12).
One service operated

When a service is operated such as boom extend,
the movement of the control lever allows pilot
pressure oil to actuate the service spool. Oil passes
across the service spool to the applicable pressure
compensator valve. The valve opens and diverts
oil to the load sense gallery and to the load hold
check valve. Pressure in the load sense gallery
increases and the flushing valve begins to close.
Main system pressure continues to increase until the
load hold check valve opens and the boom extend
ram operates.
The main system pressure will now be equal to the

load sense pressure (load from the boom lift ram)
plus the force of the flushing valve spring.
Oil from the other side of the ram flows across the
service spool and back to tank in the normal way.
For figure, refer to Load sense system, Diagram (PIL

30-00-12).
Multiple Service Operation

In the normal hydraulic system the services are
connected in parallel, this means that when multiple
services are operated simultaneously, the speed
of one service can be affected by the operating
30 - 16 9823/0300-1 30 - 16
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-17 Complex hydraulic components and circuits can
Diagram ......................................................... 30-18 be described to the engineer by using graphical
symbols. The tables illustrate and give a brief
description for some of the more common symbols
used.
There are many symbols in use and it would

be impossible to include them all here. However
it should be noted that most are only variations
or refinements on the basic principles explained
here. If more detailed information is required you
are recommended to obtain a copy of BS2917 or
IS01219.
Once familiar with the symbols, the engineer can use

hydraulic circuit diagrams as an aid to fault finding. It
will be possible to see the complete hydraulic circuit
and decipher the relationship between hydraulic
components.
30 - 17 9823/0300-1 30 - 17
00 - General
Diagram Table 254. Directional control valves

Symbol Description
Used to enclose sever-
Table 251. General al valves indicating they
are supplied as one unit
Symbol Description
Spring
Flow restriction affected 3-Position, 4-port spring
by viscosity centered pilot operated
valve
Direction of flow 3-position, 6-port spring
centered manually oper-
Indication of rotation ated valve
3-Position, 4-port spring
Indication of direction centered solenoid & pilot
and paths of flow pressure operated valve
3-Position, 4-port spring
Variable control centered detent hand
operated valve
Non-return valve
Table 252. Cylinder Rams

Non-return valve with
Symbol Description back pressure spring
Single acting Pilot operated non-re-
turn valve
Double acting
One way restrictor

Double ended
High pressure selector

Double acting with
(shuttle valve)
damping at rod area end
Throttling orifice - nor-

mally closed
Table 253. Pumps and Motors
Symbol Description
Variable capacity pump Throttling orifice - nor-
two directions of flow mally open
Fixed capacity motor

one direction of flow Relief valve
Fixed capacity motor

two directions of flow
Variable restrictor
Variable capacity motor
one direction of flow
Variable capacity motor

two directions of flow
30 - 18 9823/0300-1 30 - 18
00 - General
Table 255. Energy Symbol Description

Transmissions and Conditioning Filter or strainer
Symbol Description
Working line, return or
feed Water trap
Pilot control
Drain lines
Flexible pipe Cooler - with no indica-
tion of coolant flow
Line junction Cooler - indicating direc-

tion of coolant flow
Heater
Crossing lines
Table 256. Control Mechanisms
Symbol Description
Rotating shaft - one di-
rection
Rotating shaft - two di-
rections
Detent
Air bleed Locking device
Line plugged, also pres-

sure test point Over centre device
Line plugged with take-
off line Simple linkage
QRC (Quick Release
Coupling) - connected General control
QRC - disconnected
Push button operated
Tank - return line above
fluid level Lever operated
Tank - return line below

Pedal operated
fluid level
Stem operated
Header tank
Spring operated
Pressure sealed tank Roller operated
Accumulator Roller trip operated (one

directional)
Solenoid one winding
Solenoid two windings
30 - 19 9823/0300-1 30 - 19
00 - General
Symbol Description
Electric motor operated
M
Internal pressure pilot

operated
External pressure pilot

operated
Pressure operated
spring release
Pilot operated by sole-
noid pilot valve
Pilot operated by a so-
lenoid or separate pilot
valve
Pressure gauge
Pressure switch
30 - 20 9823/0300-1 30 - 20
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-21 A schematic wiring diagram is a simplified pictorial
Component Identification ............................... 30-22 representation of the machines hydraulic circuit. It
Diagram ......................................................... 30-25 shows the components of the circuit as simplified
hydraulic symbols, and the connections between
the different components. The schematic diagram
is used to troubleshoot problems and to make
sure that all the connections have been made and
that everything is present. Detailed schematics for
individual systems are given in the relevant PIL
section.
30 - 21 9823/0300-1 30 - 21
00 - General
Figure 961. Neutral Circuit Hoses
333/h2928-14
A Item 230 (White) B Item 270 (Grey)

C Item 160 (Brown)
Table 257.
Item Quantity Description
10 1 WA Feed Pipe
20 1 WA Steel Pipe_Tank Port_AG RI
30 - 22 9823/0300-1 30 - 22
00 - General
Item Quantity Description

30 2 1"SAE Split Flange Clamp
50 2 Clamp Plate
60 2 Clamp Dia 25-25
70 1 Bolt Flanged Hex M8 X 90 G 8.8
90 1 O Ring
100 4 Cap Screw M10 X 30 G12.9
120 1 Adaptor 3/8BSPx3/8BSPx3/8
150 1 Hose -04 BSP LP 3130mm C
160 1 Ga Steer Hose Brown Agri
190 1 Hose -12 SAE HP 2020mm B
210 1 Hose -04 BSP HP 2450mm B
220 1 Hose -06 BSP LP 640 A
230 1 Ga Hose 5/8" BSP HP 3000mm
White
240 1 Hose -04 BSP HP 2400mm C
250 1 Hose -06 BSP LP 2170mm B
260 1 Hose - 06 BSP LP 900mm B
270 1 Ga Hose 5/8" BSP HP 2420mm
Grey
290 2 Tee Adaptor M/F/F
300 1 Screw M8 X 12 Lg
310 3 Cable Tie 300mm
320 1 Clip Harness
330 3 Adaptor Pressure Test
340 1 WA Steel Pipe T
370 1 Hose -16 BSP LP 710mm A
380 1 Adaptor G5/8A X 3/4 SAE
390 1 Check Valve
400 1 BSP Adaptor 5/8X5/8X1/4
430 1 Adaptor 3/4SAE X G5/8
460 1 WA Hyd. Rtn Plate
520 2 WA Harness Tie Plate
530 1 In Line Check Valve
540 1 ABI Agri Engine Hoses
550 1 Clamp (2 Pieces)
30 - 23 9823/0300-1 30 - 23
00 - General
Figure 962. Neutral Circuit Schematic
A Variable pump B Gear pump

C Fan motor and radiator D TB valve with check valve
E Valve block F Steer orbital valve
G Hydraulic tank H Valve block- load control (park brake)
J Large hydraulic tank K Steel tube
L Hose's
30 - 24 9823/0300-1 30 - 24
00 - General
Diagram
Figure 963. For Construction Machines................................................................................. Page 30-27

Figure 964. For Agri Plus Machines.......................................................................................Page 30-31
Figure 965. For Agri Machines............................................................................................... Page 30-35
30 - 25 9823/0300-1 30 - 25
Notes:
30 - 26 9823/0300-1 30 - 26
00 - General
Page 30-28 Figure 963. For Construction Machines Page 30-29

31 11 6
29
12 OR 47
11 37 24
32 38
44
7
21 20
30
25
43
3 8
9
19
10
51
27
53
22
33 23
45
16 22
57
14
17 54 22
55 58 56
1
36
28
34
35
46
3333-G2233-10_SHEET 1
30 - 27 9823/0300-1 30 - 27
00 - General
Page Page
30-28 30-29
Figure 963. (Part 1 of 2) 31
12 OR 47
32
44
30
25
43
3
51
27
53
Page 30-29
33 23
45
16
57
17 54
55 58 56
1
34
46
30 - 28 9823/0300-1 30 - 28
00 - General
Page Page
30-28 30-29

11
29
11 37 24
38
7
21 20
9 8
19
10
Page 30-28
22
22
14
22
36
28
35
3333-G2233-10_SHEET 1
30 - 29 9823/0300-1 30 - 29
00 - General
30 - 30 9823/0300-1 30 - 30
00 - General
Page 30-32 Figure 964. For Agri Plus Machines Page 30-33
31 6
29
12 OR 47
24
32 38
44 11 37
30 26
7
5 21
20
43 9
3
45 8
19
53 60
18
51 22
33 23
16 22
57
14
54
17 22
55 59 56 28
36
46 52 39 13
22
15
41
40
3333-G2233-10_SHEET 2
30 - 31 9823/0300-1 30 - 31
00 - General
Page Page
30-32 30-33
12 OR 47
32
44
30 26
43
3
45
53
18
51
Page 30-33
33 23
16
57
54
17
55 59 56
46 52 39
41
40
30 - 32 9823/0300-1 30 - 32
00 - General
Page Page
30-32 30-33
29
24
37 38
11
7
21
20
8
19
60
22
Page 30-32
22
14
22
28
36
22 13
15
41
3333-G2233-10_SHEET 2
30 - 33 9823/0300-1 30 - 33
00 - General
30 - 34 9823/0300-1 30 - 34
00 - General
Page 30-36 Figure 965. For Agri Machines Page 30-37

31 11 6
29
12 47
24
11 37
38
44 32
7
30
21
20
26
3 43 8
51 9
19
60
27
53
22
33
45 23
16
22
57
14
17 54 22
55 58 56
1 36
28
35
4
34
46
3333-G2233-10_SHEET 3
30 - 35 9823/0300-1 30 - 35
00 - General
Page Page
30-36 30-37
12 47
44 32
30
26
3 43
51
27
53
Page 30-37
33
45 23
16
57
17 54
55 58 56
1
35
34
46
30 - 36 9823/0300-1 30 - 36
00 - General
Page Page
30-36 30-37
Figure 965. (Part 2 of 2) 11 6
29
24
11 37
38
7
21
20
8
9
19
60
Page 30-36
22
22
14
22
36
28
35
4
3333-G2233-10_SHEET 3
30 - 37 9823/0300-1 30 - 37
00 - General
Table 258. 36 Poppet valve assembly-

2 port
1 Hydraulic pump 37 Accumulator- 6.89bar
36cc/16cc + LSPV (99.9psi)
2 Valve block- agri. 38 Accumulator 18.62bar
3 Valve block load control (269.9psi)
4 Valve block- construc- 39 Pump- variable LS
tion (Load Sense) 45cc
5 Plug & brake T/Brake 40 Bosch 65cc pump
valve 41 Motor- piston- 165cc
6 Poppet valve- 2 port 2 (Linde)
position 43 Check valve 5bar
7 Non SRS lift ram (72.5psi)80L/min
110X60 44 Rear axle dana 211 Pin
8 P561 GA tilt ram Mtg 34'
130X75 45 Oil cooler
9 P561 GA ram displace- 46 Pressure transducer
ment 70X40 500bar (7,246.3psi) M14
10 GA ram extension 70 X 47 Front axle dana 211
50 LSD (Limited Slip Differ-
11 ABI lift dual C-bal valve ential) 34'
12 Front axle dana 211 Hd 51 Check valve
34' 52 Pump- gear- 14cc
13 GA hitch ram 276bar (4,000.0psi)
14 Ram- hydraulic pin lock- 53 1/2" Bspf male/female
ing CV body
15 Ball valve Inc lever 54 ABI small hydraulic tank
16 Hydac filter housing 55 ABI large hydraulic tank
17 Suction strainer 56 2" moulded hose
18 Radiator- Agri 57 Hose- 06 Bsp LP
19 ABI extend HBCV (Hose 270mm
Burst Check Valve) 58 WA Hydraulic Rtn plate
20 ABI tilt HBCV 59 WA Hydraulic Rtn plate
21 Adaptor. G1/4A - 7/16 60 GA ram extension 70 X
SAE 50
22 6 way solenoid C/O
valve
23 Filler breather cap
24 Pressure transducer
25 Fan motor 11cc
26 Variable fan motor
27 Radiator- construction
28 Accumulator
29 SRS (Smooth Ride Sys-
tem) lift ram 110X60
30 Steer valve + shocks
31 GA steer mode valve
5A4
32 Steer mode valve
33 In line check valve
34 63cc piston pump
(Bosch)
35 Motor- piston- 135cc
(Linde)
30 - 38 9823/0300-1 30 - 38
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-41

30-03-12 Suction Strainer .............................................................................................................. 30-46
30 - 39 9823/0300-1 30 - 39
Notes:
30 - 40 9823/0300-1 30 - 40
03 - Tank
00 - General
Introduction .................................................... 30-41 The hydraulic tank holds excess hydraulic oil to
Remove and Install ....................................... 30-42 accommodate volume changes due to the following.
• Cylinder ram extension and contraction.

• Temperature driven expansion and contraction.
• Hydraulic oil leaks.
The tank is also designed to aid in the separation

of air from the fluid and it also acts as a heat
accumulator to cover losses in the system when peak
power is used.
The tank also houses filters or strainers that help to

separate dirt and other particulates from the oil.
The cleanliness of this component is critical. Refer

to: PIL 30-00-00.
30 - 41 9823/0300-1 30 - 41
03 - Tank
00 - General
Remove and Install
5.2. Disconnect the tank link hose from the small

Remove hydraulic tank.
5.3. Working below the machine put a label on
WARNING! Make the machine safe before the hydraulic hoses to help identification
working on it. Park the machine on level ground when replacing.
and lower the loader arm. Stop the engine and
remove the ignition key. Make sure the park 5.4. Disconnect the hydraulic hoses.
brake is engaged. Disconnect the battery to 5.5. Remove the fuel tank bolts 1.
prevent the engine being started. Block all four
wheels. 5.6. Using appropriate lifting equipment remove
the tank from the machine.
WARNING! Hydraulic fluid at system pressure
can injure you. Before connecting or removing 6. Remove the large hydraulic tank as follows:
any hydraulic hose, residual hydraulic pressure
6.1. Remove the drain plug 2 and drain tank
trapped in the service hose line must be vented.
contents into a suitable clean container.
Make sure the hose service line has been
vented before connecting or removing hoses. Do 6.2. Slacken the clip and disconnect the hose
not start the engine with loose or open hose from the large hydraulic tank.
connections.
6.3. Disconnect the hose from the tank strainer.
1. Make the machine safe. Refer to (PIL 01-03). 6.4. Working below the machine put a label on
the hydraulic hoses to help identification
2. Release the hydraulic pressure. refer to hydraulic when replacing.
system- general, refer to (PIL 30-00).
6.5. Disconnect the hydraulic hoses.
3. Remove the undershield. Refer to (PIL 06-06).
6.6. Remove the fuel tank bolts 2.
4. Remove the hydraulic filter cover. Refer to (PIL 6.7. Using appropriate lifting equipment
06-06). attached to the lifting brackets remove the
5. Remove the small hydraulic tank as follows: tank from the machine.
5.1. Remove the drain plug 1 and drain tank

contents into a suitable clean container.
30 - 42 9823/0300-1 30 - 42
03 - Tank
00 - General
Figure 966.
B
A
C D
A Drain plug 1 B Drain plug 2

C Clip D Hose
Figure 967.
E L
H
K
F
J
G
E Small hydraulic tank F Bolts 1
30 - 43 9823/0300-1 30 - 43
03 - Tank
00 - General
G Tank link hose H Lifting brackets

J Tank strainer K Bolts 2
L Large hydraulic tank
30 - 44 9823/0300-1 30 - 44
03 - Tank
00 - General
Install
steps also:
1.1. Make sure that the hydraulic hoses are
attached to the correct tank connectors.
1.2. Fill the tank with clean hydraulic fluid. Refer
to (PIL 30-00).
1.3. Make sure all hose connections are tight
and check for leaks.
30 - 45 9823/0300-1 30 - 45
03 - Tank
12 - Suction Strainer
12 - Suction Strainer
Introduction
The suction strainer is a component used for trapping

large and coarse particles, preventing them entering
the hydraulic system. The strainer is usually located
inside the hydraulic tank, at the hydraulic pump
suction port.
30 - 46 9823/0300-1 30 - 46
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-49

30-04-09 Return Line .................................................................................................................... 30-51
30-04-60 Pilot Pressure Supply Main ............................................................................................ 30-53
30 - 47 9823/0300-1 30 - 47
Notes:
30 - 48 9823/0300-1 30 - 48
04 - Filter
00 - General
Introduction .................................................... 30-49 Hydraulic filters are an important part of the
Component Identification ............................... 30-50 machines hydraulic system. Metal particles are
continually produced by mechanical components
and need to be removed along with other
contaminants.
The hydraulic filter assemblies are designed to filter

all the contamination that is generated through use
to the required level of cleanliness.
Filters are positioned in many different locations.

Refer to the relevant hydraulic filter for the location
and removal procedure.
The filters must be serviced to the requirements

of the machine maintenance schedules. To ensure
optimum performance and reliability it is important
that the machine's hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.
30 - 49 9823/0300-1 30 - 49
04 - Filter
00 - General
• Hydraulic tank suction strainer. Refer to: PIL

There are three hydraulic filters installed on the 30-03-12.
machine. • Pilot pressure supply filter. Refer to: PIL
30-04-60. (Gear pump machines only)
• Hydraulic return filter. Refer to: PIL 30-04-09.
Figure 968.
A
A Hydraulic return filter B Tank suction strainer

C Pilot pressure supply filter
30 - 50 9823/0300-1 30 - 50
04 - Filter
09 - Return Line
09 - Return Line
Remove and Install
Figure 969.
A Filter head B Element

C Bolts
Remove 4. Get access to the top of the hydraulic tank. The

filter is located next to the filler cap.
5. Clean the top of the tank around the filter.
6. Remove the filter head securing bolts.
2. Install the safety strut.
Refer to: PIL 06-69-03. 7. Pull the filter head up from the tank until the
elements are visible.
8. Plug the open port to prevent contamination.
30 - 51 9823/0300-1 30 - 51
04 - Filter
09 - Return Line
9. Remove the filter element.
Install
1. Install the new element.
2. Replace the filter head onto the top of the tank
and secure using the bolts.
3. Check the hydraulic oil level and top up as
required.
30 - 52 9823/0300-1 30 - 52
04 - Filter
60 - Pilot Pressure Supply Main
Remove and Install
4.1. Use a spanner of the specified size -

Remove measured across the flats - to remove the
filter bowl.
1. Make the machine safe. Length/Dimension/Distance: 24mm
Refer to: PIL 01-03. 4.2. Carefully remove the filter bowl.
2. Discharge the hydraulic pressure. 4.3. Remove the filter and seal from the valve
Refer to: PIL 30-00-00. block.
4.4. Discard the seal.
3. Get access to the Pilot Pressure Supply Valve.
5. Use a suitable cleaning fluid to clean the filter at
3.1. Clean the area around the valve.
every applicable service interval.
3.2. Put a suitable size container below the filter
bowl. 6. Make sure that the filter is free from
contamination. If the filter is defective replace it
4. Remove the filter. with a new one.
7. At the applicable service interval replace the filter
with a new one.
Figure 970.
A Pilot pressure supply valve B Filter bowl
30 - 53 9823/0300-1 30 - 53
04 - Filter
C Seal D Filter
30 - 54 9823/0300-1 30 - 54
04 - Filter
Install
1. Install filter.
1.1. Use a new seal and install the filter into the
valve block.
1.2. Install the filter bowl.
2. Fill the hydraulic system to the correct oil level.
30 - 55 9823/0300-1 30 - 55
11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ........................................................................................................................... 30-57
30 - 56 9823/0300-1 30 - 56
11 - Gear Pump
00 - General
00 - General Technical Data

Technical Data ............................................... 30-57
2 Stage (Double pump)
Operation ....................................................... 30-59 Table 259. Double Pump
Check (Pressure) .......................................... 30-60 Direction of rotation Clockwise
Disassemble and Assemble .......................... 30-62 Theoretical displace- 0.000036m³
ment per RPM (Revolu-
tions Per Minute)- Main
services pump (mount-
ing flange end)
Theoretical displace- 0.000016m³
ment per RPM-Cooling
fan pump
Temperature range -20–106°C (-4.0–
222.7°F)
Control pressure 8.5–13.5bar (123.2–
195.7psi)
Maximum pressure- sec- 260 (3,768.1)
tion 1 port EF
tion 1 port P
tion 2
Maximum speed 2600 RPM
Minimum speed 500 RPM
Maximum input shaft 272N·m
torque
30 - 57 9823/0300-1 30 - 57
11 - Gear Pump
00 - General
Figure 971. Typical Double Pump
D
C
Figure 972. Typical Triple Pump
A
D
B
C
A Main services section
B Steering section (if fitted)
C Cooling fan section
D Steering priority valve
30 - 58 9823/0300-1 30 - 58
11 - Gear Pump
00 - General
Operation
The pump is a gear type and driven by the engine. the gears come into mesh the oil is forced through the
The separate sections of the gear pump assembly outlet port, or through an internal port into the integral
supply hydraulic oil to the main hydraulic circuits, to priority valve depending on the type of pump.
the steering circuit and to the hydraulic cooling fan
circuit. Some oil is allowed to circulate behind the bushes to
hold them in balance against the gears and minimise
The separate sections of the gear pump operate oil leakage.
individually as described below.
Lubrication is provided by the hydraulic oil,which is
The working principle of a gear pump depends on the directed around the unit via oil ways, by the motion
meshing of two spur gears. Oil is picked up on the of the meshing gears.
suction side of the pump by the gears and carried
round between the gear teeth and the pump body. As For the priority valve operation, refer to (PIL 25-03).
Figure 973.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
Table 260. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 59 9823/0300-1 30 - 59
11 - Gear Pump
00 - General
Check (Pressure) 4.2. Install the flow meter and the load valve
between the hose and the pump.
4.3. Make sure the load valve and flow meter
Pump Flow- Main Services Pump are connected the correct way round (with
WARNING Make the machine safe before getting the direction arrow pointing away from the
beneath it. Make sure that any attachments on pump).
the machine are correctly attached. Engage the Figure 975.
park brake, remove the ignition key, disconnect
the battery.
Notice: Make sure the load valve is in the fully
open position (adjusting knob screwed fully out)
before starting the pressure test. Failure to do this E
could damage the pump.
WARNING Take care when disconnecting
hydraulic hoses and fittings as the oil will be hot.
The gear pump assembly has isolated sections that

supply hydraulic oil to the main services circuits, to
the steering circuit and to the hydraulic cooling fan
circuit. To find if the pump, steer circuit or services D
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow all the health and
safety information. Refer to Hydraulic System-
Health and Safety (PIL 30-00). D Main services pump priority valve port (EF)
E Cooling fan pump adaptor
3. Release the hydraulic pressure. Refer to
Hydraulic System- Discharge and Pressurise 5. Start the engine and put the hydraulic system up
(PIL 30-00). to the specified working temperature.
Figure 974. Temperature: 50°C (121.9°F)
B 6. Set the steering and control valve block spools to
the neutral position.
7. Set the engine speed to 2200 RPM (Revolutions
Per Minute).
8. Carefully adjust the load valve to set the gauge
reading to
Pressure: 245bar (3,550.7psi)
9. Check and record the flow reading. Refer to
C A technical data (PIL 30-00-00).
A Flow meter
10. If the flow reading is low, or you do not get the
B Pressure gauge
required pressure. Refer to fault finding, (PIL
C Load valve
30-00).
4. Connect a flow meter and a pressure gauge
11. To check the priority valve. Refer to steering, (PIL
of specified value and a load valve into the
25-00).
discharge line from the main service pump as
follows. 12. Switch off the engine and allow to cool after the
Pressure: 0–400bar (0.0–5,797.1psi) test.
4.1. Disconnect the hose from the priority valve. 13. Disconnect the test equipment and connect the
hydraulic hoses again.
30 - 60 9823/0300-1 30 - 60
11 - Gear Pump
00 - General
Pump Flow- Cooling Fan Pump

1. To test the cooling fan pump:
1.1. Make the machine safe with the lift arm
lowered. Refer to (PIL 01-03).
1.2. Make sure that you follow all the health
and safety information. Refer to Hydraulic
System- Health and Safety (PIL 30-00).
1.3. Release the hydraulic pressure. Refer
to Hydraulic System- Discharge and
Pressurise (PIL 30-00).
1.4. Disconnect the hose from the pump adaptor
and install the flow meter and load valve
between the hose and the pump.
1.5. Make sure the load valve and flow meter
are connected the correct way round (with
the direction arrow pointing away from the
pump)
2. Repeat steps 5 to 13 above (main service pump).
30 - 61 9823/0300-1 30 - 61
11 - Gear Pump
00 - General
Consumables 5. Remove the splined coupling and the O-rings 2.

Description Part No. Size Discard the O-rings 2.
JCB Hydraulic Fluid OP 4002/2001 5L 6. Separate the pump body 2 from the end cover.
46 4002/2005 20L
4002/2003 200L 7. Remove the drive gear from its bore. Pushing it
out of the rear body will also remove the balance
JCB Multi-Gasket 4102/1212 0.05L
plate 1 complete with the seal 1 and the seal
JCB Threadlocker 4101/0250 0.01L energiser 1.
Strength) 8. Discard the seal 1 and the seal energiser 1. Note
the position of the driveshaft and the balance
Double pump plate 1 to ensure correct assembly.
9. Remove the driven gear 1, the balance plate 2,
Before you disassemble the pump, make sure that
the seal 2, and the seal energiser 2. Discard the
the performance is as per the specified value. Refer
seal 2 and the seal energiser 2.
to Hydraulic system- Technical Data, Refer to (PIL
30-00). If the performance is below the specification, 10. Remove and discard the O-ring 3.
install a new pump. Installing new components
such as gears, bearings and housings will not be 11. Remove the capscrews 2 and the nuts that hold
a permanent solution. If the output of the pump the mounting flange to the pump body 1.
is satisfactory butok hthere are signs of external
leakage, disassemble the pump for re-sealing only. 12. Separate the mounting flange from the pump
body 1.
The exterior of the pump and the working area must
be cleaned thoroughly to remove any source of 13. Remove the circlip and the shaft seal.
contamination before you disassemble the pump.
14. Remove the driveshaft from the pumpbody 1
Mark all the sections of the pump to ensure together with the balance plate 3 complete with
correct assembly and make sure you keep pump the seal 3 and seal energiser 3.
components with their respective pump sections. 15. Discard the seal 3 and the seal energiser 3.
Disassemble 16. Remove the driven gear 2, the balance plate 4,
seal 4 and the seal energiser 4. Discard the seal
1. Remove the capscrews (x3) that attach the 4 and the seal energiser 4.
priority valve to the pump body 1.
17. Remove and discard the O-ring 4.
2. Remove the priority valve and discard the O-
rings 1. 18. Remove all the sealant from the contact faces of
the mounting flange and pump body interface.
3. Remove the bolts (x4) and the washers (x4) that
clamp the pump body 1 to the pump body 2. 19. Remove all the sealant from the contact faces of
the end cover and pump body interface.
4. Separate the pump body 1 from the pump body
2 using with a soft faced hammer if required. 20. Wash all the components and immediately apply
a coat of hydraulic oil to prevent corrosion.
30 - 62 9823/0300-1 30 - 62
11 - Gear Pump
00 - General
Figure 976. Typical double pump
V B
A
E
V
G
C
AE
W
AG X
AH
C
AD AC
AB
Z Y
K AA
AF
AJ
Q
W
E
F J
U P
N
M
L
R S T
G
H
A Capscrew 1 B Priority valve

C Pump body 1 D O-rings 1
E Bolt F Washer
G Pump body 2 H Splined coupling
J O-rings 2 K End cover
L Drive gear M Balance plate 1
N Seal 1 P Seal energiser 1
Q Driven gear 1 R Balance plate 2
S Seal 2 T Seal energiser 2
U O-ring 3 V Capscrew 2
W Nuts X Mounting flange
30 - 63 9823/0300-1 30 - 63
11 - Gear Pump
00 - General
Y Circlip Z Shaft seal

AA Driveshaft AB Balance plate 3
AC Seal 3 AD Seal energiser 3
AE Driven gear 2 AF Balance plate 4
AG Seal 4 AH Seal energiser 4
AJ O-ring 4
30 - 64 9823/0300-1 30 - 64
11 - Gear Pump
00 - General
Assemble 17. Install the seal 2 and the seal energiser 2 into the
balance plate 2.
1. Apply JCB special hydraulic fluid and install new
seals and O-rings. 18. Make sure that the seals do not fall out while
attaching the balance plate 2 into the pump body
Consumable: JCB Hydraulic Fluid OP 46 2 with the two small holes through the balance
2. Install the shaft seal into the mounting flange with plate 2 to the low pressure side (i.e. side with port
its garter spring facing into the pump. blank).
3. Install the circlip into the groove on the flange. 19. Install the drive gear and engage it with the
splined coupling.
4. Coat the seal lips with high melting point grease.
20. Install the driven gear.
5. If the seal recess is scored, seal the outside
diameters with JCB multigasket to prevent 21. Install the balance plate 1 with the two small
leakage. holes on the low pressure side. Install the seal 1
and the seal energiser 1 into the balance plate.
Consumable: JCB Multi-Gasket
22. Install the O-ring 3 into the end cover.
6. Put the pump body 1 on its rear face. Install the
seal 3 and the seal energiser 3 into the balance 23. Apply a small amount of sealant on the exposed
plate 3. face of the pump body 2.
7. Make sure that the seal 3 does not fall out. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
8. Install the balance plate 3 into the bores of the
pump body 1 with the two small holes through the 24. Install the end cover as marked.
balance plate 3 to the low pressure side of the 25. Install the bolts (x4) and the washers (x4) and
body (i.e. side with the large 4 bolt port pattern). then tighten evenly and progressively.
9. Install the driveshaft and the driven gear 2 into 26. Install the priority valve to the pump body 1. Make
the bores. sure you install the new O-rings 1.
10. Install the balance plate 4 over the driveshaft and 27. Tighten the capscrews (x3) evenly and
gear stub. Insert the seal 4 and the seal energiser progressively.
4 into the balance plate 4.
28. Pour a small quantity of clean JCB hydraulic
11. Install O-ring 4 into the groove on the mounting fluid into the ports. Make sure that the drive
flange. Apply a small amount of sealant on the shaft rotates smoothly and without undue force. If
face of the pump body 1 which seals with the excessive force is required it is possible that one
mounting flange. (i.e. the face containing the or more of the balance plate seals are trapped.
clamping bolt holes). If required, disassemble and assemble the pump
Consumable: JCB Threadlocker and Sealer again.
(Medium Strength) Consumable: JCB Hydraulic Fluid OP 46
12. Install the mounting flange over the driveshaft
using the previously made marks to make sure Triple pump
it is in its previous position. Tap the flange to its
location spigot with a soft faced hammer. Before you disassemble the pump, make sure that
the performance is as per the specified value. Refer
13. Attach the mounting flange to the pump body 1 to Hydraulic system- Technical Data, Refer to (PIL
with the capscrews 2 and the nuts. 30-00). If the performance is below the specification,
install a new pump. Installing new components such
14. Make sure you support the pump assembly on as gears, bearings and housings will not be a
the mounting flange, not on the driveshaft. permanent solution. If the output of the pump is
15. Install the O-rings 2 into the grooves on the face satisfactory but there are signs of external leakage,
of the pump body 1. Install the splined coupling. disassemble the pump for re-sealing only.
16. Install the pump body 2 on the pump body 1 on The exterior of the pump and the working area must
the original position as marked. Make sure that be cleaned thoroughly to remove any source of
it locates on the dowels and the clamping bolt contamination before you disassemble the pump.
holes line up.
30 - 65 9823/0300-1 30 - 65
11 - Gear Pump
00 - General
Mark all the sections of the pump to ensure 12. Discard the O-ring 4.
correct assembly and make sure you keep pump
components with their respective pump sections. 13. Separate the end cover 2 from the pump body 2.
14. Remove the drive gear 2 from its bore. Pushing
Disassemble it out of the pump body will also remove the
1. Remove the capscrews (x3) that attach the balance plate 3 complete with the seal 3 and the
priority valve to the pump body 2. seal energiser 3.
2. Remove he priority valve and discard the O-rings 15. Discard the seal 3 and the seal energiser 3. Note
1. the position of the driveshaft and the balance
plate 1 to ensure correct assembly.
3. Remove the bolts (x4) and the serrated washers
(x4) which attach the units together. 16. Remove the driven gear 2, the balance plate 4,
the seal 4 and the seal energiser 4. Discard the
4. Separate the pump body 1 from the end cover 2 seal 4 and the seal energiser 4.
using a soft faced hammer if required.
17. Discard the O-ring 5.
5. Remove the splined coupling 1 and the O-rings
2. Discard the O-rings 2. 18. Separate the mounting flange from the pump
body 3 with a soft faced hammer if required.
6. Separate the pump body 2 from the pump body
3 with a soft faced hammer if required. 19. Remove the circlip and the shaft seal.
7. Remove the splined coupling 2 and the O-rings 20. Remove the driveshaft from the pump body 3.
3. Discard the O-rings 3. Remove the balance plate 5 complete with the
seal 5 and the seal energiser 5.
8. Separate the end cover 1 from the pump body 1
with a soft faced hammer if required. 21. Discard the seal 5 and the seal energiser 5.
9. Remove the drive gear 1 from its bore. Pushing it 22. Remove the driven gear, balance plate 6, seal 6
out of the rear body will also remove the balance and the seal energiser 6. Discard the seal 6 and
plate 1 complete with the seal 1 and the seal the seal energiser 6.
energiser 1. 23. Discard the O-ring 6.
10. Discard the seal 1 and the seal energiser 1. Note 24. Remove all the sealant from the contact faces of
the position of the driveshaft and the balance the mounting flange and pump body interface.
plate 1 to ensure correct assembly.
25. Remove all the sealant from the contact faces of
11. Remove driven gear 1, the balance plate 2, seal the end cover and pump body interface.
2 and seal energiser 2. Discard the seal 2 and
the seal energiser 2. 26. Wash all the components and immediately apply
a coat of hydraulic oil to prevent corrosion.
30 - 66 9823/0300-1 30 - 66
11 - Gear Pump
00 - General
Figure 977.
AQ AP
AN
AR
AS
AT AU
AK
AL
D
AM
C
J AJ AD AV
AC
AB
AE
AF
AH M B A
P
AA
AG
G Z U T S
V Q
W
X
Y
H
R K
A Capscrews B Priority valve

C O-rings 1 D Circlip
E Bolts F Serrated washers
G End cover 1 H Pump body 1
J End cover 2 K Splined coupling 1
L O-rings 2 M Pump body 2
N Pump body 3 P Splined coupling 2
Q O-rings 3 R Drive gear 1
S Balance plate 1 T Seal 1
U Seal energiser 1 V Driven gear 1
30 - 67 9823/0300-1 30 - 67
11 - Gear Pump
00 - General
W Balance plate 2 X Seal 2

Y Seal energiser 2 Z O-ring 4
AA Drive gear 2 AB Balance plate 2
AC Seal 3 AD Seal energiser 3
AE Driven gear 2 AF Balance plate 4
AG Seal 4 AH Seal energiser 4
AJ O-ring 5 AK Mounting flange
AL Shaft seal AM Drive shaft
AN Balance plate 5 AP Seal 5
AQ Seal energiser 5 AR Driven gear 3
AS Balance plate 6 AT Seal 6
AU Seal energiser 6 AV O-ring 6
Assemble 13. Make sure you support the pump assembly onto
the mounting flange, not on the driveshaft.
1. When carrying out the following procedure,
renew all seals and O-rings. Lubricate using JCB 14. Install the O-rings 3 into the grooves on the face
special hydraulic fluid. of the pump body 3. Install the splined coupling 2.
Consumable: JCB Hydraulic Fluid OP 46 15. Install the pump body 2 on the pump body 3 in
its original position as marked. Make sure that
2. Install the shaft seal into the mounting flange with it locates on the dowels and the clamping bolt
its garter spring facing into the pump. holes line up.
3. Install the circlip into the groove on the flange. 16. Install the seal 4 and the seal energiser 4 into the
4. Coat the seal lips with high melting point grease. balance plate 4.
5. If the seal recess is scored, seal the outside 17. Make sure that the seals to not fall out and
diameters with JCB multigasket to prevent carefully feed the balance plate 4 into the pump
leakage. body 2 with the two small holes through the
balance plate 4 to the low pressure side (i.e. side
Consumable: JCB Multi-Gasket with a port blank).
6. Put the pump body 3 on its rear face. Install the 18. Install the drive gear 2 making sure it engages
seal 5 and the seal energiser 5 into the balance with the splined coupling 2.
plate 5.
19. Install the driven gear 2.
7. Make sure that the seal 5 does not fall out while
you Install the balance plate 6 into the bores of 20. Install the balance plate 3 in its original position,
the pump body 3 with the two small holes through with the two small holes on the low pressure side.
the balance plate 6 to the low pressure side of Install the seal 3 and the seal energiser 3 into the
the body (i.e. side with the large 4 bolt pattern) balance plate.
8. Insert the driveshaft and the driven gear 3 into 21. Install the O-ring seal into the end cover 2.
the bores.
22. Apply a small amount of sealant on the exposed
9. Install the balance plate 6 over the driveshaft face of the pump body 2 (i.e. the face containing
and the gear stub. Insert the seal 6 and the seal the clamping bolt holes).
energiser 6 into the balance plate 6. Consumable: JCB Threadlocker and Sealer
10. Install O-ring 6 into the groove on the mounting (Medium Strength)
flange. 23. Install the end cover 2 in its original position as
11. Apply a small amount of threadlocker/sealant on marked.
the face of the pump body 3 which seals with 24. Install the O-rings 2 into the grooves on the face
the mounting flange (i.e. the face containing the of the pump body 1. Install the splined coupling 1.
clamping bolt holes).
Consumable: JCB Threadlocker and Sealer 25. Install the pump body 1 to the end cover 2 in
(Medium Strength) the original position as marked. Make sure that
it locates on the dowels and the clamping bolt
12. Install the mounting flange over the driveshaft holes line up.
as previously marked. Tap the flange on to its
location spigot with a soft faced hammer (if 26. Install the seal 2 and the seal energiser 2 into the
required). balance plate 2.
30 - 68 9823/0300-1 30 - 68
11 - Gear Pump
00 - General
27. Make sure that the seals do not fall out, carefully
feed the balance plate 2 into the pump body
1 with the two small holes through the balance
plate 2 to the low pressure side (i.e. side with a
port blank).
28. Install the drive gear 1 making sure it engages it
with the splined coupling 1.
29. Install the driven gear 1.
30. Install the balance plate 1 in its original position
with the two small holes on the low pressure side.
Install the seal 1 and the seal energiser 1 into the
balance plate 1.
31. Install the O-ring 4 into the end cover 1.
32. Apply a small amount of sealant on the exposed
face of the pump body 1 (i.e. the face containing
the clamping bolt holes).
(Medium Strength)
33. Install the end cover 1 in its original position as
marked.
34. Install the bolts (x4) and the serrated washers
and then tighten evenly and progressively.
35. Install the priority valve to the pump body 2 again.
Make sure you install the new O-rings 1.
36. Tighten the capscrews (x3) evenly and
progressively.
37. Pour a small quantity of clean JCB special
hydraulic fluid into the ports. Make sure that the
drive shaft rotates smoothly without undue force.
If more force is required it is possible that one or
more of the balance plate seals are trapped. If
required, disassemble and assemble the pump
again.
Consumable: JCB Hydraulic Fluid OP 46

Item Description Nm
E Bolts 100
30 - 69 9823/0300-1 30 - 69
12 - Variable Displacement Pump
Contents Page No.
30-12-00 General ........................................................................................................................... 30-71
30 - 70 9823/0300-1 30 - 70
00 - General
Introduction .................................................... 30-71 The most common variable displacement pump used
Remove and Install ....................................... 30-72 in vehicle technology is the axial piston pump. This
pump has several pistons in cylinders arranged
parallel to each other and rotating around a central
shaft. A swashplate at one end is connected to the
pistons. As the pistons rotate, the angle of the plate
causes them to move in and out of their cylinders.
A rotary valve at the opposite end from the

swashplate alternately connects each cylinder to
the fluid supply and delivery lines. By changing the
angle of the swashplate, the stroke of the pistons
can be varied continuously. If the swashplate is
perpendicular to the axis of rotation, no fluid will flow.
If it is at a sharp angle, a large volume of fluid will be
pumped.
Some pumps allow the swashplate to be moved in

both directions from the zero position, pumping fluid
in either direction without reversing the rotation of the
pump.
Piston pumps can be made variable-displacement

by inserting springs inline with the pistons. The
displacement is not positively controlled, but
decreases as the back-pressure increases.
30 - 71 9823/0300-1 30 - 71
00 - General
Remove and Install
Consumables 4. Disconnect the outlet hose from the fan pump.

5. Disconnect the electrical connector 1 from the
JCB Threadlocker and 4101/0550 0.01L pump control solenoid.
Sealer (High Strength) 4101/0552 0.2L
6. Disconnect the electrical connector 2 from the
Working Under the Machine hydraulic fluid temperature switch.
Make the machine safe before getting beneath it. 7. Remove the clips and disconnect the suction
Make sure that any attachments on the machine are hose from the pump inlet manifold.
the ignition key, disconnect the battery. If the machine 8. Plug the open port and cap the hose to prevent
has wheels use blocks to prevent unintentional loss of fluid and ingress of dirt.
movement.
9. Remove flange bolts and remove the outlet hose
Hydraulic Pressure from the pump body.
Before connecting or removing any hydraulic hose, 10. Plug the open port and cap the hose to prevent
residual hydraulic pressure trapped in the service loss of fluid and ingress of dirt.
11. Disconnect the load sense hose from the pump.
Plug the open port and cap the hose to prevent
removing hoses. Make sure the engine cannot be
loss of fluid and ingress of dirt.
12. Disconnect the case drain hose from the pump.
The fan pump is bolted to the variflow pump. This Plug the open port and cap the hose to prevent
procedure describes removing the variflow pump and loss of fluid and ingress of dirt.
fan pump as one unit.
CAUTION! This component is heavy. It must only
Before you remove the pump, make sure the exterior be removed or handled using a suitable lifting
of the pump and working area is thoroughly cleaned method and device.
and free of possible sources of contamination.
13. Make sure you use a sling around the pump
Remove assembly.
1. Make the machine safe. Refer to (PIL 01-03). 14. With the pump correctly supported, remove the
mounting bolts and carefully remove the pump
2. Discharge the hydraulic pressure. Refer to (PIL from the gearbox.
30-00).
Two bolts are hexagon head and other two are
3. Drain the hydraulic fluid from the hydraulic tank caphead bolts. Record the position of the bolts for
into a suitable clean container. correct installation.
30 - 72 9823/0300-1 30 - 72
00 - General
Figure 978.
H K J
Item Description
Table 262. F Flange bolts (x4)
G Load sense hose
Item Description
H Case drain hose
A Outlet hose
J Mounting bolts (x4)
B Fan pump
K Cap
C Electrical connector 1
D Electrical connector 2
E Clips
30 - 73 9823/0300-1 30 - 73
00 - General
Install
Before you start the engine the variflow pump body
must be filled with hydraulic fluid. If the engine is
started with no fluid in the pump, pump can be
damaged.
1. Make sure the pump flanges and gearbox mating

faces are clean and free from oil and grease
before installation.
2. Install new O-ring seals to the pump to gearbox
case mating face and inlet and outlet hose
flanges.
3. Lubricate the O-rings with clean hydraulic fluid.
4. Apply sealant to the flange bolts and tighten the
bolts to the correct torque value.
(High Strength)
5. Remove the cap and fill the pump case with clean
hydraulic fluid. Install the cap.
6. Reconnect the hydraulic hoses and suction hose
to the pump.
7. Connect the electrical connectors with the
hydraulic fluid temperature switch and the pump
control solenoid.
8. Fill the hydraulic tank to the correct level with
clean hydraulic fluid. Refer to (PIL 30-00).
9. Loosen cap and allow any trapped air to escape
from the pump body and drain hose. Tighten the
cap.
Table 263. Torque table

Item Value
J
(1)
87N·m
J
(2)
97N·m
K
(1)
84N·m
K
(2)
84–92N·m
(1) 550-80 machines only.
(2) Other machines.
30 - 74 9823/0300-1 30 - 74
15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ........................................................................................................................... 30-77

30-15-06 Lift Arm ........................................................................................................................... 30-80
30-15-08 Lift Compensating .......................................................................................................... 30-83
30-15-34 Steering .......................................................................................................................... 30-86
30-15-99 Seal Kit ........................................................................................................................... 30-96
30 - 75 9823/0300-1 30 - 75
Notes:
30 - 76 9823/0300-1 30 - 76
15 - Cylinder / Ram
00 - General
Introduction .................................................... 30-77 A hydraulic cylinder ram is a mechanical actuator
Health and Safety .......................................... 30-78 that is used to give a single directional force
Check (Condition) .......................................... 30-79 through a single action stroke. It is used in many
applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
consists of a cylinder barrel, in which a piston
connected to a piston rod moves back and forth.
The barrel is closed on one end by the cylinder

cap and the other end by the cylinder head where
the piston rod comes out of the cylinder. The piston
has sliding rings and seals. The piston divides the
inside of the cylinder into two chambers, the bottom
chamber (cap end) and the piston rod side chamber
(rod end / head end).
30 - 77 9823/0300-1 30 - 77
15 - Cylinder / Ram
00 - General
Health and Safety Caution During Use

1. Use only under designated conditions.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 1.1. If hydraulic oil other than the designated oil
Before connecting or removing any hydraulic hose, is used, the seals quickly degenerate and
residual hydraulic pressure trapped in the service become damaged. If the relief valve is set at
hose line must be vented. Make sure the hose a value higher than specified, it may cause
service line has been vented before connecting or ram damage and is dangerous.
removing hoses. Make sure the engine cannot be 1.2. In high temperature environments (approx.
started while the hoses are open. 90°C and above) or low temperature
Lifting Equipment environments (below -20°C), seals quickly
become damaged. Special seal materials
You can be injured if you use incorrect or faulty lifting are necessary so check to see if the ram
equipment. You must identify the weight of the item to that you are using is suitable or not.
enough and suitable for the job. Make sure that lifting 1.3. The number one cause of ram oil leakage is
equipment is in good condition and complies with all rod damage. Be careful not to damage the
local regulations. rod.
WARNING! A raised and badly supported machine 2. Warm up sufficiently before beginning work.
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other 2.1. In cold conditions the rod seals may
end is securely chocked. Do not rely solely on the be frozen, so if the ram is operated at
machine hydraulics or jacks to support the machine maximum pressure and maximum speed,
when working under it. Disconnect the battery, to the seals will be damaged.
prevent the machine being started while you are
2.2. There is a large amount of air in a new
beneath it.
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Precautions for Installation Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
1. Precautions when installing the ram on the
generated due to adiabatic compression
machine.
and the seals may burn.
1.1. When installing and removing from the 2.3. Before beginning work, always move the
machine, suspend the ram safely. ram at full stroke with no load and expel air
1.2. Suspending the ram by the piping is not only from the cylinder.
dangerous, but can also cause damage to
3. When stopping or storing, do it at a safe and fixed
the cylinder.
position.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. 3.1. The installed ram cannot maintain the same
Also, the rod can be damaged and become position for a long period of time, because
unusable. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
2. Welding after installing the ram may result in Stop or store the machine in a safe and
damage. fixed position.
2.1. If electric welding is done even at a point Maintenance, Inspection Points

away from the ram, there may be sparking
inside the ram and it will become necessary 1. Carry out daily maintenance and inspection.
to replace the ram with a new one.
1.1. The key point for correct long-term
3. When painting the machine, mask the ram. If ram function is daily maintenance and
paint adheres to the rod surface or to the wiper inspection. Carry out maintenance and
ring and the ram is operated, the wiper ring will inspection so that the ram functions fully at
not function properly and foreign matter and paint all times. Always remove any mud, water,
can easily enter the ram. This will cause damage dust or oil film adhering to the rod and
to the seals, drastically shortening the life of the keep it in normal condition. However, when
ram. cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
4. Install the ram only when it is clean.
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 78 9823/0300-1 30 - 78
15 - Cylinder / Ram
00 - General
should be kept to a minimum. If leaving for Check (Condition)

more than one week, apply a light coating
of suitable grease or petroleum jelly to the
exposed part of the ram piston rod. Check the primary components for scoring, damage,
wear, distortion, uneven surface (i.e. polished or
2. Use genuine JCB parts when replacing parts. pitted areas) and scratches. Replace all damaged
parts.
2.1. If parts other than genuine JCB parts
are used, the desired results may not be Check the components for burrs. Give special
obtained. Use only genuine JCB parts. attention to the traversing diameters, locking pin
holes and mounting chamfers. If minor burrs are
3. Caution during dismantling and reassembly.
seen, remove them by polishing with a fine grade
3.1. Dismantling the ram while it is still installed abrasive paper.
on the machine can be dangerous as
unexpected movements of the machine can Check pivot bushes for signs of wear or damage.
occur. Remove the ram from the machine Replace if necessary.
and then dismantle.
If a cylinder is damaged it must be replaced. New
3.2. If reassembled with dirty hands, foreign piston seals will fail after only a short period of time
matter can enter the ram causing a shorter if the cylinder is worn or damaged.
life span and also the other hydraulic
equipment may be damaged. Reassemble
in a clean state.
3.3. Follow the instructions in the diagrams
regarding torque tightening for screwed
parts. If the torque is too high or too low, it
can cause damage.
30 - 79 9823/0300-1 30 - 79
15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm
Remove and Install
Special Tools 10. Disconnect the harness electrical connectors

Description Part No. Qty. from the SRS (Smooth Ride System) solenoids/
Slide Hammer Kit 993/68100 1 pressure sensor (if installed).
11. Support the lift ram.
Remove
12. Remove the nut 1 and bolt 1.
13. Remove the pivot pin 1.
2. Follow the hydraulic care and safety procedures.
13.1. Make sure to retrieve washers.
3. Remove the attachments. Refer to (PIL 03-33).
4. Lift the lift arm to the specified angle. CAUTION! This component is heavy. It must only
Angle: 45° method and device.
5. Attach suitable lifting equipment and support the 14. Attach suitable lifting equipment to the ram rod
lift arm. eye end. Support the ram.
5.1. The lift ram will not support the weight of the 15. Remove bolt 2.
lift arm during this procedure therefore the
safety strut will not work. Danger or injury 16. Remove pivot pin 2.
will result if the lift arm is not supported fully.
6. Vent the hydraulic pressure. Refer to (PIL 30-00).
17. Make sure you do not to damage the remote
7. Put label on the hoses to help installation. grease point and pipe.
8. Disconnect the hydraulic hoses. 18. Remove the ram from the machine.

contamination.
30 - 80 9823/0300-1 30 - 80
15 - Cylinder / Ram
06 - Lift Arm
Figure 979.
B
C
A Nut 1 B Bolt 1
C Washers D Pivot pin 1
E Ram F Grease point and pipe
G Bolt 2 H Pivot pin 2
30 - 81 9823/0300-1 30 - 81
15 - Cylinder / Ram
06 - Lift Arm
Install
steps.
1.1. Grease the ram pivot pins. Refer to (PIL
75-06).
1.2. Check the hydraulic fluid level and top up if
necessary. Refer to (PIL 30-00).
1.3. Tighten bolt 1 and bolt 2 to the specified
torque value.

Item Description Nm
B Bolt 1 83
G Bolt 2 83
30 - 82 9823/0300-1 30 - 82
15 - Cylinder / Ram
08 - Lift Compensating
Remove and Install
Special Tools 9. Plug all the open ports and hoses to prevent
Description Part No. Qty. contamination.
CAUTION! This component is heavy. It must only
Remove method and device.
1. Make the machine safe. Refer to (PIL 01-03). 10. Support the displacement ram.
2. Vent the hydraulic pressure. Refer to (PIL 30-00). 11. Remove the nut 1 and the bolt 1.
3. Follow the hydraulic care and safety procedures. 12. Remove the pivot pin 1.
4. Remove the lift ram. Refer to (PIL 30-15).
13. Remove the bolt 2.
5. Support the lift arm.
14. Remove the pivot pin 2.
6. Lift the lift arm using the correct lifting equipment Special Tool: Slide Hammer Kit (Qty.: 1)
to get access to the displacement ram top pivot.
15. Remove the ram from the machine.
7. Put a label on the hoses to help installation.
8. Disconnect the hydraulic hoses.
30 - 83 9823/0300-1 30 - 83
15 - Cylinder / Ram
Figure 980.
A Displacement ram B Nut 1

C Bolt 1 D Pivot pin 1
E Bolt 2 F Pivot pin 2
30 - 84 9823/0300-1 30 - 84
15 - Cylinder / Ram
Install
procedure.
1.1. Grease the ram pivot pins. Refer to (PIL
75-06).
1.2. Check the hydraulic fluid level and top up if
necessary. Refer to (PIL 30-00).
1.3. Tighten bolt 1 and bolt 2 to the specified
torque value.

Item Description Nm
C Bolt 1 47
E Bolt 2 83
30 - 85 9823/0300-1 30 - 85
15 - Cylinder / Ram
34 - Steering
34 - Steering Component Identification

Figure 981.
E
C F
A
G
D
J
A Ball joint nut B Cylinder O-ring

C Cylinder retaining screws D Steering cylinder
E Steering sensor retaining screws F Steering sensor
G Steering sensor seal H Cylinder O-ring
J Ball joint
30 - 86 9823/0300-1 30 - 86
15 - Cylinder / Ram
34 - Steering
Disassemble and Assemble Figure 983.

J
Consumables
Cleaner/Degreaser 4104/1557 0.4L
- General purpose
solvent based parts A
cleaner
Strength)
A Ball joint nuts
Do not attempt any maintenance if the axle is hot. Hot J Ball joint
oil and components can cause personal injury. Avoid
skin contact. Wear protective gloves and glasses. 6. Remove the ball joint tapered bolt.
Refer to component identification, (PIL 30-15-34). Figure 984.
Disassemble J

27-20).
30-00).
4. Remove the retaining screws and the steering
sensor.
Figure 982. J Ball joint
7. If there is a safety collar on the piston to arm link-
lift the collar to allow disconnection.
Figure 985.
F
E
E Steering sensor retaining screws

F Steering sensor
5. Remove the ball joint retaining nuts.
8. Unscrew the link arm to piston connections on

each side of axle.
30 - 87 9823/0300-1 30 - 87
15 - Cylinder / Ram
34 - Steering
K Circlip
9. Remove the cylinder retaining screws. 12. Using a soft faced hammer tap the cylinder head
into the end cap.
Figure 987.
Figure 990.
D
C
L
C Cylinder retaining screws M

D Steering cylinder L End cap
M Cylinder head
10. Using a soft faced hammer remove the cylinder
from the axle. Make sure to drain the hydraulic 13. Remove the retaining ring from the end cap.
oil from the cylinder.
Figure 991.
Figure 988.
N Retaining ring
D Steering cylinder
14. Remove the cylinder head from the cylinder.
11. Remove the circlip from the cylinder head.
15. Make a note of the directional position of the
piston seal.
30 - 88 9823/0300-1 30 - 88
15 - Cylinder / Ram
34 - Steering
Figure 992. Consumable: Cleaner/Degreaser - General

1.3. Old sealing compound must be carefully
D removed
1.4. Use a carborundum paper to remove
scratches.
1.5. Let all the parts dry.
1.6. Check lubricating holes, grooves and
pipes for obstruction by residues, foreign
materials and protective coatings. The latter
M applies especially to new parts.
1.7. Bearings, bushes, thrust washers etc.
subjected to normal wear during operation
must be checked by skilled service
personnel before being re-used. If in doubt,
renew suspect parts.
1.8. When heating is required prior to assembly,
parts must not be subjected to direct
flame. Ideally use a hot plate, a rod
heater or a heating oven. Bearing races,
covers, flanges and other parts requiring
heat, should be pre-heated to the specified
temperature.
1.9. Hot mounted parts should be re-checked for
proper contact after cooling. Heat to
D Steering cylinder
M Cylinder head Temperature: 90–100°C (193.9–211.9°F)
16. Remove seals, anti-extrusion rings and scraper 1.10. Some parts may be cooled to
rings from the cylinder head, cylinder and piston. Temperature: 0°C (32.0°F)
Figure 993. 1.11. Before pressing components into place,
both the component and housing must be
lubricated.
2. Renew all seals, O-rings, scraper rings and back-
up rings.
3. Lubricate all seals and O-rings before
installation.
4. Apply grease to the piston rod seal ring, rod wiper
and back up washer and install into the cylinder.
Assemble
1. Check all the parts before you assemble them.
1.1. All components must be thoroughly
cleaned, with particular attention being paid
to the corners, cavities and recesses of
housings and covers.
1.2. Use JCB Cleaner/Degreaser to clean all the
parts.
30 - 89 9823/0300-1 30 - 89
15 - Cylinder / Ram
34 - Steering
Figure 994. 7. Apply grease to the piston seal, anti-extrusion

ring and magnetic ring and install onto piston.
P Q R Figure 997.
T U
V
P Piston rod seal ring

Q Back-up washer
R Piston rod wiper
5. Apply grease to the piston rod seal ring, rod wiper
and back up washer and install into the cylinder
head.
Figure 995.
R Q P
T Piston seal
U Magnetic ring
V Anti-extrusion ring
W Piston
P Piston rod seal ring
Q Back-up washer 8. Centre the piston into the cylinder, push the
R Piston rod wiper piston into the cylinder for the specified distance.
Distance: 100mm
6. Install seal to the outer surface of the cylinder
head. 9. Apply grease to the cylinder head seals, install
the head onto to the piston and push head into
Figure 996. the cylinder.
S Cylinder head seal

6.1. Do not distort or allow the seal to fold over.
30 - 90 9823/0300-1 30 - 90
15 - Cylinder / Ram
34 - Steering
N Retaining ring
11. Using levers pull the end cap forward until it is
seated on the retaining ring.
D
12. Install the circlip.
12.1. Make sure that the circlip is fully installed, if
necessary tap the circlip to seat in groove.
Figure 1001.
Figure 999.
X K
M M
K Circlip
S M Cylinder head
13. Lubricate and install new cylinder O-rings.
14. Lubricate the O-rings and install the steering
D
cylinder.
D Steering cylinder
M Cylinder head
S Cylinder head seal
X Hydraulic inlet port
9.1. To prevent damage to the head seals do not
allow the seals to pass the hydraulic inlet
port on the cylinder.
10. Install the retaining ring into the end cap.
30 - 91 9823/0300-1 30 - 91
15 - Cylinder / Ram
34 - Steering
Figure 1002. 17. Install the piston to link arm connectors and
tighten to the correct torque value.
Figure 1004.
B
H
18. Install the ball joint tapered bolt, ball joint and
retaining nuts.
19. Tighten the ball joint retaining nuts to the correct
torque value.
Figure 1005.
B Cylinder O-ring
D Steering cylinder J
H Cylinder O-ring
15. Apply threadlocker to the cylinder retaining
screws and install.
(Medium Strength)
A
16. Using a diagonal pattern tighten the cylinder
retaining screws to the correct torque value.
Figure 1003.
A Ball joint nuts
J Ball joint
D 20. Lubricate and install a new seal to the steering
C
sensor.
21. Install the steering sensor and retaining screws.
22. Tighten the steering sensor retaining screws to
Torque: 5 ± 8N·m
C Cylinder cap retaining screws

D Steering cylinder
30 - 92 9823/0300-1 30 - 92
15 - Cylinder / Ram
34 - Steering
F
E
E Steering sensor retaining screws

F Steering sensor
23. Install special tool (910.25.2367) to each hub.
For details of special tool refer to (PIL 78-94).
24. Using a level make sure both special tools are
parallel and horizontal.
Figure 1007.
1
1 Measurement of exposed piston

26.1. Move the piston from side to side in the
cylinder until it is at its mid point.
T1 26.2. The light on the sensor test equipment will
Y illuminate when each piston is at full stroke
and stop illuminating when the piston is in
the centre position.
T1 Special tool 910.25.2367 26.3. The measurement of the exposed piston

Y Level on either side of the cylinder can be
compared to make sure the piston is
25. Connect the sensor testing equipment to the positioned correctly in the centre position.
steering sensor. 26.4. If the axle does not have a steering sensor,
Figure 1008. measuring the exposed piston will indicate
the centre of the stroke.
F 27. With the piston in the centre position check the

hub alignment:
27.1. Make sure special tool (910.25.2367) is in
position on both hubs.
27.2. When measuring dimension 2 make sure
that the special tool is horizontal - the
pinion can be rotated to allow this.
27.3. Measure and record the dimensions 2 and
3 as shown.
27.4. The difference between measurements 2
F Steering sensor and 3 must not exceed the specified value.
26. Position the steering piston in the centre position. Distance: 2.5mm
30 - 93 9823/0300-1 30 - 93
15 - Cylinder / Ram
34 - Steering
27.5. Measure and record the distance from the Figure 1011.
centre of the hub to the end of the special
tool (910.25.2367) to obtain dimension 4.
27.6. Dimension 4 must be the specified value.
Distance: 400mm
27.7. If any of the dimensions 2,3 or 4 are
incorrect, adjust the length of the steering
link arm to piston connection. Turning the
link arm adjustment a full turn will either
increase or decrease the length by the
specified value.
Length: 6mm
27.8. Measure dimensions 2, 3 and 4. Repeat
adjustment until these dimensions are
correct.
Figure 1010.
T1
30. Check the steering angle:

30.1. Move the steering to full stroke.
30.2. Measure and record the dimensions 5 and
T1 6 these must both be the same.
30.3. Move the steering to the opposite full
stroke.
2 30.4. Measure and record the dimensions 5 and
6 these must both be the same.
30.5. If there is a difference between dimensions
4 5 and 6 adjust the steering stop screws.
30.6. Move the steering to full stroke in both
directions several times.
4
30.7. Repeat measurements for dimensions 5
and 6.
3 30.8. When dimensions 5 and 6 are equal the
adjustment is correct.
2 Dimension 2
3 Dimension 3 30.9. Make sure all stop screws contact the stop
4 Dimension 4 on the axle at the same time.
T1 Special tool 910.25.2367
28. When the alignment dimensions are correct
apply threadlocker to the threads and nut of the
link arm connector.
(Medium Strength)
29. Tighten the link arm to piston connections to the
30 - 94 9823/0300-1 30 - 94
15 - Cylinder / Ram
34 - Steering
Figure 1012.
5 6
5 Dimension 5
6 Dimension 6
31. Tighten the steering stop screw locknuts to the
Torque: 148N·m
Figure 1013.
30 - 95 9823/0300-1 30 - 95
15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 1014.
Remove and Install

Special Tools
Ram Protection Sleeve 892/00167 1
(90mm rod diameter)
Ram Seal Installation 892/00334 1 A Ram seal installation tool
Tool B Pins
Ram Protection Sleeve 892/01016 1 1.2. Open the seal installation tool and insert
(25mm rod diameter) the new rod seal. Install the seal behind the
Ram Protection Sleeve 892/01017 1 two front pins but in front of the rear pin as
(30mm rod diameter) shown.
Ram Protection Sleeve 892/01018 1 Figure 1015.
(40mm rod diameter)
(50mm rod diameter)
- Slew (50mm rod
diameter)
(60mm rod diameter)
- Slew (60mm rod
diameter)
A Rod seal
(65mm rod diameter) 1.3. Later ram end caps and piston heads
Ram Protection Sleeve 892/01024 1 have metric threads. The seals are also
(70mm rod diameter) different, make sure that the correct seals
Ram Protection Sleeve 892/01025 1 are installed. On metric threaded rams,
(75mm rod diameter) make sure that the seals are installed the
correct way around, as shown.
(80mm rod diameter) Figure 1016.
Ram Seal Assembly 892/01027 1
Tool
Remove
1. Remove and discard the old seals.
Install
1. Install new rod seals:
A Inner seal
1.1. Use the ram seal installation tool to install B Outer seal
rod seals, the size (diameter) and position
of pins is determined by the diameter and 1.4. Close the tool. The seal must form a
radial width of the rod seal being installed. reniform (kidney shape).
The pins are screwed into threaded holes
in the tool body, the spacing of the holes is
designed to suit small or large diameter rod
seals.
Special Tool: Ram Seal Installation Tool
(Qty.: 1)
30 - 96 9823/0300-1 30 - 96
15 - Cylinder / Ram
99 - Seal Kit
Figure 1017. Special Tool: Ram Protection Sleeve - Slew

(60mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
1.5. Before you install the rod seals, check that (80mm rod diameter) (Qty.: 1)
the seal grooves are free of contamination Special Tool: Ram Protection Sleeve
and sharp edges. (90mm rod diameter) (Qty.: 1)
1.6. Locate the seal in the end cap groove. Figure 1019.
When the seal is in position, open the tool
to release the seal. Make sure the seal is
correctly installed in its grooved and remove
the tool.
Figure 1018.
A Protection Sleeve (various sizes)

2. Install new head piston seals.
2.1. Use the Piston seal assembly tool to lever
the inner seal into the piston head seal
groove. Do not let the seal twist. There are
identification marks on the outer diameter
1.7. Install the rod wiper seal into the seal of the seal, make sure that the marks are
groove. Make sure that the seal is correctly visible and the seal is free to rotate, if not
installed as shown. Note: Some rod wipers, remove the seal and retry.
i.e. power track rod, may use a metal
encased seal which is pressed into the Special Tool: Ram Seal Assembly Tool
housing. Care must be taken to make sure (Qty.: 1)
that the seal is square before it is pressed Figure 1020.
in.
1.8. A special sleeve must be used to protect
the rod seals from damage, when installing
the end cap on to the piston rod. There are
various sizes of sleeve, make sure you use
the correct size sleeve and also make sure
that the hexagon on the end cap is towards
the eye end of the rod.
Special Tool: Ram Protection Sleeve - Slew A Piston seal assembly tool
(50mm rod diameter) (Qty.: 1) B Inner seal
Special Tool: Ram Protection Sleeve C Outer seal
30 - 97 9823/0300-1 30 - 97
15 - Cylinder / Ram
99 - Seal Kit
2.2. Use the same procedure to install the outer

seal as stated for the inner seal. Check that
the external grooves are visible.
2.3. Make sure that the O-ring is installed into
the internal seal groove on the piston head.
Screw the piston head on to the thread of
the piston rod and tighten to the correct
torque value.
2.4. Install the piston head retaining dowel.
2.5. Install wear rings, rotate the wear rings so
that the piston retention dowel is covered by
the wear ring, not as shown at C.
Figure 1021.
A Outer wear ring

B Inner wear ring
C Incorrect installation
3. Install the piston rod and head assembly into the
cylinder.
3.1. Insert the piston/rod assembly into the
cylinder ram. Align the rod and head
assembly until parallel with the cylinder ram
then push the assembly into the cylinder.
3.2. Install the end cap and assemble the ram
assembly.
30 - 98 9823/0300-1 30 - 98
18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-101
30 - 99 9823/0300-1 30 - 99
Notes:
30 - 100 9823/0300-1 30 - 100

18 - Accumulator
00 - General
Introduction .................................................. 30-101 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-102 reservoir used to store hydraulic fluid, the non-
Component Identification ............................. 30-102 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ........................... 30-103 by a compressed nitrogen gas. It is designed to
increase or relieve pressure in the hydraulic system.
Accumulators enable a hydraulic system to cope with

extremes of demand using a less powerful pump, to
respond more quickly to a temporary demand, and
to smooth out pulsations.
It is not possible to disassemble the accumulators.

The extent of permissible servicing is limited to
checking the nitrogen gas pre-charge pressure. If an
accumulator is suspected as being faulty it must be
renewed as a complete assembly.
Make sure you have read and understood the Health

and Safety implications. Refer to: PIL 30-18-00.
There are three different types of accumulator

installed on JCB machines:
• Diaphragm (sealed for life) - Non

Rechargeable.
• Diaphragm (with gas valve) - Rechargeable.
• Piston Bladder - Rechargeable.
Although some accumulators are identical in

appearance, the accumulators are charged to
different pressures. When renewing an accumulator
make sure you know the correct charge pressure,
refer to the applicable Technical Data.
Upon installation of a new accumulator the correct

label stating the charge pressure must be attached.
The original label which states a zero charge must
be removed.
30 - 101 9823/0300-1 30 - 101

18 - Accumulator
00 - General
Health and Safety Component Identification

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 1022.
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
CAUTION To reduce pressure use the
recommended charging tool or the charge valve
could be damaged which may result in rapid C
discharge of the accumulator.
WARNING You must vent all the hydraulic
pressure from the accumulators before A
disconnecting them from the hydraulic system.
Replacement accumulators will only be supplied in B

an uncharged, non pressurised condition to meet
Health and Safety, and Air freight hazardous goods
requirements.
A Diaphragm (sealed for life)-Non Rechargeable

B Diaphragm (with gas valve)-Rechargeable
C Piston Bladder-Rechargeable
30 - 102 9823/0300-1 30 - 102

18 - Accumulator
00 - General
Discharge and Pressurise Figure 1023.
Special Tools
Accumulator Charging 892/01042 1 B
Kit (Diaphragm)
Accumulator Charging 892/01043 1 A
J
Adaptor
WARNING You must vent all the hydraulic

pressure from the accumulators before
C
disconnecting them from the hydraulic system.
DANGER Use only nitrogen gas to charge F
accumulators. The use of any other gas can H G
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your D
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
E
Before removing accumulators make sure hydraulic
pressure is released.
Even when the hydraulic pressure is released the A Adaptor

accumulator still contains pressurised nitrogen gas. B Filler plug
Do not attempt to discharge the gas pressure. C Gas bottle valve
D Pressure regulator
Do not transport accumulators charged with E Charging hose
pressurised gas by air freight. F Discharge plug
G Charging unit
Charging H Charging unit knob
J Pressure gauge
Important: The following charging procedure is only 1. Hold the accumulator vertical and remove the
applicable to accumulators supplied in a discharged plastic cap from the top of the accumulator.
state.
2. Note: Some accumulators are supplied with a
Operating charge pressures: Accumulators are measured quantity of oil inside the gas chamber.
charged to different operating pressures depending Take care to prevent oil loss.
on the application. Refer to: PIL 30-18. for the
correct charge pressure. 3. With a suitable allen key, slowly remove the filler
plug.
Charge the replacement accumulator with nitrogen
as follows: 3.1. Remove the sealing washer and plug.
3.2. Lightly oil the sealing washer.
3.3. Install the new plug.
3.4. Loosen the plug by 1/8 of a turn.
4. Connect the accumulator adaptor to the
accumulator.
Special Tool: Accumulator Charging Adaptor
(Qty.: 1)
5. Connect the charging unit to the accumulator
adaptor.
Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1)
30 - 103 9823/0300-1 30 - 103

18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 1024.

regulator on the nitrogen gas bottle with the
correct adaptor.
7. Set the pressure regulator on the gas bottle to
the minimum pressure.
8. Turn the charging tool knob to open the filler plug
by three turns.
9. Open the discharge valve on the charging unit.
10. Carefully open the nitrogen gas bottle valve and
A
make sure that the nitrogen gas flows freely
through the discharge valve.
C
11. Close the gas bottle valve and the discharge
valve. B
12. Carefully open the gas bottle valve.

13. Slowly increase the pressure using the gas bottle
pressure regulator and watching the gauge on
the charging unit, allow nitrogen to flow until
the pressure reading reaches the specified value A Label position
above the operating charge pressure. B Discharged state label
Pressure: 4bar (58.0psi) C Pressurised warning label
14. Important: Do not exceed the maximum working 25. Install the accumulator and make sure the
pressure of the accumulator. The maximum pressurised warning label is clearly visible.
working pressure is marked on the accumulator
body.
15. Close the gas bottle valve.
16. Wait for the specified duration to dissipate the
heat generated during charging.
Duration: 10min
17. Carefully open and close the discharge valve to
reduce the pressure in the accumulator to the
specified operating charge pressure.
18. Turn the charging tool knob to close the filler plug
and tighten to the correct torque value.
Torque: 20N·m
19. Open the discharge valve to release the pressure
from the charging hose.
20. Disconnect the charging unit and adaptor from
the accumulator.
21. Pour oil around the filler plug to make sure that
it is gas tight.
22. Replace the plastic cap.
23. Remove the discharged state label.
24. Attach the pressurised warning label on the
accumulator at the position shown.
30 - 104 9823/0300-1 30 - 104

51 - Lift Arm Control Valve Block
Contents Page No.
30-51-00 General ......................................................................................................................... 30-107

30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-114
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-115
30-51-21 Load Sense Relief Valve .............................................................................................. 30-119
30-51-24 Flow Regulator ............................................................................................................. 30-121
30 - 105 9823/0300-1 30 - 105

Notes:
30 - 106 9823/0300-1 30 - 106

00 - General

Fault-Finding ................................................ 30-109
Disassemble and Assemble ........................ 30-112
Figure 1025. Electro Servo Control Valve
7 8
2
6
4 1
1 Sump Port 2 Proportional Solenoid

3 ARV (Auxiliary Relief Valve) 4 Inlet Port
5 Tank Return Port 6 LSRV (Load Sense Relief Valve)
7 Unloader Block 8 Dump Solenoid
9 Accumulator
30 - 107 9823/0300-1 30 - 107

00 - General
Table 266. Electro Servo Control Lever

Control Mode Control System Actuation
Control lever- AXIS One Proportional analogue Hydraulic control ECU
electrical signal (Electronic Control Unit)
via CAN (Controller Area
Network) message from
the powerbase ECU
Control lever- AXIS Two Proportional analogue Hydraulic control ECU via
electrical signal CAN message from the
powerbase ECU
Thumbwheel One Proportional analogue Hydraulic control ECU via

powerbase ECU
Thumbwheel Two Proportional analogue Hydraulic control ECU via

powerbase ECU
The control lever operates in two axies. It also

includes two thumbwheel switches.
The control lever also incorporates switches for

transmission control.
30 - 108 9823/0300-1 30 - 108

00 - General
Fault-Finding
Fault
All services lack power Table 267. Page 30-109
All services slow to operate Table 268. Page 30-110
The system pressure is too high Table 269. Page 30-110
A service stays selected Table 270. Page 30-110
System isolation not working Table 271. Page 30-111
All services inoperative Table 272. Page 30-111
Low flow from auxiliary service Table 273. Page 30-111
Lift arm operation is "Fierce" Table 274. Page 30-111
Servo operated spool services slow to operate or low auxiliary flow (The Table 275. Page 30-111
maximum auxiliary service flow available should be up to 95 L/min minimum
for 'manual' thumbwheel operation and up to 65 L/min with 'constant'
operation selected).
Table 267. All services lack power

Cause Remedy
Insufficient hydraulic fluid Check for leaks and top up as required.
LSRV (Load Sense Relief Valve) out of adjustment or Check and adjust as required.
defective
Internal leakage fault in the load sense circuit. Measure the load sense pressure.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
end section sticking open due to contamination.
Contamination in proportional solenoid valves or Dismantle and inspect valve block components.
mesh filters.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Machines with Variflow Pump: Insufficient output Check and adjust, or renew the LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS (Hydraulic Variable Control Solenoid sensor. Check condition of the associated electrical
Valve)) (if fitted) being permanently energised wiring for damage and short circuits.
and/or due to failure of the pump or internal tilting Install new pump and flush the hydraulic system to
swashplate mechanism because of contamination. remove all contamination.
Machines with Gear Pump: Low pump flow Check pump flow
Check for extra leaks, install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Electronic fault Use service master to determine the problem. Refer
to electrical system- electronic diagnostic, refer to
(PIL 33-57).
30 - 109 9823/0300-1 30 - 109

00 - General
Table 268. All services slow to operate

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as required.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
sticking open due to contamination.
Servo pilot pressure too low: Due to blocked Measure the servo pilot pressure and install new
servo pilot filter element and/or due to faulty servo servo pilot filter element.
regulating valve. Measure the servo pilot pressure and install new pilot
pressure supply valve.
Machines with Variflow Pump: Insufficient output Check and adjust, or install new LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS) (if fitted) being permanently sensor. Check condition of the associated electrical
energised and/or due to failure of the pump or wiring for damage and short circuits.
internal tilting swashplate mechanism because of Install new pump and flush the hydraulic system to
contamination. remove all the contamination.
Machines with GearPump: Low pump flow Check the pump flow.
Check for external leaks and install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Fault in electrical circuit wiring or joystick powerbase Check the condition of the associated electrical
ECU (Electronic Control Unit): Due to thumbwheel wiring for damage and that the fuses are intact.
switch defective/ solenoid at pilot pressure valve Then:
not energising/ solenoid coil faulty and/or faulty Check the function of the applicable thumbwheel
powerbase ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick powerbase ECU.
Table 269. The system pressure is too high

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Contamination in proportional solenoid valves, check Dismantle and inspect valve block components.
valve or mesh filters.
Table 270. A service stays selected

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Service spool or associated load hold check valves Dismantle and inspect the associated service spool
damaged or sticking due to contamination. or load hold check valves.
30 - 110 9823/0300-1 30 - 110

00 - General
Table 271. System isolation not working

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Blockage in unloader drain port. Clean port, replace inlet section if necessary.
Electronic fault Use service master to determine the problem. Refer
(PIL 33-57).
Table 272. All services inoperative

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Electronic fault. Use service master to determine the problem. Refer
(PIL 33-57).
Table 273. Low flow from auxiliary service

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 274. Lift arm operation is "Fierce"

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 275. Servo operated spool services slow to operate or low auxiliary flow (The maximum auxiliary
service flow available should be up to 95 L/min minimum for 'manual' thumbwheel operation and up
to 65 L/min with 'constant' operation selected).
Cause Remedy
Fault in the electrical circuit wiring, joystick controller Check the condition of the associated electrical
hydraulic control ECU. Due to defective thumbwheel wiring for damage and that the fuses are intact.
switch/ solenoid at the pilot pressure supply valve Then:
not energising/ faulty solenoid coil/ faulty joystick Check the function of the applicable thumbwheel
controller and/or faulty hydraulic control ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick controller.
Install new hydraulic control ECU.
Servo pilot pressure too low: Due to blocked servo Measure the servo pilot pressure and install new
pilot filter element/ faulty pilot pressure supply valve servo pilot filter element.
and/or due to proportional solenoid valve cartridge Measure the servo pilot pressure and install new pilot
damaged or sticking due to contamination. pressure supply valve.
Counterbalance valve not working correctly. Check operation of applicable counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of lift ram pressure sensor.
working correctly.
30 - 111 9823/0300-1 30 - 111

00 - General
Damage or contamination can cause problems with

The valve block is made up of a number of sections. valve operation.
Make sure that new valve section O-rings are Disassemble

available before you disassemble the valve block.
1. Remove the valve block from the machine.
Make sure you record the location of all components
when you disassemble the valve block. Although 2. Remove the tie rod nuts.
some components look the same they are not
interchangeable. The service spools for example 3. Move each valve section off the tie rods.
are of two different types. Make sure that the
components are installed in the correct position. 4. If the outlet section is to be replaced, remove and
retain the tie rods.
Take care when you disassemble and assemble a
valve to prevent damage to seals and seal grooves.
Figure 1026.
A
A
A
A Tie rod nuts B Inlet section

C Auxiliary section D Tilt section
E Extend / retract section F Lift / lower section
G Outlet section
30 - 112 9823/0300-1 30 - 112

00 - General
Assemble
1. The assembly procedure is the opposite of
the disassembly procedure. Additionally do the
following steps.
1.1. Clean the valve components in an
applicable solvent. Make sure that the
mating faces of the valve sections are fully
clean before assembly.
1.2. Replace the O-rings located between the
valve sections. Install the O-rings correctly.
1.3. Lubricate the parts with JCB hydraulic oil
before you assemble them. Make sure that
all the parts move freely.
1.4. If the tie rods were removed, apply sealant
to the threads before you install.
1.5. Screw the tie rods into the valve block until
they are tight.
1.6. Loosen the tie rods by one turn.
1.7. Once the valve block is fully assembled
these rods may be adjusted to allow
sufficient thread for the tie rod nuts to
tighten.
1.8. Tighten the tie rods to the correct torque
value.

Item Description Nm
A Tie rod nuts 54
30 - 113 9823/0300-1 30 - 113

03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Figure 1028.

D
N
Operation
The relief valve is located in the control valve, which EX

connects either the neutral and exhaust galleries
(Parallel Control Valves) or the load sense and A
exhaust galleries (Flowshare Control Valves). It is B
designed to prevent the circuitry from damage that
could be caused by excessive pressures.
Valve at rest
The services are in neutral and pressure in the
neutral gallery is not sufficient to operate the relief
valve which is held closed by its spring.
Figure 1027.
N A Control valve block
B Relief valve
D Hollow poppet
N Neutral gallery
EX
EX Exhaust gallery
A
B
A Control valve block

B Relief valve
C Spring
N Neutral gallery
EX Exhaust gallery
Poppet opens
A service has been selected and the pressure
generated exceeds the setting of the relief valve.
Pressure acts on the periphery of the hollow poppet
which is forced downwards against the spring
releasing the pressure into the exhaust gallery.
30 - 114 9823/0300-1 30 - 114

06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-115 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-116 complete valve must be replaced if it is defective.
Check (Pressure) ........................................ 30-117
Adjust .......................................................... 30-117 Do not remove or damage the tamper proof cap as
this may invalidate a warranty claim.
30 - 115 9823/0300-1 30 - 115

Operation Figure 1030. Poppet opens
The ARV (Auxiliary Relief Valve) are located in the

control valve to limit potentially damaging pressures
within specified services due to external loadings.
ARV may also be used to limit the maximum pressure

in a specified service to less than the LSRV (Load
Sense Relief Valve) setting.
Valve at rest EX
A service is selected but pressure in the service

gallery has not reached the setting of the ARV which
is held closed by its spring. S
S Service gallery
Figure 1029. Valve at rest
EX Exhaust gallery
Anti-cavitation mode
When a service is operated in such a way that low
pressure, or cavitation, exists in the service line, the
relatively high pressure oil in the exhaust gallery acts
on the lower poppet and flows into the service gallery
to make up the deficiency.
Figure 1031. Anti-cavitation mode

EX
S Service gallery
EX Exhaust gallery
Poppet opens
The setting of the ARV is exceeded by the service EX
pressure which causes the poppet to rise against
spring force allowing the pressure to be released into
the exhaust gallery. S
S Service gallery
EX Exhaust gallery
30 - 116 9823/0300-1 30 - 116

Check (Pressure) Adjust
Refer to check (pressure), (PIL 30-00-00). Refer to check (pressure), (PIL 30-00-00).
30 - 117 9823/0300-1 30 - 117

Remove and Install Table 277. Torque Values

Item Nm
A 44.7
Remove
The ARV (Auxiliary Relief Valve)s are not adjustable.
If the pressure is incorrect, replace the valve. Each
ARV has its pressure setting stamped on the top
face, make sure to replace the ARV with one of the
same pressure setting.
The ARV shown is for illustration purposes. Make

sure to select the correct ARV. Refer to (PIL 30-51).

2. Follow the hydraulic care and safety procedures.
3. Vent the hydraulic pressure. Refer to (PIL 30-00).
4. Remove the chassis rear cover to access the
control valve block. Refer to (PIL 06-06).
5. Remove the valve blanking pug.
6. Carefully remove the ARV from the valve block.
Figure 1032.
A A
A A
A ARV Blanking plug
Install
step.
1.1. Install new ARV into the valve block and
tighten the valve blanking pug to the
30 - 118 9823/0300-1 30 - 118

21 - Load Sense Relief Valve
21 - Load Sense Relief Valve Remove and Install

Consumables
JCB Hydraulic Fluid HP 4002/0801 5L
46 4002/0805 20L
4002/0803 200L
The LSRV (Load Sense Relief Valve) is not

serviceable. Install new LSRV if it is defective.
Remove
2. Release the hydraulic pressure. Refer to (PIL
30-00).
3. Access the valve block. Refer to (PIL 06-06).
4. Remove the valve assembly from the valve
block.
Figure 1033. Gearpump Hy-
draulic System Control Valve
A
A Valve assembly
30 - 119 9823/0300-1 30 - 119

21 - Load Sense Relief Valve
Figure 1034. Variflow Hy- Disassemble and Assemble

draulic System Control Valve
The load sense relief valve is not serviceable.

Replace the complete valve with the correct valve if
it is defective.
1 2 3 4
A
A Valve assembly
Install
steps.
1.1. Tighten the valve to the specified torque
value.
1.2. Install new O-rings and backup rings.
1.3. Lubricate the parts with JCB Hydraulic Fluid
before assembling.
Consumable: JCB Hydraulic Fluid HP 46
1.4. Adjust the pressure setting as necessary.

Item Description Nm
A Valve assembly 65
30 - 120 9823/0300-1 30 - 120

24 - Flow Regulator
24 - Flow Regulator Check (Condition)

Check (Condition) ........................................ 30-121
Inspection
1. Examine the valve components for scratches,
pitting, corrosion or any other damage.
2. Clean the filter gauze installed in the end of the
valve body.
3. If any part other than the O-rings are damaged,
replace the entire valve.
Figure 1035.
A Filler gauze
30 - 121 9823/0300-1 30 - 121

24 - Flow Regulator
Disassemble and Assemble 2.2. Lubricate the parts with JCB hydraulic fluid
before you assemble them. Make sure that
all the parts move freely.
Disassemble 2.3. Install new O-rings and back-up rings.
1. Loosen and remove the top plug. 2.4. Make sure to install the filter gauze in the
correct orientation.
2. Carefully remove the shims, the spring and the
piston. Table 279. Torque Values
3. Remove the O-rings and the seals with the Item Description Nm
correct round tool. Make sure that no damage is F Valve body 20
caused to the seal grooves.
4. Discard all the O-rings and the back-up rings.
5. Do not use worn or damaged items.
Figure 1036.
A Top plug
B Shims
C Spring
D Piston
E Filter gauze
F Valve body
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. When assembling do the following steps also:
2.1. Clean the valve components in the correct
solvent.
30 - 122 9823/0300-1 30 - 122

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-125

30-60-15 Joystick ......................................................................................................................... 30-127
30-60-27 Auxiliary Circuit ............................................................................................................ 30-129
30-60-90 Flow Regulator ............................................................................................................. 30-130
30 - 123 9823/0300-1 30 - 123

Notes:
30 - 124 9823/0300-1 30 - 124

00 - General
00 - General
Introduction
Flow Control Valves Figure 1040.
Control valves are usually represented by one or

more square boxes.
The number of boxes indicates the number of

possible valve operating positions, (3 boxes, 3
positions etc).
Figure 1037.
1 Position 1 (P1 - P2, P3 - P4)

3 Position 3 (P1 - P4, P2 - P3)
In circuit diagrams the pipework is usually shown It must be noted that not all spools are of the
connected to the box which represents the same type. Their operating designs can be seen
unoperated condition. (Hydraulic circuit diagrams are by following the path the flow arrows take in their
usually shown in the unoperated condition). respective operating squares.
Figure 1038. Three typical JCB style spools are known as 'D'
spools, 'F' spools and 'N' spools.
The 'D' spools generally control rams because when

in the neutral position the outlet ports are blocked,
preventing ram movement.
'F' spools are often shown as four position spools

A valve described as a 3-position, 4-port control with the three normal positions for neutral and
valve. Port describes the openings to and from the service control; and the forth position, which has a
valve by which the hydraulic fluid enters or leaves. In detent, connects both sides of the ram together to
an unoperated condition all ports are blocked. allow the service to 'float'.
2 Position 2 (all 4 ports blocked)

'N' spools are sometimes used to control hydraulic
If the valve spool was moved to Position 1, motors, and it can be seen from the flow arrows, that
movement of the spool would connect Port P1 to Port in neutral position both service ports are connected
P2, and Port P3 to Port P4. to the exhaust oil port
If the valve spool was moved to Position 3, Figure 1042.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 125 9823/0300-1 30 - 125

00 - General
Figure 1043. Simple Schematic Circuit Example
A
B
C G
D E
A Hydraulic tank B Strainer

C Fixed displacement pump D Relief valve
E Spool F One way valve
G Double acting hydraulic ram
Some of the symbols described on the preceding

pages have been arranged into a simple schematic
circuit.
The hydraulic tank is a pressurised tank with an

internally mounted strainer on the suction line to the
fixed displacement pump. System pressure is limited
to the setting of relief valve.
The valve spool is an open-centre spool that is in

neutral position; flow from the pump passes through
the spool and returns to the hydraulic tank.
If the lever operated spool is moved away from

neutral position hydraulic fluid is directed to either
head side or rod side of hydraulic ram. Notice that
the fluid must first open one way valve before flowing
to the ram.
30 - 126 9823/0300-1 30 - 126

15 - Joystick
15 - Joystick Component Identification

Figure 1044.
N
H J
A
K
B L
C E
D
G
A Main control lever handle B Axis 1- Raise / Lower

C Electrical connector- Thumbwheel and auxiliary D Electrical connector- Constant auxiliary button
button
E Powerbase PWM (Pulse Width Modulation)ECU F Electrical connectors- Powerbase PWMECU 1
(Electronic Control Unit)
G Electrical connectors- Powerbase PWMECU 2 H Axis 3- Thumbwheel- Extend / Retract
J Axis 4- Thumbwheel- Aux +/- K Constant flow button
L Axis 2- Carriage tilt N Neutral Position
30 - 127 9823/0300-1 30 - 127

15 - Joystick
Do not attempt to dismantle the joystick. If the joystick

is defective, a new unit must be installed.
Externally facing seals, port adaptors, gaiters and

joystick handles may be replaced if the correct parts
are available and the correct cleanliness procedures
are followed.
30 - 128 9823/0300-1 30 - 128

Discharge and Pressurise
Refer to discharge and pressurise, (PIL 30-00).
30 - 129 9823/0300-1 30 - 129

90 - Flow Regulator
90 - Flow Regulator
Introduction
Refer to (PIL 30-51-24).
30 - 130 9823/0300-1 30 - 130

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-133
30 - 131 9823/0300-1 30 - 131

Notes:
30 - 132 9823/0300-1 30 - 132

00 - General
Introduction .................................................. 30-133 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-134 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 133 9823/0300-1 30 - 133

00 - General
Check (Operation) 5.2. If the lift arm moves after the engine stops,
then the lift arm HBCV is faulty. Do not use
DANGER Before lowering the attachments to the the machine until you correct the fault.
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or Carriage tilt cylinder
close to the machine could fall and be crushed by
the attachments, or get caught in the linkages. 1. Pick up a load on the forks.
WARNING Maintenance must be done only by 2. Tilt the carriage fully back.
suitably qualified and competent persons.
Before doing any maintenance make sure the 3. Make sure to engage the park brake and put the
machine is safe, it must be correctly parked on transmission to neutral.
solid, level ground. 4. Raise the lift arm and put it in a position that, the
To prevent anyone starting the engine, remove carriage can be tilted forward fully.
the ignition key. Disconnect the battery when you
are not using electrical power. If you do not take 5. Run the engine at mid speed and operate the
these precautions you could be killed or injured. control lever to tilt the carriage forward. While the
carriage is moving, switch off the engine.
Check each movement in turn. 5.1. The carriage movement must slow as the
engine slows. The carriage movement must
Lift arm lift cylinders stop when the engine stops.
1. Start the engine. 5.2. If the carriage moves after the engine stops,
then the HBCV is faulty. Do not use the
2. Make sure to engage the park brake and put the machine until you correct the fault.
transmission to neutral.
Stabiliser cylinder (if installed)
3. Raise the lift arm to the specified angle.
Angle: 45° 1. Start the engine.
4. Run the engine at mid speed and operate the 2. Make sure to engage the park brake and put the
control lever to lower the lift arm. While the lift transmission to neutral.
arm is moving, switch off the engine. 3. Lower the stabilisers.
4.1. The lift arm movement must slow as the 4. Make sure that the stabiliser legs are in the down
engine slows. The lift arm movement must position and supports the machine weight. Make
stop when the engine stops. sure that the front wheels are lifted from the
4.2. If the lift arm moves after the engine stops, ground.
then both the lift arm HBCV (Hose Burst
Check Valve) are faulty. Do not use the 5. Stop the machine.
machine until you correct the fault.
6. Operate the stabiliser controls.
Lift arm extension cylinder 7. Make sure that the front wheels of the machine
do not lower to the ground.
7.1. If the machine moves when the stabiliser
2. Make sure to engage the park brake and put the controls are operated after the engine is
transmission to neutral. stopped, the HBCV are faulty. Do not use
the machine until you correct the fault.
3. Raise the lift arm fully.
4. Extend the lift arm fully.
5. Run the engine at mid speed and operate the
control lever to retract the lift arm. While the lift
arm is retracting, switch off the engine.
5.1. The lift arm movement must slow as the
engine slows. The lift arm movement must
stop when the engine stops.
30 - 134 9823/0300-1 30 - 134

00 - General
Figure 1045.
X Gap between the wheel and the ground
Sway cylinder (if installed)

2. Make sure to engage the park brake and put the
transmission to neutral.
3. Sway the machine body approximately halfway
to the left and release the sway control.
4. Stop the engine.
5. Operate the sway control to the left. Check that
the machine does not sway.
6. Do steps 1 to 5 again for right sway.
7. If the body moves when the sway control is
moved with the engine stopped, the hose burst
protection valves are faulty.
8. Do not use the machine until you correct the fault.
30 - 135 9823/0300-1 30 - 135

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-137

30-93-03 Lift Arm ......................................................................................................................... 30-140
30 - 136 9823/0300-1 30 - 136

93 - Hose
00 - General
Introduction .................................................. 30-137 Hydraulic hoses are used to connect different
Disconnect and Connect ............................. 30-138 components in the hydraulic circuit. The hoses
Check (Condition) ........................................ 30-139 are graded by pressure, temperature, and fluid
compatibility. Hoses are built up with rubber and steel
layers. A rubber interior is surrounded by multiple
layers of woven wire and rubber. The exterior is
designed for abrasion resistance. The bend radius
of a hydraulic hose is carefully designed into the
machine, since hose failures can be deadly, and
violating the hose's minimum bend radius will cause
failure. Hydraulic hoses generally have steel fittings
swaged on the ends.
30 - 137 9823/0300-1 30 - 137

93 - Hose
00 - General
Disconnect and Connect Figure 1048.
Some attachments are hydraulically powered. The

following procedures show how to connect and
disconnect the hydraulic hoses safely.
Connecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Check the hoses and adaptors for damage. 5. Check for leaks:
4. Connect the hoses: 5.1. Start the machine.
4.1. Make sure that the hose is not twisted. 5.2. Operate the related controls to increase the
Pressure applied to a twisted hose can pressure in the hydraulic system.
cause the hose to fail or the connections to 5.3. Stop the machine then remove the key.
loosen.
5.4. Check for indications of leakage at the hose
Figure 1046. connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Disconnect the hoses.
4.2. Make sure that the hose does not touch 4. Check the hoses and adaptors for damage.
hot parts. High ambient temperatures can
cause the hose to fail. 5. If necessary, install the blanking caps.
4.3. Make sure that the hose does not touch 6. Check for leaks:
parts which can rub or cause abrasion.
6.1. Start the machine.
4.4. Use the hose clamps (where possible) to
support long hose runs and keep the hoses 6.2. Operate the related controls to increase the
away from moving parts, etc. pressure in the hydraulic system.
Figure 1047. 6.3. Stop the machine then remove the key.
6.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
4.5. To allow for length changes when the hose

is pressurised, do not clamp at the bend.
The curve absorbs the change.
30 - 138 9823/0300-1 30 - 138

93 - Hose
00 - General
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
use the machine if a hose or hose fixture is
damaged.
WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 139 9823/0300-1 30 - 139

93 - Hose
03 - Lift Arm
03 - Lift Arm
Remove and Install
9. Put a label on the hydraulic hoses to help

Remove installation.
1. Make the machine safe. Refer to (PIL 01-03). 10. Remove the auxiliary pipe bracket retaining
bolts.
2. Extend the lift arm approximately by the specified
length. 11. Disconnect the hoses from the auxiliary pipes.
Length/Dimension/Distance: 1m 12. Disconnect the auxiliary and tilt hoses from the
lift arm pipes.
3. Remove the lift arm attachments, including forks
and fork bar. 13. Remove the hose clamp securing bolts and the
hose clamps.
4. Release the hydraulic pressure. Refer to (PIL
30-00). 14. Remove the tilt ram and auxiliary hoses.
5. Remove the valve block cover. Refer to (PIL 14.1. Pull out the hoses through guide channels
06-06). from the rear in the direction of arrow X.
6. Remove the extension ram. Refer to (PIL 30-15). 14.2. Then pull out the hoses through the
apertures under the boom M in the
7. Install a pivot pin to the lift arm rear pivot. direction of arrow Y.
8. Remove the tilt ram. Refer to (PIL 30-00). 14.3. Cap all open hoses and ports.
30 - 140 9823/0300-1 30 - 140

93 - Hose
03 - Lift Arm
Figure 1049.
A
A
B
B
Y
F K
X X K Y
M
H L
L
G J
A Hoses B Auxiliary pipe bracket retaining bolts

C Auxiliary pipes D Tilt ram
E Extension ram F Hose clamps
G Hose clamp securing bolts H Auxiliary hoses
J Guide channels K Lift arm pipes
L Tilt hoses M Lift arm
30 - 141 9823/0300-1 30 - 141

93 - Hose
03 - Lift Arm
X Arrow X Y Arrow Y
30 - 142 9823/0300-1 30 - 142

93 - Hose
03 - Lift Arm
Install
1. Install the hoses through the apertures under the
lift arm.
2. Connect the hoses to the lift arm pipes.
3. Pull the hoses through the rear of the lift arm.
4. Using a long rod with a hook end feed the hoses
into the channels. The hoses will need to be lifted
slightly to enter the channel.
5. Make sure to pull the tilt ram hoses into position
and install the tilt ram. Refer to (PIL 30-00).
6. Connect the auxiliary hoses to the auxiliary
pipes.
7. Install the auxiliary pipe bracket retaining bolts.
8. Install the hose clamps and securing bolts.
9. Install the extension ram. Refer to (PIL 30-00).
10. Install the lift arm rear cover. Refer to (PIL 06-06).
11. Check the hydraulic oil level and fill if necessary.
12. Check the operation of the lift arm services and
make sure that there are no leaks.
13. Grease all the pivot points. Refer to (PIL 75-06).
14. Check the pivot shim clearance. Refer to (PIL
06-12).
30 - 143 9823/0300-1 30 - 143

97 - Connectors
97 - Connectors
Contents Page No.
30-97-00 General ......................................................................................................................... 30-145

30-97-03 Quick Release Coupling .............................................................................................. 30-148
30-97-09 Adaptor ......................................................................................................................... 30-150
30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-152
30-97-24 Push Lock Fitting ......................................................................................................... 30-154
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-155
30 - 144 9823/0300-1 30 - 144

97 - Connectors
00 - General
00 - General
Technical Data
O-Ring Face Seal UNF Threads on the BSP Adap- BSP Adap- Hexagon Torque
ORFS Fittings tor Size tor Size (A/F) Value
Inch mm mm N·m
3/4 19.05 32mm 81N·m
Table 280. Torque Settings - ORFS
1 25.4 38mm 129N·m
UNF Thread Size Torque Value 1 1/4 31.75 50mm 206N·m
inch x pitch N·m
9/16 x 18 24–27N·m Table 282. Torque Settings - SAE Connections
11/16 x 16 40–44N·m SAE Hose SAE Port Hexagon Torque
13/16 x 16 55–60N·m Dash Size Thread (A/F) Value
1 x 14 60–66N·m Size
1 3/16 x 12 90–99N·m inch x mm N·m
pitch
1 5/16 x 12 115–126N·m
4 7/16 x 20 15.9mm 20–28N·m
1 7/16 x 12 125–138N·m
6 9/16 x 18 19.1mm 46–54N·m
1 11/16 x 12 170–187N·m
8 3/4 x 16 22.2mm 95–105N·m
2 x 12 200–220N·m
10 7/8 x 14 27mm 130–
140N·m
Adaptors Connected into Valve Blocks
12 1 1/16 x 12 31.8mm 190–
210N·m
Table 281. Torque Settings - BSP Adaptors 16 1 5/16 x 12 38.1mm 290–
310N·m
BSP Adap- BSP Adap- Hexagon Torque
tor Size tor Size (A/F) Value 20 1 5/8 47.6mm 280–
380N·m
Inch mm mm N·m
1/4 6.35 19mm 18N·m
3/8 9.525 22mm 31N·m
1/2 12.7 27mm 49N·m
5/8 15.875 30mm 60N·m
30 - 145 9823/0300-1 30 - 145

97 - Connectors
00 - General
Hoses installed into Adaptors
Figure 1050.
B
C
A B C
A
A Adaptor B Hose
C O-ring D Dimension will vary depending upon the torque
applied.
Hoses installed into adaptors seal onto an `O' ring

which is compressed into a 45° seat machined into
the face of the adaptor port.
Table 283. BSP Hose - Torque Settings
BSP Hose Size Hexagon (A/F)
Nm kgf m lbf ft
in mm
1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8
1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8
Adaptors into Component Connections with Bonded Washers

Table 284. BSP Adaptors with Bonded Washers - Torque Settings
BSP Hose Size
Nm kgf m lbf ft
in
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
30 - 146 9823/0300-1 30 - 146

97 - Connectors
00 - General
BSP Hose Size

Nm kgf m lbf ft
in
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0
Torque Stop Hose System
Figure 1051.
B
C
A B C
A
A Adaptor B Hose
C O-ring D Shoulder
E Minimum dimension fixed by shoulder.
Torque-Stop hoses installed into adaptors seal onto the 'O' ring being damaged as a result of over
an `O' ring which is compressed into a 45° seat tightening, Torque-Stop hoses have an additional
machined into the face of the adaptor port. To prevent shoulder, which acts as a physical stop.
Table 285. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)
Nm kgf m lbf ft
in. mm
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0
30 - 147 9823/0300-1 30 - 147

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-148 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-149 operator to remove and install attachments swiftly
and efficiently. Generally, your machine pipework will
have female couplings installed, and the optional
attachment hoses will have male couplings installed.
The quick release couplings will be trouble free and

relatively easy to connect and disconnect, if they are
kept clean and used correctly. The recommendations
listed below must always apply when using flat face
quick release couplings.
Read the correct connecting and releasing

procedures before you install or remove any optional
attachment connected with quick release couplings.
Figure 1052.
A B
A Female coupling
B Male coupling
Essential Do's
• Before connecting or removing any hydraulic
hose, the residual hydraulic pressure trapped
in the service hose line must be vented. Make
sure the hose service line has been vented
before connecting or removing the hoses.
• Always wipe the two mating faces clean before
connecting.
• Use caps and plugs when the couplings are
disconnected.
• Always align the external locking ball (if used)
with the notch in the locking sleeve and then pull
the locking sleeve back fully to disconnect.
• If a coupling sticks, first check that pressure
has been released. Make sure the locking ball
and notch in the locking sleeve are aligned,
pull back the sleeve and twist the couplings
apart. Sticking is normally caused by dirt in the
coupling or physical damage due to abuse.
• Connect and disconnect the new couplings
two or three times to work the PTFE seals.
Sometimes a new coupling will stick if the seal
has not been worked.
• When connecting the couplings, only apply the
spanner or grips to the hexagon and nowhere
else.
• Avoid damage to the coupling faces. Burrs
and scratches cause damage to the seals and
cause leaks. They can also impede connection
and disconnection of the couplings.
30 - 148 9823/0300-1 30 - 148

97 - Connectors
03 - Quick Release Coupling
• Periodically lubricate the internal locking balls Disconnect and Connect

on the female half of the coupling with silicone
grease.
Some attachments are hydraulically powered. The
Essential Don'ts following procedures show how to connect and
disconnect the hydraulic hoses safely.
• Never try to reconnect using a damaged half
coupling as this will destroy the seals in the
mating half and necessitate replacement of Connect
both halves. 1. Make the machine safe.
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this Refer to: PIL 01-03.
will distort the sleeve and prevent connection
and disconnection. 2. Discharge the hydraulic pressure.
• Never try to turn the sleeve when the coupling is Refer to: PIL 30-00-00.
disconnected as this will cause the locking ball
to jam under the locking sleeve and damage the 3. Wipe the two faces of the male and female
coupling. couplings and make sure they are clean.
• Never try to strip the coupling down, there are
no user serviceable parts. If the coupling is 4. Make sure that the ball in the female coupling is
damaged it must be replaced with a new one. located in one of its slots.
• Never hit the centre poppet of the coupling to 5. Connect the male coupling into the female
try and release the locked in pressure. This can coupling.
cause irreparable damage to the coupling and
serious injury. 6. Where applicable, rotate the sleeve half a turn
• When connecting the couplings, never clamp and make sure that the locking ball does not align
on the sleeve of the female or nose of the male, with the slot.
this will cause distortion and/or damage.
• Never subject the couplings to external forces, Disconnect
especially side load. This can decrease the life
of the coupling or cause failure. 1. Make the machine safe.
• Never allow the torsional forces transmitted
from the hoses to unscrew/screw together the Refer to: PIL 01-03.
couplings.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in Refer to: PIL 30-00-00.
the line unless the coupling type is specifically
designed to do so. 3. Where applicable, align the slot with the ball.
4. Pull back the sleeve to release the coupling.
Figure 1053.
C D E
C Ball
D Slot
E Sleeve
30 - 149 9823/0300-1 30 - 149

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-150 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-151 may utilise Positional Type Hydraulic Adaptors.
When you install a Positional Type Hydraulic
Adaptor, it is important to adopt the Remove and
Install procedure. Refer to: PIL 30-97-09.
If this procedure is not followed correctly, damage to

the O-ring seal can occur which can result in oil leaks.
Figure 1054.
A O-ring seal
B Locknut
C Washer
30 - 150 9823/0300-1 30 - 150

97 - Connectors
09 - Adaptor
1. Make sure that the locknut is screwed back on to

the body of the adaptor as far as possible.
2. Check that the O-ring backing washer is a tight
fit on the adaptor. Note that the washer should
not move freely, if the washer is slack do not use
the adaptor.
3. Check that the O-ring seal is installed and
that it is free from damage or nicks. Before
you install the adaptor, smear the O-ring with
clean hydraulic fluid. The dimensions and shore
hardness of the O-ring seal is critical. Should it
become necessary to replace the O-ring seal,
make sure you use JCB Genuine Parts.
Figure 1055.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.
Refer to Connectors - Technical Data.
A O-ring seal
B Locknut
C Backing washer
4. Screw the adaptor into the port of the hydraulic
component as far as possible, so that all the
threads engage and the O-ring seal is correctly
seated against the sealing face.
5. Set the angular position of the adaptor as
required, then secure by tightening the locknut.
When installed correctly no more than one thread
should be visible at Z as shown.
30 - 151 9823/0300-1 30 - 151

97 - Connectors
18 - O-Ring Face Seal (ORFS)
18 - O-Ring Face Seal (ORFS) Introduction

Introduction .................................................. 30-152 The ORFS (O-Ring Face Seal) type fittings are
Remove and Install ..................................... 30-153 adaptors that are screwed into valve blocks, they
seal on to an O-ring which is compressed into a 45°
seat machined into the face of the tapped port.
30 - 152 9823/0300-1 30 - 152

97 - Connectors
18 - O-Ring Face Seal (ORFS)
The hose fittings are for flat face components for

resistance over torque. The ORFS (O-Ring Face
Seal) offers 100% reliability.
When you remove or install components, make sure

all of the hydraulic fittings are tightened to the correct
torque value during the assembly procedure.
To prevent damage to the ORFS during the assembly 4 Swivel nut - Hand tight
procedure it is important to use the double-spanner 5 Swivel nut - Torque tightened
method to tighten the fittings.
Figure 1060.
Figure 1057.
1 Torque spanner
D
2 Open ended combination spanner
Install
1. Always coat the ORFS with hydraulic oil before
installation.
2. The rubber ORFS is compressed into a precision
machined groove in the adaptor to form a tight
seal against a flat surface of the sleeve.
Figure 1058. A Nut
3 B Sleeve
C ORFS
D Adaptor
3 ORFS
3. Use the swivel nut line marking. Tighten the nut
to the correct torque value to compress the fitting.
Refer to Technical Data.
30 - 153 9823/0300-1 30 - 153

97 - Connectors
24 - Push Lock Fitting
24 - Push Lock Fitting
Remove and Install
The fitting is installed and removed without the need

for tools, it is removable and reusable.
1. To release the tube push the collet and release

the tube. All tubes have an assembly mark to
assist installation.
Figure 1061.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 154 9823/0300-1 30 - 154

97 - Connectors
27 - Rapid Assembly Hose Fitting
27 - Rapid Assembly Hose Fitting
Remove and Install
The hose has a toolless installation. The hose is not

removable. The complete hose and fitting assembly
must be replaced.
1. To install the hose, push the tube into the fitting

body.
Figure 1062.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 155 9823/0300-1 30 - 155

Notes:
30 - 156 9823/0300-1 30 - 156

Contents Page No.
33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-7
33-00-90 Earth Point ................................................................................................................... 33-129
33-03 Battery
33-03-00 General ......................................................................................................................... 33-141
33-03-03 Isolator Switch .............................................................................................................. 33-151
33-06 Battery Cable
33-06-00 General ......................................................................................................................... 33-155
33-09 Power Distribution
33-09-00 General ......................................................................................................................... 33-157
33-09-03 Fuse ............................................................................................................................. 33-159
33-09-06 Relay ............................................................................................................................ 33-162
33-12 Harness
33-12-00 General ......................................................................................................................... 33-165
33-12-04 Chassis ......................................................................................................................... 33-183
33-12-06 Lift Arm ......................................................................................................................... 33-206
33-12-12 Operator Station ........................................................................................................... 33-217
33-12-15 Front Console ............................................................................................................... 33-249
33-15 Alarm
33-15-03 Reverse Warning .......................................................................................................... 33-269
33-21 Immobiliser
33-21-00 General ......................................................................................................................... 33-271
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-281
33-24-10 Hourmeter .................................................................................................................... 33-285
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................... 33-287
33-27-51 Hydraulic Flow .............................................................................................................. 33-291
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-295
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-299
33-45-03 Machine Control ........................................................................................................... 33-302
33-45-06 Engine .......................................................................................................................... 33-303
33-45-36 Hydraulic ...................................................................................................................... 33-307
33-48 Entertainment
33-48-03 Radio ............................................................................................................................ 33-315
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-319
33-54 Window Washer/Wipe
9823/0300-1
2018-01-22
33-54-00 General ......................................................................................................................... 33-321
33-54-09 Front Motor ................................................................................................................... 33-322
33-54-10 Rear Motor ................................................................................................................... 33-325
33-54-11 Roof Motor .................................................................................................................... 33-326
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-329
33-57-03 Servicemaster .............................................................................................................. 33-333
33-57-90 Fault Codes .................................................................................................................. 33-356
33-60 Power Socket
33-60-00 General ......................................................................................................................... 33-399
33-66 Load Motion Control System
33-66-00 General ......................................................................................................................... 33-401
33-66-03 Display Unit .................................................................................................................. 33-420
33-66-06 Transducer ................................................................................................................... 33-425
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-429
33-84-41 Lift Arm ......................................................................................................................... 33-432
33-84-72 Chassis ......................................................................................................................... 33-435
9823/0300-1
2018-01-22
Acronyms Glossary
2WD Two Wheel Drive

2WS Two Wheel Steer
4WD Four Wheel Drive
AWS All Wheel Steer
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
LCD Liquid Crystal Display
LED Light Emitting Diode
LLMI Longitudinal Load Moment Indicator
LMS Loadall Monitoring System
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MECU Machine Electronic Control Unit
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
RAS Rear Axle Stabilization
SRS Smooth Ride System
USB Universal Serial Bus
9823/0300-1
2018-01-22
Notes:
9823/0300-1
2018-01-22
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-7
33-00-90 Earth Point ................................................................................................................... 33-129
33 - 1 9823/0300-1 33 - 1
Notes:
33 - 2 9823/0300-1 33 - 2
00 - General
Introduction ...................................................... 33-3 It is important that the electrical system on the
Health and Safety ........................................... 33-4 machine is in a sound state of repair.
Technical Data ................................................. 33-4
Fault-Finding .................................................... 33-5 Make sure that all the health and safety warnings
in this section are followed. The machine must be
safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9823/0300-1 33 - 3
00 - General
The electrical circuits are protected by fuses. If a Refer to the procedure in the operator manual.
fuse blows, find out why and rectify the fault before
installing a new one.
A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.
33 - 4 9823/0300-1 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 286. Page 33-5
General Relay Fault Table 287. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 288. Page 33-6
ECM Faults Table 289. Page 33-6
Table 286. Battery Fault

Cause Remedy
Battery Voltage Switch on the ignition key and check the battery
voltage with a multimeter. If the terminal voltage of
the battery is below 9 Volt or above 16 Volt, charge
or replace the battery.
Battery Connection Fault Disconnect the electrical connection from the battery.
Check for signs of corrosion or contamination in the
battery terminals, clean the terminals. Repair as
necessary.
If no fault is found proceed to ECM (Engine Control
Module) Connection Faulty.
ECM Connection Faulty Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing an ECM).
If harness is damaged, repair or replace as
necessary.
Check the resistance between the vehicle chassis
ground and ECM ground, if the resistance is high
repair the ECM ground.
If no fault is found proceed to 'Battery Charge Circuit
Fault'.
Battery Charge Circuit Fault Check the battery charge circuit, if the circuit is found
faulty repair as necessary.
If no fault is found raise a Techweb Helpdesk call.
Table 287. General Relay Fault

Cause Remedy
Relay Supply Voltage Fault Perform the relay test routine.
If relay supply voltage is found fault, proceed to
'Relay Connection Faulty'.
If relay supply voltage is OK, raise Techweb
Helpdesk Call.
Relay Connection Faulty Check the condition of relay to harness connection,
make sure the seals are in place, check for signs
of corrosion or contamination. Repair/replace as
necessary.
If no fault is found, proceed to ECM connection fault.
33 - 5 9823/0300-1 33 - 5
00 - General
Cause Remedy
ECM Connection Fault Disconnect the harness from engine ECM and
inspect. Check seals are in place, check for signs of
corrosion or contamination.
necessary.
Check the continuity and electrical insulation, repair
or replace as necessary.
If a relay fault is found, raise Techweb Helpdesk Call.
Table 288. Electrical Network - CAN (Controller Area Network) Bus system
Cause Remedy
necessary.
If no fault is found proceed to Wiring Fault.
Wiring Fault Check the harness continuity and electrical
insulation, repair or replace as necessary.
If no fault is found, proceed to 'Network and CAN
Resistors Faulty'.
Network and CAN Resistors Faulty Check the network and CAN resistors, repair as
necessary.
If no fault is found proceed to raise Techweb
Helpdesk call.
Table 289. ECM Faults

Cause Remedy
ECM Overheat Identify the root cause and repair as necessary: – Air
intake problem – Engine too hot – Cooling fan failure
– Extreme hot soak.
If no fault is found proceed to ECM temperature fault.
ECM Temperature Fault Check the ECM temperature is consistent with
physical ECM temperature, if found faulty raise
Techweb Helpdesk call.
ECM General Fault Visually check the ECM pins and connections on the
wiring harness. If ECM pins are damaged, replace
ECM and re-flash appropriate calibration (see Re-
flashing an ECM).
If no fault is found proceed to ECM connection fault.
Check the conformity of ground connection of vehicle
chassis. If harness is damaged, repair or replace as
necessary.
necessary.
If no fault is found raise Techweb Helpdesk call.
33 - 6 9823/0300-1 33 - 6
50 - Schematic Circuit Introduction

Introduction ...................................................... 33-7 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 33-10 representation of the machines electrical circuit. It
shows the components of the circuit as simplified
electrical symbols, and the power and signal
connections between the devices. The wiring
diagram is used to troubleshoot problems and to
make sure that all the connections have been made
and that everything is present.
Use the schematics together with the correct

electrical harness drawings to reference the
connector pin details.
This section may contain more than one set of

electrical schematics for different machine variants.
Understanding Electrical Schematics

Use the applicable schematic set to trace wires
and connections between electrical devices. In most
cases it will be necessary to trace wires across more
than one schematic sheet.
The example identifies the information contained on

the diagrams. It also shows how to follow wires from
one diagram sheet to another.
The harness inter-connector codes and device

harness connector codes are the same as used on
the applicable harness drawings.
Splices are not normally accessible. Splices are

inside the harness sheath and not visible on the
outside. Wires are welded together at a splice, there
are no individual connector components.
33 - 7 9823/0300-1 33 - 7
Figure 1063.
/7.B4 TO
0.50 mm² 1009A -S012
TO SWITCH:MAIN WIPER C116 #1996
C 7
-SW5
A 701/E0089
7219/0013 SWITCH: MAIN WIPER
FROM SPLICE:BACKLIGHTING S012 #1996
-C116 8 7
0.50 mm² 1009A 8/10 7/10
/3.D1 FROM
0.50 mm² 8100J B

-S011 1 D
F F 2/10 2
L H 3 3/10
4 4/10
-IC08_M -IC08_M
0.75 mm² 8006 21/21 21/21 0.75 mm² 8006 5/10 5
/9.B5 TO
#1783 6 6/10
TO MOTOR:WIPER-UPPER C058
D GD
K J
E
7236/0002
MOTOR:WIPER UPPER 9
-C058
6/6 6/6 RED 5/6 5/6 1.00 mm² 8006 5/20 5/20 0.75 mm² 8006 FROM
/7.B4
BLACK #1783 FROM SWITCH:MAIN WIPERS C116
2/6 2/6 GREEN
YELLOW
-B8 3/6 3/6
1/6 1/6 BROWN
WHITE 4/6 4/6
A Wire size (area) and number B Device harness connector code

C Device description D Connector pin number (wire location / total)
E Device internal schematic F Harness inter-connector codes
G Harness inter-connector symbol H Splice code and symbol
J Destination reference number K Destination (harness connector code)
L Destination (diagram sheet and grid)
To help locate a wire destination from other diagram Due to space limitations, the grid is sometimes
sheets use the grid reference. This identifies the omitted.
applicable location zone on the sheet in a similar way
to a map reference.
33 - 8 9823/0300-1 33 - 8
Figure 1064. Grid reference example (D4)
1 2 3 4 5 6 7 8
F GROUND
RC012:6 /15.C5 FROM 1.00 mm² 601SP
F
GROUND 1.00 mm² 601AV
RC011:1 /13.A4 FROM
GROUND 1.00 mm² 601AX CAN SHLD

RC007:2 /13.B4 FROM
P006:5 /3.D2 FROM 0.75 mm² 601HB
GROUND 2.00 mm² 601AR 6.00 mm² 601RC1 CAN SHLD

RC009:1 /12.F6 FROM
P006:10 /3.D2 FROM 0.75 mm² 601EK

-SRC5
CAN SHLD 0.75 mm² 601HK
P007:10 /3.C2 FROM
GROUND 1.50 mm² 600WP CAN SHLD

RC18:2 /12.C6 FROM
P007:5 /3.C2 FROM 0.75 mm² 601HL
GROUND 2.00 mm² 601AW CAN SHLD

RC004:1 /12.E6 FROM
P008:10 /3.A2 FROM 0.75 mm² 601X
GROUND 2.00 mm² 601FK CAN SHLD

RC003:2 /14.F7 FROM
P008:5 /3.B2 FROM 0.75 mm² 601JJ
GROUND 2.00 mm² 601DG CAN SHLD -SP3

RC005:2 /13.C7 P101:10 1.00 mm² 601TS 3.00 mm² 601JC
E /8.D4
FROM
FROM
GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC CAN SHLD
E
RC008:2 /13.C7 FROM
P014:1 /13.F1 0.75 mm² 601LH

-RC06
FROM
-SRC6 -SRC7 M10
CAN SHLD 0.75 mm² 601SH

P014:5 /13.E1 FROM
HYD ECU SENSOR GND 0.75 mm² 699CE CAN SHLD

SP43 /30.E6 FROM
P058:4 /15.E2 FROM 1.00 mm² 601RD
HYD ECU SENSOR GND 1.00 mm² 699SK CAN SHLD CAN SHLD
SP44 /25.C5 FROM
P013:5 /8.C1 FROM 1.00 mm² 601LL P072:17 /9.C5 FROM 1.00 mm² 601DE
HYD ECU SENSOR GND 1.00 mm² 699CH CAN SHLD CAN SHLD
P095:3 /26.D1 FROM
P016:5 /11.E6 FROM 0.75 mm² 601SY P112:2 /14.C4 FROM 1.00 mm² 601HT
HYD ECU SENSOR GND 1.00 mm² 699SJ CAN SHLD CAN SHLD -SP11
P095:6 /26.D1 FROM
P016:10 /11.E6 FROM 0.75 mm² 601JB P020:7 /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
HYD ECU SENSOR GND 0.75 mm² 699CB CAN SHLD CAN SHLD
P091:2 /29.E5 FROM
P010:5 /4.E2 FROM 0.75 mm² 601NS P063:7 /9.F7 FROM 1.00 mm² 601HP
HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND CAN SHLD CAN SHLD
P092:2 /29.E5 FROM FROM
/22.B7 SC9 / P039:F7 P011:5 /10.F6 FROM 0.75 mm² 601BL P073:A /17.D1 FROM 1.00 mm² 601C
D
HYD ECU SENSOR GND 0.75 mm² 699CD CAN SHLD
P087:2 /21.B7 P036:7 /25.D2 1.00 mm² 601DZ
D
FROM
FROM
HYD ECU SENSOR GND 1.00 mm² 699CG

SP2 /27.E4 FROM
HYD ECU SENSOR GND 0.75 mm² 699CF

P111:2 /29.B6 FROM
CAN SHLD 1.00 mm² 601FV

P067:10 /14.D4 FROM
CAN SHLD 1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600 -P030 M10
P015:10 /14.D5 FROM
CAN SHLD 1.00 mm² 601V

P013:10 /10.B1 FROM
CAN SHLD 1.00 mm² 601AC

P015:5 /14.D3 FROM
CAN SHLD 2.00 mm² 601TR

P070:16 /21.C6 FROM
CAN SHLD
C CAN SHLD 1.50 mm² 606TR
P052:1 /14.E7 FROM 1.00 mm² 601DD
P070:15 /21.C6 FROM
C
CAN SHLD 1.00 mm² 601AC CAN SHLD 1.00 mm² 610ACF
CAN SHLD P017:7 /14.C5 FROM
P013:5 /14.E2 FROM
P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600

-SP61 -P035 M10 CAN SHLD
P062:7 /27.E4 FROM 1.00 mm² 601KK
CAN SHLD 2.00 mm² 601BU
P130:3 /13.D7 FROM
CAN SHLD 0.50 mm² 601P

CAN SHLD P40:10 /9.A3 FROM
P130:4 /13.D7 FROM 2.00 mm² 601AL

CAN SHLD 1.00 mm² Y
CAN SHLD P066:11 /8.B7 FROM
2.00 mm² SCR

SPMC12 /17.C3 FROM
CAN SHLD 0.75 mm² 601BF

CAN SHLD P024:7 /10.C1 FROM
2.00 mm² SCR

SVMC15 /17.D5 FROM
CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD

CAN SHLD P023:7 /10.F2 FROM
1.00 mm² 600H

P034:2 /7.C2 FROM

P026:7 /13.F3 FROM
CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P028:7 /13.B2 FROM
P017:7 /25.E3 FROM
B P029:7 /13.E3
CAN SHLD 1.00 mm² 601KA P021:7 /12.F3
CAN SHLD 1.00 mm² 601BH
B
FROM FROM
CAN SHLD 1.00 mm² 601AL CAN SHLD 1.00 mm² 601DX 2.00 mm² 601JF
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM
-SP28
CAN SHLD 1.00 mm² 601BL CAN SHLD 1.00 mm² 601KC
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM
CAN SHLD 1.00 mm² 601N

P027:7 /21.B4 FROM
CAN SHLD 0.75 mm² 601AK

P042-A /28.E2 FROM
CAN SHLD 1.00 mm² 601EN

P018:7 /30.F2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 9 9823/0300-1 33 - 9
Diagram
Figure 1065. Battery and Primary Fuses............................................................................... Page 33-13

Figure 1066. Ignition and Secondary Fuses ......................................................................... Page 33-17
Figure 1067. Engine- Fuse and Starter..................................................................................Page 33-21
Figure 1068. Engine- Kohler Tier 4 .......................................................................................Page 33-25
Figure 1069. Engine- Components.........................................................................................Page 33-29
Figure 1070. Transmission/Pump/Inching.............................................................................. Page 33-33
Figure 1071. Livelink / Immobiliser......................................................................................... Page 33-37
Figure 1072. Instruments........................................................................................................Page 33-41
Figure 1073. Road lights........................................................................................................ Page 33-45
Figure 1074. Directional Indicators.........................................................................................Page 33-49
Figure 1075. Wiper Motor.......................................................................................................Page 33-53
Figure 1076. Worklights / Beacon.......................................................................................... Page 33-57
Figure 1077. HVAC................................................................................................................. Page 33-61
Figure 1078. In Cab Entertainment........................................................................................ Page 33-65
Figure 1079. Reverse Fan......................................................................................................Page 33-69
Figure 1080. Can Bus............................................................................................................ Page 33-73
Figure 1082. Ground Panel.................................................................................................... Page 33-77
Figure 1083. Ground Chassis.................................................................................................Page 33-81
Figure 1084. 07/11 Controller ECU........................................................................................ Page 33-85
Figure 1085. Hydraulic ECU ................................................................................................. Page 33-89
Figure 1086. Hydraulics..........................................................................................................Page 33-93
Figure 1087. Valve Block .......................................................................................................Page 33-97
Figure 1088. Auxiliary Hydraulics......................................................................................... Page 33-101
Figure 1089. Steer Mode......................................................................................................Page 33-105
Figure 1090. SRS ................................................................................................................ Page 33-109
Figure 1091. LLMI.................................................................................................................Page 33-113
Figure 1092. Braking ........................................................................................................... Page 33-117
Figure 1093. Joystick............................................................................................................Page 33-121
Table 290. Schematic Diagram Sheets Sheet Page Reference
Sheet Page Reference 10 of 30 Road lights Refer to Figure
2 of 30 Battery and pri- Refer to Figure 1073.
mary fuses 1065. 11 of 30 Directional indi- Refer to Figure
3 of 30 Ignition and Refer to Figure cators 1074.
secondary fus- 1066. 12 of 30 Wiper motors Refer to Figure
es 1075.
4 of 30 Engine- Fuse Refer to Figure 13 of 30 Worklights and Refer to Figure
and starter mo- 1067. beacon 1076.
tor 14 of 30 HVAC (Heating Refer to Figure
5 of 30 Engine- Kohler Refer to Figure Ventilation Air 1077.
T4i 1068. Conditioning)
6 of 30 Engine- Com- Refer to Figure 15 of 30 In cab enter- Refer to Figure
ponents 1069. tainment 1078.
7 of 30 Transmis- Refer to Figure 16 of 30 Reverse fan Refer to Figure
sion/pump/inch- 1070. 1079.
ing 17 of 30 CAN (Controller Refer to Figure
8 of 30 Live link and Refer to Figure Area Network) 1080.
immobiliser 1071. BUS
9 of 30 Instruments Refer to Figure 18 of 30 Switch illumina- Refer to Figure
1072. tion splice 1081.
33 - 10 9823/0300-1 33 - 10
Sheet Page Reference Sheet Page Reference

19 of 30 Ground panel Refer to Figure 25 of 30 Auxiliary hy- Refer to Figure
splices 1082. draulics 1088.
20 of 30 Ground chassis Refer to Figure 26 of 30 Steer mode Refer to Figure
1083. 1089.
21 of 30 07/11 Controller Refer to Figure 27 of 30 SRS (Smooth Refer to Figure
1084. Ride System) 1090.
22 of 30 Hydraulics ECU Refer to Figure 28 of 30 LLMI (Longitu- Refer to Figure
(Electronic Con- 1085. dinal Load Mo- 1091.
trol Unit) ment Indicator)
23 of 30 Hydraulics Refer to Figure 29 of 30 Braking Refer to Figure
1086. 1092.
24 of 30 Valve block Refer to Figure 30 of 30 Joystick Refer to Figure
1087. 1093.
33 - 11 9823/0300-1 33 - 11
Notes:
33 - 12 9823/0300-1 33 - 12
Page 33-14 Figure 1065. Battery and Primary Fuses Page 33-15
95.00 mm² RED BATT +VE TO
/4.F5 C033
C/D A/B
PRIMARY FUSE
-P041 -C059 -C146 50A 50A -C145 -C059 -P041
BATT +VE 4.00 mm² 200D D/16 D/16 4.00 mm² 200D B/2 B/2 4.00 mm² 200A A/16 A/16 4.00 mm² 200A BATT +VE
P004:5 /3.E6 TO TO
/3.F1 P043:1
5 3
-P041 -C059 50A 50A -C059 -P041
BATT +VE 4.00 mm² 200C C/16 C/16 4.00 mm² 200C A/2 A/2 4.00 mm² 200B B/16 B/16 4.00 mm² 200B BATT +VE
P003:11 /3.B4 TO TO
/3.D1 SP35
4 2
1
FUSE LINK BOX BLUE FUSE LINK BOX GREY
-B001
M6
16.00 mm² RED
ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm² RED -S1
M8
M8 -CS1 20.00 mm² RED
16.00 mm² RED

M8
-C001
-B002
M10
G/H E/F
M6
CHASSIS GROUND -C148 50A 50A -C147 -C059 -P041
BATT +VE 2 4 BATT +VE
1
E001:E /4.B2 4.00 mm² 319 A/2 A/2 4.00 mm² 200F F/16 F/16 4.00 mm² 200F
TO TO
/3.C1 SP30
-P041 -C059 50A 50A -C059 -P041
BATT +VE 4.00 mm² 200H H/16 H/16 4.00 mm² 200H B/2 3 5 B/2 4.00 mm² 200E E/16 E/16 4.00 mm² 200E BATT +VE
SP4 /3.E1 TO TO
/3.B1 SP15
FUSE LINK BOX BLUE 2 FUSE LINK BOX GREY 2

PRIMARY FUSE
160/G6925-2

/4.D4 CS1:1
33 - 13 9823/0300-1 33 - 13
Page Page
33-14 33-15
Figure 1065. (Part 1 of 2) 95.00 mm² RED BATT +VE TO

/4.F5 C033
BATT +VE 4.00 mm² 200D

P004:5 /3.E6 TO
BATT +VE 4.00 mm² 200C

P003:11 /3.B4 TO
ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm²
M8
M8 -CS1 20.00 mm² RED
M8
-C001
M10
CHASSIS GROUND
BATT +VE
E001:E /4.B2 TO
BATT +VE 4.00 mm² 200H

SP4 /3.E1 TO
Page 33-15
/4.D4 CS1:1
33 - 14 9823/0300-1 33 - 14
Page Page
33-14 33-15
Figure 1065. (Part 2 of 2)

/4.F5 C033
C/D A/B
PRIMARY FUSE
-P041 -C059 -C146 50A 50A -C145 -C059 -P041
200D D/16 D/16 4.00 mm² 200D B/2 B/2 4.00 mm² 200A A/16 A/16 4.00 mm² 200A BATT +VE
TO
/3.F1 P043:1
5 3
-P041 -C059 50A 50A -C059 -P041
200C C/16 C/16 4.00 mm² 200C A/2 A/2 4.00 mm² 200B B/16 B/16 4.00 mm² 200B BATT +VE
TO
/3.D1 SP35
4 2
1
FUSE LINK BOX BLUE FUSE LINK BOX GREY
-B001
M6
16.00 mm² RED
25.00 mm² RED -S1

16.00 mm² RED
-B002
G/H E/F
M6
-C148 50A 50A -C147 -C059 -P041

2 4 BATT +VE
1
4.00 mm² 319 A/2 A/2 4.00 mm² 200F F/16 F/16 4.00 mm² 200F TO
/3.C1 SP30
-P041 -C059 50A 50A -C059 -P041
200H H/16 H/16 4.00 mm² 200H B/2 3 5 B/2 4.00 mm² 200E E/16 E/16 4.00 mm² 200E BATT +VE
TO
/3.B1 SP15
Page 33-14
FUSE LINK BOX BLUE 2 FUSE LINK BOX GREY 2

PRIMARY FUSE
160/G6925-2
/4.D4 CS1:1
33 - 15 9823/0300-1 33 - 15
33 - 16 9823/0300-1 33 - 16
Page 33-18 Figure 1066. Ignition and Secondary Fuses Page 33-19
-P043 -P044
IGNITION SWITCH III START -P001 -P004
HEAT
FUSE BOX A FUSE BOX D

PRE
0 OFF
I ON
II
BATT +VE 4.00 mm² 200A 1 5 4.00 mm² 001A 4.00 mm² 010B 1 5A 2 1.00 mm² 121 IGNITION +VE 4.00 mm² 005A 1 30A 2 4.00 mm² 004 STARTER
C145:B /2.D7 FROM TO
/15.B3 P065:1 TO
/4.E2 P010:1
2 6 4.00 mm² 014A 1 31
3 4.00 mm² 005B 3 15A 4 1.50 mm² 114 IGNITION +VE FOG 1.00 mm² 832B 3 3A 4 1.00 mm² 905 FOG
TO
/25.D2 P017:2 SP21 /10.C3 FROM TO
/10.F2 P023:2
4 2 32
-SP5
8 5 25A 6 2.00 mm² 116 IGNITION +VE BATT +VE 4.00 mm² 200D 5 25A 6 2.00 mm² 312 BATT +VE
TO
/14.E4 P015:6 C146:B /2.D4 FROM TO
/13.C3 P011:6
9 3 33
7 7 3A 8 1.00 mm² Y IGNITION +VE 7 20A 8 2.00 mm² 306 BATT +VE
TO
/8.D4 P101:6 TO
/10.C1 P013:6
4 34
4.00 mm² 011B 9 30A 10 2.00 mm² 102 IGNITION +VE 9 25A 10 2.00 mm² 308 BATT +VE
TO
/14.D1 P033:3 TO
/13.D3 P012:1
5 35
4.00 mm² 001A 11 3A 12 1.00 mm² 104 IGNITION +VE 11 15A 12 2.00 mm² 309 BATT +VE
TO
/11.B1 P038:14 TO
/13.C3 P012:6
6 36 1.00 mm² 200RDM BATT +VE TO
/6.E3 C057:1
13 20A 14 2.00 mm² 997 IGNITION +VE 13 15A 14 1.50 mm² 200ACF BATT +VE
TO
/14.D2 P015:1 TO
/14.F1 P013:1
7 37 IGNITION +VE
2.00 mm² 151
-P006 IGNITION +VE
TO
/14.F4 RC002:1 / P049:7
15 3A 16 1.00 mm² 100 TO
/3.D1 SP20 4.00 mm² 015H 15 20A 16
IGNITION +VE
1.50 mm² 151B
IGNITION RELAY 1 8 38 TO
/14.E4 P059:1
4 17 SPARE 18 2.00 mm² 103A IGNITION +VE 17 10A 18 1.00 mm² 181 IGNITION +VE
TO
/13.B4P042:1 TO
/15.E2 P058:1
BATT +VE 4.00 mm² 200H -SP4 4.00 mm² 200H1 1 2 4.00 mm² 015H 9 39
C148:B /2.C4 FROM
19 10A 20 1.50 mm² 109RA IGNITION +VE 1.00 mm² 601LL 19 5A 20 1.00 mm² 601L LIVELINK GND
TO
/10.D3 P009:6 TO
/8.C4 P068:9
IGNITION +VE 1.00 mm² 100 0.75 mm² 100J 3 5 0.75 mm² 601HB CAN SHLD 10 40
P001:16 /3.E5 FROM TO
/19.F4 SP3
-SP20 -P039 -C004 LIVE LINK PERM GROUND
1.00 mm² 601LL -C053
M10
B2/84 B2/84
4.00 mm² 200H2

-P002 -P005
-P006 FUSE BOX B FUSE BOX E
IGNITION RELAY 2
9 4.00 mm² 013F 1 20A 2 2.00 mm² 133 IGNITION +VE 4.00 mm² 200E1 1 20A 2 2.00 mm² 203 BATT +VE
TO
/12.D3 SP16 TO
/22.D1 C045 / P039:C8
BATT +VE 4.00 mm² 200B -SP35 4.00 mm² 200B2 6 7 4.00 mm² 010B 11 41
C145:A /2.D7 FROM
3 15A 4 1.50 mm² 110 IGNITION +VE 3 15A 4 2.00 mm² 300TR BATT +VE
TO
/12.A2 SP33 TO
/21.D5 SP39
0.75 mm² 100B 8 10 0.75 mm² 601EK CAN SHLD 12 42
TO
/19.F4 SP3
5 10A 6 1.00 mm² 108 IGNITION +VE 5 5A 6 1.00 mm² 299LL BATT +VE
TO
/10.F5 P011:1 TO
/8.D2 P068:4
13 43
DIPPED BEAM 2.00 mm² 833 7 15A 8 1.50 mm² 834B DIPPED BEAM 7 10A 8 1.50 mm² 275 BATT +VE
P038:9 /10.B3 FROM TO
/10.B4 SFC3 TO
/11.E5 SP25
14 44
MAIN BEAM 2.00 mm² 836 9 20A 10 2.00 mm² 838 MAIN BEAM 9 15A 10 1.00 mm² 301E BATT +VE
P038:13 /10.B3 FROM TO
/10.B4 SP19 TO
/9.C3 SP40 / P071
-P007 15 45
IGNITION RELAY 3 SWITCH ILLUMINATION 2.00 mm² 942D 11 7.5A 12 1.50 mm² 829E SWITCH ILLUMINATION 4.00 mm² 017E 11 3A 12 1.00 mm² 100TR IGNITION +VE
SP22 /10.C3 FROM TO
/18.D3 SP7 TO
/21.E5 P070:1
4 16 46
4.00 mm² 200F2 1 2 4.00 mm² 013F SWITCH ILLUMINATION 2.00 mm² 942E 13 5A 14 0.75 mm² 830 SWITCH ILLUMINATION 13 5A 14 1.00 mm² 110LL IGNITION +VE
SP22 /10.C3 FROM TO
/10.C4 P039:E2 TO
/8.C1 P009:1
17 47
0.75 mm² 100H 3 5 0.75 mm² 601HL CAN SHLD 4.00 mm² 200H2 15 15A 16 2.00 mm² 303AU BATT +VE 1.00 mm² 109CS IGNITION +VE 15 3A 16 1.00 mm² 101A IGNITION +VE
TO
/19.F4 SP3 TO
/15.A3 P039:C3 TO
/7.B1 SP65 / P037 TO
/28.E2 P042-A
18 48
-P039 -C004
4.00 mm² 014A 17 5A 18 1.00 mm² 109 D2/84 D2/84 1.00 mm² 109 17 3A 18 1.00 mm² 106 IGNITION +VE
TO
/9.E3 P071:2
19 49
-P041
4.00 mm² 005C 19 5A 20 4.00 mm² 1842 J/16 19 5A 20 1.50 mm² 155 IGNITION +VE
TO
/22.B2 SC12 / P039:F9
20 50
-P007
IGNITION RELAY 4
9
BATT +VE 4.00 mm² 200F 4.00 mm² 200F1 6 7 4.00 mm² 012F
C147:A /2.C7 FROM
-SP30 1.00 mm² 109SS IGNITION +VE

-P003 -SC5 TO
/6.A3 E014:1
0.75 mm² 100G 8 10 0.75 mm² 601HK CAN SHLD
TO
/19.F4 SP3
FUSE BOX C 1.00 mm² 109SA IGNITION +VE
TO
/23.B3 V010:1
-P041 -P039 -C004
4.00 mm² 200E1 K/16 4.00 mm² 319G 1 5A 2 1.00 mm² 318 A8/84 A8/84 1.00 mm² 318C 07/11 SENSOR GROUND 1.00 mm² 109FB IGNITION +VE
TO
/5.E2 E030:C8 TO
/29.E3 C149:2
21
-P008 4.00 mm² 012F 3 3A 4 0.50 mm² 106C IGNITION +VE 1.00 mm² 100C IGNITION +VE
TO
/9.A5 P040:20 TO
/7.B5 ST1
IGNITION RELAY 5 22
4 5 3A 6 1.00 mm² 107PB IGNITION +VE 1.00 mm² 109FA IGNITION +VE
/29.B2 RC012:3 / P049:10
TO TO
/26.E6 C026:B
BATT +VE 4.00 mm² 200E 4.00 mm² 200E2 1 2 4.00 mm² 017E 23
C147:B /2.C7 FROM
-P039 -C004
-SP15 7 3A 8 1.00 mm² 107B E7/84 E7/84 1.00 mm² 107B IGNITION +VE 1.00 mm² 109RA IGNITION +VE
TO
/5.E3 E030:D7 TO
/26.D6 C024:B
0.75 mm² 100F 3 5 0.75 mm² 601JJ CAN SHLD 24
TO
/19.E4 SP3
9 3A 10 1.00 mm² 107SP IGNITION +VE TO
/15.C3 RC012:1 / P049:14
25 1.00 mm² 100LL IGNITION +VE
TO
/8.C1 P013:3
BATT +VE 4.00 mm² 200C 11 10A 12 2.00 mm² 307 BATT +VE
C146:A /2.D4 FROM TO
/10.C1 P024:2
26 0.75 mm² 100QA IGNITION +VE
TO
/13.C1 P126:1
-P008 13 25A 14 2.00 mm² 304A BATT +VE
TO
/10.B1 P038:4
IGNITION RELAY 6 27 0.75 mm² 100K IGNITION +VE
TO
/9.E7 P063:2
9 15 7.5A 16 1.00 mm² 310 BATT +VE 2.00 mm² 304B BATT +VE
TO
/13.B1 P028:2 TO
/7.B1 P037:11
4.00 mm² 200B1 6 7 4.00 mm² 011B 28 0.75 mm² 100M IGNITION +VE
TO
/21.B4 P027:2
17 10A 18 1.00 mm² 301 -SP27 1.00 mm² 301J BATT +VE TO
/13.A1 RC010:1 / P049:9
0.75 mm² 100A 8 10 0.75 mm² 601X CAN SHLD 29 1.00 mm² 100P IGNITION +VE
TO
/19.F4 SP3 TO
/16.E2 P061:2
19 3A 20 1.00 mm² 300 BATT +VE 1.00 mm² 301F BATT +VE
TO
/11.C3 P020:5 TO
/15.E2 P058:2
30 0.75 mm² 100D IGNITION +VE
160/G6925-2 Sheet 3 TO
/10.C1 P024:8
1.00 mm² Y BATT +VETO
/8.D5 P066:7
0.75 mm² 100C IGNITION +VE
TO
/10.C1 P013:8
1.00 mm² 301MBATT +VE TO
/17.D1 P073:B
1.00 mm² 100RDM IGNITION +VE
TO
/6.F3 C057:8
33 - 17 9823/0300-1 33 - 17
Page Page
33-18 33-19

-P043 -P044
IGNITION SWITCH -P001
III START
HEAT
FUSE BOX A
PRE
0 OFF
I ON
II
BATT +VE 4.00 mm² 200A 1 5 4.00 mm² 001A 4.00 mm² 010B 1 5A
C145:B /2.D7 FROM
2 6 4.00 mm² 014A

3 4.00 mm² 005B 3 15A
4
-SP5
8 5 25A
9
7 7 3A
4.00 mm² 011B 9 30A
4.00 mm² 001A 11 3A
13 20A
-P006 15 3A
IGNITION RELAY 1
4 17 SPARE
BATT +VE 4.00 mm² 200H -SP4 4.00 mm² 200H1 1 2 4.00 mm² 015H
C148:B /2.C4 FROM
19 10A
IGNITION +VE 1.00 mm² 100 0.75 mm² 100J 3 5 0.75 mm² 601HB CAN SHLD
P001:16 /3.E5 FROM TO
/19.F4 SP3
-SP20
4.00 mm² 200H2

-P002
-P006 FUSE BOX B
IGNITION RELAY 2
9 4.00 mm² 013F 1 20A
BATT +VE 4.00 mm² 200B -SP35 4.00 mm² 200B2 6 7 4.00 mm² 010B
C145:A /2.D7 FROM
3 15A
0.75 mm² 100B 8 10 0.75 mm² 601EK CAN SHLD
TO
/19.F4 SP3
5 10A
DIPPED BEAM 2.00 mm² 833 7 15A

P038:9 /10.B3 FROM
MAIN BEAM 2.00 mm² 836 9 20A

P038:13 /10.B3 FROM
-P007
IGNITION RELAY 3 SWITCH ILLUMINATION 2.00 mm² 942D 11 7.5A
SP22 /10.C3
Page 33-19
FROM
4.00 mm² 200F2 1 2 4.00 mm² 013F SWITCH ILLUMINATION 2.00 mm² 942E 13 5A
SP22 /10.C3 FROM
0.75 mm² 100H 3 5 0.75 mm² 601HL CAN SHLD 4.00 mm² 200H2 15 15A
TO
/19.F4 SP3
4.00 mm² 014A 17 5A
4.00 mm² 005C 19 5A
-P007
IGNITION RELAY 4
9
BATT +VE 4.00 mm² 200F 4.00 mm² 200F1 6 7 4.00 mm² 012F
C147:A /2.C7 FROM
-SP30
8 10 CAN SHLD -P003
0.75 mm² 100G 0.75 mm² 601HK TO
/19.F4 SP3
FUSE BOX C
-P041
4.00 mm² 200E1 K/16 4.00 mm² 319G 1 5A
-P008 4.00 mm² 012F 3 3A

IGNITION RELAY 5
4 5 3A
BATT +VE 4.00 mm² 200E 4.00 mm² 200E2 1 2 4.00 mm² 017E
C147:B /2.C7 FROM
-SP15 7 3A
0.75 mm² 100F 3 5 0.75 mm² 601JJ CAN SHLD
TO
/19.E4 SP3
9 3A
BATT +VE 4.00 mm² 200C 11 10A

C146:A /2.D4 FROM
-P008 13 25A
IGNITION RELAY 6
9 15 7.5A
4.00 mm² 200B1 6 7 4.00 mm² 011B
17 10A
0.75 mm² 100A 8 10 0.75 mm² 601X CAN SHLD
TO
/19.F4 SP3
19 3A
160/G6925-2 Sheet 3
33 - 18 9823/0300-1 33 - 18
Page Page
33-18 33-19

-P001 -P004
FUSE BOX A FUSE BOX D
1 5A 2 1.00 mm² 121 IGNITION +VE 4.00 mm² 005A 1 30A 2 4.00 mm² 004 STARTER
TO
/15.B3 P065:1 TO
/4.E2 P010:1
1 31
3 15A 4 1.50 mm² 114 IGNITION +VE FOG 1.00 mm² 832B 3 3A 4 1.00 mm² 905 FOG
TO
/25.D2 P017:2 SP21 /10.C3 FROM TO
/10.F2 P023:2
2 32
5 25A 6 2.00 mm² 116 IGNITION +VE BATT +VE 4.00 mm² 200D 5 25A 6 2.00 mm² 312 BATT +VE
TO
/14.E4 P015:6 C146:B /2.D4 FROM TO
/13.C3 P011:6
3 33
7 3A 8 1.00 mm² Y IGNITION +VE 7 20A 8 2.00 mm² 306 BATT +VE
TO
/8.D4 P101:6 TO
/10.C1 P013:6
4 34
9 30A 10 2.00 mm² 102 IGNITION +VE 9 25A 10 2.00 mm² 308 BATT +VE
TO
/14.D1 P033:3 TO
/13.D3 P012:1
5 35
11 3A 12 1.00 mm² 104 IGNITION +VE 11 15A 12 2.00 mm² 309 BATT +VE
TO
/11.B1 P038:14 TO
/13.C3 P012:6
6 36 1.00 mm² 200RDM BATT +VE TO
/6.E3 C057:1
13 20A 14 2.00 mm² 997 IGNITION +VE 13 15A 14 1.50 mm² 200ACF BATT +VE
TO
/14.D2 P015:1 TO
/14.F1 P013:1
7 37 IGNITION +VE
2.00 mm² 151
IGNITION +VE
TO
/14.F4 RC002:1 / P049:7
15 3A 16 1.00 mm² 100 TO
/3.D1 SP20 4.00 mm² 015H 15 20A 16
IGNITION +VE
1.50 mm² 151B
8 38 TO
/14.E4 P059:1
17 SPARE 18 2.00 mm² 103A IGNITION +VE 17 10A 18 1.00 mm² 181 IGNITION +VE
TO
/13.B4P042:1 TO
/15.E2 P058:1
9 39
19 10A 20 1.50 mm² 109RA IGNITION +VE 1.00 mm² 601LL 19 5A 20 1.00 mm² 601L LIVELINK GND
TO
/10.D3 P009:6 TO
/8.C4 P068:9
10 40
-P039 -C004 LIVE LINK PERM GROUND

1.00 mm² 601LL -C053
M10
B2/84 B2/84
-P002 -P005
FUSE BOX B FUSE BOX E
1 20A 2 2.00 mm² 133 IGNITION +VE 4.00 mm² 200E1 1 20A 2 2.00 mm² 203 BATT +VE
TO
/12.D3 SP16 TO
/22.D1 C045 / P039:C8
11 41
3 15A 4 1.50 mm² 110 IGNITION +VE 3 15A 4 2.00 mm² 300TR BATT +VE
TO
/12.A2 SP33 TO
/21.D5 SP39
12 42
5 10A 6 1.00 mm² 108 IGNITION +VE 5 5A 6 1.00 mm² 299LL BATT +VE
TO
/10.F5 P011:1 TO
/8.D2 P068:4
13 43
7 15A 8 1.50 mm² 834B DIPPED BEAM 7 10A 8 1.50 mm² 275 BATT +VE
TO
/10.B4 SFC3 TO
/11.E5 SP25
14 44
9 20A 10 2.00 mm² 838 MAIN BEAM 9 15A 10 1.00 mm² 301E BATT +VE
TO
/10.B4 SP19 TO
/9.C3 SP40 / P071
15 45
11 7.5A 12 1.50 mm² 829E SWITCH ILLUMINATION 4.00 mm² 017E 11 3A 12 1.00 mm² 100TR IGNITION +VE
/18.D3 SP7 /21.E5 P070:1
Page 33-18
TO TO
16 46
13 5A 14 0.75 mm² 830 SWITCH ILLUMINATION 13 5A 14 1.00 mm² 110LL IGNITION +VE
TO
/10.C4 P039:E2 TO
/8.C1 P009:1
17 47
15 15A 16 2.00 mm² 303AU BATT +VE 1.00 mm² 109CS IGNITION +VE 15 3A 16 1.00 mm² 101A IGNITION +VE
TO
/15.A3 P039:C3 TO
/7.B1 SP65 / P037 TO
/28.E2 P042-A
18 48
-P039 -C004
17 5A 18 1.00 mm² 109 D2/84 D2/84 1.00 mm² 109 17 3A 18 1.00 mm² 106 IGNITION +VE
TO
/9.E3 P071:2
19 49
-P041
19 5A 20 4.00 mm² 1842 J/16 19 5A 20 1.50 mm² 155 IGNITION +VE
TO
/22.B2 SC12 / P039:F9
20 50
1.00 mm² 109SS IGNITION +VE

-P003 -SC5 TO
/6.A3 E014:1
FUSE BOX C 1.00 mm² 109SA IGNITION +VE

TO
/23.B3 V010:1
-P039 -C004
1 5A 2 1.00 mm² 318 A8/84 A8/84 1.00 mm² 318C 07/11 SENSOR GROUND 1.00 mm² 109FB IGNITION +VE
TO
/5.E2 E030:C8 TO
/29.E3 C149:2
21
3 3A 4 0.50 mm² 106C IGNITION +VE 1.00 mm² 100C IGNITION +VE
TO
/9.A5 P040:20 TO
/7.B5 ST1
22
5 3A 6 1.00 mm² 107PB IGNITION +VE 1.00 mm² 109FA IGNITION +VE
TO
/29.B2 RC012:3 / P049:10 TO
/26.E6 C026:B
23 -P039 -C004
7 3A 8 1.00 mm² 107B E7/84 E7/84 1.00 mm² 107B IGNITION +VE 1.00 mm² 109RA IGNITION +VE
TO
/5.E3 E030:D7 TO
/26.D6 C024:B
24
9 3A 10 1.00 mm² 107SP IGNITION +VE TO
/15.C3 RC012:1 / P049:14
25 1.00 mm² 100LL IGNITION +VE
TO
/8.C1 P013:3
11 10A 12 2.00 mm² 307 BATT +VE TO
/10.C1 P024:2
26 0.75 mm² 100QA IGNITION +VE
TO
/13.C1 P126:1
13 25A 14 2.00 mm² 304A BATT +VE
TO
/10.B1 P038:4
27 0.75 mm² 100K IGNITION +VE
TO
/9.E7 P063:2
15 7.5A 16 1.00 mm² 310 BATT +VE 2.00 mm² 304B BATT +VE
TO
/13.B1 P028:2 TO
/7.B1 P037:11
28 0.75 mm² 100M IGNITION +VE
TO
/21.B4 P027:2
17 10A 18 1.00 mm² 301 -SP27 1.00 mm² 301J BATT +VE TO
/13.A1 RC010:1 / P049:9
29 1.00 mm² 100P IGNITION +VE
TO
/16.E2 P061:2
19 3A 20 1.00 mm² 300 BATT +VE 1.00 mm² 301F BATT +VE
TO
/11.C3 P020:5 TO
/15.E2 P058:2
30 0.75 mm² 100D IGNITION +VE
TO
/10.C1 P024:8
1.00 mm² Y BATT +VETO
/8.D5 P066:7
0.75 mm² 100C IGNITION +VE
TO
/10.C1 P013:8
1.00 mm² 301MBATT +VE TO
/17.D1 P073:B
1.00 mm² 100RDM IGNITION +VE
TO
/6.F3 C057:8
33 - 19 9823/0300-1 33 - 19
33 - 20 9823/0300-1 33 - 20
Page 33-22 Figure 1067. Engine- Fuse and Starter Page 33-23
-P010
NEUTRALS TART 1.00 mm² 842A STARTER
TO
/5.E2 E030:C10
4 GRID HEATER
-P041 -C059
STARTER 4.00 mm² 004 1 2 4.00 mm² 842 G/16 G/16 4.00 mm² 842 4.00 mm² 842B STARTER
P004:2 /3.F7 FROM TO
/5.E2 E030:G2
-SE035 -CS2 -CS4 -C002 M6 1
NEUTRALS TART 1.00 mm² 100NS 3 5 GRID HEATER FUSE
P069:15 /21.C3 FROM
-E020 12V
BATT+VE 20.00 mm² RED 1 2 20.00 mm² RED 70 A
BATTERY /2.B4 FROM
GRID HEATER
CAN SHLD
150A
SP3 /19.D4 TO 0.75 mm² 601NS
-CS5 M6 M6 -C001 20.00 mm² RED
-E001 GRID HEATER

1.00 mm² 115E 1/2 2/2 1.00 mm² 116E
FUSE/RELAYBOX
TO
/5.E4 E030:F12
STARTSIGNAL
(MICRO RELAY)
K2
G B
F3
N 1.00 mm² 408S STARTER TO
/5.E4 E030:B6
F5 - 10A
K
F6 - 10A
J
FUELPUMP
(MICRO RELAY)
-E003
K3 FUELPUMP
F2 - 10A
L 1 2 GROUND
2.00 mm² 801E M 2.00 mm² 604C TO
/20.D3 SE02
F4 - 3A
M 1.00 mm² 408E FUELPUMP
FROM
/5.E4 E030:E11
F7 - 10A
H 1.00 mm² 115E
F8 - 10A
X 1.50 mm² 109E
F9 - 10A
W 1.50 mm² 108E
F17 - 10A
V 1.50 mm² 107E
F16 - 10A
U 1.50 mm² 106E 6.00 mm² 110E ENGINE ECU PWR
POWER HOLD RELAY TO
/5.E2 E030:G1
D K1 -SE034
BATT+VE 4.00 mm² 319 E F15 - 10A
T ECU POWER
C148:A /2.C4 FROM
F1 - 3A F14 - 10A
S
F13 - 5A
R
F11 - 5A
A 1.00 mm² 604AE EGR TO
/5.E2 E030:C12
F12 - 3A
F 1.00 mm² 112E AGGLOMERATOR TO
/6.D4 E002:A
F10 - 5A
C
P 1.00 mm² 400E PURGE HOLD

TO
/5.E2 E030:C9
25.00 mm² RED

BATT+VE 95.00 mm² RED
BATTERY /2.E4 FROM
-ST03 M10
STARTER MOTOR
ALTERNATOR
-B002 30
-P039 -C004
D+ 407B 1.00 mm² -SP14 407 1.00 mm² B5/84 B5/84 407 1.00 mm² D+ M10
V-Batt
P071:11 /9.D3 TO FROM

/5.E5 E030:D8
50 U
V
W
Start
Control
M DF W B+
M8 B+
D-
M5 W
W B+
L
D+ REGULATOR
L
407F 1.00 mm²
/13.F1 P014:3
31
TO
GND
-E033
-ST05
-P039 -C004
W 412 1.00 mm² 412 1.00 mm² A5/84 A5/84 412 1.00 mm² -SE036 1.00 mm² 412A 25.00 mm² RED
P072:7 /9.E5 TO
-E037
ALTERNATOR EXCITE RES
1.00 mm² 412B 1/2 2/2 1.00 mm² 155R IGNITION +VE SC11
/22.A4
160/G6925-2 Sheet 4
FROM
33 - 21 9823/0300-1 33 - 21
Page Page
33-22 33-23
Figure 1067. (Part 1 of 2) -P010

NEUTRALS TART 1.00 mm² 842A STARTER
TO
/5.E2 E030:C10
4
-P041 -C059
STARTER 4.00 mm² 004 1 2 4.00 mm² 842 G/16 G/16 4.00 mm² 842 4.00 mm² 842B STARTER
/5.E2 E030:G2
-SE035
NEUTRALS TART 1.00 mm² 100NS 3 5
P069:15 /21.C3 FROM

BATTERY /2.B4 FROM
CAN SHLD 0.75 mm² 601NS

SP3 /19.D4 TO
-E001
FUSE/RELAYBOX
STARTSIGNAL
(MICRO RELAY)
K2
G B
F3
N 1.00 mm² 408S STARTER TO
F5 - 10A
K
F6 - 10A
J
FUELPUMP
(MICRO RELAY)
K3
F2 - 10A
L 2.00 mm² 801E
F4 - 3A
M 1.00 mm² 408E FUELPUMP
F7 - 10A
H 1.00 mm² 115E
F8 - 10A
X 1.50 mm² 109E
F9 - 10A
W 1.50 mm² 108E
F17 - 10A
V 1.50 mm² 107E
Page 33-23
POWER HOLD RELAY
F16 - 10A
U 1.50 mm² 106E
D K1
BATT+VE 4.00 mm² 319 E F15 - 10A
T
C148:A /2.C4 FROM
F1 - 3A F14 - 10A
S
F13 - 5A
R
F11 - 5A
A 1.00 mm² 604AE EGR TO
F12 - 3A
F 1.00 mm² 112E AGGLOMERAT TO
F10 - 5A
C
P 1.00 mm² 400E PURGE HOLD TO
BATT+VE
BATTERY /2.E4 FROM
-P039 -C004
D+ 407B 1.00 mm² -SP14 407 1.00 mm² B5/84 B5/84 407 1.00 mm² D+
P071:11 /9.D3 TO FROM
/5.E5 E030:D8
D+
407F 1.00 mm² TO
/13.F1 P014:3
P072:7 /9.E5
33 - 22 9823/0300-1 33 - 22
Page Page
33-22 33-23

/5.E2 E030:C10
GRID HEATER
/5.E2 E030:G2
-CS2 -CS4 -C002 M6 1
GRID HEATER FUSE -E020 12V
20.00 mm² RED 1 2 20.00 mm² RED 70 A
GRID HEATER
150A
-CS5 M6 M6 -C001 20.00 mm² RED
1.00 mm² 115E 1/2 2/2 1.00 mm² 116E GRID HEATER
TO
/5.E4 E030:F12
1.00 mm² 408S STARTER TO

/5.E4 E030:B6
-E003
FUELPUMP
1 2 GROUND
2.00 mm² 801E M 2.00 mm² 604C TO
/20.D3 SE02
1.00 mm² 408E FUELPUMP

FROM
/5.E4 E030:E11
1.00 mm² 115E
1.50 mm² 109E
1.50 mm² 108E
1.50 mm² 107E

Page 33-22
1.50 mm² 106E 6.00 mm² 110E ENGINE ECU PWR TO

/5.E2 E030:G1
-SE034
ECU POWER
1.00 mm² 604AE EGR TO

/5.E2 E030:C12
1.00 mm² 112E AGGLOMERATOR TO

/6.D4 E002:A
1.00 mm² 400E PURGE HOLD

TO
/5.E2 E030:C9
25.00 mm² RED

RY /2.E4 FROM
-ST03 M10
STARTER MOTOR
ALTERNATOR
-B002 30
V-Batt
M10
50 U
V
W
Start
Control
M DF W B+
M8 B+
D-
M5 W
W B+
L
REGULATOR
L
31
GND
-E033
-ST05
-P039 -C004
W 412 1.00 mm² 412 1.00 mm² A5/84 A5/84 412 1.00 mm² -SE036 1.00 mm² 412A 25.00 mm² RED
P072:7 /9.E5 TO
-E037
ALTERNATOR EXCITE RES
1.00 mm² 412B 1/2 2/2 1.00 mm² 155R IGNITION +VE SC11
/22.A4
160/G6925-2 Sheet 4
FROM
33 - 23 9823/0300-1 33 - 23
33 - 24 9823/0300-1 33 - 24
EGR
2
5
3
6
1
4
M3
SCV
M10
EARTH STUD
TAPPO
TAPPO
-E031
ZV 0.75
C 0.75
ZR 0.75
S 0.75
1
2
33 - 25
CA
160/G6925-2 Sheet 5
SU5
16.00 mm² 600D
SU4
BL 0.75
GV 0.75
0.75
OPSW2
1
Oil press. Sens.
-SE04
ECU EARTH
TAPPO
L 0.75
18 0,75 EGR
1.00 mm² 604AE FROM
20 0,75 0.75 S C12 /4.A5 E001:A

0.75 1.00 mm² 604CE
7 0,75 ZR C11 STARTER
1.00 mm² 842A FROM
54 0.75 MR 0.75 MR C10 /4.F5 P010:2

PURGE HOLD
1.00 mm² 400E FROM
34 0.75 NB SU10 0,75 NB C9 /4.A5 E001:P

33 0,75 NB 07/11 SENSOR GROUND
1.00 mm² 318C FROM
46 0,75 0,75 BH C8 /3.B5 P003:2

6.00 mm² 110E ENGINE ECU PWR FROM
6 2,5 SU22 6 V G1 /4.B6 SE034

STARTER
4.00 mm² 842B FROM
5 2,5 4 HB G2 /4.E5 P010:2

4.00 mm² 604AE
3 1,5 SU21 6 RN A1
4 2,5 2,5 NZ A3
6 4.00 mm² 604BE
1 2,5 SU20 CB A2
2 2,5 G3
21 0,75 0,75 HG E1
Page 33-26
43 0,75 0,75 BV D10

53 0,75 0,75 HV E2
42 0,75 0,75 MG E3
9 0,75 0,75 ZA E4
30 0,75 0,75 MZ E5
52 0,75 ZV 0,75 C D12
ECU B
51 0,75 C 0,75 ZV D11
SU17
40 0,75 L 0,75 L D4
41 0,75 0,75 MC D3 CAN HI
0.50 mm² CAN L FROM
39 0,75 0,75 NH D2 /17.B7 CAN LO

CAN HI
0.50 mm² CAN H FROM
38 0,75 0,75 MB D1 /17.B7 CAN HI

FOOT THROTTLE
1.00 mm² 565 FROM
12 0,75 0,75 LN C6 /7.F3 C056:6

FOOT THROTTLE
1.00 mm² 564 FROM
11 0,75 0,75 HL C5 /7.F3 C056:5

1.00 mm² 563A FOOT THROTTLE TO
10 0,75 0,75 G C4 /7.F3 C056:4

FOOT THROTTLE
1.00 mm² 560A FROM
25 0,75 0,75 CR C3 FOOT THROTTLE

/7.F3 C056:3
1.00 mm² 561B FROM
24 0,75 0,75 BG C2 FOOT THROTTLE

/7.F3 C056:2
1.00 mm² 562 TO
23 0,75 0,75 AV C1 /7.F3 C056:1

36 0,75 0,75 Z B12
0,75 IGNITION +VE
48 LV 1.00 mm² 107B FROM
SU19 0,75 LV D7 /3.B5 P003:8

47 0,75 LV
55 0,75 0,75 BS D6
INCHING HAND THRO
TO
22 0,75 0,75 E6 /7.C2 C008:10

1.00 mm² 401E AGGLOMERATOR FROM
78 0,75 0,75 ZR E9 /6.D3 E002:B

11 0,75 0,75 HZ E10 FUEL PUMP
1.00 mm² 408E TO
94 0,75 0,75 E11 /4.C5 E001:M

80 0,75 0,75 N C7
63 0,75 0,75 A F1
62 0,75 0,75 C D9
47 0,75 0,75 GV F2
37 0,75 0,75 LS F3 INCHING HAND THRO
FROM
36 0,75 0,75 VN E7 /7.C2 C008:12

15 0,75 0,75 H F5
13 0,75 0,75 M F6
10 0,75 0,75 LM F7
9 0,75 0,75 HA F8 INCHING HAND THRO
FROM
8 0,75 0,75 LN E8 /7.C2 C008:11

STARTER
1.00 mm² 408S FROM
91 0,75 0,75 Z B6 GRID HEATER

/4.C5 E001:N
1.00 mm² 116E FROM
85 0,75 0,75 R E12 /4.C7 E020:2

34 0,75 0,75 SR F4
67 0,75 0,75 NV F9
9823/0300-1
87 0,75 0,75 LB F10
88 0,75 0,75 MA F11
71 0,75 0,75 CB F12
72 0,75 0,75 CA B11
70 0,75 0,75 A B10
69 0,75 0,75 LC B9
68 0,75 0,75 ZB B8
79 0,75 0,75 LA B7
83 0,75 0,75 ZR D5
86 0,75 0,75 HG B5
82 0,75 0,75 AB B4 INCHING HAND THRO
0.75 mm² 699E FROM
58 0,75 0,75 GR B3 /7.D2 C008:8

INCHING HAND THRO
0.75 mm² 435C FROM
32 0,75 0,75 HM B2 /7.D2 C008:9

0.75 mm² 456A INCHING HAND THRO
TO
21 0,75 0,75 LV B1 /7.D2 C008:7

1.00 mm² 407 D+ TO
41 0,75 GN 0,75 MR D8 /4.E6 P071:11

Figure 1068. Engine- Kohler Tier 4
SU14
40 0,75 H
ECU A
45 0,75 Molex Connect or
16 0,75 N
SU1
55 0,75
51 0,75
0,75
56 0,75
74 0,75
SU18
73 0,75 SN
MR 1
49 0,75 AV
B+
D+
3 0,75
6 0,75
ALT
26 0,75
54 0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
39 0,75
1
7 0,75 BN
B+
31 0,75
CL
LM
ML
ZC
ZC
ZC
BM
BM
BM
SU3
24 0,75
0,75
0,75
18 0,75
1
2
2
1
2
42 0,75
ZC
BM
46 0,5
3 B6
1 I NJ4
2 I NJ1
I NJ2
0,75
0,75
0,75
0,75
0,75
0,75
0,75
19 0,5
2
Mot or
St ar t er
43 0,5
38 0,75
RL
ZV
RV
GL
BN
BN
HR
0,5
0,5
0,5
23 0,75
1 I NJ3
14 0,75
1
3
2
1
2
1
61 0,75
BR
AN
CN
B1 4 I NJECTOR
B3
0,75
0,75
0,75
0,75
1
2
3
AR 1
CV 2
S 3
MN 4
T- MAPS
Cam shaft Sensor
Page 33-27
2B7 Fuel t em perat ure sensor

Coolant t em perat ure sensor
B2 Crankshaft Sensor
33 - 25
EGR
2
5
3
6
1
4
M3
SCV
M10
EARTH STUD
Figure
33 - 26
TAPPO
TAPPO
-E031
ZV 0.75
C 0.75
ZR 0.75
S 0.75
1
2
CA
160/G6925-2 Sheet 5
SU5
16.00 mm² 600D
SU4
BL 0.75
GV 0.75
0.75
OPSW2
1
Oil press. Sens.
1068. (Part 1-SE04
ECU EARTH
TAPPO
L 0.75
of 2)
18 0,75 EGR
1.00 mm² 604AE FROM
20 0,75 0.75 S C12 /4.A5 E001:A

0.75 1.00 mm² 604CE
7 0,75 ZR C11 STARTER
1.00 mm² 842A FROM
54 0.75 MR 0.75 MR C10 /4.F5 P010:2

PURGE HOLD
1.00 mm² 400E FROM
34 0.75 NB SU10 0,75 NB C9 /4.A5 E001:P

33 0,75 NB 07/11 SENSOR GROUND
1.00 mm² 318C FROM
46 0,75 0,75 BH C8 /3.B5 P003:2

6.00 mm² 110E ENGINE ECU PWR FROM
6 2,5 SU22 6 V G1 /4.B6 SE034

STARTER
4.00 mm² 842B FROM
5 2,5 4 HB G2 /4.E5 P010:2

4.00 mm² 604AE
3 1,5 SU21 6 RN A1
4 2,5 2,5 NZ A3
6 4.00 mm² 604BE
1 2,5 SU20 CB A2
2 2,5 G3
21 0,75 0,75 HG E1
43 0,75 0,75 BV D10
53 0,75 0,75 HV E2
42 0,75 0,75 MG E3
9 0,75 0,75 ZA E4
30 0,75 0,75 MZ E5
52 0,75 ZV 0,75 C D12
9823/0300-1
ECU B
51 0,75 C 0,75 ZV D11
SU17
40 0,75 L 0,75 L D4
41 0,75 0,75 MC D3 CAN HI
0.50 mm² CAN L FROM
39 0,75 0,75 NH D2 /17.B7 CAN LO

CAN HI
0.50 mm² CAN H FROM
38 0,75 0,75 MB D1 /17.B7 CAN HI

FOOT THROTTLE
1.00 mm² 565 FROM
12 0,75 0,75 LN C6 /7.F3 C056:6

FOOT THROTTLE
1.00 mm² 564 FROM
11 0,75 0,75 HL C5 /7.F3 C056:5

1.00 mm² 563A FOOT THROTTLE
TO
10 0,75 0,75 G C4 /7.F3 C056:4

FOOT THROTTLE
1.00 mm² 560A FROM
25 0,75 0,75 CR C3 /7.F3 C056:3

FOOT THROTTLE
1.00 mm² 561B FROM
24 0,75 0,75 BG C2 FOOT THROTTLE

/7.F3 C056:2
1.00 mm² 562 TO
23 0,75 0,75 AV C1 /7.F3 C056:1

36 0,75 0,75 Z B12
IGNITION +VE
48 0,75 LV 1.00 mm² 107B FROM
SU19 0,75 LV D7 /3.B5 P003:8

47 0,75 LV
55 0,75 0,75 BS D6
INCHING HAND THRO
TO
22 0,75 0,75 E6 /7.C2 C008:10

1.00 mm² 401E AGGLOMERATOR FROM
78 0,75 0,75 ZR E9 /6.D3 E002:B

11 0,75 0,75 HZ E10 FUEL PUMP
1.00 mm² 408E TO
94 0,75 0,75 E11 /4.C5 E001:M

80 0,75 0,75 N C7
63 0,75 0,75 A F1
62 0,75 0,75 C D9
47 0,75 0,75 GV F2
37 0,75 0,75 LS F3 INCHING HAND THRO
FROM
36 0,75 0,75 VN E7 /7.C2 C008:12

15 0,75 0,75 H F5
13 0,75 0,75 M F6
33 - 26
10 0,75 0,75 LM F7
Page
33-26
Page 33-27
Page
33-27
Page 33-26
15 0,75 0,75 H F5
13 0,75 0,75 M F6
10 0,75 0,75 LM F7
FROM
8 0,75 0,75 LN E8 /7.C2 C008:11

STARTER
1.00 mm² 408S FROM
33 - 27
91 0,75 0,75 Z B6 GRID HEATER
/4.C5 E001:N
1.00 mm² 116E FROM
85 0,75 0,75 R E12 /4.C7 E020:2

34 0,75 0,75 SR F4
67 0,75 0,75 NV F9
87 0,75 0,75 LB F10
88 0,75 0,75 MA F11
71 0,75 0,75 CB F12
72 0,75 0,75 CA B11
70 0,75 0,75 A B10
69 0,75 0,75 LC B9
68 0,75 0,75 ZB B8
79 0,75 0,75 LA B7
83 0,75 0,75 ZR D5
86 0,75 0,75 HG B5
82 0,75 0,75 AB B4 INCHING HAND THRO
0.75 mm² 699E FROM
58 0,75 0,75 GR B3 /7.D2 C008:8

INCHING HAND THRO
0.75 mm² 435C FROM
32 0,75 0,75 HM B2 /7.D2 C008:9

0.75 mm² 456A INCHING HAND THRO
TO
21 0,75 0,75 LV B1 /7.D2 C008:7

1.00 mm² 407 D+ TO
41 0,75 GN 0,75 MR D8 /4.E6 P071:11
SU14
40 0,75 H
ECU A
45 0,75 Molex Connect or
16 0,75 N
SU1
55 0,75
51 0,75
0,75
56 0,75
74 0,75
SU18
73 0,75 SN
MR 1
49 0,75 AV
B+
9823/0300-1
D+
3 0,75
6 0,75
ALT
26 0,75
54 0,75 0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
0,75
39 0,75
1
7 0,75 BN
B+
31 0,75
CL
LM
ML
ZC
ZC
ZC
BM
BM
BM
SU3
24 0,75
0,75
0,75
18 0,75
1
2
2
1
2
42 0,75 1
ZC
BM
46 0,5
3 B6
1 I NJ4
2 I NJ1
I NJ2
0,75
0,75
0,75
0,75
0,75
0,75
0,75
19 0,5
2
Mot or
St ar t er
43 0,5
38 0,75
RL
ZV
RV
GL
BN
BN
HR
0,5
0,5
0,5
23 0,75
14 0,75 1 I NJ3
1
3
2
1
2
1
61 0,75
BR
AN
CN
B1 4 I NJECTOR
B3
0,75
0,75
0,75
0,75
1
2
3
S
CV
AR
MN
1
2
3
4
T- MAPS
Cam shaft Sensor

2B7 Fuel t em perat ure sensor
33 - 27
Coolant t em perat ure sensor
B2 Crankshaft Sensor
Page
33-26
Page
33-27
33 - 28 9823/0300-1 33 - 28
Page 33-30 Figure 1069. Engine- Components Page 33-31

-P039 -C004
IGNITION +VE B9/84 B9/84
SP20 /3.A7 FROM
GROUND 2.00 mm² 600RDM

SC12 /20.E4 TO
-P039 -C004
BATT+VE 1.00 mm² 200RDM B8/84 B8/84
P004:14 /3.E7 FROM
-C057
RDM
11/20 1/20 1.00 mm² 200RDM

12/20 2/20 1.00 mm² 601RDM -SC2
13/20 3/20 0.50 mm² CAN 10 L 0.50 mm² CAN 10 L CAN LO
FROM
/17.E4 CAN L
14/20 4/20 0.50 mm² CAN 10 H 0.50 mm² CAN 10 H CAN HI
FROM
/17.E4 CAN H
15/20 5/20 FROM
/6.E5
-P039 -C004 16/20 6/20 -C009
AUX COOLING FAN 1.00 mm² 800ACF B11/84 B11/84 1.00 mm² 800ACF 17/20 7/20 1.00 mm² 500AMB
P013:3 /14.E1 TO TO
/6.E5
18/20 8/20 1.00 mm² 100RDM
AUX VENT 1.00 mm² 500VEN 19/20 9/20
C010:1 /23.C3 TO
20/20 10/20
GROUND 1.00 mm² 600VEN

C010:2 /23.C3 FROM
-C007
AMBIENT SENSOR
-E002
1.00 mm² 600AMB 1/2
AGGLOMERATOR
A/3 1.00 mm² 112E AGGLOMERATOR 1.00 mm² 500AMB 2/2

FROM
/4.A5 E001:F
AGGLOMERATOR 1.00 mm² 401E B/3
E030:E9 /5.E4 TO
C/3 GROUND
1.00 mm² 604B TO
/20.D3 SE02 -E014
GROUND 1.00 mm² 604SS SPEED SENSOR
SC7 /20.D4 TO
1 1/6
B+ (RED)
2/6 2
-P039 -C004 GND (BLK)
SPEED SENSOR 1.00 mm² 593 F5/84 F5/84 1.00 mm² 593 3/6 3
P072:8 /9.D5 TO
OUTA (WHITE)
4
B+ (ORANGE)
5
GND (BROWN)
6
OUTB (YELLOW)
-E006
VACUUM SWITCH IGNITION +VE
SC5 /3.C6 FROM 1.00 mm² 109SS
-P039 -C004
VACUUM SWITCH 1.00 mm² 402 B7/84 B7/84 0.75 mm² 402 1 2 1.00 mm² 604D GROUND
P072:1 /9.E5 TO TO
/20.E3 SE02
-C035
FUELLEVE LSENSOR
-P039 -C004
FUELLEVEL 1.00 mm² 408 B6/84 B6/84 1.00 mm² 408 B/2 1 2 A/2 1.00 mm² 610A GROUND
P072:11 /9.D5 TO
Sig GND TO
/20.C4 SC9
160/G6925-2 Sheet 6
33 - 29 9823/0300-1 33 - 29
Page Page
33-30 33-31
Figure 1069. (Part 1 of 2) -P039 -C004

IGNITION +VE B9/84 B9/84
SP20 /3.A7 FROM

SC12 /20.E4 TO
-P039 -C004
BATT+VE 1.00 mm² 200RDM B8/84 B8/84
P004:14 /3.E7 FROM
-C057
RDM
11/20 1/20 1.00 mm² 200RDM

12/20 2/20 1.00 mm² 601RDM
13/20 3/20 0.50 mm² CAN 10 L
14/20 4/20 0.50 mm² CAN 10 H
15/20 5/20
-P039 -C004 16/20 6/20

AUX COOLING FAN 1.00 mm² 800ACF B11/84 B11/84 1.00 mm² 800ACF 17/20 7/20 1.00 mm² 500AMB
P013:3 /14.E1 TO
18/20 8/20 1.00 mm² 100RDM

AUX VENT 1.00 mm² 500VEN 19/20 9/20
C010:1 /23.C3 TO
20/20 10/20
GROUND 1.00 mm² 600VEN

C010:2 /23.C3 FROM
-E002
AGGLOMERATOR
Page 33-31
A/3 1.00 mm² 112E AGGLOMERATOR
FROM
/4.A5 E001:F
AGGLOMERATOR 1.00 mm² 401E B/3
E030:E9 /5.E4 TO
C/3 1.00 mm² 604B GROUND TO

/20.D3 SE02
SC7
-P039
SPEED SENSOR 1.00 mm² 593 F5/84
P072:8 /9.D5 TO
-E006
VACUUM SWITCH
SC5
-P039 -C004
VACUUM SWITCH 1.00 mm² 402 B7/84 B7/84 0.75 mm² 402 1 2
P072:1 /9.E5 TO
-C035
FUELLEVE LSENSOR
-P039 -C004
FUELLEVEL 1.00 mm² 408 B6/84 B6/84 1.00 mm² 408 B/2 1 2 A/2
P072:11 /9.D5 TO
Sig GND
33 - 30 9823/0300-1 33 - 30
Page Page
33-30 33-31

-C004
B9/84
2.00 mm² 600RDM
-C004
B8/84
1.00 mm² 200RDM

1.00 mm² 601RDM -SC2
0.50 mm² CAN 10 L 0.50 mm² CAN 10 L CAN LO
FROM
/17.E4 CAN L
0.50 mm² CAN 10 H 0.50 mm² CAN 10 H CAN HI
FROM
/17.E4 CAN H
FROM
/6.E5
-C009
1.00 mm² 500AMB TO
/6.E5
1.00 mm² 100RDM
-C007
AMBIENT SENSOR
1.00 mm² 600AMB 1/2

Page 33-30
E001:F 1.00 mm² 500AMB 2/2
SE02 -E014
GROUND 1.00 mm² 604SS SPEED SENSOR
SC7 /20.D4 TO
1 1/6
B+ (RED)
2/6 2
-P039 -C004 GND (BLK)
593 F5/84 F5/84 1.00 mm² 593 3/6 3
OUTA (WHITE)
4
B+ (ORANGE)
5
GND (BROWN)
6
OUTB (YELLOW)
UUM SWITCH IGNITION +VE

SC5 /3.C6 FROM 1.00 mm² 109SS
2 1.00 mm² 604D GROUND TO

/20.E3 SE02
SENSOR
2 A/2 1.00 mm² 610A GROUND
GND TO
/20.C4 SC9
160/G6925-2 Sheet 6
33 - 31 9823/0300-1 33 - 31
33 - 32 9823/0300-1 33 - 32
Page 33-34 Figure 1070. Transmission/Pump/Inching Page 33-35

-C056
FOOT THROTTLE FOOT THROTTLE
/5.E3
FROM
E030:C1
1.00 mm² 562 1 2 1.00 mm² 561B FOOT THROTTLE
+5V TR1 SIG TO
/5.E3 E030:C2
3 1.00 mm² 560A FOOT THROTTLE
TR1 GND TO
/5.E3 E030:C3
FOOT THROTTLE
/5.E3
FROM
E030:C4
5 1.00 mm² 564 FOOT THROTTLE
TR2 SIG TO
/5.E3 E030:C5
1.00 mm² 563A 4 6 1.00 mm² 565 FOOT THROTTLE
+5V TR2 GND TO
/5.E3 E030:C6
-T002
PUMPFO RWARD
-P039 -C004
PUMPFO RWARD 1.00 mm² 521 C6/84 C6/84 1.00 mm² 521 1/2
P069:6 /21.E3 FROM
-C150
-P039 -C004
INCHING PEDAL HYD ECU 5V REF PUMPFO RWARD RTN 1.00 mm² 523 G4/84 G4/84 1.00 mm² 523 2/2
/22.C6 SC31
FROM
P069:1 /21.E3 TO
0.75 mm² 456IP 1 2 0.75 mm² 468B INCHING SIGNAL

+5V TR1 SIG /21.D1SC15
TO
3 0.75 mm² 699IP HYD ECU SENSOR GND

TR1 GND /22.B6 SC28
TO
-T003
5 PUMPREVERSE
TR2 SIG -P039 -C004
4 6 PUMPREVERSE 1.00 mm² 522 B12/84 B12/84 1.00 mm² 522 1/2
+5V TR2 GND P069:5 /21.E3 FROM
-P039 -C004
PUMPREVERSE RTN 1.00 mm² 535 G3/84 G3/84 1.00 mm² 535 2/2
P069:13 /21.D3 TO
-C008 -T005
HAND THROTTLE/CREEP MOTOR FAST/SLOW
-P039 -C004
1/12 0.75 mm² 457C1 07/11 5V REF MOTOR FAST/SLOW 1.00 mm² 526 A2/84 A2/84 1.00 mm² 526 1/2 1/2
FROM
/21.D6 SC3 P069:17 /21.C3 FROM
-P039 -C004
2/12 0.75 mm² 688C1 07/11 SENSOR GROUND MOTOR FAST/SLOW RTN 1.00 mm² 527 A3/84 A3/84 1.00 mm² 527 2/2 2/2
TO
/21.D6 SC1 P069:7 /21.D3 TO
3/12 0.75 mm² 560 INCHING DIAL TO

/21.D1 P069:12
INCHING DIAL
07/11 5V REF -T007
4/12 0.75 mm² 457C2 FROM
/21.D6 SC3 PUMPPRESSURE
5/12 0.75 mm² 688C2 07/11 SENSOR GROUND 07/11 SENSOR GROUND 1.00 mm² 688PP 1/4
TO
/21.D6 SC1 SC1/21.D6 TO
-C001
6/12 0.75 mm² 561 1 2 0.75 mm² 561A INCHING DIAL 07/11 5V REF 1.00 mm² 457PP 2/4
TO
/21.D6 P70:14 SC3 /21.D6 FROM
/7.C1
3/4
7/12 0.75 mm² 456A INCHING HAND THRO
FROM
/5.E5 E030:B1 -P039 -C004
PUMPPRESSURE 0.75 mm² 419PP A4/84 A4/84 1.00 mm² 419PP 4/4
P069:8 /21.D3 TO
8/12 0.75 mm² 699E INCHING HAND THRO

TO
/5.E5 E030:B3
-P034
9/12 INCHING HAND THRO
0.75 mm² 435C TO
/5.E5 E030:B2 HORN
HAND THROTTLE
INCHING HAND THRO CAN SHLD
-T006
10/12 0.75 mm² 456B E030:E6 1.00 mm² 600H
FROM
/5.E4 TO
/19.B1 SP61 TRANSMISSION SPEED SENSOR
2
11/12 0.75 mm² 699F INCHING HAND THRO IGNITION +VE 1.00 mm² 100C -ST1 1.00 mm² 100CA 1/6
TO
/5.E4 E030:E8 SC5 /3.B6 FROM
12/12 0.75 mm² 436 INCHING HAND THRO 1.00 mm² 699DA 2/6
TO
/5.E4 E030:E7
/7.D1
-P037 TRANS SPEED SENSOR
P047:5 /22.E4 1.00 mm² 480 3/6
COLUMN SWITCH L/H
TO
1.00 mm² 100CB 4/6

BATT+VE 2.00 mm² 304B 11/14 8/14 1.00 mm² 814
P003:14 /3.B5 FROM
HORN
HYD ECU SENSOR GND 0.75 mm² 699D 1.00 mm² 699DB 5/6
SC28 /22.B6 TO
-ST2
TRANS SPEED SENSOR 1.00 mm² 481 6/6
C046:11 /22.F2 TO
IGNITION +VE 1.00 mm² 109CS -SP65 1.00 mm² 109CS2 14/14
P002:18 /3.C6 FROM
-P039 -C004
4/14 1.00 mm² 416F C10/84 C10/84 1.00 mm² 416F F
F TO
/22.E4 C047:9
-P039 -C004
1.00 mm² 109CS1 7/14 6/14 1.00 mm² 416N E12/84 E12/84 1.00 mm² 416N N
N TO
/22.E1 C046:4
-P039 -C004
R
160/G6925-2 Sheet 7
R 10/14 1.00 mm² 416R D9/84 D9/84 1.00 mm² 416R TO
/22.F4 C047:3
33 - 33 9823/0300-1 33 - 33
Page Page
33-34 33-35

-C056
FOOT THROTTLE FOOT THROTTLE
/5.E3
FROM
E030:C1
1.00 mm² 562 1 2 1.00 mm² 561B FOOT THROTTLE
+5V TR1 SIG TO
/5.E3 E030:C2
3 1.00 mm² 560A FOOT THROTTLE
TR1 GND TO
/5.E3 E030:C3
FOOT THROTTLE
/5.E3
FROM
E030:C4
5 1.00 mm² 564 FOOT THROTTLE
TR2 SIG TO
/5.E3 E030:C5
1.00 mm² 563A 4 6 1.00 mm² 565 FOOT THROTTLE
+5V TR2 GND TO
/5.E3 E030:C6
P069:6 /21.E3
-C150
INCHING PEDAL HYD ECU 5V REF
/22.C6 SC31
FROM
P069:1 /21.E3
0.75 mm² 456IP 1 2 0.75 mm² 468B INCHING SIGNAL
+5V TR1 SIG /21.D1SC15
TO
3 0.75 mm² 699IP HYD ECU SENSOR GND

TR1 GND /22.B6 SC28
TO
5
TR2 SIG
4 6
+5V TR2 GND P069:5 /21.E3
P069:13 /21.D3
-C008
HAND THROTTLE/CREEP
1/12 0.75 mm² 457C1 07/11 5V REF

FROM
/21.D6 SC3 P069:17 /21.C3
2/12 0.75 mm² 688C1 07/11 SENSOR GROUND

TO
/21.D6 SC1 P069:7 /21.D3
3/12 0.75 mm² 560 INCHING DIAL TO

/21.D1 P069:12
INCHING DIAL
4/12 0.75 mm² 457C2 07/11 5V REF
FROM
/21.D6 SC3

TO
/21.D6 SC1
Page 33-35
-C001
6/12 0.75 mm² 561 1 2 0.75 mm² 561A INCHING DIAL TO
/21.D6 P70:14
/7.C1
7/12 0.75 mm² 456A INCHING HAND THRO

FROM
/5.E5 E030:B1
P069:8 /21.D3
8/12 0.75 mm² 699E INCHING HAND THRO
TO
/5.E5 E030:B3
-P034
9/12 INCHING HAND THRO
0.75 mm² 435C TO
/5.E5 E030:B2 HORN
HAND THROTTLE
10/12 0.75 mm² 456B INCHING HAND THRO 1.00 mm² 600H CAN SHLD
FROM
/5.E4 E030:E6 TO
/19.B1
2
11/12 0.75 mm² 699F INCHING HAND THRO

TO
/5.E4 E030:E8
1
12/12 0.75 mm² 436 INCHING HAND THRO

TO
/5.E4 E030:E7
/7.D1
-P037
COLUMN SWITCH L/H
BATT+VE 2.00 mm² 304B 11/14 8/14 1.00 mm² 814

P003:14 /3.B5 FROM
HORN
IGNITION +VE 1.00 mm² 109CS -SP65 1.00 mm² 109CS2 14/14
P002:18 /3.C6 FROM
F 4/14 1.00 mm² 416F
1.00 mm² 109CS1 7/14 N 6/14 1.00 mm² 416N
R 10/14 1.00 mm² 416R
33 - 34 9823/0300-1 33 - 34
Page Page
33-34 33-35
-T002
PUMPFO RWARD
-P039 -C004
PUMPFO RWARD 1.00 mm² 521 C6/84 C6/84 1.00 mm² 521 1/2
P069:6 /21.E3 FROM
-P039 -C004
PUMPFO RWARD RTN 1.00 mm² 523 G4/84 G4/84 1.00 mm² 523 2/2
P069:1 /21.E3 TO
-T003
PUMPREVERSE
-P039 -C004
PUMPREVERSE 1.00 mm² 522 B12/84 B12/84 1.00 mm² 522 1/2
P069:5 /21.E3 FROM
-P039 -C004
PUMPREVERSE RTN 1.00 mm² 535 G3/84 G3/84 1.00 mm² 535 2/2
P069:13 /21.D3 TO
-T005
MOTOR FAST/SLOW
-P039 -C004
MOTOR FAST/SLOW 1.00 mm² 526 A2/84 A2/84 1.00 mm² 526 1/2 1/2
P069:17 /21.C3 FROM
-P039 -C004
MOTOR FAST/SLOW RTN 1.00 mm² 527 A3/84 A3/84 1.00 mm² 527 2/2 2/2
P069:7 /21.D3 TO
-T007
PUMPPRESSURE
07/11 SENSOR GROUND 1.00 mm² 688PP 1/4
SC1/21.D6 TO
Page 33-34
07/11 5V REF 1.00 mm² 457PP 2/4

SC3 /21.D6 FROM
3/4
-P039 -C004
PUMPPRESSURE 0.75 mm² 419PP A4/84 A4/84 1.00 mm² 419PP 4/4
P069:8 /21.D3 TO
CAN SHLD
-T006
TO
/19.B1 SP61 TRANSMISSION SPEED SENSOR
IGNITION +VE 1.00 mm² 100C -ST1 1.00 mm² 100CA 1/6
SC5 /3.B6 FROM
1.00 mm² 699DA 2/6

P047:5 /22.E4 TO
1.00 mm² 100CB 4/6

1.00 mm² 814
HYD ECU SENSOR GND 0.75 mm² 699D 1.00 mm² 699DB 5/6
SC28 /22.B6 TO
-ST2
C046:11 /22.F2 TO
-P039 -C004
1.00 mm² 416F C10/84 C10/84 1.00 mm² 416F F TO
/22.E4 C047:9
-P039 -C004
1.00 mm² 416N E12/84 E12/84 1.00 mm² 416N N TO
/22.E1 C046:4
-P039 -C004
R
160/G6925-2 Sheet 7
1.00 mm² 416R D9/84 D9/84 1.00 mm² 416R TO
/22.F4 C047:3
33 - 35 9823/0300-1 33 - 35
33 - 36 9823/0300-1 33 - 36
Page 33-38 Figure 1071. Livelink / Immobiliser Page 33-39

-P068 -P066
LIVE LINK IMMOBILISER
CAN SHLD
CAN SCR /17.E3 FROM
-P010
CAN LO 0.50 mm² CAN 5 SCR C1 IMMOBILISER IGN RELAY BATT +VE 1.00 mm² Y B7 G1
CAN L /17.E3 FROM
CAN_SHD P002:18 / SP27 /3.A5 FROM
+12/24VDC Key 7
0.50 mm² CAN 5 L C2 9 BATT Feed G2
CAN_L Key 6
CAN HI 0.50 mm² CAN 5 H C11 IGNITION +VE 1.00 mm² Y 6 7 1.00 mm² Y B8 G3
CAN H /17.E3 FROM
CAN_H P001:8 /3.E5 FROM
+12/24VDC Key 5
IGN Feed G4
Key 4
BATT +VE 1.00 mm² 299LL C4 1.00 mm² Y 8 10 G5
P005:6 /3.D7 FROM
V_BATT Key 3
C3 G6
V_PWR Key 2
C7 G7
ENG_RUN Key 1
1.00 mm² 110LLA C8 C6 CAN SHLD 1.00 mm² 601TS G8
V_IGN RLY_0 SP3 /19.E4 TO
Key 0
-P009 D8 C12 G9
CH_1_1 RLY_1 Status LED LS Out
LIVE LINK RELAY D4 G10
CH_2_1 Status LED 5V Feed
4 D10 G11
CH_3_1 Antenna Coil
IGNITION +VE 1.00 mm² 110LL 1 2 D5 G12
P005:14 /3.C7 FROM
CH_4_1 Antenna Coil
IGNITION +VE 1.00 mm² 100LL 3 5 D1 C5 Relay 1

P001:2 / SP20 /3.B7 FROM
RS232_TX GND
D2
RS232_DTR C9 LIVELINK GND
D3 1.00 mm² 601L
RS232_DCD GND-BATT FROM
/3.E7 P004:20 NO
D6 B12 MAX 7A B5
CAN SHLD 1.00 mm² 601LL RS232_CTS C10 B6
SP3 /19.E4 TO D7 GND_PWR COM
RS232_RTS
D12 NC
RS232_RX D9 Relay 2
GND
D11
SATCOM_RING
B3 MAX 7A B4
COM NO
Relay 3
B1 MAX 7A B2
COM NO
CAN HI 0.50 mm² CAN H B9
CAN H /17.B3 FROM
CAN_H
160/G6925-2 Sheet 8 0.50 mm² CAN L B10 B11 1.00 mm² Y CAN SHLD
CAN_L GND TO
/19.C4 SP6
CAN HI
CAN L /17.B3 FROM
33 - 37 9823/0300-1 33 - 37
Page Page
33-38 33-39
-P068
Figure 1071. (Part 1 of 2) LIVE LINK
CAN SHLD
CAN SCR /17.E3 FROM
CAN LO 0.50 mm² CAN 5 SCR C1

CAN L /17.E3 FROM
CAN_SHD
0.50 mm² CAN 5 L C2
CAN_L
CAN HI 0.50 mm² CAN 5 H C11 IGNITION +VE
CAN H /17.E3 FROM
CAN_H P001:8 /3.E5 FROM
BATT +VE 1.00 mm² 299LL C4

P005:6 /3.D7 FROM
V_BATT
C3
V_PWR
C7
ENG_RUN
1.00 mm² 110LLA C8 C6 CAN SHLD
V_IGN RLY_0 SP3 /19.E4 TO
-P009 D8 C12
CH_1_1 RLY_1
LIVE LINK RELAY D4
CH_2_1
4 D10
CH_3_1
IGNITION +VE 1.00 mm² 110LL 1 2 D5
P005:14 /3.C7 FROM
CH_4_1
IGNITION +VE 1.00 mm² 100LL 3 5 D1 C5

P001:2 / SP20 /3.B7 FROM
RS232_TX GND
D2
RS232_DTR C9 LIVELINK GND
D3 1.00 mm² 601L
RS232_DCD GND-BATT FROM
/3.E7 P004:20
D6
CAN SHLD 1.00 mm² 601LL RS232_CTS C10
SP3 /19.E4 TO D7 GND_PWR
RS232_RTS
D12
RS232_RX D9
GND
D11
SATCOM_RING
Page 33-39
33 - 38 9823/0300-1 33 - 38
Page Page
33-38 33-39
-P066
Figure 1071. (Part 2 of 2) IMMOBILISER
-P010
IMMOBILISER IGN RELAY BATT +VE 1.00 mm² Y B7 G1
P002:18 / SP27 /3.A5 FROM
+12/24VDC Key 7
9 BATT Feed G2
Key 6
IGNITION +VE 1.00 mm² Y 6 7 1.00 mm² Y B8 G3
/3.E5 FROM
+12/24VDC Key 5
IGN Feed G4
Key 4
1.00 mm² Y 8 10 G5
Key 3
G6
Key 2
G7
Key 1
CAN SHLD 1.00 mm² 601TS G8
/19.E4 TO
Key 0
G9
Status LED LS Out
G10
Status LED 5V Feed
G11
Antenna Coil
G12
Antenna Coil
Relay 1
/3.E7 P004:20 NO
B12 MAX 7A B5
COM B6
NC
Relay 2
B3 MAX 7A B4
COM NO
Relay 3
B1 MAX 7A B2
COM NO
CAN HI 0.50 mm² CAN H B9
Page 33-38
CAN H /17.B3 FROM

CAN_H
160/G6925-2 Sheet 8 0.50 mm² CAN L B10 B11 1.00 mm² Y CAN SHLD
CAN_L GND TO
/19.C4 SP6
CAN HI
CAN L /17.B3 FROM
33 - 39 9823/0300-1 33 - 39
33 - 40 9823/0300-1 33 - 40
Page 33-42 Figure 1072. Instruments Page 33-43

CAN SHLDTO
/19.D6 SP11
-P063
-P071 -P072 INFO BUTTON
INSTRUMENT CLUSTER INSTRUMENT CLUSTER 7 8 SWITCH ILLUMINATION
1.00 mm² 601HP 1.00 mm² 829AH FROM
/18.D5 SP7
SWITCH ILLUMINATION 1.00 mm² 829AB 1/20 1/20 1.00 mm² 402 VACUUM SWITCH
SP7 /18.D5 FROM FROM
/6.C2 E006:1 / P039:B7
J1 J2
IGNITION +VE 1.00 mm² 106 2/20 2/20
P005:18 /3.C7 FROM

FROM
/3.B7 SP20
AC 1.00 mm² 884AC 3/20 3/20 0.75 mm² 2910 0.75 mm² 2910 3
P015:3 /14.D2 TO
1.00 mm² 877 4/20 4/20 0.75 mm² 800R DI R/H

FROM
/11.B3 P038:10
5/20 5/20 1.00 mm² 887A AC TO

/14.C5 P019A:2
6/20 6/20 1.00 mm² 1840C REV FAN SW

FROM
/16.E3 P061:6
CAN LO 0.50 mm² CAN 7 L 7/20 7/20 1.00 mm² 412 W
CAN L /17.E4 FROM FROM
/4.E5 C005:B / P039:A5
CAN HI 0.50 mm² CAN 7 H 8/20 8/20 1.00 mm² 593 SPEED SENSOR
CAN H /17.E3 FROM FROM
/6.B2 E014:3 / C029:18
9/20 9/20 1.00 mm² 801A HEATER

FROM
/14.C1 SP50
1.00 mm² 301EA 10/20 10/20 2.00 mm² 805F DI L/H TO

/11.B5 SP8
D+ 1.00 mm² 407B 11/20 11/20 1.00 mm² 408 FUEL LEVEL
SP14 /4.E5 FROM FROM
/6.C2 C010:B / P039:B6
REV FAN SOL 1.00 mm² 1840 12/20 12/20
E012:2 / P039:A10 /16.E4 TO
HAZARDS 0.75 mm² 509 13/20 13/20

P020:6 /11.C3 FROM
DI R/H 0.75 mm² 806RC 14/20 14/20

P016:7 / SP36 /11.E7 FROM
AC/BLOWER SWITCH 1.00 mm² 610 15/20 15/20 1.00 mm² 481B FRON/REAR AUX
SP13 /14.C2 FROM FROM
/25.D4 P017:3
DI L/H 0.75 mm² 805LC 16/20 16/20
P016:2 / SP37 /11.E7 FROM
DI L/H 0.75 mm² 800L 17/20 17/20 1.00 mm² 601DE CAN SHLD
RH P038:11 /11.B3 FROM TO
/19.E6 SP11
REV FAN SW 1.00 mm² 1840D 18/20 18/20 1.00 mm² 997 AC/BLOWER SWITCH
P061:3 /16.E3 FROM TO
/14.B5 SP17
19/20 19/20 1.00 mm² 592 PROPORTIONAL FAN

TO
/16.E4 P039:F6
BATT +VE 1.00 mm² 301E 1.00 mm² 301EB 20/20 20/20 2.00 mm² 806A DI R/H
P005:10 /3.D7 FROM TO
/11.B5 SP9
-SP40 /9.C4 /9.C4
-P040
CENTER CLUSTER
SWITCH ILLUMINATION 0.50 mm² 829WL 1/20 11/20 0.50 mm² 941A FOG
SP7 /18.C5 FROM FROM
/10.E4 P023:3
MAIN BEAM 0.50 mm² 838A 2/20 12/20
SP19 /10.A4 FROM
-P014
TRAILER SENSE HAZARDS 0.50 mm² 804B 3/20 13/20
SP49 /11.C3 FROM
9
CAN SHLD 0.75 mm² 601TS 6 7 0.50 mm² 601TSW 0.50 mm² 601TSW 4/20 14/20
P014:5 /13.E1 FROM
1.00 mm² 877 8 10 0.75 mm² 601TSA 5/20 15/20
REAR WORKLIGHTS 0.50 mm² 609BC 6/20 16/20

P026:6 /13.F5 FROM
FRONT WORKLIGHTS 0.50 mm² 609AB 7/20 17/20

P026:3 /13.F5 FROM
BOOM WORKLIGHTS 0.50 mm² 610AB 8/20 18/20

P029:3 /13.E5 FROM
160/G6925-2 Sheet 9
9/20 19/20
CAN SHLD 0.50 mm² 601P 10/20 IGN 20/20 0.50 mm² 106C IGNITION +VE
SP6 /19.C4 TO FROM
/3.B5 P003:4
33 - 41 9823/0300-1 33 - 41
Page Page
33-42 33-43
-P071
INSTRUMENT CLUSTER INSTRUMENT CLU
SWITCH ILLUMINATION 1.00 mm² 829AB 1/20
SP7 /18.D5 FROM
J1
IGNITION +VE 1.00 mm² 106 2/20
P005:18 /3.C7 FROM
AC 1.00 mm² 884AC 3/20

P015:3 /14.D2 TO
1.00 mm² 877 4/20
5/20
6/20
CAN LO 0.50 mm² CAN 7 L 7/20

CAN L /17.E4 FROM
CAN HI 0.50 mm² CAN 7 H 8/20

CAN H /17.E3 FROM
9/20
1.00 mm² 301EA 10/20
D+ 1.00 mm² 407B 11/20

SP14 /4.E5 FROM
REV FAN SOL 1.00 mm² 1840 12/20

E012:2 / P039:A10 /16.E4 TO
HAZARDS 0.75 mm² 509 13/20

P020:6 /11.C3 FROM
DI R/H 0.75 mm² 806RC 14/20

P016:7 / SP36 /11.E7 FROM
AC/BLOWER SWITCH 1.00 mm² 610 15/20

SP13 /14.C2 FROM
DI L/H 0.75 mm² 805LC 16/20

P016:2 / SP37 /11.E7 FROM
DI L/H 0.75 mm² 800L 17/20

RH P038:11 /11.B3 FROM
REV FAN SW 1.00 mm² 1840D 18/20

P061:3 /16.E3 FROM
Page 33-43
19/20
BATT +VE 1.00 mm² 301E 1.00 mm² 301EB 20/20

P005:10 /3.D7 FROM
-SP40 /9.C4
-P040
CENTER CLUSTER
SWITCH ILLUMINATION 0.50 mm² 829WL 1/20

SP7 /18.C5 FROM
MAIN BEAM 0.50 mm² 838A 2/20

SP19 /10.A4 FROM
-P014
TRAILER SENSE HAZARDS 0.50 mm² 804B 3/20
SP49 /11.C3 FROM
9
CAN SHLD 0.75 mm² 601TS 6 7 0.50 mm² 601TSW 0.50 mm² 601TSW 4/20
P014:5 /13.E1 FROM
1.00 mm² 877 8 10 0.75 mm² 601TSA 5/20
REAR WORKLIGHTS 0.50 mm² 609BC 6/20

P026:6 /13.F5 FROM
FRONT WORKLIGHTS 0.50 mm² 609AB 7/20

P026:3 /13.F5 FROM
BOOM WORKLIGHTS 0.50 mm² 610AB 8/20

P029:3 /13.E5 FROM
9/20
CAN SHLD 0.50 mm² 601P 10/20 IGN

SP6 /19.C4 TO
33 - 42 9823/0300-1 33 - 42
Page Page
33-42 33-43
CAN SHLD
Figure 1072. (Part 2 of 2) TO
/19.D6 SP11
-P063
-P072 INFO BUTTON
UMENT CLUSTER INSTRUMENT CLUSTER 7 8 SWITCH ILLUMINATION
1.00 mm² 601HP 1.00 mm² 829AH FROM
/18.D5 SP7
1/20 1.00 mm² 402 VACUUM SWITCH
FROM
/6.C2 E006:1 / P039:B7
J2
2/20
FROM
/3.B7 SP20
3/20 0.75 mm² 2910 0.75 mm² 2910 3
4/20 0.75 mm² 800R DI R/H

FROM
/11.B3 P038:10
5/20 1.00 mm² 887A AC TO

/14.C5 P019A:2
6/20 1.00 mm² 1840C REV FAN SW

FROM
/16.E3 P061:6
7/20 1.00 mm² 412 W

FROM
/4.E5 C005:B / P039:A5
8/20 1.00 mm² 593 SPEED SENSOR

FROM
/6.B2 E014:3 / C029:18
9/20 1.00 mm² 801A HEATER

FROM
/14.C1 SP50
10/20 2.00 mm² 805F DI L/H TO

/11.B5 SP8
11/20 1.00 mm² 408 FUEL LEVEL

FROM
/6.C2 C010:B / P039:B6
12/20
13/20
14/20
15/20 1.00 mm² 481B FRON/REAR AUX

FROM
/25.D4 P017:3
16/20
17/20 1.00 mm² 601DE CAN SHLD TO

/19.E6 SP11
18/20 1.00 mm² 997 AC/BLOWER SWITCH

TO
/14.B5 SP17
Page 33-42
19/20 1.00 mm² 592 PROPORTIONAL FAN

TO
/16.E4 P039:F6
20/20 2.00 mm² 806A DI R/H TO

/11.B5 SP9
/9.C4
-P040
CENTER CLUSTER
11/20 0.50 mm² 941A FOG

FROM
/10.E4 P023:3
12/20
13/20
14/20
15/20
16/20
17/20
18/20
160/G6925-2 Sheet 9
19/20
IGN 20/20 0.50 mm² 106C IGNITION +VE

FROM
/3.B5 P003:4
33 - 43 9823/0300-1 33 - 43
33 - 44 9823/0300-1 33 - 44
Page 33-46 Figure 1073. Road lights Page 33-47

CAN SHLD
SP6 /19.C4 TO
-P011
-P023 BRAKE LIGHTS
FOG LIGHT SWITCH 4 1.00 mm² 816
SWITCH ILLUMINATION 1.00 mm² 829AE 8 7 1.00 mm² 601DC IGNITION +VE 1.00 mm² 108 1 2
SP7 /18.D5 FROM
P002:6 /3.D5 FROM
BRAKE LIGHTS 0.75 mm² 116B 3 5 0.75 mm² 601BL CAN SHLD -C020
P069:16 /21.C3 FROM TO
/19.D4 SP3
NUMBER PLATE LIGHT
FOG 1.00 mm² 905 2 1.00 mm² 829E 1/2
P004:4 /3.E7 FROM
3 1.00 mm² 941

0.50 mm² 941A FOG 1.00 mm² 605D 2/2
TO
/9.B5 P040:11
-C018
L/H REAR LIGHTS
1.00 mm² 816 A7/84 A7/84 1.50 mm² 816 -SC21 1.50 mm² 816A 1/6 BRAKE
1.00 mm² 807A 2/6 REVERSE
1.00 mm² 829A D11/84 D11/84 1.00 mm² 829 -SC17 1.00 mm² 829D 3/6 SIDE
1.00 mm² 941 E5/84 E5/84 1.00 mm² 941 -SC22 1.00 mm² 941A 5/6 FOG
DI L/H 2.00 mm² 805D D4/84 D4/84 1.00 mm² 805J 1.00 mm² 805F 6/6 DI
P031:1 / SP8 /11.C6 FROM
-SC13 2.00 mm² 605A 4/6 GND
-C017
R/H REAR LIGHTS
C7/84 C7/84 1.00 mm² 807 -SC10 1.00 mm² 807B 1/6 REVERSE
1.00 mm² 941B 2/6 FOG
0.75 mm² 830 E2/84 E2/84 1.00 mm² 830 -SC18 1.00 mm² 830D 3/6 SIDE
1.50 mm² 816B 5/6 BRAKE
DI R/H 2.00 mm² 806C D3/84 D3/84 2.00 mm² 806J -SC14 1.00 mm² 806F 6/6
P032:1 / SP9 /11.C6 FROM
DI
-P009 2.00 mm² 605B 4/6 GND
REVERSE ALARM
9 SWITCH ILLUMINATION 0.75 mm² 830E
C022:8 /23.F3 TO
1.50 mm² 807A 7 6 1.50 mm² 109RA IGNITION +VE -C021

FROM
/3.E5 P001:20
SWITCH ILLUMINATION 0.75 mm² 830G REVERSE ALARM
C153:8 /23.E3 TO
0.75 mm² 601RA 10 8 0.50 mm² 807 REV ALARM

FROM
/21.D3 P069:14
SWITCH ILLUMINATION 0.75 mm² 830H 1.00 mm² 807C 1
C154:8 /23.D3 TO
CAN SHLD 1.00 mm² 605C 2

FROM
/10.B1 P013:10
-P064B
DIODE
2.00 mm² 942C 2 1 2.00 mm² 947B BOOM WORKLIGHTS -C019
FROM
/13.E6 SP31
TRAILOR SOCKET
CAN SHLD 0.75 mm² 601BF DI L/H 1.00 mm² 805A 1/8
SP6 /19.C4 TO
-P064A C004:E10 /11.E7 FROM
DIODE 1.00 mm² 807D 2/8

2.00 mm² 831J WORKLIGHTS FRONT
2.00 mm² 942A FROM
/13.E6 SP23 2.00 mm² 605E 3/8
IGNITION +VE 0.75 mm² 100D -P024 2 1 DI R/H 1.00 mm² 806A 4/8
P001:16 / SP20 /3.A7 FROM
C004:E11 /11.E7 FROM
HEADLIGHTS 1.00 mm² 830C 5/8

8 7 0.75 mm² 601BF 2.00 mm² 942D SWITCH ILLUMINATION SWITCH ILLUMINATION 1.50 mm² 816C 6/8
TO
/3.C4 P002:11 SP7 /18.C5 FROM
BATT +VE 2.00 mm² 307 1.00 mm² 829C 7/8

P003:12 /3.B5 FROM
1.00 mm² 941C 8/8

1
-P013 2 2.00 mm² 942E SWITCH ILLUMINATION SWITCH ILLUMINATION
TO
/3.C4 P002:13 P002:14 /3.C5 FROM
ROADLIGHTS 3 2.00 mm² 942B -SP22 GROUND 2.00 mm² 605BW -SC16 4.00 mm² 605 GROUND
C032:2 /13.B7 FROM TO
/20.C4 SC9
9 4 1.00 mm² 891 WORKLIGHTS TO
/13.D3 P012:3
BATT +VE
2.00 mm² 306 6 7 2.00 mm² 828 5 GROUND 1.50 mm² 605AO
P004:8 /3.E7 FROM
C032:4 /25.D6 FROM
6 2.00 mm² 832 1.00 mm² 891R WORKLIGHTS -C002

TO
/13.B4 P042:3
IGNITION +VE 0.75 mm² 100C 8 10 LH HEADLIGHT
P001:2 / SP20 /3.A7 FROM
1.00 mm² 832B FOG TO

/3.E6 P005:9 Dipped
-SP21 2.00 mm² 834A 2
CAN SHLD 1.00 mm² 601RA
P009:10 /10.D3 TO
Main
2.00 mm² 838A 3
CAN SHLD 1.00 mm² 601V 6 2.00 mm² 606 GROUND
SP29 /19.D4 TO
Side TO
/20.B4 SC9
1.00 mm² 829B 4
-P038 DI
1.00 mm² 805G 5
COLUMN SWITCH R/H 1
3/14
TWO SPEED
ONLY
2/14 -C005
RH HEADLIGHTS
BATT +VE 2.00 mm² 304A 4/14
P003:14 /3.B5 FROM
-P039 -C004 Dipped
9/14 2.00 mm² 833 DIPPED BEAM DIPPED BEAM 1.50 mm² 834B D10/84 D10/84 2.00 mm² 834 1.00 mm² 834B 2
TO
/3.D4 P002:7 P002:8 /3.D5 FROM
2.00 mm² 832A 8/14 HEADLIGHT -SC19

FLASHER -P039 -C004 Main
13/14 2.00 mm² 836 MAIN BEAM MAIN BEAM 2.00 mm² 838 -SP19 2.00 mm² 838B A11/84 A11/84 2.00 mm² 838 2.00 mm² 838B 3
TO
/3.D4 P002:9 P002:10 /3.D5 FROM
-SC20 6 2.00 mm² 607 GROUND

Side TO
/20.B4 SC9
1.00 mm² 830B 4
10/14 MAIN BEAM 0.50 mm² 838A

L P040:2 /9.B3 TO
DI
14/14 INDICATORS 2.00 mm² 806G 5
11/14 1
R
160/G6925-2
7/14
1/14 WIPER 12/14
WASHER 6/14
33 - 45 9823/0300-1 33 - 45
Page Page
33-46 33-47

CAN SHLD
SP6 /19.C4 TO
-P023
FOG LIGHT SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AE 8 7 1.00 mm² 601DC
SP7 /18.D5 FROM
P002:6
P069:16
FOG 1.00 mm² 905 2

P004:4 /3.E7 FROM
3 1.00 mm² 941

0.50 mm² 941A FOG TO
/9.B5 P040:11
1.00 mm² 816
1.00 mm² 829A

1.00 mm² 941
DI L/H 2.00 mm² 805D
P031:1 / SP8 /11.C6 FROM
0.75 mm² 830
DI R/H 2.00 mm² 806C

P032:1 / SP9 /11.C6 FROM
-P009
REVERSE ALARM
9
1.50 mm² 807A 7 6 1.50 mm² 109RA IGNITION +VE

FROM
/3.E5 P001:20
0.75 mm² 601RA 10 8 0.50 mm² 807 REV ALARM

FROM
/21.D3 P069:14
CAN SHLD
FROM
/10.B1 P013:10
-P064B
DIODE
2.00 mm² 942C 2 1 2.00 mm² 947B BOOM WORKLIGHTS
FROM
/13.E6 SP31
Page 33-47
SP6 /19.C4 TO
-P064A
DIODE
2.00 mm² 942A FROM
/13.E6 SP23
IGNITION +VE 0.75 mm² 100D -P024 2 1
P001:16 / SP20 /3.A7 FROM
HEADLIGHTS
8 7 0.75 mm² 601BF 2.00 mm² 942D SWITCH ILLUMINATION SWITCH ILLUMINATION
TO
/3.C4 P002:11 SP7 /18.C5 FROM
BATT +VE 2.00 mm² 307

P003:12 /3.B5 FROM
1
-P013 2 2.00 mm² 942E SWITCH ILLUMINATION SWITCH ILLUMINATION
TO
/3.C4 P002:13 P002:14 /3.C5 FROM
ROADLIGHTS 3 2.00 mm² 942B -SP22

9 4 1.00 mm² 891 WORKLIGHTS TO
/13.D3 P012:3
BATT +VE
2.00 mm² 306 6 7 2.00 mm² 828 5
P004:8 /3.E7 FROM
6 2.00 mm² 832 1.00 mm² 891R WORKLIGHTS TO

/13.B4 P042:3
IGNITION +VE 0.75 mm² 100C 8 10
P001:2 / SP20 /3.A7 FROM
1.00 mm² 832B FOG TO

/3.E6 P005:9
-SP21
CAN SHLD 1.00 mm² 601RA
P009:10 /10.D3 TO

SP29 /19.D4 TO
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY
2/14
BATT +VE 2.00 mm² 304A 4/14

P003:14 /3.B5 FROM
9/14 2.00 mm² 833 DIPPED BEAM DIPPED BEAM

TO
/3.D4 P002:7 P002:8 /3.D5 FROM
2.00 mm² 832A 8/14 HEADLIGHT

FLASHER MAIN BEAM MAIN BEAM -SP19
13/14 2.00 mm² 836 2.00 mm² 838
TO
/3.D4 P002:9 P002:10 /3.D5 FROM
10/14 MAIN BEAM 0.50 mm² 838A

L P040:2 /9.B3 TO
14/14 INDICATORS
R 11/14
7/14
1/14 WIPER 12/14
WASHER 6/14
33 - 46 9823/0300-1 33 - 46
Page Page
33-46 33-47
Figure 1073. (Part 2 of 2)-P011

BRAKE LIGHTS
4 1.00 mm² 816
IGNITION +VE 1.00 mm² 108 1 2
P002:6 /3.D5 FROM
BRAKE LIGHTS 0.75 mm² 116B 3 5 0.75 mm² 601BL CAN SHLD -C020
P069:16 /21.C3 FROM TO
/19.D4 SP3
NUMBER PLATE LIGHT
1.00 mm² 829E 1/2
P040:11 1.00 mm² 605D 2/2

/9.B5
-C018
L/H REAR LIGHTS
1.00 mm² 816 A7/84 A7/84 1.50 mm² 816 -SC21 1.50 mm² 816A 1/6 BRAKE
1.00 mm² 807A 2/6 REVERSE
1.00 mm² 829A D11/84 D11/84 1.00 mm² 829 -SC17 1.00 mm² 829D 3/6 SIDE
1.00 mm² 941 E5/84 E5/84 1.00 mm² 941 -SC22 1.00 mm² 941A 5/6 FOG
2.00 mm² 805D D4/84 D4/84 1.00 mm² 805J 1.00 mm² 805F 6/6 DI
-SC13 2.00 mm² 605A 4/6 GND
-C017
R/H REAR LIGHTS
C7/84 C7/84 1.00 mm² 807 -SC10 1.00 mm² 807B 1/6 REVERSE
1.00 mm² 941B 2/6 FOG
0.75 mm² 830 E2/84 E2/84 1.00 mm² 830 -SC18 1.00 mm² 830D 3/6 SIDE
1.50 mm² 816B 5/6 BRAKE
2.00 mm² 806C D3/84 D3/84 2.00 mm² 806J -SC14 1.00 mm² 806F 6/6 DI
2.00 mm² 605B 4/6 GND
SWITCH ILLUMINATION 0.75 mm² 830E

C022:8 /23.F3 TO
-C021
SWITCH ILLUMINATION 0.75 mm² 830G REVERSE ALARM
C153:8 /23.E3 TO
SWITCH ILLUMINATION 0.75 mm² 830H 1.00 mm² 807C 1

C154:8 /23.D3 TO
1.00 mm² 605C 2
-C019
TRAILOR SOCKET
Page 33-46
DI L/H 1.00 mm² 805A 1/8

C004:E10 /11.E7 FROM
1.00 mm² 807D 2/8

2.00 mm² 605E 3/8
DI R/H 1.00 mm² 806A 4/8
C004:E11 /11.E7 FROM
1.00 mm² 830C 5/8

1.50 mm² 816C 6/8
1.00 mm² 829C 7/8
1.00 mm² 941C 8/8
GROUND 2.00 mm² 605BW -SC16 4.00 mm² 605 GROUND

C032:2 /13.B7 FROM TO
/20.C4 SC9
GROUND 1.50 mm² 605AO
C032:4 /25.D6 FROM
-C002
LH HEADLIGHT
Dipped
2.00 mm² 834A 2
Main
2.00 mm² 838A 3
6 2.00 mm² 606 GROUND
Side TO
/20.B4 SC9
1.00 mm² 829B 4
DI
1.00 mm² 805G 5
1
-C005
RH HEADLIGHTS
-P039 -C004 Dipped

1.50 mm² 834B D10/84 D10/84 2.00 mm² 834 1.00 mm² 834B 2
-P039 -C004 -SC19 Main

2.00 mm² 838 -SP19 2.00 mm² 838B A11/84 A11/84 2.00 mm² 838 2.00 mm² 838B 3
-SC20 6 2.00 mm² 607 GROUND

Side TO
/20.B4 SC9
1.00 mm² 830B 4
0.50 mm² 838A DI

2.00 mm² 806G 5
1
160/G6925-2
33 - 47 9823/0300-1 33 - 47
33 - 48 9823/0300-1 33 - 48
Page 33-50 Figure 1074. Directional Indicators Page 33-51

-P016
TRAILER L/H DIRECTIONAL
4
BATT +VE 1.50 mm² 275 1.00 mm² 275LH 1 2 1.00 mm² 805LB -SP37 0.75 mm² 805LC DI L/H
P005:16 /3.D7 FROM TO
/9.C3 P071:16
-SP25
0.75 mm² 805E 3 5 0.75 mm² 601SY CAN SHLD
TO
/19.E4 SP3
-P039 -C004
1.50 mm² 805LA E10/84 E10/84 1.00 mm² 805A DI L/H TO
/10.C5 C043:1
-P039 -C004
1.50 mm² 806RA E11/84 E11/84 1.00 mm² 806A DI R/H TO
/10.C5 C043:4
-P016
TRAILER R/H DIRECTIONAL
9
1.00 mm² 275RH 6 7 1.00 mm² 806RB 0.75 mm² 806RC DI R/H TO
/9.D3 P071:14
-SP36
0.50 mm² 806D 8 10 0.75 mm² 601JB CAN SHLD
TO
/19.E4 SP3
CAN SHLD 0.75 mm² 601AD
SP11 /19.E6 TO
-SP49
0.75 mm² 804D
-P020
HARZARD SWITCH
8 7
-P031
L/H TURN SIGNAL DIODE
1 2.00 mm² 804 2.00 mm² 805B 2.00 mm² 805D DI L/H TO
/10.E4 RL002:3 / P039:D4
0.75 mm² 804A 2 2 1 -SP8
3
4
-P032
BATT +VE 1.00 mm² 300 5
P003:20 /3.A5 FROM R/H TURN SIGNAL DIODE
6 2.00 mm² 804C 2.00 mm² 806B 2.00 mm² 806C DI R/H TO
/10.D4 RL003:3 / P039:D3
2 1 -SP9
-P038
COLUMN SWITCH R/H
3/14 HAZARDS 0.75 mm² 509
P071:13 /9.D3 TO
TWO SPEED
ONLY HAZARDS
2/14 0.50 mm² 804B
P040:3 /9.B3 TO
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
160/G6925-2 Sheet 11
R 10/14 0.75 mm² 800R DI R/H DI L/H 2.00 mm² 805F
TO
/9.E5 P072:4 P072:10 /9.D5 FROM
IGNITION +VE 1.00 mm² 104 14/14 INDICATORS

P001:12 /3.E5 FROM
L 11/14 0.75 mm² 800L DI L/H INSTRUMENT CLUSTER DI R/H 2.00 mm² 806A
TO
/9.C3 P071:17 P072:20 /9.C5 FROM
7/14
1/14 WIPER 12/14
WASHER 6/14
33 - 49 9823/0300-1 33 - 49
Page Page
33-50 33-51
P005:16
CAN SHLD 0.75 mm² 601AD

SP11 /19.E6 TO
-SP49
0.75 mm² 804D
-P020
HARZARD SWITCH
8 7
L/H TURN SIGNA

1 2.00 mm² 804
0.75 mm² 804A 2
3
4
BATT +VE 1.00 mm² 300 5
P003:20 /3.A5 FROM R/H TURN SIGNA
6 2.00 mm² 804C
-P038
COLUMN SWITCH R/H
3/14 HAZARDS 0.75 mm² 509
P071:13 /9.D3 TO
TWO SPEED
ONLY HAZARDS
2/14 0.50 mm² 804B
P040:3 /9.B3 TO
Page 33-51
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
R 10/14 0.75 mm² 800R DI R/H TO

/9.E5 P072:4 P072:10
IGNITION +VE 1.00 mm² 104 14/14 INDICATORS
P001:12 /3.E5 FROM
L 11/14 0.75 mm² 800L DI L/H INSTRUMENT CLUSTER

TO
/9.C3 P071:17 P072:20
7/14
1/14 WIPER 12/14
WASHER 6/14
33 - 50 9823/0300-1 33 - 50
Page Page
33-50 33-51

TRAILER L/H DIRECTIONAL
4
BATT +VE 1.50 mm² 275 1.00 mm² 275LH 1 2 1.00 mm² 805LB -SP37 0.75 mm² 805LC DI L/H
P005:16 /3.D7 FROM TO
/9.C3 P071:16
-SP25
0.75 mm² 805E 3 5 0.75 mm² 601SY CAN SHLD
TO
/19.E4 SP3
-P039 -C004
1.50 mm² 805LA E10/84 E10/84 1.00 mm² 805A DI L/H TO
/10.C5 C043:1
-P039 -C004
1.50 mm² 806RA E11/84 E11/84 1.00 mm² 806A DI R/H TO
/10.C5 C043:4
-P016
TRAILER R/H DIRECTIONAL
9
1.00 mm² 275RH 6 7 1.00 mm² 806RB 0.75 mm² 806RC DI R/H TO
/9.D3 P071:14
-SP36
0.50 mm² 806D 8 10 0.75 mm² 601JB CAN SHLD
TO
/19.E4 SP3
-P031
L/H TURN SIGNAL DIODE
2.00 mm² 804 2.00 mm² 805B 2.00 mm² 805D DI L/H TO
/10.E4 RL002:3 / P039:D4
2 1 -SP8
-P032
R/H TURN SIGNAL DIODE
2.00 mm² 804C 2.00 mm² 806B 2.00 mm² 806C DI R/H TO
/10.D4 RL003:3 / P039:D3
2 1 -SP9
Page 33-50
160/G6925-2 Sheet 11
DI L/H 2.00 mm² 805F
P072:10 /9.D5 FROM
RUMENT CLUSTER DI R/H 2.00 mm² 806A

P072:20 /9.C5 FROM
33 - 51 9823/0300-1 33 - 51
33 - 52 9823/0300-1 33 - 52
Page 33-54 Figure 1075. Wiper Motor Page 33-55

CAN SHLD
SP28 /19.B6 TO
-P021
ROOF WIPER
SWITCH ILLUMINATION 1.00 mm² 829M 8 7 1.00 mm² 601BH
SP7 /18.D5 FROM
GROUNDTO
/19.F1 SRC5
1 2.00 mm² 854
2.00 mm² 849 2 -RC09
3 2.00 mm² 133E ROOF WIPER
4 2.00 mm² 601AR 1
5
6 2.00 mm² 901 2.00 mm² 133F 3
-
w
-P049 -RC01
+
2.00 mm² 854 2/20 2/20 2.00 mm² 854 2.00 mm² 854 2
2.00 mm² 849 3/20 3/20 2.00 mm² 849 2.00 mm² 849 4
2.00 mm² 925 5/20 5/20 2.00 mm² 925

CAN SHLD
SP28 /19.B6 TO
GROUNDTO
/19.E1 SRC5
-P022
REAR WASH WIPE
SWITCH ILLUMINATION 1.00 mm² 829AF 8 7 1.00 mm² 601DX -RC04
SP7 /18.D5 FROM
REAR WIPER
2.00 mm² 601AW 1
1 2.00 mm² 926 2.00 mm² 926 4/20 4/20 2.00 mm² 926
2.00 mm² 925 2 2.00 mm² 133B 1/20 1/20 2.00 mm² 133B 2.00 mm² 133D 3
-
3 -SRC3
w
2.00 mm² 133C
4 -SP16
+
5 2.00 mm² 926 2
6 2.00 mm² 901B 2.00 mm² 925 4
IGNITION +VE -RC18

P002:2 /3.D5 2.00 mm² 133
WASHER PUMPS
FROM
-P049 -RC01
1.50 mm² 839A 17/20 17/20 1.50 mm² 839 1/2
1.50 mm² 600WP 2/2
GROUND
TO
/19.E1 SRC6
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY 2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
-P055
FRONT WIPER MOTOR
L 10/14 1.50 mm² 983 4/8 1/8 2.00 mm² 600P CAN SHLD
/19.C1 SP61
1.50 mm² 110D
TO
14/14 INDICATORS
R 11/14 1.50 mm² 982 3/8
7/14 1.50 mm² 840 2/8 6/8 1.50 mm² 110D

IGNITION +VE 1.50 mm² 110 1.50 mm² 110E 1/14 WIPER 12/14 1.50 mm² 841 5/8
P002:4 /3.D5 FROM
-SP33
WASHER 6/14 7/8
1.50 mm² 839 1.50 mm² 839B
160/G6925-2 Sheet 12
-SP32
33 - 53 9823/0300-1 33 - 53
Page Page
33-54 33-55
Figure 1075. (Part 1 of 2) CAN SHLD

SP28 /19.B6 TO
-P021
ROOF WIPER
SWITCH ILLUMINATION 1.00 mm² 829M 8 7 1.00 mm² 601BH
SP7 /18.D5 FROM
1 2.00 mm² 854

2.00 mm² 849 2
3 2.00 mm² 133E
4
5
6 2.00 mm² 901
-P049 -RC01
2.00 mm² 854 2/20
2.00 mm² 849 3/20
2.00 mm² 925 5/20
CAN SHLD
SP28 /19.B6 TO
-P022
REAR WASH WIPE
SWITCH ILLUMINATION 1.00 mm² 829AF 8 7 1.00 mm² 601DX
SP7 /18.D5 FROM
1 2.00 mm² 926 2.00 mm² 926 4/20

2.00 mm² 925 2 2.00 mm² 133B 1/20
3 2.00 mm² 133C
4 -SP16
5
6 2.00 mm² 901B
Page 33-55
IGNITION +VE 2.00 mm² 133
P002:2 /3.D5 FROM
-P038
COLUMN SWITCH R/H
3/14
TWO SPEED
ONLY 2/14
4/14
13/14
8/14 HEADLIGHT
FLASHER
9/14
L 10/14 1.50 mm² 983

1.50 mm² 110D
14/14 INDICATORS
R 11/14 1.50 mm² 982
7/14 1.50 mm² 840

IGNITION +VE 1.50 mm² 110 1.50 mm² 110E 1/14 WIPER 12/14 1.50 mm² 841
P002:4 /3.D5 FROM
-SP33
WASHER 6/14 1.50 mm² 839
-SP32
33 - 54 9823/0300-1 33 - 54
Page Page
33-54 33-55
GROUNDTO
/19.F1 SRC5
-RC09
ROOF WIPER
2.00 mm² 601AR 1
2.00 mm² 133F 3
-
w
-P049 -RC01
+
854 2/20 2/20 2.00 mm² 854 2.00 mm² 854 2
849 3/20 3/20 2.00 mm² 849 2.00 mm² 849 4
925 5/20 5/20 2.00 mm² 925
GROUNDTO
/19.E1 SRC5
-RC04
REAR WIPER
2.00 mm² 601AW 1
926 4/20 4/20 2.00 mm² 926

133B 1/20 1/20 2.00 mm² 133B 2.00 mm² 133D 3
-
-SRC3
w
+
2.00 mm² 926 2
2.00 mm² 925 4

Page 33-54
-RC18
WASHER PUMPS
-P049 -RC01
1.50 mm² 839A 17/20 17/20 1.50 mm² 839 1/2
1.50 mm² 600WP 2/2
GROUND
TO
/19.E1 SRC6
-P055
FRONT WIPER MOTOR
4/8 1/8 2.00 mm² 600P CAN SHLD
TO
/19.C1 SP61
3/8
840 2/8 6/8 1.50 mm² 110D

5/8
7/8
839 1.50 mm² 839B
160/G6925-2 Sheet 12
-SP32
33 - 55 9823/0300-1 33 - 55
33 - 56 9823/0300-1 33 - 56
Page 33-58 Figure 1076. Worklights / Beacon Page 33-59

-P026
WORKLIGHTS
SWITCH ILLUMINATION 1.00 mm² 829J 8 7 1.00 mm² 601AC CAN SHLD
SP7 /18.C5 FROM TO
/19.B4 SP6
-P014
ENGINE RUNNING
4 1
CAN SHLD 1 2 2
SP3 /19.E4 TO
0.75 mm² 601LH 0.75 mm² 609LH 0.75 mm² 609LH
3 0.50 mm² 609AB 0.50 mm² 609AB FRONT WORKLIGHTS
TO
/9.B3 P040:7
D+ 1.00 mm² 407F 3 5 4 0.75 mm² 609AA
SP14 /4.D6 FROM
0.75 mm² 609RH 5

6 0.50 mm² 609BC 0.50 mm² 609BC REAR WORKLIGHTS
TO
/9.B3 P040:6
0.75 mm² 609BB
SP3 /19.E4 TO
0.50 mm² 610AB BOOM WORKLIGHTS

TO
/9.B3 P040:8
CAN SHLD 0.75 mm² 601TS -P029
P014:6 /9.B2 TO
BOOM WORKLIGHTS
SWITCH ILLUMINATION 1.00 mm² 829AJ 8 7 1.00 mm² 601KA CAN SHLD
SP7 /18.C5 FROM TO
/19.B4 SP6
0.75 mm² 610 2

3 0.50 mm² 610AB
0.75 mm² 610A
FRONT WORK LIGHTS DIODE

BOOM WORKLIGHTS
REAR WORK LIGHTS DIODE

2.00 mm² 947B
BOOM WORKLIGHT DIODE

TO
/10.D3 P064B:1
2
TO
/10.C3 P064A:1
-P128
-P129
-P130
-P012 -WLF003
FRONT WORKLIGHTS LH FRONT WORKLIGHT
1
4
-P051 -WLF001 -WLF001 -P051
BATT +VE 2.00 mm² 308 1 2 2.00 mm² 831 2.00 mm² 831 2.00 mm² 831B 1/4 2/4 2.00 mm² RED 1 2 2.00 mm² BLACK 4/4 3/4 2.00 mm² 601BU CAN SHLD
P004:10 /3.E7 FROM TO
/19.C1 SP61
-SP23
WORKLIGHTS 1.00 mm² 891 3 5 0.75 mm² 609A
P024:4 /10.C3 FROM
1.00 mm² 891A

-WLF002
RH FRONT WORKLIGHT
-P051 -WLF001 -WLF001 -P051

2.00 mm² 831K 2/4 1/4 2.00 mm² RED 1 2 2.00 mm² BLACK 3/4 4/4 2.00 mm² 601AL CAN SHLDTO
/19.C1 SP61
-P012 -WLR003
REAR WORKLIGHTS LH REAR WORKLIGHT
9
-P049 -RC01 -RC05 -WLR001 -WLR003 -WLR001 -RC05
BATT +VE 2.00 mm² 309 6 7 2.00 mm² 945 6/20 6/20 2.00 mm² 945 2.00 mm² 945A 1/2 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601DG GROUND
P004:12 /3.E7 FROM TO
/19.E1 SCR6
-SRC2
1.00 mm² 891A 8 10 0.75 mm² 609B
1.00 mm² 891B 1.00 mm² 609BC
2.00 mm² 947B
-P011 -WLR004
BOOM WORK LIGHTS RH REAR WORKLIGHT
9
-P127 -P127 -RC08 -WLR002 -WLR004 -WLR002 -RC08
1/2 0.75 mm² LINK 2/2 BATT +VE 2.00 mm² 312 6 7 2.00 mm² 947 2.00 mm² 945B 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601KG GROUND
P004:6 /3.E7 FROM TO
/19.E1 SCR6
-P126 ITALIAN HEAD LIGHTS (DEL) -P126 -SP31
IGNITION +VE 0.75 mm² 100QA 1/2 2/2 1.00 mm² 100QB 8 10 1.00 mm² 610B
P001:2 / SP20 /3.B7 FROM
1.00 mm² 891B
-P042
REAR HITCH LIGHT
4
-P039
IGNITION +VE 2.00 mm² 103A 1 2 2.00 mm² 830RH A9/84
P001:18 /3.E5 FROM
WORKLIGHTS 1.00 mm² 891R 3 5 1.00 mm² 609BC

P024:4 /10.C3 FROM
-B002
BOOM WORKLIGHT
-P028 A
-P039 -C004 -C032 -B001 -B001 -C032
BEACON SWITCH 2.00 mm² 947A A1/84 A1/84 2.00 mm² 947 1/6 1/6 2.00 mm² 947A 1 2 2.00 mm² 601GB 2/6 2/6 2.00 mm² 605BW GROUNDTO
/10.C5 SC16
SWITCH ILLUMINATION 1.00 mm² 829U 8 7 1.00 mm² 601AY CAN SHLD
SP7 /18.C5 FROM TO
/19.B4 SP6
-RC07
BATT +VE 1.00 mm² 310 2 BEACON SOCKET
P003:16 /3.B5 FROM
-P049 -RC01
3 1.00 mm² 844A 8/20 8/20 1.00 mm² 844A 2 1 1.00 mm² 601AX GROUND TO
/19.F1 SRC5
GND
160/G6925-2 Sheet 13
INTERIOR LIGHT
-P049 -RC01 -RC10 -RC11
BATT +VE 1.00 mm² 301J 9/20 9/20 1.00 mm² 301J 1/1 1/1 1.00 mm² 601AV GROUND
SP27 /3.A5 FROM TO
/19.F1 SRC5
33 - 57 9823/0300-1 33 - 57
Page Page
33-58 33-59
-P026
Figure 1076. (Part 1 of 2) WORKLIGHTS
SWITCH ILLUMINATION 1.00 mm² 829J 8 7 1.00 mm² 601AC CAN SHLD
SP7 /18.C5 FROM TO
/19.B4 SP6
-P014
ENGINE RUNNING
4 1
CAN SHLD 1 2 2
SP3 /19.E4 TO
0.75 mm² 601LH 0.75 mm² 609LH 0.75 mm² 609LH
3 0.50 mm² 609AB
D+ 1.00 mm² 407F 3 5 4 0.75 mm² 609AA
SP14 /4.D6 FROM
0.75 mm² 609RH 5

6 0.50 mm² 609BC
0.75 mm² 609BB
SP3 /19.E4 TO
CAN SHLD 0.75 mm² 601TS -P029

P014:6 /9.B2 TO
BOOM WORKLIGHTS
SWITCH ILLUMINATION 1.00 mm² 829AJ 8 7 1.00 mm² 601KA CAN SHLD
SP7 /18.C5 FROM TO
/19.B4 SP6
0.75 mm² 610 2

3 0.50 mm² 610AB
0.75 mm² 610A
FRONT WORK LIGHTS DIODE

2
2
-P128
-P129
-P130
-P012
FRONT WORKLIGHTS
1
4
BATT +VE 2.00 mm² 308 1 2 2.00 mm² 831
P004:10 /3.E7 FROM
WORKLIGHTS 1.00 mm² 891 3 5 0.75 mm² 609A

P024:4 /10.C3 FROM
1.00 mm² 891A
Page 33-59
-P012
REAR WORKLIGHTS
9
-P049
BATT +VE 2.00 mm² 309 6 7 2.00 mm² 945 6/20
P004:12 /3.E7 FROM
1.00 mm² 891A 8 10 0.75 mm² 609B

1.00 mm² 891B 1.00 mm² 609BC
2.00 mm² 947B

-P011
BOOM WORK LIGHTS
9
-P127 -P127
1/2 0.75 mm² LINK 2/2 BATT +VE 2.00 mm² 312 6 7 2.00 mm² 947
P004:6 /3.E7 FROM
-P126 ITALIAN HEAD LIGHTS (DEL) -P126 -SP31

IGNITION +VE 0.75 mm² 100QA 1/2 2/2 1.00 mm² 100QB 8 10 1.00 mm² 610B
P001:2 / SP20 /3.B7 FROM
1.00 mm² 891B
IGNITION +VE 2.00 mm² 103A

P001:18 /3.E5 FROM
WORKLIGHTS 1.00 mm² 891R

P024:4 /10.C3 FROM
-P028 A
BEACON SWITCH
SWITCH ILLUMINATION 1.00 mm² 829U 8 7 1.00 mm² 601AY CAN SHLD
SP7 /18.C5 FROM TO
/19.B4 SP6
-RC07
BATT +VE 1.00 mm² 310 2 BEACON SOCKET
P003:16 /3.B5 FROM
-P049 -RC01
3 1.00 mm² 844A 8/20 8/20 1.00 mm² 844A 2 1 1.00 mm² 601AX GROUND TO
/19.F1 SRC5
GND
INTERIOR LIGHT
-P049 -RC01 -RC10 -RC11
BATT +VE 1.00 mm² 301J 9/20 9/20 1.00 mm² 301J 1/1 1/1 1.00 mm² 601AV GROUND
SP27 /3.A5 FROM TO
/19.F1 SRC5
33 - 58 9823/0300-1 33 - 58
Page Page
33-58 33-59
0.50 mm² 609AB FRONT WORKLIGHTS

TO
/9.B3 P040:7
0.50 mm² 609BC REAR WORKLIGHTS

TO
/9.B3 P040:6
0.50 mm² 610AB BOOM WORKLIGHTS

TO
/9.B3 P040:8
BOOM WORKLIGHTS
2.00 mm² 947B

/10.D3 P064B:1
BOOM WORKLIGHT DIODE
TO
2

TO
/10.C3 P064A:1
-P130
-WLF003
LH FRONT WORKLIGHT
1
-P051 -WLF001 -WLF001 -P051

2.00 mm² 831 2.00 mm² 831B 1/4 2/4 2.00 mm² RED 1 2 2.00 mm² BLACK 4/4 3/4 2.00 mm² 601BU CAN SHLDTO
/19.C1 SP61
-SP23
-WLF002
RH FRONT WORKLIGHT
-P051 -WLF001 -WLF001 -P051

2.00 mm² 831K 2/4 1/4 2.00 mm² RED 1 2 2.00 mm² BLACK 3/4 4/4 2.00 mm² 601AL CAN SHLDTO
/19.C1 SP61
Page 33-58
-WLR003
LH REAR WORKLIGHT
-P049 -RC01 -RC05 -WLR001 -WLR003 -WLR001 -RC05

6/20 6/20 2.00 mm² 945 2.00 mm² 945A 1/2 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601DG GROUND TO
/19.E1 SCR6
-SRC2
-WLR004
RH REAR WORKLIGHT
-RC08 -WLR002 -WLR004 -WLR002 -RC08

2.00 mm² 945B 1/2 1/2 1 2 2/2 2/2 2.00 mm² 601KG GROUND TO
/19.E1 SCR6
-P042
REAR HITCH LIGHT
4
-P039
IGNITION +VE 2.00 mm² 103A 1 2 2.00 mm² 830RH A9/84
WORKLIGHTS 1.00 mm² 891R 3 5 1.00 mm² 609BC
-B002
BOOM WORKLIGHT
-P039 -C004 -C032 -B001 -B001 -C032
2.00 mm² 947A A1/84 A1/84 2.00 mm² 947 1/6 1/6 2.00 mm² 947A 1 2 2.00 mm² 601GB 2/6 2/6 2.00 mm² 605BW GROUNDTO
/10.C5 SC16
/19.F1 SRC5
160/G6925-2 Sheet 13
/19.F1 SRC5
33 - 59 9823/0300-1 33 - 59
33 - 60 9823/0300-1 33 - 60
Page 33-62 Figure 1077. HVAC Page 33-63

-RC03
AIR SEAT
-P049 -RC01
IGNITION +VE 2.00 mm² 151 7/20 7/20 2.00 mm² 151 2.00 mm² 151 1/2 2/2 2.00 mm² 601FK GROUND
P004:16 /3.E7 FROM TO
/19.E1 SRC5
-P013
AUXILIARY COOLING FAN -P039 -C004 -C006
4 COOLING FAN
BATT +VE 1.50 mm² 200ACF 1 2 1.50 mm² 102ACF B10/84 B10/84 1.50 mm² 102ACF 1/2 2/2 1.50 mm² 600ACF GROUND
P004:14 /3.E7 FROM TO
/20.B4 SC9
AUX COOLING FAN 1.00 mm² 800ACF 3 5 1.00 mm² 610ACF CAN SHLD
/6.E2 FROM TO
/19.C6 SP62
-P059
FACE LEVEL FAN
IGNITION +VE 1.50 mm² 151B 1/2 1/2 2/2 2/2 1.00 mm² 601DD CAN SHLD
P004:16 /3.E7 FROM TO
/19.C6 SP62
-P015
ROOF AC FANS
9
-P049
IGNITION +VE 2.00 mm² 116 6 7 2.00 mm² 2855 12/20
P001:6 /3.E5 FROM
-P015
AIR CON 2.00 mm² 886B 8 10 1.00 mm² 601KP CAN SHLD
-P049 TO
/19.D4 SP29
4 2.00 mm² 2856 15/20
IGNITION +VE 2.00 mm² 997 1 2 2.00 mm² 883
P001:14 /3.E5 FROM
AC 1.00 mm² 884AC 3 5 1.00 mm² 601AC CAN SHLD

/19.C4 SP29
-P039 -C004
C11/84 C11/84 2.00 mm² 885
-P042 -E024-1 -E024-2 -E025

-P033 FREEZE VALVE BINARY SWITCH AC COMPRESSOR
HEATER CONNECTOR 9
2.00 mm² 883
-P039 -C004
IGNITION +VE 2.00 mm² 102 3/6 4/6 2.00 mm² 883A 6 7 2.00 mm² 884A A12/84 A12/84 2.00 mm² 884 1/1 1 2 1/1 2.00 mm² 886D 2.00 mm² 886C 1/2 2/2 2.00 mm² 604AC GROUND
P001:10 /3.E5 FROM TO
/20.D4 SE07
-SE03
M10 8 10 CAN SHLD
-P025 2.00 mm² 600T 1/6 5/6 2.00 mm² 884 1.00 mm² 601FV
HEATER GROUND TO
/19.D4 SP29
1.00 mm² 801 2/6 6/6
-P112
HEATER 100R
HEATER 1 2 CAN SHLD
P072:9 /9.D5 TO
1.00 mm² 801A 1.00 mm² 801B 1.00 mm² 601HT TO
/19.E6 SP11
-SP50
-P019
AIR CON SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AC 8 7 1.00 mm² 601AC CAN SHLD
SP7 /18.E5 FROM TO
/19.C4 SP6
-P019A
AC/BLOWER SWITCH 1.00 mm² 610 -SP13 1.00 mm² 610AC 2 AIR CON SWITCH 1K RES
P071:15 /9.D3 TO
3 1.00 mm² 887 1 2 1.00 mm² 887A AC

FROM
/9.E5 P072:5
-P052
BLOWER SWITCH
SWITCH ILLUMINATION 1.00 mm² 829BL 8 7 1.00 mm² 601BL CAN SHLD
SP7 /18.D5 FROM TO
/19.B4 SP6
-P052B
HEATER BLOWER RES 3.3K
1 1.00 mm² 803A 1 2 1.00 mm² 997B -SP17 1.00 mm² 997 AC/BLOWER SWITCH 160/G6925-2 Sheet 14
FROM
/9.C5 P072:18
1.00 mm² 610A 2
3
4
5 -P052A
1.00 mm² 610B HEATER BLOWER RES 2K
6 1.00 mm² 802A 1 2 1.00 mm² 997A
33 - 61 9823/0300-1 33 - 61
Page Page
33-62 33-63

P004:16 /3.E7 FROM
-P013
AUXILIARY COOLING FAN -P039 -C004 -C006
4 COOLING FAN
BATT +VE 1.50 mm² 200ACF 1 2 1.50 mm² 102ACF B10/84 B10/84 1.50 mm² 102ACF 1/2 2/2 1.50 mm² 600ACF GROUND
P004:14 /3.E7 FROM TO
/20.B4 SC9
AUX COOLING FAN 1.00 mm² 800ACF 3 5 1.00 mm² 610ACF CAN SHLD
/6.E2 FROM TO
/19.C6 SP62
IGNITION +VE 1.50 mm² 151B

P004:16 /3.E7 FROM
IGNITION +VE 2.00 mm²

P001:6 /3.E5 FROM
-P015
AIR CON 2.00 mm²
-P049
4 2.00 mm² 2856 15/20
IGNITION +VE 2.00 mm² 997 1 2 2.00 mm² 883
P001:14 /3.E5 FROM
AC 1.00 mm² 884AC 3 5 1.00 mm² 601AC CAN SHLD

/19.C4 SP29
-P039 -C004
C11/84 C11/84 2.00 mm²
-P042
-P033 FREEZE VALVE
HEATER CONNECTOR 9
2.00 mm² 883
-P039 -C004
IGNITION +VE 2.00 mm² 102 3/6 4/6 2.00 mm² 883A 6 7 2.00 mm² 884A A12/84 A12/84
P001:10 /3.E5 FROM
M10 8 10 CAN SHLD

-P025 2.00 mm² 600T 1/6 5/6 2.00 mm² 884 1.00 mm² 601FV
HEATER GROUND TO
/19.D4 SP29
1.00 mm² 801 2/6 6/6
-P112
HEATER 100R
HEATER 1 2 CAN SHLD
Page 33-63
P072:9 /9.D5 TO
1.00 mm² 801A 1.00 mm² 801B 1.00 mm² 601HT TO
/19.E6 SP11
-SP50
-P019
AIR CON SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AC 8 7 1.00 mm² 601AC
SP7 /18.E5 FROM
-P019A
AC/BLOWER SWITCH 1.00 mm² 610 -SP13 1.00 mm² 610AC 2 AIR CON SWITCH 1K RES
P071:15 /9.D3 TO
3 1.00 mm² 887 1 2
-P052
BLOWER SWITCH
SWITCH ILLUMINATION 1.00 mm² 829BL 8 7 1.00 mm² 601BL
SP7 /18.D5 FROM
-P052B
1 1.00 mm² 803A 1 2
1.00 mm² 610A 2

3
4
5 -P052A
1.00 mm² 610B HEATER BLOWER RES 2K
6 1.00 mm² 802A 1 2
33 - 62 9823/0300-1 33 - 62
Page Page
33-62 33-63
-RC03
Figure 1077. (Part 2 of 2) AIR SEAT
-P049 -RC01
IGNITION +VE 2.00 mm² 151 7/20 7/20 2.00 mm² 151 2.00 mm² 151 1/2 2/2 2.00 mm² 601FK GROUND TO
/19.E1 SRC5
/20.B4 SC9
-P059
FACE LEVEL FAN
IGNITION +VE 1.50 mm² 151B 1/2 1/2 2/2 2/2 1.00 mm² 601DD CAN SHLD
TO
/19.C6 SP62
-P015
ROOF AC FANS
9
-P049
IGNITION +VE 2.00 mm² 116 6 7 2.00 mm² 2855 12/20
2.00 mm² 886B 8 10 1.00 mm² 601KP CAN SHLD TO

/19.D4 SP29
-C004
C11/84 2.00 mm² 885
-E024-1 -E024-2 -E025

BINARY SWITCH AC COMPRESSOR
-C004
A12/84 2.00 mm² 884 1/1 1 2 1/1 2.00 mm² 886D 2.00 mm² 886C 1/2 2/2 2.00 mm² 604AC GROUND
TO
/20.D4 SE07
-SE03
/19.D4 SP29
Page 33-62
/19.E6 SP11
CAN SHLD TO
/19.C4 SP6
-P019A
AIR CON SWITCH 1K RES
2 1.00 mm² 887A AC
FROM
/9.E5 P072:5
CAN SHLD
TO
/19.B4 SP6
-P052B
2 1.00 mm² 997B -SP17 1.00 mm² 997 AC/BLOWER SWITCH 160/G6925-2 Sheet 14
FROM
/9.C5 P072:18
-P052A
HEATER BLOWER RES 2K
2 1.00 mm² 997A
33 - 63 9823/0300-1 33 - 63
33 - 64 9823/0300-1 33 - 64
Page 33-66 Figure 1078. In Cab Entertainment Page 33-67

-P058 -RH01 L/H SPEAKER
IGNITION +VE 1.00 mm² 181 1/4 1/4 1.00 mm² 181 -RH02 -RH03
P003:8 /3.E7 FROM
-RH04
1.00 mm² 445 1/1 +
RADIO
BATT +VE 1.00 mm² 301F 2/4 2/4 1.00 mm² 301F
P002:18 / SP27 /3.A5 FROM
-RH05
A2 SPEED A1 1.00 mm² 446 1/1 -
MUTE SIGNAL
SWITCH ILLUMINATION 1.00 mm² 829AM 3/4 3/4 1.00 mm² 829AM 1.00 mm² 301F A4 A3
SP7 /18.C5 FROM
BATT + N/C
1.00 mm² 829AM A6 AUTO A5
ILLUM
CAN SHLD A8 ANNA A7
SP3 /19.E4 TO
1.00 mm² 601RD 4/4 4/4 1.00 mm² 601AG 1.00 mm² 601AG GND IGN 1.00 mm² 181
B2 B1
RR(-) RR(+)
1.00 mm² 448 B4 B3 1.00 mm² 447
RF(-) RF(+)
1.00 mm² 446 B6 B 1.00 mm² 445
LF(-) LF(+)
B8 B7
LR(-) LR(+) R/H SPEAKER
-RH06
1.00 mm² 447 1/1 +
-RH07
1.00 mm² 448 1/1 -
-RC17
SEAT PRESSURE SWITCH
4 4/6 1.00 mm² 847SS
-P049 -RC01 -SRC4
Channel 1 (NC)
IGNITION +VE 1.00 mm² 107SP 14/20 14/20 1.00 mm² 107SS 1.00 mm² 107SA 1/6 1 Supply 5 5/6 1.00 mm² 846SS
P003:10 /3.B5 FROM
(12Vdc)
Channel 2 (NO)
1.00 mm² 107SB 2/6 6 GROUND

6/6 1.00 mm² 601SP
1.00 mm² 107SC 3/6
GND TO
/19.F1 SRC5
-P049 -RC01
SEAT PRESSURE 1.00 mm² 846SS 20/20 20/20 1.00 mm² 846SS
P069:9 /21.D3 TO
-P049 -RC01
P069:10 /21.D3 TO
160/G6925-2 Sheet 15
-P065
AUXILLIARY CONNECTOR
IGNITION +VE 1.00 mm² 121 1 2 1.00 mm² 601KC CAN SHLD
/19.B6 SP28
GND
-C054
AUXILLIARY SOCKET
-P039 -C004
BATT +VE 2.00 mm² 303AU C3/84 C3/84 2.00 mm² 303AU 1/2 1 2 2/2 2.00 mm² 614 GROUND
P002:16 /3.C5 FROM TO
/20.B4 SC9
GND
33 - 65 9823/0300-1 33 - 65
Page Page
33-66 33-67

-P058 -RH01
IGNITION +VE 1.00 mm² 181 1/4 1/4 1.00 mm² 181 -RH02
P003:8 /3.E7 FROM
BATT +VE 1.00 mm² 301F 2/4 2/4 1.00 mm² 301F
P002:18 / SP27 /3.A5 FROM
SWITCH ILLUMINATION 1.00 mm² 829AM 3/4 3/4 1.00 mm² 829AM 1.00 mm² 301F
SP7 /18.C5 FROM
1.00 mm² 829AM

CAN SHLD
SP3 /19.E4 TO
1.00 mm² 601RD 4/4 4/4 1.00 mm² 601AG 1.00 mm² 601AG
1.00 mm² 448

1.00 mm² 446
-P049 -RC01 -SRC4

IGNITION +VE 1.00 mm² 107SP 14/20 14/20 1.00 mm² 107SS 1.00 mm² 107SA
P003:10 /3.B5
Page 33-67
FROM
1.00 mm² 107SB

1.00 mm² 107SC
-P049 -RC01
P069:9 /21.D3 TO
-P049 -RC01
P069:10 /21.D3 TO

P001:6 /3.F5 FROM
-P039 -C004
BATT +VE 2.00 mm² 303AU C3/84 C3/84 2.00 mm² 303AU
P002:16 /3.C5 FROM
33 - 66 9823/0300-1 33 - 66
Page Page
33-66 33-67
-RH03 L/H SPEAKER

-RH02 -RH04
1.00 mm² 445 1/1 +
RADIO
-RH05
A2 SPEED A1 1.00 mm² 446 1/1 -
MUTE SIGNAL
1.00 mm² 301F A4 A3
BATT + N/C
1.00 mm² 829AM A6 AUTO A5
ILLUM
A8 ANNA A7
1.00 mm² 601AG GND IGN 1.00 mm² 181
B2 B1
RR(-) RR(+)
1.00 mm² 448 B4 B3 1.00 mm² 447
RF(-) RF(+)
1.00 mm² 446 B6 B 1.00 mm² 445
LF(-) LF(+)
B8 B7
LR(-) LR(+) R/H SPEAKER
-RH06
1.00 mm² 447 1/1 +
-RH07
1.00 mm² 448 1/1 -
-RC17
SEAT PRESSURE SWITCH
4
Channel 1 (NC) 4/6 1.00 mm² 847SS
1.00 mm² 107SA 1/6 1 Supply 5
Channel 2 (NO) 5/6 1.00 mm² 846SS
Page 33-66
(12Vdc)
1.00 mm² 107SB 2/6 6 GROUND

6/6 1.00 mm² 601SP
1.00 mm² 107SC 3/6
GND TO
/19.F1 SRC5
1.00 mm² 846SS
1.00 mm² 847SS
160/G6925-2 Sheet 15
-P065
AUXILLIARY CONNECTOR
121 1 2 1.00 mm² 601KC CAN SHLD
TO
/19.B6 SP28
GND
-C054
AUXILLIARY SOCKET
303AU 1/2 1 2 2/2 2.00 mm² 614 GROUND TO
/20.B4 SC9
GND
33 - 67 9823/0300-1 33 - 67
33 - 68 9823/0300-1 33 - 68
Page 33-70 Figure 1079. Reverse Fan Page 33-71

-E012
CAN SHLD REV FAN
SP6 /19.B4 TO
-P039 -C004
REV FAN SOL 1.00 mm² 1840 A10/84 A10/84 1.00 mm² 1840 1/2
P071:12 /9.D3 FROM
-P061 GROUND 1.00 mm² 604T 2/2

SC7 /20.D4 TO
REVERSE FAN
SWITCH ILLUMINATION 1.00 mm² 829AL 8 7 1.00 mm² 601AL
SP7 /18.D5 FROM
1
IGNITION +VE 2 -E013
SP20 /3.A7 1.00 mm² 100P
PROPORTIONAL FAN
FROM
3 1.00 mm² 1840D REV FAN SW

TO
/9.C3 P071:18 -P039 -C004
4 PROPORTIONAL FAN 1.00 mm² 592
P072:19 F6/84 F6/84 1.00 mm² 592 1/2
5
/9.C5 FROM
1.00 mm² 100 PA

6 1.00 mm² 1840C REV FAN SW GROUND
TO
/9.E5 P072:6 SC7 /20.D4 TO 1.00 mm² 604F 2/2
160/G6925-2 Sheet 16
33 - 69 9823/0300-1 33 - 69
Page Page
33-70 33-71

CAN SHLD
SP6 /19.B4 TO
P071:12
-P061
REVERSE FAN
SWITCH ILLUMINATION 1.00 mm² 829AL 8 7 1.00 mm² 601AL
SP7 /18.D5 FROM
1
IGNITION +VE 1.00 mm² 100P 2
SP20 /3.A7 FROM
3 1.00 mm² 1840D REV FAN SW

TO
/9.C3 P071:18
4
P072:19
1.00 mm² 100 PA 5
6 1.00 mm² 1840C REV FAN SW
TO
/9.E5 P072:6
Page 33-71
33 - 70 9823/0300-1 33 - 70
Page Page
33-70 33-71
Figure 1079. (Part 2 of 2) -E012

REV FAN
-P039 -C004
REV FAN SOL 1.00 mm² 1840 A10/84 A10/84 1.00 mm² 1840 1/2
P071:12 /9.D3 FROM
GROUND 1.00 mm² 604T 2/2

SC7 /20.D4 TO
-E013
PROPORTIONAL FAN
-P039 -C004
PROPORTIONAL FAN 1.00 mm² 592 F6/84 F6/84 1.00 mm² 592 1/2
P072:19 /9.C5 FROM
GROUND 1.00 mm² 604F 2/2

SC7 /20.D4 TO
160/G6925-2 Sheet 16
Page 33-70
33 - 71 9823/0300-1 33 - 71
33 - 72 9823/0300-1 33 - 72
Page 33-74 Figure 1080. Can Bus Page 33-75
/9.D3 TO INSTRUMENT CLUSTER J1
/9.E3 TO INSTRUMENT CLUSTER J1
TO DAILY CHECKS
TO DAILY CHECKS
TO LIVE LINK
TO LIVE LINK
/28.E2 TO LLMI CAN
/28.E2 TO LLMI CAN
/28.E2 TO LLMI CAN

TO LIVELINK
P042-B:C
P042-B:B
P042-B:A
P068:11
P068:2
P137:4
P137:3
P068:1
P071:8
P071:7
/8.D2
/8.D2
/8.D2
/6.E5
/6.E5
-SCREEN 9 -SCREEN 7
TO
TO
TO
TO
TO
TO
TO
TO
TO
TO
CAN SHLD
CAN SHLD
CAN LO
CAN LO
CAN LO
CAN LO
CAN HI
CAN HI
CAN HI
CAN HI
VEHICLE BUS (250KB/S)
0.50 mm² CAN 10 SCR

0.50 mm² CAN 5 SCR
0.50 mm² CAN 7 SCR
0.50 mm² CAN SCR

0.50 mm² CAN 10 H
0.50 mm² CAN 10 L

0.50 mm² CAN 5 H
0.50 mm² CAN 7 H

0.50 mm² CAN 5 L
0.50 mm² CAN 7 L
0.50 mm² CAN H
0.50 mm² CAN L

CAN INTERFACE
CAN TERMINATOR RES
CAN TERMINATION
-P074 -SVMC01 -P039 -C004 -SVMC19 -C051
A A/3 0.50 mm² CAN 1 H 0.50 mm² CAN 3 H 0.50 mm² CAN 4 H 0.50 mm² CAN 6 H 0.50 mm² CAN 8 H 0.50 mm² CAN 11 H G12/84 G12/84 0.50 mm² CAN H 0.50 mm² CAN H A/3 A
-SVMC04 -SVMC07 -SVMC10 -SVMC13 -P039 -C004

B -SVMC02 -SVMC20 B
B/3 0.50 mm² CAN 1 L 0.50 mm² CAN 3 L 0.50 mm² CAN 4 L 0.50 mm² CAN 6 L 0.50 mm² CAN 8 L 0.50 mm² CAN 11 L G11/84 G11/84 0.50 mm² CAN L 0.50 mm² CAN L B/3
C C/3 -SVMC05 -SVMC08 -SVMC11 -SVMC14 0.50 mm² SCR C/3 C
-SVMC03 -P039 -C004 -SVMC21
0.50 mm² CAN 1 SCR 0.50 mm² CAN 3 SCR 0.50 mm² CAN 4 SCR 0.50 mm² CAN 6 SCR 0.50 mm² CAN 8 SCR 0.50 mm² CAN 11 SCR G10/84 G10/84 0.50 mm² SCR
-SVMC06 -SVMC09 -SVMC12 -SVMC15
0.50 mm² CAN SCR
TO 07/11 CONNECTOR 2 CAN HI 0.50 mm² CAN H 2.00 mm² SCR CAN SHLD TO GROUND
0.50 mm² CAN H
/21.D5 /19.B1
0.50 mm² CAN L
TO TO
FROM FUSE 19B BATT +VE P070:10 SPLICE SP61

/3.A5 FROM
P002:18 / SP27 TO 07/11 CONNECTOR 2 CAN LO 0.50 mm² CAN L

/21.E5 TO
TO GROUND CAN SHLD P070:4

/19.D6 TO
SPLICE SP11 0.50 mm² CAN SCR

-PC01-V
-SCREEN 8
1/2 0.50 mm² CAN H CAN HI TO HYDRAULICS ECU J4
-P073
TO
/22.C2
C049:18
DIAGNOSTIC CONNECTOR CAN LO TO HYDRAULICS ECU J4
2/2 0.50 mm² CAN L TO
/22.D2
A/9 1.00 mm² 601C
C049:12
0.50 mm² SCR CAN SHLD TO HYDRAULICS ECU J4
-SCREEN 1 TO
/22.C1
B/9 1.00 mm² 301M
C049:16
-P0D1
E/9 C/9 1/2 MATE TO PC01-V 0.50 mm² CAN H CAN HI TO HYDRAULICS ECU J4
TO
/22.C2
C049:17
F/9 OR PC02-P
CAN HI TO HYDRAULICS ECU J4
G/9 D/9 2/2 FOR CAN 0.50 mm² CAN L TO
/22.D2
C049:11
COMMUNICATION CAN SHLD TO HYDRAULICS ECU J4
0.50 mm² SCR TO
/22.D1
-SCREEN 4 -SCREEN 2 C049:5
H/9
J/9
-PC02-P TO JOYSTICK CAN H CAN HI 0.50 mm² CAN H
/30.D3 TO
1/2
C014:28
TO JOYSTICK CAN L CAN HI 0.50 mm² CAN L
/30.D3 TO
2/2
C014:29
TO JOYSTICK CAN SCR CAN SHLD 0.50 mm² SCR
POWERTRAIN BUS (250KB/S)

/30.D3 TO
C014:17
-SCREEN 5
0.50 mm² CAN SCR
2.00 mm² SCR CAN SHLD TO GROUND

0.50 mm² CAN H
/19.B1
0.50 mm² CAN L
TO
SPLICE SP61
CHASSIS CONNECTOR ENGINE POD CONNECTOR
-P125
-P039 -C004
A -SPMC10 CAN HI TO ENGINE ECU
TERMINATOR
A/3 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H G9/84 G9/84 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H TO
/5.E3
-SPMC16 -SPMC07 -SPMC04 -SPMC01 E030:D1
-P039 -C004
B B/3 0.50 mm² CAN L 0.50 mm² CAN L -SPMC11 0.50 mm² CAN L G8/84 G8/84 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L CAN HI TO ENGINE ECU
TO
/5.E3
C C/3 -SPMC17 -SPMC08 -SPMC05 -SPMC02 E030:D2
-P039 -C004
0.50 mm² SCR 0.50 mm² SCR -SPMC12 0.50 mm² SCR G7/84 G7/84 0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR
-SPMC18 -SPMC09 -SPMC06 -SPMC03
0.50 mm² CAN H
0.50 mm² CAN L

0.50 mm² SCR
0.50 mm² SCR -E034 M10
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
B
C
A
-SCREEN 3
160/G6925-2 Sheet 17
CAN HI
CAN HI
-E010
TO
TO
TERMINATOR RESISTOR
/8.B5
/8.B5
P066:10
P066:9
TO IMMOBILISER
TO IMMOBILISER
33 - 73 9823/0300-1 33 - 73
Page Page
33-74 33-75
/9.D3 TO INSTRUMENT CLUSTER J1
/9.E3 TO INSTRUMENT CLUSTER J1
TO DAILY CHECKS
TO DAILY CHECKS
TO LIVE LINK
TO LIVE LINK
TO LIVELINK
P068:11
P068:2
P137:4
P068:1
P071:8
P071:7
/8.D2
/8.D2
/8.D2
/6.E5
-SCREEN 9
TO
TO
TO
TO
TO
TO
CAN SHLD
CAN LO
CAN LO
CAN LO
CAN HI
CAN HI
CAN HI
0.50 mm² CAN 5 SCR
0.50 mm² CAN 7 SCR
0.50 mm² CAN 10 H
0.50 mm² CAN 10 L

0.50 mm² CAN 5 H
0.50 mm² CAN 7 H

0.50 mm² CAN 5 L
0.50 mm² CAN 7 L

CAN TERMINATOR RES
-P074 -SVMC01
A A/3 0.50 mm² CAN 1 H 0.50 mm² CAN 3 H 0.50 mm² CAN 4 H 0.50 mm² CAN 6 H
-SVMC04 -SVMC07 -SVMC10
B -SVMC02
B/3 0.50 mm² CAN 1 L 0.50 mm² CAN 3 L 0.50 mm² CAN 4 L 0.50 mm² CAN 6 L
C C/3 -SVMC05 -SVMC08
-SVMC03
0.50 mm² CAN 1 SCR 0.50 mm² CAN 3 SCR 0.50 mm² CAN 4 SCR 0.50 mm² CAN 6 SCR
-SVMC06 -SVMC09
0.50 mm² CAN SCR
TO 07/11 CONNECTOR 2 CAN HI 0.50 mm² CAN H

0.50 mm² CAN H
/21.D5
0.50 mm² CAN L
TO
FROM FUSE 19B BATT +VE P070:10

/3.A5 FROM
P002:18 / SP27 TO 07/11 CONNECTOR 2 CAN LO 0.50 mm² CAN L

/21.E5 TO
TO GROUND CAN SHLD P070:4

/19.D6 TO
SPLICE SP11 0.50 mm² CAN SCR

-PC01-V
-SCREEN 8
1/2
-P073
DIAGNOSTIC CONNECTOR
2/2
A/9 1.00 mm² 601C
-SCREEN 1
B/9 1.00 mm² 301M
-P0D1
E/9 C/9 1/2 MATE TO PC01-V
Page 33-75
F/9 OR PC02-P
G/9 D/9 2/2 FOR CAN
COMMUNICATION
-SCREEN 4 -SCREEN 2
H/9
J/9
-PC02-P TO JOYSTICK CAN H
1/2
TO JOYSTICK CAN L
2/2
TO JOYSTICK CAN SCR
-SCREEN 5
0.50 mm² CAN SCR

0.50 mm² CAN H
/19.B1
0.50 mm² CAN L
TO
SPLICE SP61
CHASSIS CONNECT
-P125
-P039 -C004
A -SPMC10
TERMINATOR
A/3 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H G9/84 G9/84
-SPMC16 -P039 -C004
B B/3 0.50 mm² CAN L 0.50 mm² CAN L -SPMC11 0.50 mm² CAN L G8/84 G8/84
C C/3 -SPMC17 -P039 -C004
0.50 mm² SCR 0.50 mm² SCR -SPMC12 0.50 mm² SCR G7/84 G7/84
-SPMC18
0.50 mm² CAN H
0.50 mm² CAN L
0.50 mm² SCR
-SCREEN 3
CAN HI
CAN HI
TO
TO
/8.B5
/8.B5
P066:10
P066:9
TO IMMOBILISER
TO IMMOBILISER
33 - 74 9823/0300-1 33 - 74
Page Page
33-74 33-75

TO DAILY CHECKS
TO DAILY CHECKS
/28.E2 TO LLMI CAN
/28.E2 TO LLMI CAN
/28.E2 TO LLMI CAN

P042-B:C
P042-B:B
P042-B:A
P137:4
P137:3
/6.E5
/6.E5
-SCREEN 7
TO
TO
TO
TO
TO
CAN SHLD
CAN LO
CAN LO
CAN HI
CAN HI
VEHICLE BUS (250KB/S)

0.50 mm² CAN 10 SCR
0.50 mm² CAN SCR

0.50 mm² CAN 10 H
0.50 mm² CAN 10 L
0.50 mm² CAN H
0.50 mm² CAN L
CAN INTERFACE
CAN TERMINATION
-P039 -C004 -SVMC19 -C051
0.50 mm² CAN 8 H 0.50 mm² CAN 11 H G12/84 G12/84 0.50 mm² CAN H 0.50 mm² CAN H A/3 A
-SVMC10 -SVMC13 -P039 -C004 -SVMC20 B

0.50 mm² CAN 8 L 0.50 mm² CAN 11 L G11/84 G11/84 0.50 mm² CAN L 0.50 mm² CAN L B/3
-SVMC11 -SVMC14 0.50 mm² SCR C/3 C
-P039 -C004 -SVMC21
CAN 6 SCR 0.50 mm² CAN 8 SCR 0.50 mm² CAN 11 SCR G10/84 G10/84 0.50 mm² SCR
-SVMC12 -SVMC15

TO
/19.B1
SPLICE SP61
0.50 mm² CAN H CAN HI TO HYDRAULICS ECU J4

TO
/22.C2
C049:18
0.50 mm² CAN L CAN LO TO HYDRAULICS ECU J4
TO
/22.D2
C049:12
TO
/22.C1
C049:16
0.50 mm² CAN H CAN HI TO HYDRAULICS ECU J4

/22.C2
Page 33-74
TO
C049:17
0.50 mm² CAN L CAN HI TO HYDRAULICS ECU J4
TO
/22.D2
C049:11
TO
/22.D1
C049:5
TO JOYSTICK CAN H CAN HI 0.50 mm² CAN H

/30.D3 TO
C014:28
TO JOYSTICK CAN L CAN HI 0.50 mm² CAN L
/30.D3 TO
C014:29
TO JOYSTICK CAN SCR CAN SHLD 0.50 mm² SCR
POWERTRAIN BUS (250KB/S)

/30.D3 TO
C014:17
CHASSIS CONNECTOR ENGINE POD CONNECTOR
-C004
G9/84 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H 0.50 mm² CAN H CAN HI TO ENGINE ECU
TO
/5.E3
-SPMC07 -SPMC04 -SPMC01 E030:D1
-C004
G8/84 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L 0.50 mm² CAN L CAN HI TO ENGINE ECU
TO
/5.E3
-SPMC08 -SPMC05 -SPMC02 E030:D2
-C004
G7/84 0.50 mm² SCR 0.50 mm² SCR 0.50 mm² SCR
-SPMC09 -SPMC06 -SPMC03
0.50 mm² CAN H
0.50 mm² CAN L

0.50 mm² SCR
0.50 mm² SCR -E034 M10

B
C
A
160/G6925-2 Sheet 17
-E010
TERMINATOR RESISTOR
33 - 75 9823/0300-1 33 - 75
Figure 1081. Switch Illumination
1.00 mm² 829AX SWITCH ILLUMINATION

TO
/25.C2 P036:8
1.00 mm² 829AC SWITCH ILLUMINATION

TO
/14.C2 P019:8
1.00 mm² 829X SWITCH ILLUMINATION

TO
/25.E2 P017:8
1.00 mm² 829AL SWITCH ILLUMINATION

TO
/16.F2 P061:8
1.00 mm² 829AB SWITCH ILLUMINATION

TO
/9.E3 P071:1
1.00 mm² 829AH SWITCH ILLUMINATION

TO
/9.E7 P063:8
1.00 mm² 829BL SWITCH ILLUMINATION

TO
/14.B2 P052:8
1.00 mm² 829AE SWITCH ILLUMINATION

TO
/10.F2 P023:8
1.00 mm² 829AF SWITCH ILLUMINATION

TO
/12.E3 P022:8
SWITCH ILLUMINATION -SP7 SWITCH ILLUMINATION
P002:12 /3.C5 FROM
1.50 mm² 829E 1.00 mm² 829M TO
/12.F3 P021:8
1.00 mm² 829A SWITCH ILLUMINATION

TO
/10.C4 P039:D11
1.00 mm² 829J SWITCH ILLUMINATION

TO
/13.F2 P026:8
1.00 mm² 829U SWITCH ILLUMINATION

TO
/13.B1 P028:8
1.00 mm² 829AM SWITCH ILLUMINATION

TO
/15.E2 P058:3
0.50 mm² 829WL SWITCH ILLUMINATION

TO
/9.B3 P040:1
1.00 mm² 829V SWITCH ILLUMINATION

TO
/21.B4 P027:8
1.00 mm² 829AJ SWITCH ILLUMINATION

TO
/13.E2 P029:8
1.00 mm² 829AR SWITCH ILLUMINATION

TO
/27.E2 P062:8
1.00 mm² 829Y SWITCH ILLUMINATION

TO
/30.F2 P018:8
160/G6925-2 Sheet 18
33 - 76 9823/0300-1 33 - 76
Page 33-78 Figure 1082. Ground Panel Page 33-79

CAN SHLD 0.75 mm² 601HB
P006:5 /3.D2 FROM
GROUND 1.00 mm² 601SP

RC012:6 /15.C5 FROM
CAN SHLD 0.75 mm² 601EK

P006:10 /3.D2 FROM

RC011:1 /13.A4 FROM

P007:10 /3.C2 FROM
GROUND 1.00 mm² 601AX

RC007:2 /13.B4 FROM
CAN SHLD 0.75 mm² 601HL

P007:5 /3.C2 FROM
GROUND 2.00 mm² 601AR 6.00 mm² 601RC1

RC009:1 /12.F6 FROM
CAN SHLD
-SRC5 P008:10 /3.A2 FROM 0.75 mm² 601X
CAN SHLD 0.75 mm² 601JJ

P008:5 /3.B2 FROM
GROUND 1.50 mm² 600WP

RC18:2 /12.C6
-SP3
FROM
CAN SHLD 1.00 mm² 601TS 3.00 mm² 601JC

P101:10 /8.D4 FROM
GROUND 2.00 mm² 601AW

RC004:1 /12.E6 FROM
CAN SHLD 0.75 mm² 601LH

P014:1 /13.F1 FROM
GROUND 2.00 mm² 601FK

RC003:2 /14.F7 FROM

P014:5 /13.E1 FROM
GROUND 2.00 mm² 601DG

RC005:2 /13.C7 FROM
CAN SHLD 1.00 mm² 601RD

P058:4 /15.E2 FROM
GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC
RC008:2 /13.C7 FROM
-RC06 M10 CAN SHLD CAN SHLD

-SRC6 -SRC7 P013:5 /8.C1 FROM 1.00 mm² 601LL P072:17 /9.C5 FROM 1.00 mm² 601DE
CAN SHLD 0.75 mm² 601SY CAN SHLD 1.00 mm² 601HT
P016:5 /11.E6 FROM
P112:2 /14.C4 FROM
HYD ECU SENSOR GND 0.75 mm² 699CE

SP43 /30.E6 FROM
-SP11
CAN SHLD 0.75 mm² 601JB CAN SHLD 0.75 mm² 601AD 3.00 mm² 601JE
P016:10 /11.E6 FROM
P020:7 /11.D3 FROM
HYD ECU SENSOR GND 1.00 mm² 699SK

SP44 /25.C5 FROM
CAN SHLD 0.75 mm² 601NS CAN SHLD 1.00 mm² 601HP
P010:5 /4.E2 FROM
P063:7 /9.F7 FROM
HYD ECU SENSOR GND 1.00 mm² 699CH

P095:3 /26.D1 FROM
CAN SHLD 0.75 mm² 601BL CAN SHLD 1.00 mm² 601C
P011:5 /10.F6 FROM
P073:A /17.D1 FROM
HYD ECU SENSOR GND 1.00 mm² 699SJ

P095:6 /26.D1 FROM
CAN SHLD 1.00 mm² 601DZ

P036:7 /25.D2 FROM
HYD ECU SENSOR GND 0.75 mm² 699CB

P091:2 /29.E5 FROM
HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND
/22.B7 SC9 / P039:F7
HYD ECU SENSOR GND 0.75 mm² 699CD
P087:2 /21.B7 FROM
HYD ECU SENSOR GND 1.00 mm² 699CG

SP2 /27.E4 FROM

P067:10 /14.D4 FROM

P111:2 /29.B6
-SP29 -SP62 -P030
FROM
CAN SHLD M10

P015:10 /14.D5 FROM 1.00 mm² 601KP 3.00 mm² 601JH 10.00 mm² 600

P013:10 /10.B1 FROM

P015:5 /14.D3 FROM

P070:16 /21.C6 FROM
CAN SHLD 1.00 mm² 601DD

P052:1 /14.E7 FROM
P017:7 /14.C5 FROM
P013:5 /14.E2 FROM
CAN SHLD 1.00 mm² 601KK

P062:7 /27.E4 FROM
CAN SHLD CAN SHLD 0.50 mm² 601P

P070:15 /21.C6 FROM
1.50 mm² 606TR P40:10 /9.A3 FROM
CAN SHLD CAN SHLD 1.00 mm² Y

P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600 P066:11 /8.B7 FROM
-SP61 -P035 M10

CAN SHLD CAN SHLD 0.75 mm² 601BF
P130:3 /13.D7 FROM 2.00 mm² 601BU P024:7 /10.C1 FROM
CAN SHLD CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD
P130:4 /13.D7 FROM 2.00 mm² 601AL P023:7 /10.F2 FROM
CAN SHLD CAN SHLD 1.00 mm² 601AC

SPMC12 /17.C3 FROM
2.00 mm² SCR P026:7 /13.F3 FROM
CAN SHLD CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
SVMC15 /17.D5 FROM
2.00 mm² SCR P028:7 /13.B2 FROM
P017:7 /25.E3 FROM
CAN SHLD CAN SHLD 1.00 mm² 601KA CAN SHLD 1.00 mm² 601BH
P034:2 /7.C2 FROM
1.00 mm² 600H P029:7 /13.E3 FROM
P021:7 /12.F3 FROM
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM
-SP28
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM

P027:7 /21.B4 FROM
160/G6925-2 Sheet 19
P042-A /28.E2 FROM

P018:7 /30.F2 FROM
33 - 77 9823/0300-1 33 - 77
Page Page
33-78 33-79
Figure 1082.
GROUND
(Part 1 of 2) P006:5 /3.D2
CAN SHLD
FROM 0.75 mm² 601HB
RC012:6 /15.C5 FROM 1.00 mm² 601SP

P006:10 /3.D2 FROM

RC011:1 /13.A4 FROM

P007:10 /3.C2 FROM
GROUND 1.00 mm² 601AX

RC007:2 /13.B4 FROM

P007:5 /3.C2 FROM
GROUND 2.00 mm² 601AR 6.00 mm² 601RC1

RC009:1 /12.F6 FROM
CAN SHLD
-SRC5 P008:10 /3.A2 FROM 0.75 mm² 601X

P008:5 /3.B2 FROM
GROUND 1.50 mm² 600WP

RC18:2 /12.C6 FROM
CAN SHLD 1.00 mm² 601TS

P101:10 /8.D4 FROM
GROUND 2.00 mm² 601AW

RC004:1 /12.E6 FROM

P014:1 /13.F1 FROM
GROUND 2.00 mm² 601FK

RC003:2 /14.F7 FROM

P014:5 /13.E1 FROM
GROUND 2.00 mm² 601DG

RC005:2 /13.C7 FROM

P058:4 /15.E2 FROM
GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC
RC008:2 /13.C7 FROM
-RC06 M10 CAN SHLD

-SRC6 -SRC7 P013:5 /8.C1 FROM 1.00 mm² 601LL
CAN SHLD 0.75 mm² 601SY

P016:5 /11.E6 FROM
HYD ECU SENSOR GND 0.75 mm² 699CE

SP43 /30.E6 FROM
CAN SHLD 0.75 mm² 601JB

P016:10 /11.E6 FROM
HYD ECU SENSOR GND 1.00 mm² 699SK

SP44 /25.C5 FROM
CAN SHLD 0.75 mm² 601NS

P010:5 /4.E2 FROM
HYD ECU SENSOR GND 1.00 mm² 699CH

P095:3 /26.D1 FROM
CAN SHLD 0.75 mm² 601BL

P011:5 /10.F6 FROM
HYD ECU SENSOR GND 1.00 mm² 699SJ

P095:6 /26.D1 FROM
HYD ECU SENSOR GND 0.75 mm² 699CB

P091:2 /29.E5 FROM
HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND
/22.B7 SC9 / P039:F7
HYD ECU SENSOR GND 0.75 mm² 699CD
P087:2 /21.B7 FROM
HYD ECU SENSOR GND
Page 33-79
SP2 /27.E4 FROM 1.00 mm² 699CG
CAN SHLD 1.00 mm²
P067:10 /14.D4 FROM

P111:2 /29.B6 FROM
CAN SHLD 1.00 mm²

P015:10 /14.D5 FROM
CAN SHLD 1.00 mm²

P013:10 /10.B1 FROM
CAN SHLD 1.00 mm²

P015:5 /14.D3 FROM
CAN SHLD 1.00 mm²

P017:7 /14.C5 FROM
CAN SHLD 1.00 mm²

P062:7 /27.E4 FROM
CAN SHLD CAN SHLD 0.50 mm²

P070:15 /21.C6 FROM
1.50 mm² 606TR P40:10 /9.A3 FROM

P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600 P066:11 /8.B7 FROM
-SP61 -P035 M10

P130:3 /13.D7 FROM 2.00 mm² 601BU P024:7 /10.C1 FROM

P130:4 /13.D7 FROM 2.00 mm² 601AL P023:7 /10.F2 FROM

SPMC12 /17.C3 FROM
2.00 mm² SCR P026:7 /13.F3 FROM

SVMC15 /17.D5 FROM
2.00 mm² SCR P028:7 /13.B2 FROM

P034:2 /7.C2 FROM
1.00 mm² 600H P029:7 /13.E3 FROM
CAN SHLD 1.00 mm²

P061:7 /16.F2 FROM
CAN SHLD 1.00 mm²

P052:7 /14.B5 FROM
33 - 78 9823/0300-1 33 - 78
Page Page
33-78 33-79
CAN SHLD
0.75 mm² 601HB
CAN SHLD 0.75 mm² 601X
CAN SHLD 1.00 mm² 601TS -SP3 3.00 mm² 601JC
CAN SHLD 1.00 mm² 601LL CAN SHLD 1.00 mm² 601DE
P072:17 /9.C5 FROM
CAN SHLD 0.75 mm² 601SY CAN SHLD 1.00 mm² 601HT
P112:2 /14.C4 FROM
CAN SHLD CAN SHLD -SP11

0.75 mm² 601JB P020:7 /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
CAN SHLD 0.75 mm² 601NS CAN SHLD 1.00 mm² 601HP
P063:7 /9.F7 FROM
CAN SHLD 0.75 mm² 601BL CAN SHLD 1.00 mm² 601C
P073:A /17.D1 FROM

P036:7 /25.D2 FROM
Page 33-78
CAN SHLD 1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600 -P030 M10

P070:16 /21.C6 FROM
CAN SHLD 1.00 mm² 601DD

P052:1 /14.E7 FROM
P013:5 /14.E2 FROM
CAN SHLD 1.00 mm² 601KK
CAN SHLD 0.50 mm² 601P
CAN SHLD 1.00 mm² Y
CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD
CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P017:7 /25.E3 FROM
CAN SHLD 1.00 mm² 601KA CAN SHLD 1.00 mm² 601BH
P021:7 /12.F3 FROM
P022:7 /12.E3 FROM
-SP28
P065:2 /15.B5 FROM

P027:7 /21.B4 FROM
160/G6925-2 Sheet 19
P042-A /28.E2 FROM

P018:7 /30.F2 FROM
33 - 79 9823/0300-1 33 - 79
33 - 80 9823/0300-1 33 - 80
Page 33-82 Figure 1083. Ground Chassis Page 33-83

GROUND 1.00 mm² 604D
E006:2 /6.C5 FROM
GROUND
SC2 2.00 mm² 600RDM
/6.F4 FROM
GROUND 1.00 mm² 604B

E002:C /6.D4 FROM
GROUND
C048:11 /22.F7 FROM 1.00 mm² 601D
GROUND 2.00 mm² 604C 2.00 mm² 604A
E003:2 /4.C7 FROM
GROUND
C047:12 /22.F5 1.00 mm² 601C
-SE02 FROM
GROUND
C047:11 /22.F5 FROM
GROUND
GROUND 2.00 mm² 604AC C046:12 /22.F2 1.00 mm² 601A
E025:2 /14.D7
FROM
FROM
GROUND 2.00 mm² 601

GROUND 1.00 mm² 604T C014:2 /30.D5 1.00 mm² 605H
E012:2 /16.E5
FROM
FROM
-SC12
GROUND
ECU GROUND
E014:2 1.00 mm² 604SS
/6.B3 FROM
GROUND 1.00 mm² 604F -SC7 6.00 mm² 604

E013:2 /16.E5 FROM
GROUND 1.00 mm² 605AE

C149:1 /29.F3 FROM
GROUND 1.00 mm² 610A

C035:2 /6.C5 FROM
GROUND 1.00 mm² 601CO

C027:2 /25.D5 FROM

SC16 /10.C7 FROM
GROUND 0.75 mm² 613C

C154:7 /23.D5 FROM

C153:7 /23.E5 FROM
-C037
GROUND -SC9 GROUND
1.00 mm² 602H 10.00 mm² GROUND
C026:C /26.D6 FROM
M10
C024:C /26.D6 FROM

C022:7 /23.F5 FROM

C002:6 /10.B7 FROM

C005:6 /10.B7 FROM
GROUND 1.50 mm² 600ACF

C006:2 /14.F4 FROM
GROUND1.00 mm²,1.00 mm² 602LM,609LM

C025:1 & 6 /28.E6 FROM

C054:2 /15.A5 FROM
160/G6925-2 Sheet 20
33 - 81 9823/0300-1 33 - 81
Page Page
33-82 33-83

E006:2 /6.C5 FROM
SC2
E002:C /6.D4 FROM
C048:11 /22.F7
GROUND 2.00 mm² 604C 2.00 mm² 604A
E003:2 /4.C7 FROM
-SE02 C047:12 /22.F5

GROUND
C047:11 /22.F5
GROUND 2.00 mm² 604AC C046:12 /22.F2

E025:2 /14.D7 FROM
GROUND 1.00 mm² 604T C014:2 /30.D5

E012:2 /16.E5 FROM
GROUND 1.00 mm² 604SS

E014:2 /6.B3 FROM
GROUND 1.00 mm² 604F -SC7 6.00 mm² 604

E013:2 /16.E5 FROM
GROUND 1.00 mm² 605AE

C149:1 /29.F3 FROM

C035:2 /6.C5 FROM
Page 33-83
GROUND 1.00 mm² 601CO
C027:2 /25.D5 FROM

SC16 /10.C7 FROM

C154:7 /23.D5 FROM

C153:7 /23.E5 FROM
GROUND 1.00 mm² 602H

C026:C /26.D6 FROM

C024:C /26.D6 FROM

C022:7 /23.F5 FROM

C002:6 /10.B7 FROM

C005:6 /10.B7 FROM
GROUND 1.50 mm² 600ACF

C006:2 /14.F4 FROM
GROUND1.00 mm²,1.00 mm² 602LM,609LM

C025:1 & 6 /28.E6 FROM

C054:2 /15.A5 FROM
33 - 82 9823/0300-1 33 - 82
Page Page
33-82 33-83

SC2 /6.F4 FROM

C048:11 /22.F7 FROM

C047:12 /22.F5 FROM

C047:11 /22.F5 FROM

C046:12 /22.F2 FROM
GROUND 1.00 mm² 605H 2.00 mm² 601

C014:2 /30.D5 FROM
-SC12
ECU GROUND
Page 33-82
-C037
-SC9 GROUND
10.00 mm² GROUND
M10
160/G6925-2 Sheet 20
33 - 83 9823/0300-1 33 - 83
33 - 84 9823/0300-1 33 - 84
Page 33-86 Figure 1084. 07/11 Controller ECU Page 33-87

-P069 -P070
07/11 CONNECTOR 07/11 CONNECTOR
PUMP FORWARD RTN 1.00 mm² 523 1/18 1/18 1.00 mm² 100TR IGNITION +VE
P039:G4 /7.D4 FROM FROM
/3.C7 P005:12
-P039
B1/84 1.00 mm² 525 2/18 2/18
-P039
D5/84 0.75 mm² 580 3/18 3/18
-C004 -P039
HYD TEMP 0.75 mm² 538 E8/84 E8/84 1.00 mm² 538 4/18 4/18 0.50 mm² CAN L CAN LO
C033:2 /23.B3 TO FROM
/17.D4 SVMC11
PUMP REVERSE 1.00 mm² 522 5/18 5/18
P039:B12 /7.D4 TO
-P039 -C004
PUMP FORWARD 1.00 mm² 521 6/18 6/18 1.00 mm² 457 C1/84 C1/84 1.00 mm² 457 -SC3 0.75 mm² 489A 07/11 5V REF
P039:C6 /7.D4 TO TO
/30.C2 C055:1
MOTOR FAST/SLOW RTN 1.00 mm² 527 7/18 7/18 1.00 mm² 457PP 07/11 5V REF
T005:2 /7.C4 FROM TO
/7.C5 T077:2
PUMP PRESSURE 0.75 mm² 419PP 8/18 8/18 0.75 mm² 457C1 07/11 5V REF
T007:4 /7.B4 FROM TO
/7.E2 C008:1
SEAT PRESSURE 1.00 mm² 846SS 9/18 9/18 0.75 mm² 457C2 07/11 5V REF
RC012:5 / P049:20 /15.C3 FROM TO
/7.D2 C008:4
INCHING SIGNAL 1.00 mm² 468 SEAT PRESSURE 1.00 mm² 847SS 10/18 10/18 0.50 mm² CAN H CAN HI
C149:4 /29.F5 FROM
RC012:4 / P049:19 /15.B3 FROM FROM
/17.D4 SVMC10
-C004 -P039 -P039 -C004 -SC1
INCHING SIGNAL 0.75 mm² 468B 0.75 mm² 468 D6/84 D6/84 0.75 mm² 581 11/18 11/18 1.00 mm² 688 E1/84 E1/84 1.00 mm² 688C 1.00 mm² 688PP 07/11 SENSOR GROUND
C150:2 /7.E3 FROM FROM
/7.C5 T007:1
-SC15 -C004 -P039
INCHING DIAL 0.75 mm² 560 E9/84 E9/84 0.75 mm² 560 12/18 12/18 1.00 mm² 300TR -SP39 300TR 2.00 mm² BATT +VE 0.75 mm² 688C1 07/11 SENSOR GROUND
C008:3 /7.D2 FROM FROM
/3.D7 P005:4 FROM
/7.D2 C008:2
PUMP REVERSE RTN 1.00 mm² 535 13/18 13/18 0.75 mm² 688C2 07/11 SENSOR GROUND
P039:G3 /7.C4 FROM FROM
/7.D2 C008:5
-P039 -C004
REV ALARM INCHING DIAL 07/11 SENSOR GROUND
P010:8 /10.D3 TO
0.50 mm² 807 14/18 14/18 0.75 mm² 561 F8/84 F8/84 0.75 mm² 561A FROM
/7.D3 C001:2 0.75 mm² 688E FROM
/23.B3 C033:1
NEUTRAL START 1.00 mm² 100NS 15/18 15/18 1.50 mm² 606TR CAN SHLD
P010:3 /4.E2 TO TO
/19.C1 SP61
BRAKE LIGHTS 0.75 mm² 116B 16/18 16/18 2.00 mm² 601TR CAN SHLD
P011:3 /10.F5 TO TO
/19.C6 SP62
MOTOR FAST/SLOW 1.00 mm² 526 17/18 17/18 1.00 mm² 300TR
T005:1 /7.C4 TO
-P039
C5/84 1.00 mm² 524 18/18 18/18 1.00 mm² 300TR
/21.C4 /21.C3
CAN SHLD
SP28 /19.B6 TO
-P027
FOUR WHEEL DRIVE
SWITCH ILLUMINATION 1.00 mm² 829V 8 7 1.00 mm² 601N
SP7 /18.C5 FROM
-P088
2/4 WD 5K 6R
1 0.75 mm² 818B 1 2 0.75 mm² 818D
IGNITION +VE 0.75 mm² 100M 2
SP20 /3.A7 FROM
3
4
5 -P089 -P087
0.75 mm² 100MA
2/4 WD 33K 2/4 WD 1K 8R
6 0.75 mm² 818C 1 2 0.75 mm² 818E 0.75 mm² 818G 1 2 0.75 mm² 699CD HYD ECU SENSOR GND
TO
/19.D1 SP42
-SP12
160/G6925-2 Sheet 21
-C004 -P039
4WD SWITCH 1.00 mm² 818A F2/84 F2/84 0.75 mm² 818
C047:10 /22.F5 TO
33 - 85 9823/0300-1 33 - 85
Page Page
33-86 33-87

07/11 CONNECTOR
PUMP FORWARD RTN 1.00 mm² 523 1/18

P039:G4 /7.D4 FROM
-P039
B1/84 1.00 mm² 525 2/18
-P039
D5/84 0.75 mm² 580 3/18
-C004 -P039
HYD TEMP 0.75 mm² 538 E8/84 E8/84 1.00 mm² 538 4/18
C033:2 /23.B3 TO
PUMP REVERSE 1.00 mm² 522 5/18

P039:B12 /7.D4 TO
PUMP FORWARD 1.00 mm² 521 6/18

P039:C6 /7.D4 TO
MOTOR FAST/SLOW RTN 1.00 mm² 527 7/18

T005:2 /7.C4 FROM
PUMP PRESSURE 0.75 mm² 419PP 8/18

T007:4 /7.B4 FROM
SEAT PRESSURE 1.00 mm² 846SS 9/18

RC012:5 / P049:20 /15.C3 FROM
INCHING SIGNAL 1.00 mm² 468 SEAT PRESSURE 1.00 mm² 847SS 10/18
C149:4 /29.F5 FROM
RC012:4 / P049:19 /15.B3 FROM
-C004 -P039
INCHING SIGNAL 0.75 mm² 468B 0.75 mm² 468 D6/84 D6/84 0.75 mm² 581 11/18
C150:2 /7.E3 FROM
-SC15 -C004 -P039

INCHING DIAL 0.75 mm² 560 E9/84 E9/84 0.75 mm² 560 12/18
C008:3 /7.D2 FROM
PUMP REVERSE RTN 1.00 mm² 535 13/18

P039:G3 /7.C4 FROM
REV ALARM
P010:8 /10.D3 TO
0.50 mm² 807 14/18
NEUTRAL START 1.00 mm² 100NS 15/18

P010:3 /4.E2 TO
BRAKE LIGHTS 0.75 mm² 116B 16/18

P011:3 /10.F5 TO
MOTOR FAST/SLOW 1.00 mm² 526 17/18

T005:1 /7.C4
Page 33-87
TO
-P039
C5/84 1.00 mm² 524 18/18
/21.C4
CAN SHLD
SP28 /19.B6 TO
-P027
FOUR WHEEL DRIVE
SWITCH ILLUMINATION 1.00 mm² 829V 8 7 1.00 mm² 601N
SP7 /18.C5 FROM
1 0.75 mm² 818B

IGNITION +VE 0.75 mm² 100M 2
SP20 /3.A7 FROM
3
4
0.75 mm² 100MA 5

6 0.75 mm² 818C
-C004
4WD SWITCH 1.00 mm² 818A F2/84
C047:10 /22.F5 TO
33 - 86 9823/0300-1 33 - 86
Page Page
33-86 33-87
Figure 1084. (Part

-P070
2 of 2)
07/11 CONNECTOR
1/18 1.00 mm² 100TR IGNITION +VE

FROM
/3.C7 P005:12
2/18
3/18
4/18 0.50 mm² CAN L CAN LO

FROM
/17.D4 SVMC11
5/18
-P039 -C004
6/18 1.00 mm² 457 C1/84 C1/84 1.00 mm² 457 -SC3 0.75 mm² 489A 07/11 5V REF
TO
/30.C2 C055:1
7/18 1.00 mm² 457PP 07/11 5V REF

TO
/7.C5 T077:2
8/18 0.75 mm² 457C1 07/11 5V REF

TO
/7.E2 C008:1
9/18 0.75 mm² 457C2 07/11 5V REF

TO
/7.D2 C008:4
10/18 0.50 mm² CAN H CAN HI

FROM
/17.D4 SVMC10
-P039 -C004 -SC1
11/18 1.00 mm² 688 E1/84 E1/84 1.00 mm² 688C 1.00 mm² 688PP 07/11 SENSOR GROUND
FROM
/7.C5 T007:1
12/18 1.00 mm² 300TR -SP39 300TR 2.00 mm² BATT +VE 0.75 mm² 688C1 07/11 SENSOR GROUND
FROM
/3.D7 P005:4 FROM
/7.D2 C008:2

FROM
/7.D2 C008:5
-P039 -C004
14/18 0.75 mm² 561 F8/84 F8/84 0.75 mm² 561A INCHING DIAL 0.75 mm² 688E 07/11 SENSOR GROUND
FROM
/7.D3 C001:2 FROM
/23.B3 C033:1
15/18 1.50 mm² 606TR CAN SHLD TO

/19.C1 SP61
16/18 2.00 mm² 601TR CAN SHLD TO

/19.C6 SP62
17/18 1.00 mm² 300TR

Page 33-86
18/18 1.00 mm² 300TR

/21.C3
1.00 mm² 601N
-P088
2/4 WD 5K 6R
0.75 mm² 818B 1 2 0.75 mm² 818D
-P089 -P087
2/4 WD 33K 2/4 WD 1K 8R
0.75 mm² 818C 1 2 0.75 mm² 818E 0.75 mm² 818G 1 2 0.75 mm² 699CD HYD ECU SENSOR GND
TO
/19.D1 SP42
-SP12
160/G6925-2 Sheet 21
-C004 -P039
F2/84 F2/84 0.75 mm² 818
33 - 87 9823/0300-1 33 - 87
33 - 88 9823/0300-1 33 - 88
Page 33-90 Figure 1085. Hydraulic ECU Page 33-91

-C046 -C047 -C048
HYDRAULICS ECU HYDRAULICS ECU HYDRAULICS ECU
J1 J2 J3
1.00 mm² 203J 1/18 10/18 0.75 mm² 452EC RETRACT PROX CRAB STEER 1.00 mm² 824 1/18 10/18 1.00 mm² 818A 4WD SWITCH LIFT 1.00 mm² 420 1/18 10/18
FROM
/28.E4 SC6 C031:1 /26.C4 TO FROM
/21.A5 SP12 / C015:F2 V003:1 /24.E3 TO
1.00 mm² 203B 2/18 11/18 1.00 mm² 481 TRANS SPEED SENSOR ALL WHEEL STEER 1.00 mm² 848 2/18 11/18 1.00 mm² 601B GROUND EXTEND 1.00 mm² 423 2/18 11/18 1.00 mm² 601D GROUND
FROM
/7.A5 C044:6 / SP68 C030:1 /26.C4 TO TO
/20.E4 SC12 V005:1 /24.E5 TO TO
/20.E4 SC12
1.00 mm² 203C 3/18 12/18 1.00 mm² 601A GROUND R 1.00 mm² 416R 3/18 12/18 1.00 mm² 601C GROUND BOOM ANGLE 0.75 mm² 449 3/18 12/18
TO
/20.E4 SC12 P037:10 / C015:D9 /7.A3 FROM TO
/20.E4 SC12 C074:2 /28.C5 FROM
-C004
N 1.00 mm² 416N 4/18 13/18 1.00 mm² 424 RETRACT FOOTBRAKE SWITCH 1.00 mm² 876 4/18 13/18 1.00 mm² 826 4 WHEEL STEER CHASSIS ANGLE 0.75 mm² 475 4/18 13/18 1.00 mm² 145TS F1/84
P037:6 / C004:E12 /7.A3 FROM TO
/24.E5 V004:1 P050:3 / SP1 /29.D5 FROM TO
/26.B4 C029:1 C052:2 /28.C2 FROM
5/18 14/18 0.75 mm² 435 BOOM AUX TRANS SPEED SENSOR 1.00 mm² 480 5/18 14/18 1.00 mm² 421 LOWER CHASSIS ANGLE 0.75 mm² 476 5/18 14/18 1.00 mm² 441 DRAIN SOL
TO
/25.D6 C032:5 C044:3 (07/11) / TR25:3 (HMH) /7.B5 FROM TO
/24.E3 V002:1 C052:5 /28.C2 FROM TO
/27.B5 C040:2
EXTEND/RETRACT RTN 0.75 mm² 425 6/18 15/18 0.75 mm² 819PB PARK BRAKE LEVER ISOLATION SOL 0.75 mm² 611 6/18 15/18 ACCU/DRAIN RTN 1.00 mm² 608ST 6/18 15/18 1.00 mm² 433JB JOYSTICK ISO
SV2 /24.E5 FROM FROM
/29.C3 C152:4 V010:2 /23.B3 FROM
C040:8 /27.C5 FROM TO
/30.E1 P018:2
1.00 mm² 203D 7/18 16/18 1.00 mm² 436AV AUX VENT 2 WHEEL STEER 1.00 mm² 825 7/18 16/18 1.00 mm² 489 HYD ISO SWITCH 7/18 16/18 0.75 mm² 499A SRS
FROM
/23.C3 SJ7 / JS01:4 C028:1 /26.B4 TO FROM
/30.C2 C055:3 TO
/27.E1 P062:2 / C015:F10
1.00 mm² 203E 8/18 17/18 1.00 mm² 422 LIFT/LOWER RTN PIN LOCK 1.00 mm² 435LP 8/18 17/18 0.75 mm² 444 SRS TRANSD 8/18 17/18 1.00 mm² 428 DUMP/CROWD RTN
FROM
/24.E3 SV1 SC153 /23.E7 FROM FROM
/27.C5 C040:5 FROM
/24.D3 SV3
1.00 mm² 203G 9/18 18/18 1.00 mm² 431 AUX A/AUX B RTN F 1.00 mm² 416F 9/18 18/18 2.00 mm² 602 STEER SOL GND 9/18 18/18 0.75 mm² 818C PARK BRAKE VALVE RTN
FROM
/24.D5 SV4 P037:4 / C015:C10 /7.A3 FROM FROM
/26.A4 SC8 FROM
/29.C4 C151:2
-P039 -C004
BATT +VE 2.00 mm² 203 C8/84 C8/84 2.00 mm² 203A
P005:2 /3.D7 FROM
-SC4
-C049 -C050
HYDRAULICS ECU HYDRAULICS ECU
J4 J5
-C004 -P039
CROWD 1.00 mm² 426 1/18 10/18 2ND AUX VALVE 1.50 mm² 851 1/18 10/18 1.00 mm² 888C STEER MODE 1.00 mm² 456CB D1/84 D1/84 1.50 mm² 456PC HYD ECU 5V REF
V007:1 /24.D3 TO
C032:3 /25.D6 TO FROM
/26.D4 P095:5 / C015:G6 TO
/26.E1 SP10
ACCUMULATOR SOL 1.00 mm² 442 2/18 11/18 0.50 mm² CAN L CAN HI BOOM AUX B 1.00 mm² 430 2/18 11/18 1.00 mm² 819 FRONT PROX
C040:3 /27.C5 TO FROM
/17.D7 SPMC05 V008:1 /24.D5 TO FROM
/26.E6 C008:3
3/18 12/18 0.50 mm² CAN L CAN LO REAR PROX 1.00 mm² 820 3/18 12/18 0.75 mm² 456E HYD ECU 5V REF
FROM
/17.D7 SVMC20 C011:3 /26.D6 FROM TO
/27.D5 C040:1
4/18 13/18 1.00 mm² 427 DUMP TILT LOCK 0.75 mm² 445R 4/18 13/18 0.75 mm² 818B PARK BRAKE VALVE 0.75 mm²,0.75 mm² 456G,456F HYD ECU 5V REF
TO
/24.D3 V006:1 C022:2 /23.F3 TO TO
/29.C4 C151:1 TO
/28.C2 C052:1 & 4
CAN SHLD 0.50 mm² SCR 5/18 14/18 1.00 mm² 429 BOOM AUX A CONSTANT AUX 1.00 mm² 447CA 5/18 14/18 2.00 mm² 456 -SC31 0.75 mm²,0.75 mm² 456H,456J HYD ECU 5V REF
SPMC06 /17.C7 FROM TO
/24.D5 V009:1 P036:2 /25.C1 TO TO
/28.C5 C023:1 / C023:4
CAN SHLD 0.50 mm² SCR 6/18 15/18 FRONT PROX 1.00 mm² 819B 6/18 15/18 1.00 mm² 155EC 0.75 mm² 456IP HYD ECU 5V REF
SVMC21 /17.D7 FROM
C008:6 /26.E6 FROM TO
/7.E3 C150:1
REAR PROX 1.00 mm² 820B 7/18 16/18 1.00 mm² 699 7/18 16/18 0.75 mm² 443 SRS TRANSD 0.75 mm² 456PB HYD ECU 5V REF
C011:6 /26.D6 FROM FROM
/27.C5 C040:4 TO
/29.C3 C152:2
BOOM ANGLE 0.75 mm² 448 8/18 17/18 0.50 mm² CAN H CAN HI PARK BRAKE LEVER 0.75 mm² 818 8/18 17/18 1.00 mm² 895CA JOYSTICK
C074:5 /28.C5 FROM FROM
/17.D7 SPMC04 C152:3 /29.C3 FROM FROM
/30.D3 C034:1 / JS01:15
9/18 18/18 0.50 mm² CAN H CAN HI STEER MODE 1.00 mm² 888A 9/18 18/18 1.00 mm² 203H
FROM
/17.D7 SVMC19 P095:2 / C015:G5 /26.D4 FROM
1.00 mm² 699
HYD ECU SENSOR GND 1.00 mm² 699AV

C154C /23.C7 FROM
HYD ECU SENSOR GND 1.00 mm² 699LP

C153C /23.E7 FROM
HYD ECU SENSOR GND 1.00 mm² 699G

C040:7 /27.C5 FROM
HYD ECU SENSOR GND 0.75 mm²,0.75 mm² 699K,699L

C052:3 & 6 /28.C2 FROM
1.00 mm² 155EC HYD ECU SENSOR GND 0.75 mm²,0.75 mm² 609C,609B
C023:3 / C023:6 /28.C5 FROM
-C004 -P039
1.00 mm² 155AV IGNITION +VE HYD ECU SENSOR GND 0.75 mm² 699BB -SC28 1.50 mm² 699CB F7/84 F7/84 1.50 mm² 699CA HYD ECU SENSOR GND
TO
/23.C3 C154:2 C045C:2 /28.D6 FROM TO
/19.D3 SP42
0.75 mm²,0.75 mm² 155SA,155SB IGNITION +VE HYD ECU SENSOR GND 0.75 mm² 699D
TO
/28.D2 C045:1 & 4 C044:2 /7.A5 FROM
-P039 -C004
IGNITION +VE 1.50 mm² 155 F9/84 F9/84 1.50 mm² 155 -SC11 1.00 mm² 155LM IGNITION +VE HYD ECU SENSOR GND 0.75 mm²,0.75 mm²,0.75 mm² 699TC,699TD,699TB
P005:20 /3.C7 FROM TO
/28.F6 C010:4 C022 /23.F6 FROM
1.00 mm² 155PL IGNITION +VE HYD ECU SENSOR GND 0.75 mm² 699IP
TO
/23.E3 C153:2 C150:3 /7.E3 FROM
160/G6925-2 Sheet 22
1.00 mm² 155JS IGNITION +VE HYD ECU SENSOR GND 0.75 mm² 699PB
TO
/30.D3 C014:1 C152:1/29.C3 FROM
1.00 mm² 155R IGNITION +VE TO

/4.E8 E037:2
33 - 89 9823/0300-1 33 - 89
Page Page
33-90 33-91
Figure 1085. (Part 1 of 2) -C046

HYDRAULICS ECU
-C047
HYDRAULICS ECU
J1 J2
1.00 mm² 203J 1/18 10/18 0.75 mm² 452EC RETRACT PROX CRAB STEER 1.00 mm² 824 1/18 10/18
FROM
/28.E4 SC6 C031:1 /26.C4 TO
1.00 mm² 203B 2/18 11/18 1.00 mm² 481 TRANS SPEED SENSOR ALL WHEEL STEER 1.00 mm² 848 2/18 11/18
FROM
/7.A5 C044:6 / SP68 C030:1 /26.C4 TO
1.00 mm² 203C 3/18 12/18 1.00 mm² 601A GROUND R 1.00 mm² 416R 3/18 12/18
TO
/20.E4 SC12 P037:10 / C015:D9 /7.A3 FROM
N 1.00 mm² 416N 4/18 13/18 1.00 mm² 424 RETRACT FOOTBRAKE SWITCH 1.00 mm² 876 4/18 13/18
P037:6 / C004:E12 /7.A3 FROM TO
/24.E5 V004:1 P050:3 / SP1 /29.D5 FROM
5/18 14/18 0.75 mm² 435 BOOM AUX TRANS SPEED SENSOR 1.00 mm² 480 5/18 14/18
TO
/25.D6 C032:5 C044:3 (07/11) / TR25:3 (HMH) /7.B5 FROM
EXTEND/RETRACT RTN 0.75 mm² 425 6/18 15/18 0.75 mm² 819PB PARK BRAKE LEVER ISOLATION SOL 0.75 mm² 611 6/18 15/18
SV2 /24.E5 FROM FROM
/29.C3 C152:4 V010:2 /23.B3 FROM
1.00 mm² 203D 7/18 16/18 1.00 mm² 436AV AUX VENT 2 WHEEL STEER 1.00 mm² 825 7/18 16/18
FROM
/23.C3 SJ7 / JS01:4 C028:1 /26.B4 TO
1.00 mm² 203E 8/18 17/18 1.00 mm² 422 LIFT/LOWER RTN PIN LOCK 1.00 mm² 435LP 8/18 17/18
FROM
/24.E3 SV1 SC153 /23.E7 FROM
1.00 mm² 203G 9/18 18/18 1.00 mm² 431 AUX A/AUX B RTN F 1.00 mm² 416F 9/18 18/18
FROM
/24.D5 SV4 P037:4 / C015:C10 /7.A3 FROM
-P039 -C004
BATT +VE 2.00 mm² 203 C8/84 C8/84 2.00 mm² 203A
P005:2 /3.D7 FROM
-SC4
-C049 -C050
HYDRAULICS ECU HYDRAULICS ECU
J4 J5
CROWD 1.00 mm² 426 1/18 10/18 2ND AUX VALVE 1.50 mm² 851 1/18 10/18
V007:1 /24.D3 TO
C032:3 /25.D6 TO
ACCUMULATOR SOL 1.00 mm² 442 2/18 11/18 0.50 mm² CAN L CAN HI BOOM AUX B 1.00 mm² 430 2/18 11/18
C040:3 /27.C5 TO FROM
/17.D7 SPMC05 V008:1 /24.D5 TO
3/18 12/18 0.50 mm² CAN L CAN LO REAR PROX 1.00 mm² 820 3/18 12/18
FROM
/17.D7 SVMC20 C011:3 /26.D6 FROM
4/18 13/18 1.00 mm² 427 DUMP TILT LOCK 0.75 mm² 445R 4/18 13/18
TO
/24.D3 V006:1 C022:2 /23.F3 TO
CAN SHLD 0.50 mm² SCR 5/18 14/18 1.00 mm² 429 BOOM AUX A CONSTANT AUX 1.00 mm² 447CA 5/18 14/18
SPMC06 /17.C7 FROM TO
/24.D5 V009:1 P036:2 /25.C1 TO
CAN SHLD 0.50 mm² SCR 6/18 15/18 FRONT PROX 1.00 mm² 819B 6/18 15/18
SVMC21 /17.D7 FROM
C008:6 /26.E6 FROM
Page 33-91
REAR PROX 1.00 mm² 820B 7/18 16/18 1.00 mm² 699 7/18 16/18
C011:6 /26.D6 FROM
BOOM ANGLE 0.75 mm² 448 8/18 17/18 0.50 mm² CAN H CAN HI PARK BRAKE LEVER 0.75 mm² 818 8/18 17/18
C074:5 /28.C5 FROM FROM
/17.D7 SPMC04 C152:3 /29.C3 FROM
9/18 18/18 0.50 mm² CAN H CAN HI STEER MODE 1.00 mm² 888A 9/18 18/18
FROM
/17.D7 SVMC19 P095:2 / C015:G5 /26.D4 FROM
1.00 mm² 155EC
1.00 mm² 155AV IGNITION +VE TO

/23.C3 C154:2
0.75 mm²,0.75 mm² 155SA,155SB IGNITION +VE TO

/28.D2 C045:1 & 4
-P039 -C004
IGNITION +VE 1.50 mm² 155 F9/84 F9/84 1.50 mm² 155 -SC11 1.00 mm² 155LM IGNITION +VE
P005:20 /3.C7 FROM TO
/28.F6 C010:4
1.00 mm² 155PL IGNITION +VE TO

/23.E3 C153:2
1.00 mm² 155JS IGNITION +VE TO

/30.D3 C014:1
1.00 mm² 155R IGNITION +VE TO

/4.E8 E037:2
33 - 90 9823/0300-1 33 - 90
Page Page
33-90 33-91
-C047
HYDRAULICS ECU Figure 1085. (Part 2 of 2) -C048
HYDRAULICS ECU
J2 J3
10/18 1.00 mm² 818A 4WD SWITCH LIFT 1.00 mm² 420 1/18 10/18
FROM
/21.A5 SP12 / C015:F2 V003:1 /24.E3 TO
11/18 1.00 mm² 601B GROUND EXTEND 1.00 mm² 423 2/18 11/18 1.00 mm² 601D GROUND
TO
/20.E4 SC12 V005:1 /24.E5 TO TO
/20.E4 SC12
12/18 1.00 mm² 601C GROUND BOOM ANGLE 0.75 mm² 449 3/18 12/18
TO
/20.E4 SC12 C074:2 /28.C5 FROM
-C004
13/18 1.00 mm² 826 4 WHEEL STEER CHASSIS ANGLE 0.75 mm² 475 4/18 13/18 1.00 mm² 145TS F1/84
TO
/26.B4 C029:1 C052:2 /28.C2 FROM
14/18 1.00 mm² 421 LOWER CHASSIS ANGLE 0.75 mm² 476 5/18 14/18 1.00 mm² 441 DRAIN SOL
TO
/24.E3 V002:1 C052:5 /28.C2 FROM TO
/27.B5 C040:2
15/18 ACCU/DRAIN RTN 1.00 mm² 608ST 6/18 15/18 1.00 mm² 433JB JOYSTICK ISO
C040:8 /27.C5 FROM TO
/30.E1 P018:2
16/18 1.00 mm² 489 HYD ISO SWITCH 7/18 16/18 0.75 mm² 499A SRS
FROM
/30.C2 C055:3 TO
/27.E1 P062:2 / C015:F10
17/18 0.75 mm² 444 SRS TRANSD 8/18 17/18 1.00 mm² 428 DUMP/CROWD RTN
FROM
/27.C5 C040:5 FROM
/24.D3 SV3
18/18 2.00 mm² 602 STEER SOL GND 9/18 18/18 0.75 mm² 818C PARK BRAKE VALVE RTN
FROM
/26.A4 SC8 FROM
/29.C4 C151:2
-C050
HYDRAULICS ECU
J5
-C004 -P039
10/18 1.00 mm² 888C STEER MODE 1.00 mm² 456CB D1/84 D1/84 1.50 mm² 456PC HYD ECU 5V REF
FROM
/26.D4 P095:5 / C015:G6 TO
/26.E1 SP10
11/18 1.00 mm² 819 FRONT PROX

FROM
/26.E6 C008:3
12/18 0.75 mm² 456E HYD ECU 5V REF

TO
/27.D5 C040:1
13/18 0.75 mm² 818B PARK BRAKE VALVE 0.75 mm²,0.75 mm² 456G,456F HYD ECU 5V REF
TO
/29.C4 C151:1 TO
/28.C2 C052:1 & 4
14/18 2.00 mm² 456 -SC31 0.75 mm²,0.75 mm² 456H,456J HYD ECU 5V REF
TO
/28.C5 C023:1 / C023:4
15/18 1.00 mm² 155EC 0.75 mm² 456IP HYD ECU 5V REF
TO
/7.E3 C150:1
Page 33-90
16/18 0.75 mm² 443 SRS TRANSD 0.75 mm² 456PB HYD ECU 5V REF
FROM
/27.C5 C040:4 TO
/29.C3 C152:2
17/18 1.00 mm² 895CA JOYSTICK

FROM
/30.D3 C034:1 / JS01:15
18/18 1.00 mm² 203H
1.00 mm² 699
HYD ECU SENSOR GND 1.00 mm² 699AV

C154C /23.C7 FROM
HYD ECU SENSOR GND 1.00 mm² 699LP

C153C /23.E7 FROM
HYD ECU SENSOR GND 1.00 mm² 699G

C040:7 /27.C5 FROM
HYD ECU SENSOR GND 0.75 mm²,0.75 mm² 699K,699L

C052:3 & 6 /28.C2 FROM
HYD ECU SENSOR GND 0.75 mm²,0.75 mm² 609C,609B

C023:3 / C023:6 /28.C5 FROM
-C004 -P039
HYD ECU SENSOR GND 0.75 mm² 699BB -SC28 1.50 mm² 699CB F7/84 F7/84 1.50 mm² 699CA HYD ECU SENSOR GND
C154:2 C045C:2 /28.D6 FROM TO
/19.D3 SP42
HYD ECU SENSOR GND 0.75 mm² 699D
C045:1 & 4 C044:2 /7.A5 FROM
HYD ECU SENSOR GND 0.75 mm²,0.75 mm²,0.75 mm² 699TC,699TD,699TB

C010:4 C022 /23.F6 FROM
HYD ECU SENSOR GND 0.75 mm² 699IP

C153:2 C150:3 /7.E3 FROM
160/G6925-2 Sheet 22
HYD ECU SENSOR GND 0.75 mm² 699PB
C014:1 C152:1/29.C3 FROM
33 - 91 9823/0300-1 33 - 91
33 - 92 9823/0300-1 33 - 92
Page 33-94 Figure 1086. Hydraulics Page 33-95

1.00 mm² 435LP PIN LOCK TO
/22.E4 C047:8
-C153
PIN LOCK SWITCH
SWITCH ILLUMINATION 0.75 mm² 830G 8 7 0.75 mm² 613B GROUND
SC18 /10.D5 FROM TO
/20.C4 SC9
-C153A -C153C
PIN LOCK 5K6 PIN LOCK 1K8
1 0.75 mm² 435A 1 2 1.00 mm² 435D -SC153 0.75 mm² 699C 1 2 1.00 mm² 699LP HYD ECU SENSOR GND
TO
/22.C6 SC28
IGNITION +VE 1.00 mm² 155PL 2
SC11 /22.B4 FROM
3
4
5 -C153B
1.00 mm² 155PM
PIN LOCK 33K
6 0.75 mm² 435B 1 2 1.00 mm² 435E
-C154
AUX VENTING
SWITCH ILLUMINATION 0.75 mm² 830H 8 7 0.75 mm² 613C GROUND
SC18 /10.D5 FROM TO
/20.C4 SC9
-C154A
AUX VENT5K6
1 1.00 mm² 436A 1 2 1.00 mm² 436D
IGNITION +VE 1.00 mm² 155AV 2
SC11 /22.B4 FROM
3
4
-C154B -C154C
1.00 mm² 155B 5
AUX VENT33K AUX VENT1K8
6 1.00 mm² 436B 1 2 1.00 mm² 436E -SC154 1.00 mm² 699AX 1 2 1.00 mm² 699AV HYD ECU SENSOR GND
TO
/22.C6 SC28
AUX VENT 1.00 mm² 436AV 1.00 mm² 436AV

C046:16 /22.E2 TO
-C022
TILTLOCK
SWITCH ILLUMINATION 0.75 mm² 830E 8 7 1.00 mm² 613 GROUND
SC18 /10.D5 FROM TO
/20.C4 SC9
-C022B
TILTLOCK 1K 300R
1 0.75 mm² 445TC 1 2 0.75 mm² 699TC HYD ECU SENSOR GND
TO
/22.B6
TILTLOCK 0.75 mm² 445R 2
C050:4 /22.D4 FROM
1.00 mm² 445 TA 4

-C022C
5
TILTLOCK 5K 360R
6 0.75 mm² 445TD 1 2 0.75 mm² 699TD
-C022A
TILTLOCK 10K
0.75 mm² 445TB 1 2 0.75 mm² 699TB
-C010
VENTING VALVE
AUX VENT 1.00 mm² 500VEN 1/2
-C033 C057:19 /6.E3 FROM
HYD TEMPSENSOR
GROUND 1.00 mm² 600VEN 2/2
07/11 SENSOR GROUND SC2 /6.D3 TO
SC1 /21.D6 TO 0.75 mm² 688E 1/2
HYD TEMP 0.75 mm² 538 2/2 -V010

P069:4 /21.E1 FROM
ISOLATION SOLENOID
IGNITION +VE 1.00 mm² 109SA 1/2
SC5 /3.B6 FROM
C047:6 /22.E4
ISOLATION SOL
TO 0.75 mm² 611 2/2 160/G6925-2 Sheet 23
33 - 93 9823/0300-1 33 - 93
Page Page
33-94 33-95

-C153
PIN LOCK SWITCH
SWITCH ILLUMINATION 0.75 mm² 830G 8 7 0.75 mm² 613B
SC18 /10.D5 FROM
-C153A
PIN LOCK 5K6
1 0.75 mm² 435A 1 2
IGNITION +VE 1.00 mm² 155PL 2
SC11 /22.B4 FROM
3
4
5 -C153B
1.00 mm² 155PM
PIN LOCK 33K
6 0.75 mm² 435B 1 2
-C154
AUX VENTING
SWITCH ILLUMINATION 0.75 mm² 830H 8 7 0.75 mm² 613C
SC18 /10.D5 FROM
-C154A
AUX VENT5K6
1 1.00 mm² 436A 1 2
IGNITION +VE 1.00 mm² 155AV 2
SC11 /22.B4 FROM
3
4
-C154B
1.00 mm² 155B 5
AUX VENT33K
6 1.00 mm² 436B 1 2
AUX VENT
Page 33-95
C046:16 /22.E2 TO 1.00 mm² 436AV
-C022
TILTLOCK
SWITCH ILLUMINATION 0.75 mm² 830E 8 7 1.00 mm² 613
SC18 /10.D5 FROM
-C022B
TILTLOCK 1K 300R
1 0.75 mm² 445TC 1 2
TILTLOCK 0.75 mm² 445R 2
C050:4 /22.D4 FROM
1.00 mm² 445 TA 4

-C022C
5
TILTLOCK 5K 360R
6 0.75 mm² 445TD 1 2
-C022A
TILTLOCK 10K
0.75 mm² 445TB 1 2
-C033
HYD TEMPSENSOR
07/11 SENSOR GROUND 0.75 mm² 688E 1/2
SC1 /21.D6 TO
HYD TEMP 0.75 mm² 538 2/2

P069:4 /21.E1 FROM
IGNITION +VE
SC5 /3.B6 FROM
ISOLATION SOL
C047:6 /22.E4 TO
33 - 94 9823/0300-1 33 - 94
Page Page
33-94 33-95

1.00 mm² 435LP PIN LOCK TO
/22.E4 C047:8
GROUND TO
/20.C4 SC9
-C153A -C153C
PIN LOCK 5K6 PIN LOCK 1K8
2 1.00 mm² 435D -SC153 0.75 mm² 699C 1 2 1.00 mm² 699LP HYD ECU SENSOR GND
TO
/22.C6 SC28
-C153B
PIN LOCK 33K
2 1.00 mm² 435E
GROUND TO
/20.C4 SC9
-C154A
AUX VENT5K6
2 1.00 mm² 436D
-C154B -C154C
AUX VENT33K AUX VENT1K8
2 1.00 mm² 436E -SC154 1.00 mm² 699AX 1 2 1.00 mm² 699AV HYD ECU SENSOR GND
TO
/22.C6 SC28
Page 33-94
1.00 mm² 436AV
GROUND
TO
/20.C4 SC9
-C022B
LOCK 1K 300R
2 0.75 mm² 699TC HYD ECU SENSOR GND
TO
/22.B6
-C022C
LOCK 5K 360R
2 0.75 mm² 699TD
-C022A
LOCK 10K
2 0.75 mm² 699TB
-C010
VENTING VALVE
AUX VENT 1.00 mm² 500VEN 1/2
C057:19 /6.E3 FROM
GROUND 1.00 mm² 600VEN 2/2

SC2 /6.D3 TO
-V010
ISOLATION SOLENOID
IGNITION +VE 1.00 mm² 109SA 1/2
/3.B6 FROM
/22.E4
ISOLATION SOL
TO 0.75 mm² 611 2/2 160/G6925-2 Sheet 23
33 - 95 9823/0300-1 33 - 95
33 - 96 9823/0300-1 33 - 96
Page 33-98 Figure 1087. Valve Block Page 33-99

-V003 -V005
BOOM RAISE EXTEND
1/2 1.00 mm² 420 LIFT EXTEND 1.00 mm² 423 1/2
FROM
/22.F6 C048:1 C048:2 /22.F6 FROM
2/2 1.00 mm² 422A 1.00 mm² 425A 2/2
A -V002 -V004 B
BOOM LOWER RETRACT
1/2 1.00 mm² 421 LOWER RETRACT 1.00 mm² 424 1/2
FROM
/22.E5 C047:14 C046:13 /22.E2 FROM
2/2 1.00 mm² 422B 1.00 mm² 422 LIFT/LOWER RTN EXTEND/RETRACT RTN 0.75 mm² 425 1.00 mm² 425B 2/2
TO
/22.E2 C046:17 C046:6 /22.E1 TO
-SV1 -SV2
-V006 -V009
DUMP BOOM AUX A
1/2 1.00 mm² 427 DUMP BOOM AUX A 1.00 mm² 429 1/2
FROM
/22.D2 C049:13 C049:14 /22.D2 FROM
2/2 1.00 mm² 428B 1.00 mm² 431A 2/2
D -V007 -V008 C
CROWD AUX B
1/2 1.00 mm² 426 CROWD BOOM AUX B 1.00 mm² 430 1/2
FROM
/22.D1 C049:1 C050:2 /22.D4 FROM
2/2 1.00 mm² 428A 1.00 mm² 428 DUMP/CROWD RTN AUX A/AUX B RTN 1.00 mm² 431 -SV4 1.00 mm² 431B 2/2
TO
/22.E7 C048:17 C046:18 /22.E2 TO
-SV3
160/GG6925-2 Sheet 24
0.75 mm² 431C AUX A/AUX B RTN
FROM
/25.C6 C032:6
33 - 97 9823/0300-1 33 - 97
Page Page
33-98 33-99
Figure-V003
1087. (Part 1 of 2)
BOOM RAISE
1/2 1.00 mm² 420 LIFT

FROM
/22.F6 C048:1
2/2 1.00 mm² 422A
A -V002
BOOM LOWER
1/2 1.00 mm² 421 LOWER

FROM
/22.E5 C047:14
2/2 1.00 mm² 422B 1.00 mm² 422 LIFT/LOWER RTN

TO
/22.E2 C046:17
-SV1
-V006
DUMP
1/2 1.00 mm² 427 DUMP

FROM
/22.D2 C049:13
2/2 1.00 mm² 428B
D -V007
CROWD
1/2 1.00 mm² 426 CROWD

FROM
/22.D1 C049:1
2/2 1.00 mm² 428A 1.00 mm² 428 DUMP/CROWD RTN

/22.E7 C048:17
Page 33-99
TO
-SV3
33 - 98 9823/0300-1 33 - 98
Page Page
33-98 33-99
-V005
EXTEND
EXTEND 1.00 mm² 423 1/2
C048:2 /22.F6 FROM
1.00 mm² 425A 2/2
-V004 B
RETRACT
RETRACT 1.00 mm² 424 1/2
C046:13 /22.E2 FROM
EXTEND/RETRACT RTN 0.75 mm² 425 1.00 mm² 425B 2/2

C046:6 /22.E1 TO
-SV2
-V009
BOOM AUX A
BOOM AUX A 1.00 mm² 429 1/2
C049:14 /22.D2 FROM
1.00 mm² 431A 2/2
-V008 C
AUX B
BOOM AUX B 1.00 mm² 430 1/2
C050:2 /22.D4 FROM
AUX A/AUX B RTN 1.00 mm² 431 -SV4 1.00 mm² 431B 2/2
C046:18 /22.E2
Page 33-98
TO
160/GG6925-2 Sheet 24
0.75 mm² 431C AUX A/AUX B RTN
FROM
/25.C6 C032:6
33 - 99 9823/0300-1 33 - 99
A Lift/Lower spool B Extend/Retract spool

C Auxiliary spool D Crowd/Dump spool
33 - 100 9823/0300-1 33 - 100

Page 33-102 Figure 1088. Auxiliary Hydraulics Page 33-103

-P017
FRONT / REAR AUX
SWITCH ILLUMINATION 1.00 mm² 829X 8 7 1.00 mm² 601BB CAN SHLD
SP7 /18.D5 FROM TO
/19.B6 SP28
-C027
IGNITION +VE 2 AUX C/O VALVE
P001:4 /3.E5 FROM 1.50 mm² 114 -P039 -C004
3 1.50 mm² 850 A6/84 A6/84 1.50 mm² 850 1.50 mm² 850 1/2
GROUND 1.00 mm² 601CO 2/2

SC9 /20.C4 TO
1.00 mm² 481B FRON/REAR AUX

TO
/9.D5 P072:15
-B003
AUX
-C032 -B001
2ND AUX VALVE 1.50 mm² 851 3/6 3/6 1.50 mm² 851 1/4 1/4
C050:1 /22.D4 FROM
GROUND 1.50 mm² 605AO 4/6 4/6 1.50 mm² 600AT 2/4 2/4
SC16 /10.C5 TO
CAN SHLD 1.00 mm² 601DZ BOOM AUX 0.75 mm² 435 5/6 5/6 0.75 mm² 435 3/4 3/4
SP11/19.D6 TO
C046:14 /22.E2 FROM
AUX A/AUX B RTN 0.75 mm² 431C 6/6 6/6 0.75 mm² 431C 4/4 4/4
SV4 /24.C6 TO
-P036
CONSTANT AUX SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AX 8 7
SP7 /18.E5 FROM
-P081
CONST AUX 1K 300R
1 0.75 mm² 485AA 1 2 1.00 mm² 699SA -SP44 1.00 mm² 699SK HYD ECU SENSOR GND
-C004 -P039 TO
/19.E1 SP42
CONSTANT AUX 1.00 mm² 447CA F11/84 F11/84 0.75 mm² 485D 2
C050:5 /22.D4 FROM
0.75 mm² 485E 4

5 -P082
CONST AUX 5K 360R
6 0.75 mm² 485BB 1 2 1.00 mm² 699SC
-P083
CONST AUX 10K
0.75 mm² 485F 1 2 1.00 mm² 699SB
33 - 101 9823/0300-1 33 - 101

Page Page
33-102 33-103

FRONT / REAR AUX
SWITCH ILLUMINATION 1.00 mm² 829X 8 7 1.00 mm² 601BB CAN SHLD
SP7 /18.D5 FROM TO
/19.B6 SP28
IGNITION +VE 1.50 mm² 114 2

P001:4 /3.E5 FROM
-P039 -C004
3 1.50 mm² 850 A6/84 A6/84
1.00 mm² 481B FRON/REAR AUX

TO
/9.D5

SP11/19.D6 TO
-P036
CONSTANT AUX SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AX 8 7
SP7 /18.E5 FROM
-P081
CONST AUX 1K 300R
1 0.75 mm² 485AA 1 2
-C004 -P039
CONSTANT AUX 1.00 mm² 447CA F11/84 F11/84 0.75 mm² 485D 2
C050:5 /22.D4 FROM
0.75 mm² 485E 4

5 -P082
CONST AUX 5K 360R
6 0.75 mm² 485BB 1 2
Page 33-103
-P083
CONST AUX 10K
0.75 mm² 485F 1 2
33 - 102 9823/0300-1 33 - 102

Page Page
33-102 33-103
-C027
AUX C/O VALVE
-C004
A6/84 1.50 mm² 850 1.50 mm² 850 1/2
GROUND 1.00 mm² 601CO 2/2

SC9 /20.C4 TO
FRON/REAR AUX TO
/9.D5 P072:15
-B003
AUX
-C032 -B001
2ND AUX VALVE 1.50 mm² 851 3/6 3/6 1.50 mm² 851 1/4 1/4
C050:1 /22.D4 FROM
GROUND 1.50 mm² 605AO 4/6 4/6 1.50 mm² 600AT 2/4 2/4
SC16 /10.C5 TO
BOOM AUX 0.75 mm² 435 5/6 5/6 0.75 mm² 435 3/4 3/4
C046:14 /22.E2 FROM
AUX A/AUX B RTN 0.75 mm² 431C 6/6 6/6 0.75 mm² 431C 4/4 4/4
SV4 /24.C6 TO
CONST AUX 1K 300R

2 1.00 mm² 699SA -SP44 1.00 mm² 699SK HYD ECU SENSOR GND
TO
/19.E1 SP42
CONST AUX 5K 360R

2 1.00 mm² 699SC
Page 33-102
CONST AUX 10K

2 1.00 mm² 699SB
33 - 103 9823/0300-1 33 - 103

33 - 104 9823/0300-1 33 - 104

Page 33-106 Figure 1089. Steer Mode Page 33-107

HYD ECU 5V REF 0.75 mm² 456FB
P090:1 /29.D5 TO
-P095
FRONT PROX -C026
STEER MODE SWITCH C050:6 /22.C4 1.00 mm² 819B
FRONT STEER SENSOR
TO
FRONT PROX 1.00 mm² 819 1.00 mm² 819A A/3 A/3
C050:11 /22.D5 TO
HYD ECU 5V REF 1.50 mm² 456PC -SP10 1.00 mm² 456SA 1/6 -SSN026
SC14 / P039:D1 /22.D7 FROM
IGNITION +VE 1.00 mm² 109FA B/3 B/3

-P039 -C004 SC5 /3.B6 FROM
2/6 888A 1.00 mm² G5/84 G5/84 1.00 mm² 888A STEER MODETO
/22.C4 P050:9
GROUND 1.00 mm² 602H C/3 C/3
SC9 /20.C4 TO
HYD ECU SENSOR GND 1.00 mm² 699CH 3/6

SP42 /19.D1 TO
REAR PROX -C024

1.00 mm² 456SB 4/6 C049:7 /22.C1 1.00 mm² 820B
REAR STEER SENSOR
TO
-P039 -C004
STEER MODE REAR PROX
5/6 888C 1.00 mm² G6/84 G6/84 1.00 mm² 888C TO
/22.D5 P050:10 C050:3 /22.D4 TO 1.00 mm² 820 1.00 mm² 820A A/3 A/3
-SSN024
HYD ECU SENSOR GND 1.00 mm² 699SJ 6/6 IGNITION +VE 1.00 mm² 109RA B/3 B/3
SP42 /19.D1 TO
SC5 /3.B6 FROM
GROUND 1.00 mm² 603A C/3 C/3

SC9 /20.C4 TO
-C031
CRAB STEER
CRAB STEER 1.00 mm² 824 1/2 2/2 1.00 mm² 602D
C047:1 /22.F4 FROM
-C030
ALL WHEEL STEER
ALL WHEEL STEER 1.00 mm² 848 1/2 2/2 1.00 mm² 602C
C047:2 /22.F4 FROM
-C028
2 WHEEL STEER
2 WHEEL STEER 1.00 mm² 825 1/2 2/2 1.00 mm² 602A
C047:7 /22.E4 FROM
-C029 160/G6925-2 Sheet 26

4 WHEEL STEER
4 WHEEL STEER 1.00 mm² 826 1/2 2/2 1.00 mm² 602B
C047:13 /22.E5 FROM
-SC8
STEER SOL GND 2.00 mm² 602

C047:18 /22.E5 TO
33 - 105 9823/0300-1 33 - 105

Page Page
33-106 33-107
HYD ECU 5V REF

Figure 1089. (Part 10.75of
P090:1 /29.D5 TO
2)
mm² 456FB
-P095
STEER MODE SWITCH
HYD ECU 5V REF 1.50 mm² 456PC -SP10 1.00 mm² 456SA 1/6
SC14 / P039:D1 /22.D7 FROM
-P039 -C004
2/6 888A 1.00 mm² G5/84 G5/84 1.00 mm²
HYD ECU SENSOR GND 1.00 mm² 699CH 3/6

SP42 /19.D1 TO
1.00 mm² 456SB 4/6
-P039 -C004
5/6 888C 1.00 mm² G6/84 G6/84 1.00 mm²
HYD ECU SENSOR GND 1.00 mm² 699SJ 6/6

SP42 /19.D1 TO
CRAB STEER 1.00 mm² 824

C047:1 /22.F4 FROM
Page 33-107
ALL WHEEL STEER 1.00 mm² 848
C047:2 /22.F4 FROM
2 WHEEL STEER 1.00 mm² 825

C047:7 /22.E4 FROM
4 WHEEL STEER 1.00 mm² 826

C047:13 /22.E5 FROM
STEER SOL GND 2.00 mm² 602

C047:18 /22.E5 TO
33 - 106 9823/0300-1 33 - 106

Page Page
33-106 33-107
FRONT PROX -C026

C050:6 /22.C4 1.00 mm² 819B
FRONT STEER SENSOR
TO
FRONT PROX 1.00 mm² 819 1.00 mm² 819A A/3 A/3
C050:11 /22.D5 TO
-SSN026
IGNITION +VE 1.00 mm² 109FA B/3 B/3
-C004 SC5 /3.B6 FROM
G5/84 1.00 mm² 888A STEER MODETO

/22.C4 P050:9
GROUND 1.00 mm² 602H C/3 C/3
SC9 /20.C4 TO
REAR PROX -C024

C049:7 /22.C1 1.00 mm² 820B
REAR STEER SENSOR
TO
-C004
STEER MODE REAR PROX
G6/84 1.00 mm² 888C TO
/22.D5 P050:10 C050:3 /22.D4 TO 1.00 mm² 820 1.00 mm² 820A A/3 A/3
-SSN024
IGNITION +VE 1.00 mm² 109RA B/3 B/3
SC5 /3.B6 FROM
GROUND 1.00 mm² 603A C/3 C/3

SC9 /20.C4 TO
-C031
CRAB STEER
824 1/2 2/2 1.00 mm² 602D
-C030
ALL WHEEL STEER
Page 33-106
848 1/2 2/2 1.00 mm² 602C
-C028
2 WHEEL STEER
825 1/2 2/2 1.00 mm² 602A
-C029 160/G6925-2 Sheet 26

4 WHEEL STEER
826 1/2 2/2 1.00 mm² 602B -SC8
602
33 - 107 9823/0300-1 33 - 107

33 - 108 9823/0300-1 33 - 108

Page 33-110 Figure 1090. SRS Page 33-111

-P062
SRS SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AR 8 7 1.00 mm² 601KK CAN SHLD
SP7 /18.C5 FROM TO
/19.C4 SP6
1 0.75 mm² 699DD -SP2 1.00 mm² 699CG HYD ECU SENSOR GND
-C004 -P039 TO
/19.D1 SP42
SRS 0.75 mm² 499A F10/84 F10/84 1.00 mm² 499A 2 -P075
C048:16 /22.E7 FROM
SRS 1K 300R
3 1.00 mm² 499AA 1 2 0.75 mm² 699AA
1.00 mm² 499L 4
5 -P076
SRS 5K 360R
6 0.75 mm² 499BB 1 2 0.75 mm² 699BB
-P077
SRS 10K
1.00 mm² 499M 1 2 1.00 mm² 699CC
-SR02
SRS TRANSDUCER
-C040 -SR01
HYD ECU 5V REF 0.75 mm² 456E 1/8 1/8 0.75 mm² 456E 2 1 1.00 mm² 609G
SC31 /22.D6 FROM
+ -
3 0.75 mm² 443
SW O/P
4 0.75 mm² 444
OUTPUT
SRS TRANSD 0.75 mm² 444 5/8 5/8 0.75 mm² 444
C047:17 /22.E5 TO
SRS TRANSD 0.75 mm² 443 4/8 4/8 0.75 mm² 443
C050:16 /22.C5 TO
HYD ECU SENSOR GND 1.00 mm² 699G 7/8 7/8 1.00 mm² 609G
SC28 /22.B6 TO
-SR03
ACCUMULATOR SOLENOID
ACCUMULATOR SOL 1.00 mm² 442 3/8 3/8 1.00 mm² 442 1/2
C049:2 /22.D1 FROM
ACCU/DRAIN RTN -SSR1

C048:6 /22.E6 TO 1.00 mm² 608ST 8/8 8/8 1.00 mm² 608E 1.00 mm² 608AS 2/2
-SR04
DRAIN SOLENOID
DRAIN SOL 1.00 mm² 441 2/8 2/8 1.00 mm² 441 1/2
C048:14 /22.E7
160/G6925-2 Sheet 27
FROM
1.00 mm² 608DS 2/2
33 - 109 9823/0300-1 33 - 109

Page Page
33-110 33-111

SRS SWITCH
SWITCH ILLUMINATION 1.00 mm² 829AR 8
SP7 /18.C5 FROM
-C004 -P039
SRS 0.75 mm² 499A F10/84 F10/84 1.00 mm² 499A 2
C048:16 /22.E7 FROM
1.00 mm² 499L

5
1.00 mm² 499M
-C040 -SR01
HYD ECU 5V REF 0.75 mm² 456E 1/8 1/8 0.75 mm²
SC31 /22.D6 FROM
Page 33-111
SRS TRANSD 0.75 mm² 444 5/8 5/8 0.75 mm²
C047:17 /22.E5 TO
SRS TRANSD 0.75 mm² 443 4/8 4/8 0.75 mm²

C050:16 /22.C5 TO
HYD ECU SENSOR GND 1.00 mm² 699G 7/8 7/8 1.00 mm²
SC28 /22.B6 TO
ACCUMULATOR SOL 1.00 mm² 442 3/8 3/8 1.00 mm²

C049:2 /22.D1 FROM
ACCU/DRAIN RTN 1.00 mm² 608ST 8/8 8/8 1.00 mm²

C048:6 /22.E6 TO
DRAIN SOL 1.00 mm² 441 2/8 2/8 1.00 mm²

C048:14 /22.E7 FROM
33 - 110 9823/0300-1 33 - 110

Page Page
33-110 33-111
-P062
SRS SWITCH
8 7 1.00 mm² 601KK CAN SHLD TO
/19.C4 SP6
1 0.75 mm² 699DD -SP2 1.00 mm² 699CG HYD ECU SENSOR GND
TO
/19.D1 SP42
2 -P075
SRS 1K 300R
3 1.00 mm² 499AA 1 2 0.75 mm² 699AA
4
5 -P076
SRS 5K 360R
6 0.75 mm² 499BB 1 2 0.75 mm² 699BB
-P077
SRS 10K
1 2 1.00 mm² 699CC
-SR02
SRS TRANSDUCER
-SR01
1/8 0.75 mm² 456E 2 1 1.00 mm² 609G
+ -
3 0.75 mm² 443
SW O/P
Page 33-110
4 0.75 mm² 444

OUTPUT
5/8 0.75 mm² 444
4/8 0.75 mm² 443
7/8 1.00 mm² 609G
-SR03
ACCUMULATOR SOLENOID
3/8 1.00 mm² 442 1/2
-SSR1
8/8 1.00 mm² 608E 1.00 mm² 608AS 2/2
-SR04
DRAIN SOLENOID
2/8 1.00 mm² 441 1/2

160/G6925-2 Sheet 27
1.00 mm² 608DS 2/2
33 - 111 9823/0300-1 33 - 111

33 - 112 9823/0300-1 33 - 112

Page 33-114 Figure 1091. LLMI Page 33-115

-C025
-P042-A LLMI TRANSDUCER
LLMI 1/6 4/6 1.00 mm² 155LM IGNITION +VE
FROM
/22.B4 SC11
-P039 -C004
IGNITION +VE 1.00 mm² 101A 1/4 2/4 0.75 mm² 413 B3/84 B3/84 1.00 mm² 413 2/6 5/6
P005:16 /3.C7 FROM
-P039 -C004
CAN SHLD 0.75 mm² 601AK 4/4 3/4 0.75 mm² 414 B4/84 B4/84 1.00 mm² 414 3/6 6/6 1.00 mm² 602LM GROUND
SP28 /19.B6 TO TO
/20.B4 SC9
CAN HI 0.50 mm² CAN H A/3 1.00 mm² 609LM

SVMC13 /17.E5 FROM
CAN LO 0.50 mm² CAN L B/3

SVMC14 /17.E5 FROM
CAN SHLD 0.50 mm² CAN SCR C/3

SVMC15 /17.E5 FROM
-P042-B
RETRACT PROX 0.75 mm² 452EC
P046:10 /22.F2 TO
-B004 -C045C
RETRACT PROXIMITY SWITCH -C045B
-B005 -C045 BOOM RETRACT 5K6R BOOM RETRACT 1K8R
2/4 1.00 mm² 1915A 2/4 2/4 0.75 mm² 450 1 2 0.75 mm² 452A -SC6 0.75 mm² 452C 1 2 0.75 mm² 699BB HYD ECU SENSOR GND
-C045 -B005 TO
/22.B6 SC28
IGNITION +VE 0.75 mm² 155SA 1/4 1/4 1.00 mm² 107H 1/4
SC11 /22.B4 FROM
-C045A
0.75 mm² 155SB 4/4 4/4 1.00 mm² 601A 4/4 BOOM RETACT 33K
3/4 1.00 mm² 1915 3/4 3/4 0.75 mm² 451 1 2 0.75 mm² 452B
-C052 -C023
CHASSIS ANGLE SENSOR BOOM ANGLE SENSOR
HYD ECU 5V REF 0.75 mm² 456F 1/6 HYD ECU 5V REF 0.75 mm² 456H 1/6
SC31 /22.D6 FROM
SC31 /22.D6 FROM
CHASSIS ANGLE 0.75 mm² 475 2/6 BOOM ANGLE 0.75 mm² 448 2/6
C048:4 /22.E6 TO
C049:8 /22.C1 TO
HYD ECU SENSOR GND 0.75 mm² 699K 3/6 HYD ECU SENSOR GND 0.75 mm² 609C 3/6
SC28 /22.B6 TO
SC28 /22.B6 TO
0.75 mm² 456G 4/6 0.75 mm² 456J 4/6
CHASSIS ANGLE 0.75 mm² 476 5/6 BOOM ANGLE 0.75 mm² 449 5/6
C048:5 /22.E6 TO
C048:3 /22.F6 TO
160/G6925-2 Sheet 28
0.75 mm² 699L 6/6 0.75 mm² 609B 6/6
33 - 113 9823/0300-1 33 - 113

Page Page
33-114 33-115
Figure 1091. (Part 1 of 2) -P042-A

LLMI
-P039
IGNITION +VE 1.00 mm² 101A 1/4 2/4 0.75 mm² 413 B3/84
P005:16 /3.C7 FROM
-P039
CAN SHLD 0.75 mm² 601AK 4/4 3/4 0.75 mm² 414 B4/84
SP28 /19.B6 TO
CAN HI 0.50 mm² CAN H A/3

SVMC13 /17.E5 FROM
CAN LO 0.50 mm² CAN L B/3

SVMC14 /17.E5 FROM
CAN SHLD 0.50 mm² CAN SCR C/3

SVMC15 /17.E5 FROM
-P042-B
-B004
RETRACT PROXIMITY SWITCH
-B005 -C045
-C045 -B005 2/4 1.00 mm² 1915A 2/4 2/4 0.75 mm²
IGNITION +VE 0.75 mm² 155SA 1/4 1/4 1.00 mm² 107H 1/4
SC11 /22.B4 FROM
0.75 mm² 155SB 4/4 4/4 1.00 mm² 601A 4/4

3/4 1.00 mm² 1915 3/4 3/4 0.75 mm²
Page 33-115
-C052
CHASSIS ANGLE SENSOR
HYD ECU 5V REF 0.75 mm² 456F 1/6
SC31 /22.D6 FROM
CHASSIS ANGLE 0.75 mm² 475 2/6

C048:4 /22.E6 TO
HYD ECU SENSOR GND 0.75 mm² 699K 3/6

SC28 /22.B6 TO
0.75 mm² 456G 4/6
CHASSIS ANGLE 0.75 mm² 476 5/6

C048:5 /22.E6 TO
0.75 mm² 699L 6/6
33 - 114 9823/0300-1 33 - 114

Page Page
33-114 33-115
-C025
Figure 1091. (Part 2 of 2) LLMI TRANSDUCER
1/6 4/6 1.00 mm² 155LM IGNITION +VE

FROM
/22.B4 SC11
-P039 -C004
413 B3/84 B3/84 1.00 mm² 413 2/6 5/6
-P039 -C004
414 B4/84 B4/84 1.00 mm² 414 3/6 6/6 1.00 mm² 602LM GROUND TO
/20.B4 SC9
1.00 mm² 609LM
RETRACT PROX 0.75 mm² 452EC

P046:10 /22.F2 TO
-C045C
-C045B
-C045 BOOM RETRACT 5K6R BOOM RETRACT 1K8R
2/4 0.75 mm² 450 1 2 0.75 mm² 452A -SC6 0.75 mm² 452C 1 2 0.75 mm² 699BB HYD ECU SENSOR GND TO
/22.B6 SC28
-C045A
BOOM RETACT 33K
3/4 0.75 mm² 451 1 2 0.75 mm² 452B
Page 33-114
-C023
BOOM ANGLE SENSOR
HYD ECU 5V REF 0.75 mm² 456H 1/6
SC31 /22.D6 FROM
BOOM ANGLE 0.75 mm² 448 2/6

C049:8 /22.C1 TO
HYD ECU SENSOR GND 0.75 mm² 609C 3/6

SC28 /22.B6 TO
0.75 mm² 456J 4/6
BOOM ANGLE 0.75 mm² 449 5/6

C048:3 /22.F6 TO
160/G6925-2 Sheet 28
0.75 mm² 609B 6/6
33 - 115 9823/0300-1 33 - 115

33 - 116 9823/0300-1 33 - 116

Page 33-118 Figure 1092. Braking Page 33-119

-C149
FOOTBRAKE TRANSDUCER
GROUND 1.00 mm² 605AE 1/4 4/4 1.00 mm² 468 INCHING SIGNAL
SC9 /20.C4 TO TO
/21.D1
IGNITION +VE 1.00 mm² 109FB 2/4 3/4
SC5 /3.B6 FROM
-P050
FOOTBRAKE SWITCH -P092
FOOTBRAKE 5K 360R
1/3 0.75 mm² 887 1 2 0.75 mm² 699CC HYD ECU SENSOR GND
TO
/19.D1 SP42
0.75 mm² 876B 3/3
2/3 0.75 mm² 886 1 2 0.75 mm² 699CB HYD ECU SENSOR GND
TO
/19.D1 SP42
-P091
FOOTBRAKE 1K 300R
-P090
FOOTBRAKE 10K
0.75 mm² 876A 2 1 0.75 mm² 456FB HYD ECU 5V REF
-SP1 FROM
/26.E1 SP10
-P039 -C004
0.75 mm² 876 C2/84 C2/84 1.00 mm² 876 FOOTBRAKE SWITCH
TO
/22.E4 C047:4
-C152
PARK BRAKE LEVER
-C151
1/4 0.75 mm² 699PB HYD ECU SENSOR GND
TO
/22.B6 SC28 PARK BRAKE VALVE
2/4 0.75 mm² 456PB HYD ECU 5V REF PARK BRAKE VALVE 0.75 mm² 818B 1/2
FROM
/22.C6 SC31 C050:13 /22.D5 FROM
3/4 0.75 mm² 818 PARK BRAKE LEVER PARK BRAKE VALVE RTN 0.75 mm² 818C 2/2
TO
/22.C4 C050:8 C048:18 /22.E7 TO
4/4 0.75 mm² 819PB PARK BRAKE LEVER

TO
/22.E2 C046:15
-P039
0.75 mm² 875 C12/84
-P111
-P109
-RC01 -P049 PARKBRAKE 33K PARKBRAKE 1K8
-RC12 0.75 mm² 815B 13/20 13/20 0.75 mm² 815B 1 2 0.75 mm² 875B -SP45 0.75 mm² 875CC 1 2 0.75 mm² 699CF HYD ECU SENSOR GND
PARK BRAKE
TO
/19.D1 SP42
-P049 -RC01 2/3

IGNITION +VE 1.00 mm² 107PB 10/20 10/20 1.00 mm² 107PB 3/3
P003:6 /3.B5 FROM
1/3 -P110
160/G6925-2 Sheet 29
-RC01 -P049 PARKBRAKE 5K6
0.75 mm² 815A 11/20 11/20 0.75 mm² 815A 1 2 0.75 mm² 875AA
33 - 117 9823/0300-1 33 - 117

Page Page
33-118 33-119
Figure 1092. (Part 1 of 2) -C149

GROUND 1.00 mm² 605AE 1/4 4/4

SC9 /20.C4 TO
IGNITION +VE 1.00 mm² 109FB 2/4 3/4

SC5 /3.B6 FROM
-P050
FOOTBRAKE SWITCH
1/3 0.75 mm² 887

0.75 mm² 876B 3/3
2/3 0.75 mm² 886
-SP1 0.75 mm² 876A
0.75 mm² 876
-C152
PARK BRAKE LEVER
1/4 0.75 mm² 699PB HYD ECU SENSOR GND

TO
/22.B6 SC28
HYD ECU 5V REF PARK BRAKE VALVE
Page 33-119
2/4 0.75 mm² 456PB FROM
/22.C6 SC31 C050:13 /22.D5 FROM
3/4 0.75 mm² 818 PARK BRAKE LEVER PARK BRAKE VALVE RTN
TO
/22.C4 C050:8 C048:18 /22.E7
4/4 0.75 mm² 819PB PARK BRAKE LEVER

TO
/22.E2 C046:15
-RC01 -P049
-RC12 0.75 mm² 815B 13/20 13/20 0.75 mm²
PARK BRAKE
-P049 -RC01 2/3

IGNITION +VE 1.00 mm² 107PB 10/20 10/20 1.00 mm² 107PB 3/3
P003:6 /3.B5 FROM
1/3
-RC01 -P049
0.75 mm² 815A 11/20 11/20 0.75 mm²
33 - 118 9823/0300-1 33 - 118

Page Page
33-118 33-119
Figure 1092.
-C149
(Part 2 of 2)
4/4 1.00 mm² 468 INCHING SIGNAL

TO
/21.D1
3/4
-P092
FOOTBRAKE 5K 360R
0.75 mm² 887 1 2 0.75 mm² 699CC HYD ECU SENSOR GND
TO
/19.D1 SP42
0.75 mm² 886 1 2 0.75 mm² 699CB HYD ECU SENSOR GND
TO
/19.D1 SP42
-P091
FOOTBRAKE 1K 300R
-P090
FOOTBRAKE 10K
0.75 mm² 876A 2 1 0.75 mm² 456FB HYD ECU 5V REF
FROM
/26.E1 SP10
-P039 -C004
0.75 mm² 876 C2/84 C2/84 1.00 mm² 876 FOOTBRAKE SWITCH
TO
/22.E4 C047:4
-C151
PARK BRAKE VALVE
PARK BRAKE VALVE
Page 33-118
C050:13 /22.D5 FROM 0.75 mm² 818B 1/2
PARK BRAKE VALVE RTN 0.75 mm² 818C 2/2

C048:18 /22.E7 TO
-P039
0.75 mm² 875 C12/84
-P111
-P109
-P049 PARKBRAKE 33K PARKBRAKE 1K8
13/20 0.75 mm² 815B 1 2 0.75 mm² 875B -SP45 0.75 mm² 875CC 1 2 0.75 mm² 699CF HYD ECU SENSOR GND
TO
/19.D1 SP42
-P110
160/G6925-2 Sheet 29
-P049 PARKBRAKE 5K6
11/20 0.75 mm² 815A 1 2 0.75 mm² 875AA
33 - 119 9823/0300-1 33 - 119

33 - 120 9823/0300-1 33 - 120

Page 33-122 Figure 1093. Joystick Page 33-123

SP28 /19.B6 TO
-P018
JOYSTICK ISOLATION
SWITCH ILLUMINATION 1.00 mm² 829Y 8 7
SP7 /18.C5 FROM
-P084
JOYSTICK ISO. 1K 300R
1 0.75 mm² 433AA 1 2 0.75 mm² 699JJ -SP43 0.75 mm² 699CE HYD ECU SENSOR GND
-C004 -P039 TO
/19.E1 SP42
JOYSTICK ISO 1.00 mm² 433JB F4/84 F4/84 0.75 mm² 433A 2
C048:15 /22.E7 FROM
0.75 mm² 433B 4

5 -P085
6 0.75 mm² 433BB 1 2 0.75 mm² 699KK
-P086
JOYSTICK ISO. 10K
0.75 mm² 433C 1 2 0.75 mm² 699LL
JOYSTICK
-C014
IGNITION +VE 1.00 mm² 155JS 1 2 1.00 mm² 605H GROUND
SC11 /22.B4 FROM
V BATT GND TO
/20.E4 SC12
3
-
4
-
CAN HI 0.50 mm² CAN H 5
SPMC07 /17.C5 FROM
CAN H
6
CAN L
CAN HI 0.50 mm² CAN L
SPMC08 /17.C5 FROM
-C013
CAN SHLD 0.50 mm² SCR 1
SPMC09 /17.C5 FROM
YELLOW 1
-SCREEN 2
YELLOW 5
JOYSTICK 1.00 mm² 895CA 3
C050:17 /22.C5 TO
YELLOW 6
4
-
160/G6925-2 Sheet 30
-C055
HYDRAULIC ISO SWITCH
2
07/11 5V REF 0.75 mm² 489A 1
SC3 /21.E6 FROM
HYD ISO SWITCH 1.00 mm² 489 3

C047:16 /22.E5 TO
4 1.00 mm² 489B
33 - 121 9823/0300-1 33 - 121

Page Page
33-122 33-123
CAN SHLD
Figure 1093. (Part 1SP28
of/19.B6
2) TO 1.00 mm² 601EN
-P018
JOYSTICK ISOLATION
SWITCH ILLUMINATION 1.00 mm² 829Y 8 7
SP7 /18.C5 FROM
1
-C004 -P039
JOYSTICK ISO 1.00 mm² 433JB F4/84 F4/84 0.75 mm² 433A 2
C048:15 /22.E7 FROM
0.75 mm² 433B 4

5
6
JOYSTICK
-C014
IGNITION +VE 1.00 mm² 155JS 1
SC11 /22.B4 FROM
V BATT GND
3
-
4
-
CAN HI 0.50 mm² CAN H 5
SPMC07 /17.C5 FROM
CAN H
6
CAN L
CAN HI 0.50 mm² CAN L
SPMC08 /17.C5 FROM
-C013
CAN SHLD 0.50 mm² SCR 1
SPMC09 /17.C5 YELLOW 1
Page 33-123
FROM
-SCREEN 2
YELLOW 5
JOYSTICK 1.00 mm² 895CA 3
C050:17 /22.C5 TO
YELLOW 6
4
-
-C055
07/11 5V REF 0.75 mm² 489A 1

SC3 /21.E6 FROM
HYD ISO SWITCH 1.00 mm² 489 3

C047:16 /22.E5 TO
33 - 122 9823/0300-1 33 - 122

Page Page
33-122 33-123
-P018
JOYSTICK ISOLATION
7
-P084
1 0.75 mm² 433AA 1 2 0.75 mm² 699JJ -SP43 0.75 mm² 699CE HYD ECU SENSOR GND
TO
/19.E1 SP42
3
4
-P085
6 0.75 mm² 433BB 1 2 0.75 mm² 699KK
-P086
JOYSTICK ISO. 10K
0.75 mm² 433C 1 2 0.75 mm² 699LL
JOYSTICK
2 1.00 mm² 605H GROUND
GND TO
/20.E4 SC12
YELLOW 1
Page 33-122
YELLOW 5
YELLOW 6
160/G6925-2 Sheet 30
-C055
2
4 1.00 mm² 489B
33 - 123 9823/0300-1 33 - 123

Table 291.
Connector Code Device
B002 Starter Motor
B002 Boom Worklight
B003 Auxiliary
B004 Retract Proximity Switch
C002 LH Headlight
C005 RH Headlights
C006 Cooling Fan
C007 Ambient Sensor
C008 Hand Throttle/Creep
C010 Venting Valve
C013 Joystick
C014 Joystick
C017 RH Rear Lights
C018 LH Rear Lights
C019 Trailer Socket
C020 Number Plate Light
C021 Reverse Alarm
C022 Tilt Lock
C022A Tilt Lock 10K
C022B Tilt Lock 1K 300R
C022C Tilt Lock 5K 360R
C023 Boom Angle Sensor
C024 Rear Steer Sensor
C025 LLMITransducer
C026 Front Steer Sensor
C027 Auxiliary Changeover Valve
C028 2WS (Two Wheel Steer)
C029 4WS (Four Wheel Steer)
C030 AWS (All Wheel Steer)
C031 Crab Steer
C033 Hydraulic Temperature Sensor
C035 Fuel Level Sensor
C037 Ground
C045A Boom Retract 33K
C045B Boom Retract 5K6R
C045C Boom Retract 1K8R
C046 Hydraulics ECU
C047 Hydraulics ECU
C048 Hydraulics ECU
C049 Hydraulics ECU
C050 Hydraulics ECU
C051 Can Termination
C052 Chassis Angle Sensor
C052 Chassis Angle Sensor
C054 Auxiliary Socket
C055 Hydraulic ISO Switch
C056 Foot Throttle
33 - 124 9823/0300-1 33 - 124


C057 Rdm
C149 Foot brake Transducer
C150 Inching Pedal
C151 Park Brake Valve
C152 Park Brake Lever
C153 Pin Lock Switch
C153A Pin Lock 5K6
C153B Pin Lock 33K
C153C Pin Lock 1K8
C154 Auxiliary Venting
C154A Auxiliary Vent 5K6
C154B Auxiliary Vent 33K
C154C Auxiliary Vent 1K8
E001 Fuse/Relay Box
E002 Agglomerator
E003 Fuel Pump
E006 Vacuum Switch
E010 Terminator Resistor
E012 Reverse Fan
E013 Proportional Fan
E014 Speed Sensor
E020 70A Grid Heater
E024-1 Binary Switch
E024-2 Binary Switch
E025 Air Conditioning Compressor
E037 Alternator Excite Resistor
K1 Power Hold Relay
K2 Start Signal (Micro Relay)
K3 Fuel Pump (Micro Relay)
P001 Fuse Box A
P002 Fuse Box B
P003 Fuse Box C
P004 Fuse Box D
P005 Fuse Box E
P006 Ignition Relay 1
P009 Live Link Relay
P009 Reverse Alarm
P010 Neutral Start
P010 Immobiliser Ign Relay
P011 Brake Lights
P011 Boom Work Lights
P012 Front Worklights
P012 Rear Worklights
P013 Road lights
33 - 125 9823/0300-1 33 - 125


P013 Auxiliary Cooling Fan
P014 Trailer Sense
P014 Engine Running
P015 Air Con
P015 Roof Air Conditioning Fans
P016 Trailer LH Directional
P016 Trailer RH Directional
P017 Front/Rear Auxiliary
P018 Joystick Isolation
P019 Air Conditioning Switch
P019A Air Conditioning Switch 1K Res
P020 Hazard Switch
P021 Roof Wiper
P022 Rear Wash Wipe
P023 Fog Light Switch
P024 Headlights
P026 Worklights
P027 Four Wheel Drive
P028 Beacon Switch
P029 Boom Worklights
P031 LH Turn Signal Diode
P032 RH Turn Signal Diode
P033 Heater Connector
P034 Horn
P036 Constant Aux Switch
P037 Column Switch LH
P038 Column Switch RH
P040 Centre Cluster
P042 Rear Hitch Light
P042 Freeze Valve
P042A LLMI
P043 Ignition Switch
P044 Ignition Switch
P050 Foot brake Switch
P052A Heater Blower
P052B Heater Blower Resistor
P055 Front Wiper Motor
P059 Face Level Fan
P061 Reverse Fan
P062 SRS Switch
P063 Information button
P065 Auxiliary Connector
P066 Immobiliser
P068 Live Link
P069 07/11 Connector
P070 07/11 Connector
P071 Instrument panel
P072 Instrument panel
P073 Diagnostic Connector
33 - 126 9823/0300-1 33 - 126


P074 Can Terminator Resistor
P075 SRS 1K 300R
P076 SRS 5K 360R
P077 SRS 10K
P081 Constant Auxiliary 1K 300R
P082 Constant Auxiliary 5K 360 R
P083 Constant Auxiliary 10K
P084 Joystick ISO 1K 300R
P086 Joystick ISO 10K
P087 2/4WD 1K 8R
P088 2/4WD 5K 6R
P089 2/4WD 33K
P090 Foot brake 10K
P091 Foot brake 1K 300R
P092 Foot brake 5K 360R
P095 Steer Mode Switch
P0D1
P109 Park brake 33K
P110 Park brake 5K6
P111 Park brake 1Kb
P112 Heater 100R
P125 Terminator
P128 Front Worklights Diode
P129 Rear Worklights Diode
P130 Boom Worklight Diode
PC01-V
RC03 Air Seat
RC04 Rear Wiper
RC07 Beacon Socket
RC09 Roof Wiper
RC12 Park Brake
RC17 Seat Pressure Switch
RC18 Washer Pumps
RH02 Radio
RH03 Radio
RH04 LH Speaker
RH05 LH Speaker
RH06 RH Speaker
RH07 RH Speaker
SC12 ECU Ground
SE02 Ground
SE034 ECU Power
SR02 SRS Transducer
SR03 Accumulator Solenoid
SR04 Drain Solenoid
T002 Pump Forward
T003 Pump Reverse
T005 Motor Fast/Slow
33 - 127 9823/0300-1 33 - 127


T007 Pump Pressure
V002 Boom Lower
V003 Boom Raise
V004 Retract
V005 Extend
V006 Dump
V007 Crowd
V008 Auxiliary B
V009 Boom Auxiliary A
V010 Isolation Solenoid
WLF002 RH Front Worklight
WLF003 LH Front Worklight
WLR003 LH Rear Worklight
WLR004 RH Rear Worklight
33 - 128 9823/0300-1 33 - 128

90 - Earth Point
90 - Earth Point Introduction

Introduction .................................................. 33-129 The ground or earth refers to the reference point in an
Component Identification ............................. 33-130 electrical circuit from which voltages are measured,
a common return path for electrical current, or a
direct physical connection to earth. Electrical circuits
may be connected to ground or earth to prevent
user contact with dangerous voltage if the electrical
insulation fails.
Earth points can be useful when tracing electrical

faults typically when several electrical devices are
malfunctioning.
33 - 129 9823/0300-1 33 - 129

90 - Earth Point
Chassis Earth Locations
Figure 1094.
A Engine- chassis earth lead B Hydraulic ECU (Electronic Control Unit) ground
and various machine sensors
C Engine harness earth and CAN (Controller Area D Engine ECU earth and battery negative lead
Network)bus earth
E Livelink ECU earth, connects to the battery
isolator
33 - 130 9823/0300-1 33 - 130

90 - Earth Point
Engine- chassis earth lead
Figure 1095.
2
1
1 Engine 2 Chassis
33 - 131 9823/0300-1 33 - 131

90 - Earth Point
Hydraulic ECU ground and various machine

sensors
Figure 1096. Hydraulic ECU Ground
3
3 C037 sensor
33 - 132 9823/0300-1 33 - 132

90 - Earth Point
Figure 1097. Earth Lead Between the Cab- Chassis, Connects at C037 Also
33 - 133 9823/0300-1 33 - 133

90 - Earth Point
Engine harness earth and CANbus earth

Figure 1098. Engine Har-
ness Earth (Upper Boss)
Figure 1099. E034- CANbus Earth (Lower Stud)
4 Earth boss 5 Earth stud
33 - 134 9823/0300-1 33 - 134

90 - Earth Point
Engine ECU earth and battery negative lead
Figure 1100.
6 Engine ECU earth 7 Battery negative
33 - 135 9823/0300-1 33 - 135

90 - Earth Point
Livelink ECU earth, connects to the battery isolator
Figure 1101.
8 Isolator
33 - 136 9823/0300-1 33 - 136

90 - Earth Point
Cab Earth Locations

P025, P030 & P035- Panel harness earth stud
Figure 1102.
33 - 137 9823/0300-1 33 - 137

90 - Earth Point
Cab roof harness earth stud
Figure 1103.
33 - 138 9823/0300-1 33 - 138

03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ......................................................................................................................... 33-141

33-03-03 Isolator Switch .............................................................................................................. 33-151
33 - 139 9823/0300-1 33 - 139

Notes:
33 - 140 9823/0300-1 33 - 140

03 - Battery
00 - General
Introduction .................................................. 33-141 Batteries used in normal temperate climate
Health and Safety ........................................ 33-142 applications should not need topping up. However,
Technical Data ............................................. 33-143 in certain conditions (such as prolonged operation
Fault-Finding ................................................ 33-144 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Disconnect and Connect ............................. 33-145 frequently and topped up as necessary.
Check (Condition) ........................................ 33-148
Charge ......................................................... 33-149 The electrolyte level should be checked in
Remove and Install ..................................... 33-149 accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
machine is operating at high ambient temperatures
or continuously for long periods.
Later Machines may have the new type batteries

installed which include a sight glass to check the
condition of the battery. New batteries should be
used as replacements if replacing the battery on
earlier machines.
Figure 1104.
A Maintenance free battery
Maintenance
To make sure that the battery provides optimum
performance the following steps should be observed:
• Make sure that the electrical connections are

clean and tight. Smear petroleum jelly on
connectors to prevent corrosion.
• When applicable - never allow the electrolyte
level to fall below the recommended level of
6mm above the plates. Use only distilled water
for topping up.
• Keep the battery at least three quarters
charged, otherwise the plates may become
sulphated (hardened) - this condition makes
recharging the battery very difficult.
Extra precautions must be taken when bench

charging maintenance free batteries, they are more
prone to damage by overcharging than the standard
type of battery:
• Never boost charge a maintenance free battery

(if installed).
33 - 141 9823/0300-1 33 - 141

03 - Battery
00 - General
• Never charge a battery at a voltage in excess Health and Safety

of 15.8V.
• Never continue to charge a battery after it DANGER Batteries give off an explosive gas.
begins to gas. Do not smoke when handling or working on the
battery. Keep the battery away from sparks and
Quiescent Current Drain flames.
Battery electrolyte contains sulphuric acid. It can
If the machine has no permanently live circuits there burn you if it touches your skin or eyes. Wear
should be zero quiescent current drain, when the goggles. Handle the battery carefully to prevent
key-switch is off and all the lights are switched off. spillage. Keep metallic items (watches, rings, zips
etc) away from the battery terminals. Such items
It should be noted that some permanently live circuits could short the terminals and burn you.
will place a quiescent drain on the battery. Typically
the quiescent drain will be in the range of 10–20 Set all switches to off before disconnecting and
mA. If the quiescent drain measures 40 mA or more, connecting the battery. When disconnecting the
there is a problem with the wiring insulation or the battery, take off the earth (-) lead first.
accessories, if the fault is not rectified it will continue Re-charge the battery away from the machine,
to drain the battery. in a well ventilated area. Switch the charging
circuit off before connecting or disconnecting the
battery. When you have installed the battery in the
machine, wait 5min before connecting it up.
When reconnecting, attach the positive (+) lead
first.
WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it
happens you can get burned.
WARNING Battery electrolyte is toxic and
corrosive. Do not breathe the gases given off
by the battery. Keep the electrolyte away from
your clothes, skin, mouth and eyes. Wear safety
glasses.
WARNING Do not top the battery up with acid.
The electrolyte could boil out and burn you.
CAUTION Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION The machine is negatively earthed.
Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first.
DANGER If you try to charge a frozen battery, or
jump start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
33 - 142 9823/0300-1 33 - 142

03 - Battery
00 - General
suitable closed receptacle and must be disposed Technical Data

of in accordance with local environmental waste
regulations.
Table 292.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to Voltage Cold Cranking Battery Type
protect the circuits and components. The battery Amps (CCA)
must still be disconnected even if a battery 12V 1000 1131XMF Main-
isolator is installed. tenance free
33 - 143 9823/0300-1 33 - 143

03 - Battery
00 - General
Fault-Finding
The most obvious sign of a battery problem is a
machine not being able to start. However, because
the battery is part of a larger electrical system
connected to other parts of the machine, a flat battery
may indicate another problem.
If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition.
33 - 144 9823/0300-1 33 - 144

03 - Battery
00 - General
Disconnect and Connect
Notice: Before you install a pair of batteries to Figure 1105. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.
Disconnect 12 V 24 V
1. Make the machine safe. D B D B
Refer to: PIL 01-03-27. Figure 1106. Twin Battery 12V Ma-
chines- Parallel Connection (Example)
2. Get access to the battery or batteries (depending
on the specification of your machine). The actual B
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key. C
4. Disconnect the battery negative lead first.
5. Disconnect the battery positive lead and store
away from the batteries.
A
A D
6. Disconnect and remove the battery link lead or
leads.
A Battery
B Positive lead
C Battery link lead
D Negative lead
33 - 145 9823/0300-1 33 - 145

03 - Battery
00 - General
Figure 1107. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 146 9823/0300-1 33 - 146

03 - Battery
00 - General
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 1108.
Figure 1108.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
33 - 147 9823/0300-1 33 - 147

03 - Battery
00 - General
Check (Condition) Table 293. Fault Diagnosis

Battery Tester Read- Remedy
ings
Battery Test CHECK: 0 -12.6 Volts: Renew battery
LOAD: less than 6 Volts
This test is to determine the electrical condition of
the battery and to give an indication of the remaining CHECK: 6 -12.4 Volts: Recharge and re-test. If
useful life. LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery
Before you test the battery, make sure that the mains in yellow zone
battery is at least 75% charged (Specific Gravity of CHECK: less than 10 Indicates battery has
1.23 to 1.25 for ambient temperature up to 27°C). Volts: LOAD: less than 3 been over-discharged
Volts and unlikely to recover.
Make sure that the battery is completely Renew battery
disconnected from the vehicle. CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover
Figure 1109. steady
Specific Gravity Test

The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings
should be taken using a hydrometer, when the
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one
hour (or slightly discharge the battery) to dissipate
the surface charge before testing.
Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15°C

(60°F) a 'correction factor' must be applied to the
reading obtained. Add 0.07 per 10°C (18°F) if the
A Battery voltage switch temperature is higher than 15°C (60°F) and subtract
B Check load switch the same if the temperature is lower.
Connect up the battery tester as follows: Table 294. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. Ambient Fully Half Dis- Fully Dis-
Temper- Charged charged charged
2. Set the battery voltage switch to 12V. ature de-
grees C
3. Connect the red flying lead to the battery positive (degrees
(+) terminal and the black flying lead to the F)
battery negative (-) terminal.
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
4. Set the Check/Load switch to CHECK to read the (80)
battery no-load voltage which should be at least Above 27 1.240-1.260 1.170-1.190 1.090-1.110
12.4 volts. (80)
5. Set the Check/Load switch to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 148 9823/0300-1 33 - 148

03 - Battery
00 - General
Charge Remove and Install

Notice: Do not disconnect the battery while the
Precautions before Charging engine is running, otherwise the electrical circuits
may be damaged.
Follow all the precautions described below, to CAUTION The machine is negatively earthed.
prevent damage to the alternator and battery. Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
Refer to: PIL 01-03-27. (-) lead last.
2. Make sure that the battery negative terminal is When disconnecting the battery, disconnect the
connected to the earth cable. earth (-) lead first.
3. Do not connect or disconnect the battery
Remove
or alternator connections, or any part of the 1. Make the machine safe. Refer to (PIL 01-03).
charging circuit while the engine is in operation.
If you disregard this instruction, the regulator or 2. Follow the care and safety procedures. Refer to
rectifying diodes will be damaged. (PIL 01-03).
4. Main output cables are always in an active state 3. Access the battery. Refer to (PIL 06-06).
of current flow even when the engine is not in
operation. If the alternator connector is removed, 4. Disconnect the battery. Refer to (PIL33-03).
do not earth the moulded plug.
5. Make sure that all battery connection wires are
5. When you do arc welding on the machine, clear of battery top cover.
remove the moulded plug (or if the separate
output cables are installed, remove the cables) 6. Remove the handnuts and disconnect the battery
to protect the alternator. clamp.
6. If it is necessary to jump start the battery, do the 7. Lift the clamp clear off the battery.
following steps. 8. Remove the battery from the machine.
6.1. Connect a secondary battery in parallel Figure 1110.
without disconnecting the vehicle battery
from the charging circuit.
6.2. Connect the batteries using suitable jump
leads. Connect the positive lead to the
positive terminals of both batteries. Connect A
the negative lead to the negative terminals
of both batteries.
6.3. After the jump start, safely disconnect the
jump leads and remove the secondary
battery. B
A
A Handnuts
B Battery clamp
C Battery
33 - 149 9823/0300-1 33 - 149

03 - Battery
00 - General
Install
removal procedure.
33 - 150 9823/0300-1 33 - 150

03 - Battery
03 - Isolator Switch
03 - Isolator Switch Introduction

Introduction .................................................. 33-151 The battery isolator switch is used to disconnect the
Disconnect and Connect ............................. 33-152 battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect. Refer to: PIL
33-03-00.
33 - 151 9823/0300-1 33 - 151

03 - Battery
03 - Isolator Switch
Disconnect and Connect
Disconnect
If the machine has an electronically controlled
engine, you must wait a period of time before you
isolate the battery. This is to allow the ECM (Engine
Control Module) to shutdown correctly. The time
period starts when you turn the ignition off. Check the
isolator switch label and the operators manual for the
correct time period.
In the event of an emergency, if required, remove the

isolator key without waiting.
If a radio is installed, you may lose any settings.

2. Turn the ignition key to the off position.
3. Wait for the engine ECM to shutdown correctly (if
applicable).
4. Get access to the isolator key.
5. Turn the battery isolator key in the indicated
direction and remove.
Connect
1. Make sure the ignition is set to off.
2. Insert the battery isolator key and turn in the
indicated direction.
33 - 152 9823/0300-1 33 - 152

06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ......................................................................................................................... 33-155
33 - 153 9823/0300-1 33 - 153

Notes:
33 - 154 9823/0300-1 33 - 154

06 - Battery Cable
00 - General
00 - General
Introduction
The cables connect the battery positive and negative

terminals to the machine electrical system.
33 - 155 9823/0300-1 33 - 155

09 - Power Distribution
Contents Page No.
33-09-00 General ......................................................................................................................... 33-157

33-09-03 Fuse ............................................................................................................................. 33-159
33-09-06 Relay ............................................................................................................................ 33-162
33 - 156 9823/0300-1 33 - 156

00 - General
Introduction .................................................. 33-157 The electrical circuits are protected by fuses. If a
Health and Safety ........................................ 33-158 fuse blows, find out why and rectify the fault before
installing a new one.
A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.
33 - 157 9823/0300-1 33 - 157

00 - General
Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
33 - 158 9823/0300-1 33 - 158

03 - Fuse
03 - Fuse
Figure 1111.
1A 11B 21C 31D 41E

2A 12B 22C 32D 42E
3A 13B 23C 33D 43E
4A 14B 24C 34D 44E
5A 15B 25C 35D 45E
6A 16B 26C 36D 46E
7A 17B 27C 37D 47E
8A 18B 28C 38D 48E
9A 19B 29C 39D 49E
10A 20B 30C 40D 50E
Table 295.
Fuse Circuits Rating
A
1A Auxiliary 5
2A Auxiliary/hitch hydraulics 15
3A Air-conditioning 25
4A Immobiliser 3
5A Heater 30
6A Directional indicators 3
7A Air-conditioning 20
8A Ignition 3
9A Spare
10A Reverse alarm/lights 10
11B Rear and roof wash/wipe 20
12B Front wash/wipe 15
13B Brake lights 10
14B Dipped headlights 15
15B Main beam lights 20
16B Side lights 7.5
17B Side lights 5
18B 12V Power socket 15
19B Ignition 5
20B Crank signal 5
21C Engine fuse 5
22C Warning cluster 3
23C Park Brake 3
24C Engine fuse 3
25C Seat switch 3
26C Road lights 10
33 - 159 9823/0300-1 33 - 159

03 - Fuse

A
27C Horn and headlight flash 25
28C Beacon 7.5
29C Interior light and radio 10
30C Hazards 3
31D Starter solenoid 30
32D Fog lights 3
33D Lift arm work lights 25
34D Road lights 20
35D Front work lights 25
36D Rear work lights 15
37D Bonnet fan 15
38D Heated seat/air suspension seat 20
39D Radio 10
40D Livelink 5
41E Hydraulics ECU (Electronic Control Unit) 20
42E Transmission 15
43E LiveLink 5
44E Trailer electrics 10
45E Instrument panel 15
46E Transmission 3
47E LiveLink 5
48E LLMI (Longitudinal Load Moment Indicator) (if installed) 3
49E Clocks 3
50E Hydraulic ECU 5
Primary Fuses
Figure 1112.
A C
B D
E G
F H
Table 296.
A Ignition switch 50A
B Ignition relay 2 and 6 50A
C Fuse 33D Refer to Table 295. 50A
D Fuse 13B Refer to Table 295. 50A
E Ignition relay 3 and 4 50A
F Ignition relay 2 and fuse 41E Refer 50A
to Table 295.
33 - 160 9823/0300-1 33 - 160

03 - Fuse

G Engine fuse box supply 50A
H Ignition relay 1 and fuse 18B Refer 50A
to Table 295.
33 - 161 9823/0300-1 33 - 161

06 - Relay
06 - Relay
Figure 1113.
A B C D E F G H
1
2 R
RAC
3
AUX
Table 297.
Relay Circuit
A1 Ignition
A2 Ignition
A3 Ignition
B1 Ignition
B2 Ignition
B3 Ignition
C1 Trailer directional
C2 Trailer directional
C3 Road light
D1 Trailer directional
D2 Starter motor solenoid
D3 Cooling fan
E1 Boom work lights
E2 Roof air-conditioning
E3 Transmission
F1 Brake lights
F2 Air-conditioning pump
F3 Starter motor solenoid
G1 Work lights
G2 Reverse alarm/lights
G3 Air-conditioning
H1 Work lights
H2 Livelink
H3 Hitch lights
33 - 162 9823/0300-1 33 - 162

12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ......................................................................................................................... 33-165

33-12-04 Chassis ......................................................................................................................... 33-183
33-12-06 Lift Arm ......................................................................................................................... 33-206
33-12-12 Operator Station ........................................................................................................... 33-217
33-12-15 Front Console ............................................................................................................... 33-249
33 - 163 9823/0300-1 33 - 163

Notes:
33 - 164 9823/0300-1 33 - 164

12 - Harness
00 - General
Introduction .................................................. 33-165
Health and Safety ........................................ 33-166
Harness Drawings
Component Identification ............................. 33-167 Drawings are reproduced from production electrical
Operation ..................................................... 33-172 harness drawings. Each harness drawing includes
Repair .......................................................... 33-177 tables showing wire connections and destinations
for all the connectors on the harness. To identify
Check (Condition) ........................................ 33-179
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.
33 - 165 9823/0300-1 33 - 165

12 - Harness
00 - General
Health and Safety

Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
Harness Repair (Butane Heater)

WARNING In addition to the warnings
incorporated into this procedure, extreme care
should be taken when handling the gas heating
tool to ensure that the flame does not damage or
set fire to any items in the vicinity of the repair,
i.e. other wires, floor panels, floor mats, sound
proofing, paintwork, etc. This tool should not be
used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas
or similar safety parameters apply. No other heat
source should be used to attempt a sealed joint.
CAUTION When the heater is in use, the reflector
and the air coming out are extremely hot. Keep
away to avoid accidental burns. Do not touch the
reflector until it has had time to cool down after
switching off. If flame reappears at the reflector
when the heater is in use, the catalytic element is
damaged or used up. Stop work immediately and
replace the heater.
33 - 166 9823/0300-1 33 - 166

12 - Harness
00 - General
Wire and Harness Number Identification

This section details the allocation of wire numbers
and the identification of wires in the wiring harness.
Figure 1114.
The illustration shows a typical connector and wires. it's length. The number stamped on the wire identifies
Each wire has an individual identification number the following:
permanently marked on it, at regular intervals along
Table 298. Wire and Harness Number Identification

Identification Number Description
# The # indicates the start of the identification num-
ber. It is always printed to the left of the identification
number.
B If applicable- The colour of the flying lead that the
harness wire should mate with. For instance, if wire
819 from harness 719/37100 mated with a flying lead
coloured black (colour code B) then the number print-
ed on the wire would be B-819 9/371.
819 The wire's unique identification number. The wire
functions and numbers allocated to them are consis-
tent through out the JCB range of products. Refer to
Wire Numbers and Functions.
9/371 If applicable- The part number of the harness that the
wire originates from. If the harness part number is
719/37100, the number printed on the harness wires
will be 9/371 (71 and 00 are common numbers and
therefore deleted).
Wire Numbers and Functions Table 300. Wires 200-399 (These

numbers are reserved for battery feeds)
Table 299. Wires 000-199 (These Wire Number Description
numbers are reserved for ignition feeds,
heater start circuits and start circuits) Wires 200 - 299 Unfused battery feeds
Wires 300 - 399 Fused battery feeds
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds
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12 - Harness
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Table 301. Wires 400-599 Figure 1116.

Wires 400-599 These numbers are re-
served for instruments,
i.e. alternators to tachos,
temperature switches
to warning lights, etc.
and signal wires used in
electronic systems
Table 302. Wires 600-799

Wires 600-799 These numbers are
used for earth wires.
When the number is
printed on to a wire it General Points
is prefixed by the Earth
1. Wires continue to have the same number even
symbol. This symbol is
after passing through a connector block to
printed onto the wire, it
another harness.
may however be omitted
from harness drawings 2. If all the numbers in a category have been
allocated, then the category is re-used with an
additional prefix '1', i.e. 1832.
Figure 1115.
Electrical Connectors- RAS System
The RAS (Rear Axle Stabilization) system is not
600 installed on all Loadall machines.
The table shows the harness connectors that

connect to the electrical devices. The connectors
are shown looking at the mating face when
disconnected. Remember that the drawings show
Table 303. Wires 800-999 the harness connectors and not the device
Wire Number Description connectors.
Wires 800-999 These numbers are re- Use the table and the relevant electrical schematic
served for switched sup- to identify the pins in the harness connectors.
plies to electrical loads, Continuity checks on the harness wires can be
i.e. to lights, etc. carried out using a multimeter. Do not touch the ECU
(Electronic Control Unit) connector pins. Do not use
a multimeter on ECU connector pins.
Table 304. Wires In Splices
Various The main input wire is
allocated with a wire
number and a suitable
description, i.e. Wire 640
earth splice to earth.
The additional wires in
the splice are allocated
the same wire number
and a postfix, i.e. 640A,
640B, etc.
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12 - Harness
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Table 305. Electrical Connectors- RAS System

Device Description Location Harness Con-
nector
1042A Stabiliser isolation switch Located on the instrument panel. Re-
move the switch to get access to the
connector.
1058 Sway spool switch Located on the parallel valve block

sway valve spool.
1062A Right stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1062B Left stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1063 Left stabiliser switch Located on the parallel valve block

left stabiliser valve spool.
1064 Right stabiliser switch Located on the parallel valve block

right stabiliser valve spool.
1065 Lift arm proximity switch- 60° Inside face of the right side chassis
(stabiliser isolation) near the lift arm pivot.
1066 Lift arm proximity switch- 60° Inside face of the left side chassis
near the lift arm pivot.
1067 Lift arm extend proximity TBA

switch
2000 Relays Refer to electrical system- fuse and

relay, refer to (PIL 33-09).
3054 Sway / stabiliser isolation Located on the parallel valve block.
valve solenoid
3055 Lift pilot pressure supply isola- Located on the pilot pressure supply
tion valve solenoid valve.
4013 LMS (Loadall Monitoring Sys- The ECU connectors are located be- 10 1
tem) display connector J2 hind the LMS display unit. Be sure to
identify the correct connector. Con- 20 11
nector J2 is coloured black.

4018A ECU connector1 (black) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
4018B ECU connector2 (white) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
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12 - Harness
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Device Description Location Harness Con-

nector
8000 Harness interconnections Refer to electrical system- harness,
9000 Fuses Refer to electrical system- fuse and
relay, refer to (PIL 33-09).
Electrical Connectors- Gearbox Harness Use the table and the relevant electrical schematic
to identify the pins in the harness connectors.
The table shows the harness connectors that Continuity checks on the harness wires can be
connect to the electrical devices. The connectors carried out using a multimeter. Do not touch ECU
are shown looking at the mating face when connector pins. Do not use a multimeter on ECU
disconnected. The drawings show the harness connector pins.
connectors, not the device connectors.
Table 306. Gearbox Harness Electrical Connectors

Device Description Location Harness connector
1013 Column Switch L/H A cable and connector
connects to the panel har-
ness at the steering col-
umn below the steering
wheel. Refer to driveline-
semi-automatic gearbox,
1068 Transmission Dump The switch is installed
Switch to the hydraulic control
lever. A cable and con-
necter connects to the
chassis harness below
the hydraulic control
lever. Refer to driveline-
1057 Park Brake Switch The switch is installed to
the park brake lever. A
cable and connector con-
nects to the rear cab har-
ness at the park brake
lever. Refer to driveline-
2000 Relays Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
3021 Forward high solenoid Located on the gearbox.
3022 Forward low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
3029 Layshaft solenoid
fer to (PIL 27-06).
3033 Mainshaft solenoid
3040 Reverse high solenoid Located on the gearbox.
3041 Reverse low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
fer to (PIL 27-06).
7014 Diode Gate- Gearbox Connects to the panel
harness below the left
side instrument console.
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12 - Harness
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Device Description Location Harness connector

8000 Harness interconnections Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
9000 Fuseboxes Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
-000 Earth Points Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
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12 - Harness
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Operation
Figure 1117. Example- Horn Energised................................................................................Page 33-173

This section contains sets of electrical schematics for cases it will be necessary to trace wires across more
different machine variants. than one schematic sheet.
Use the applicable schematic set to trace the wires The example shows how to follow a typical set of
and connections between electrical devices. In most wires from a power supply (+ ve) through to the path
to earth (- ve).
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12 - Harness
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Page 33-174 Figure 1117. Example- Horn Energised Page 33-175

SHEET 14 SHEET 7
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12 - Harness
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Page Page
33-174 33-175
SHEET 14 SHEET 7
Page 33-175
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12 - Harness
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Page Page
33-174 33-175

Page 33-174
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12 - Harness
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Table 307.
Item
(1)
Description State Pins
(2)
Wire No. Sheet Explanation
CP27 Fuse box B + ve supply 6 118 14 Power supply
from 7.5 fuse
CP18 Relay closed 1-2 7 completes cir-
cuit to horn
CP06 / MF01 Harness inter- 30 871 7
connection
MF40A / Harness inter- 16 7
RL15A connection
MF33 Horn energised 1-2 7
SRL2 Splice
(3)
600EL 7
MF40A / Harness inter- 8 600ET 7
RL15A connection
SMF3 Splice 7
MF22 Earth - ve earth 600A 7 Connects to
chassis earth
point
(1) Item identification code is the same as the connector code shown on the applicable harness drawing.
(2) The pin number is the same as the pin number of the harness connector shown on the applicable harness
drawing.
(3) Splices are not normally accessible. Splices are inside the harness sheath and not visible on the outside.
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12 - Harness
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Repair 2. Using the correct sized splice, attach the new

section of wire required or auxiliary flying
Special Tools lead to the existing harness and secure using
Description Part No. Qty. the crimp tool. Note that each of the splices
Wiring Crimp Tool 892/00349 1 detailed is colour-coded to make size and range
readily visible. They are secured using the
Butane Heater 892/00350 1 corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
Consumables This tool also incorporates a ratchet closing
Description Part No. Size mechanism which will not release until the splice
Wiring Splice 892/00351 - is fully closed to the correct compression size.
(0.5-1.5mm Red,
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
contains 50 off)
Wiring Splice 892/00352 - Consumable: Wiring Splice (1.5-2.5mm Blue,
(1.5-2.5mm Blue, contains 50 off)
contains 50 off) Consumable: Wiring Splice (3-6mm Yellow,
Wiring Splice (3-6mm 892/00353 - contains 50 off)
Yellow, contains 50 off)
3. With the Butane heater assembly, seal the
Instances occur where it is necessary to incorporate connection.
auxiliary electrical components into existing electrical Special Tool: Butane Heater (Qty.: 1)
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires 3.1. Remove the cap from the end of the
within a harness. This will also apply to other disposable gas cartridge.
machines in addition to those of manufacture.
Figure 1119.
To make sure that either the inclusion of an auxiliary
electrical component or a repair within a harness is
completed to an acceptable standard it is strongly A
recommended that the following tools, equipment
and procedures are always used. Note that JCB
harnesses have an Ingress Protection rating of 67
(I.P.67). B
The sheath covering of the recommended splice is A Cap

heat shrunk onto the original wire insulation. This B Gas cartridge
results in a seal and corresponding joint to IP 67
specifications. 3.2. Before assembling the gas cartridge to the
reflector element, turn the red ring to the left,
Procedure (in the direction of the minus sign marked
on the ring).
1. Cut the wire and remove the protective insulation
for a suitable distance dependent upon the size Figure 1120.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 1118.
A
C Reflector element
D Red ring
3.3. Position the tube hanging down from inside
the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas
A Distance for splice (check size)
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12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 1123.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 1121.
D Red ring
3.6. Hold the heater vertically and, using a
match or cigarette lighter, light the gas as
shown. Hold the heater vertically for 1 to 2
minutes until the catalytic reaction occurs.
This is indicated when the blue flame fades
3.4. Turn the small ring so that the air holes are and the ceramic element glows red. Then
completely closed. turn the small ring until the air holes at
are completely open. The tool is ready
Figure 1122. for use. Note: The fact that the sound of
liquid cannot be heard when the cartridge is
shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
Figure 1124.
E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the E Small ring
gas. Important: Before turning the heater F Air holes
on, make sure that the cartridge is not hotter
than the reflector element. This may occur 3.7. The heater can be used in two modes:
if the cartridge is held in the hand for a long
time. The temperature difference between 3.8. Side wings down, reflector head completely
the cartridge and the reflector element may open. In this mode the infra-red heat waves
cause long yellow flames to appear on are dominant (recommended for the light
ignition. coloured plastic splices).
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12 - Harness
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Figure 1125. Check (Condition)
This section describes how to use electrical

measuring devices that are used in electrical fault
finding.
Use of Multimeters
In order to obtain the maximum benefit from the
fault finding information contained in the Electrical
Section, it is important that the technician fully
understands the approach to fault finding and the
use of the recommended test equipment, in this case
a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer analogue multimeter. The approach
is based on a fault finding check list. In tracing
G Side wings the fault from the symptoms displayed you will be
directed to make measurements using a multimeter.
3.9. Side wings up, reflector head opening These instructions are intended to cover the use of
reduced. In this mode the heating is done the recommended meters.
only by the hot gas (use for dark coloured
plastic splices). 1. Make sure that the test leads are plugged into
the correct sockets. The black test lead should
Figure 1126.
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that
the test probes have a good clean contact with
bare metal, free from grease, dirt, and corrosion
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
D Red ring there is no 12V range, set the selector to the next
G Side wings range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.
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12 - Harness
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Figure 1127. Fluke 85 Multimeter Figure 1128. AVO 2003 Multimeter
1.2. On the AV0 meter, move the right slider

switch to position A, and the left hand slider 1.3. On an analogue meter, turn the dial to the
switch to the appropriate range. appropriate DC Volts range.
Figure 1129. Typical Analogue Multimeter
2. Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
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Measuring Resistance Measuring Frequency

1. Make sure that there is no power to the part of The AVO meter and the analogue meter are not
the circuit you are about to measure. capable of measuring frequency, therefore a digital
multimeter must be used.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the 1. Insert the black plug into the COM socket on
other end. It does not matter which way round the the meter and attach the probe to the nearest
two probes are placed. suitable earth point on the chassis, for example,
the battery negative terminal.
3. Select the correct range on the multimeter.
2. Insert the red probe into socket J.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the 3. Turn the selector switch to position A and
right hand side of the display window is on. depress G repeatedly until F is highlighted on the
If the F sign is on instead, press the blue top row of the display.
button G to change the reading to Ω. Touch
the meter lead probes together and press 4. Press button H once.
the REL3 key on the meter to eliminate the
lead resistance from the meter reading. 5. Touch or connect the red probe to the frequency
source to be measured. Press and hold the
3.2. On the AV0 meter, move the right hand button if an average reading is required.
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω) Testing a Diode or a Diode Wire
range.
3.3. On an analogue meter, move the dial to the A diode wire is a diode with male connector installed
appropriate Ohms (Ω) range. on one end and a female connector installed on the
other end. The diode is sealed in heatshrink sleeving.
Measuring Continuity To test a Diode or a Diode Wire.
1. Make sure that there is no power to the part of 1. On the digital multimeter:
the circuit you are checking for continuity.
1.1. Turn the switch to position D.
2. Connect one probe to one end of the component 1.2. Press the HOLD button and check that the
or wire to be checked and the other probe to the H sign appears at the top right hand side of
other end. It does not matter which way round the the display window.
two probes are placed.
1.3. Connect the black probe to the end of the
3. Select the correct range on the multimeter. diode with a band or to the male connector
of the diode wire. Connect the red probe
3.1. On the digital multimeter, turn the switch to the other end of the diode or diode wire.
to position C and check that the beeper If the beeper does not sound the diode or
symbol appears at the left hand side of diode wire is faulty.
the display window. If the F sign is on
instead, press the button labelled F. If there 1.4. Connect the red probe to the end of the
is continuity in the circuit, the beeper will diode marked with a band, or to the male
sound. If there is no continuity (open circuit), connector of the diode wire, the black probe
the beeper will not sound. should be connected to the other end of the
diode or diode wire. If the beeper sounds or
3.2. On the AV0 meter, move the right hand the meter does not read O.L., the diode or
slider switch to position B, and the left diode wire is faulty.
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between 1.5. Press the HOLD button and check that the
two points the buzzer will sound. H sign disappears from the right hand side
of the display window.
3.3. On an analogue meter, turn the dial to
the lowest Ohms (Ω) range. If there is 2. On the AV0 meter:
continuity (i.e. very low resistance) between
two points the needle will move across fully 2.1. Move the right hand slider to position A, and
(or almost fully) to the right hand side of the the left hand slider switch to position C.
scale. 2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
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12 - Harness
00 - General
diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
2.3. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
diode or diode wire. If the Avo meter does
not read 1 the diode is faulty.
3. On an analogue meter:
3.1. Select the Ohms 1000s (1k) range, connect
the black probe to the end of the diode
marked with a band, or to the male
connector of the diode wire, the red probe
diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
diode is faulty.
3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
the diode wire, the black probe should
be connected to the other end of the
diode or diode wire. The meter should read
300-400Ω, if it reads less than this the diode
is faulty.
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12 - Harness
04 - Chassis
04 - Chassis
Diagram
Figure 1130. Chassis Harness (721/H0047-1)..................................................................... Page 33-187

Table 308. Chassis Harness (721/H0047-1)

Item Description
C001 5K6 Resistor
C002 LH headlamp
C004 Chassis to panel
C005 RH Headlamp
C006 Cooling fan
C007 Ambient sensor
C008 Hand throttle creep control
C013 Joystick 1
C014 Joystick 2
C017 RH tail lamp
C018 LH tail lamp
C019 Trailer harness
C020 Number plate lamp
C021 Reverse alarm
C022 Tilt lock switch
C022A Tilt lock 10 K
C022B Tilt lock 1K 300R
C022C Tilt lock 5K 360R
C023 Angle sensor
C024 Rear steer sensor
C025 LLMI (Longitudinal Load Moment Indicator) transduc-
er
C026 Front steer sensor
C027 Front / rear aux
C028 Steer valve A
C029 Steer valve B
C030 Steer valve C
C031 Steer valve D
C032 Boom harness
C033 Hyd temp sensor
C035 Fuel sender
C037 Ground
C040 SRS
C045 Boom retract switch
C045A Resistor boom back 33K
C045B Resistor boom back 5K6
C045C Resistor boom back 1K8R
C046 Hyd ECU (Electronic Control Unit) J1
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12 - Harness
04 - Chassis
Item Description
C047 Hyd ECU J2
C048 Hyd ECU J3
C049 Hyd ECU J4
C050 Hyd ECU J5
C051 CAN (Controller Area Network) terminator
C052 Chassis angle sensor
C053 Live link ground
C054 Auxiliary socket
C055 Hydraulic isolation switch
C056 Floor throttle
C057 RDM
C059 Panel connector 2
C145 Primary fuse A & B
C146 Primary fuse C &D
C147 Primary fuse E & F
C148 Primary fuse G & H
C149 Footbrake dump
C151 Park brake valve
C152 Park brake lever
C153 Pin locking switch
C154 Aux vent
E001 Fuse / relay box
E002 Agglomerator
E003 Fuel lift pump
E006 Vacuum switch
E010 Powertrain CAN bus resistor
E012 Rev fan
E013 Proportional fan
E014 Speed sensor
E020 Grid heater
E023 Kohler CAN bus resistor
E024-1 Binary switch 1
E024-2 Binary switch 2
E025 AC compressor
E030 Kohler ECU
E031 Earth stud
E033 Alternator W
E034 CAN Ground
E037 Alternator excitation resistor
V002 Boom lower
V003 Boom raise
V004 Retract
V005 Extend
V006 Dump
V007 Crowd
V008 Aux B
V009 Aux A
V010 Isolation solenoid
T002 Pump forward
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12 - Harness
04 - Chassis
Item Description
T003 Pump reverse
T005 Motor fast / slow
T006 Speed sensor
T007 Pump pressure
33 - 185 9823/0300-1 33 - 185

Notes:
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12 - Harness
04 - Chassis
Page 33-188 Figure 1130. Chassis Harness (721/H0047-1) Page 33-189
SEE SHEET 2 ZONE 7B
721/H0047-1 Sheet 1
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12 - Harness
04 - Chassis
Page Page
33-188 33-189
Page 33-189
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12 - Harness
04 - Chassis
Page Page
33-188 33-189
SEE SHEET 2 ZONE 7B

Page 33-188
721/H0047-1 Sheet 1
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12 - Harness
04 - Chassis
33 - 190 9823/0300-1 33 - 190

12 - Harness
04 - Chassis
SEE SHEET 3 ZONE3D
J5 J3 J2 J1
J4
721/H0047-1 Sheet 2
SEE SHEET 1 ZONE10F
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12 - Harness
04 - Chassis
Page Page
33-192 33-193
Page 33-193
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12 - Harness
04 - Chassis
Page Page
33-192 33-193
SEE SHEET 3 ZONE3D

Page 33-192
J5 J3 J2 J1
J4
721/H0047-1 Sheet 2
SEE SHEET 1 ZONE10F
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12 - Harness
04 - Chassis
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12 - Harness
04 - Chassis
SEE SHEET 2 ZONE10E
A /B
C/D
721/H0047-1 Sheet 3
E/F
G/H
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12 - Harness
04 - Chassis
Page Page
33-196 33-197
Page 33-197
SEE SHEET 2 ZONE10E
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12 - Harness
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Page Page
33-196 33-197

Page 33-196
A /B
C/D
721/H0047-1 Sheet 3
E/F
G/H
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12 - Harness
04 - Chassis
721/H0047-1 Sheet 4
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12 - Harness
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Page Page
33-200 33-201
Page 33-201
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Page Page
33-200 33-201

Page 33-200
721/H0047-1 Sheet 4
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721/H0047-1 Sheet 5
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Page Page
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Page 33-205
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Page Page
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Page 33-204
721/H0047-1 Sheet 5
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12 - Harness
06 - Lift Arm
06 - Lift Arm
Diagram
Figure 1135. Lift arm harness 721/C1956-1.........................................................................Page 33-207

Figure 1136. Inner lift arm harness 721/C1012-2.................................................................Page 33-213
Table 309.
Lift arm harness Refer to Figure 1135.
Inner lift arm harness Refer to Figure 1136.
Lift arm harness 721/C1956-1
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12 - Harness
06 - Lift Arm
Page 33-208 Figure 1135. Lift arm harness 721/C1956-1 Page 33-209
721/C1956-1
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12 - Harness
06 - Lift Arm
Page Page
33-208 33-209
Page 33-209
33 - 208 9823/0300-1 33 - 208

12 - Harness
06 - Lift Arm
Page Page
33-208 33-209
721/C1956-1
Page 33-208
33 - 209 9823/0300-1 33 - 209

12 - Harness
06 - Lift Arm
B001 Chassis harness connector B002 Work lights

B003 Auxiliary changeover solenoid B004 Boom retract switch
B005 Chassis / inner lift arm harness connector
33 - 210 9823/0300-1 33 - 210

12 - Harness
06 - Lift Arm
Inner lift arm harness 721/C1012-2
33 - 211 9823/0300-1 33 - 211

Notes:
33 - 212 9823/0300-1 33 - 212

12 - Harness
06 - Lift Arm
Page 33-214 Figure 1136. Inner lift arm harness 721/C1012-2 Page 33-215
721-C1012-2
33 - 213 9823/0300-1 33 - 213

12 - Harness
06 - Lift Arm
Page Page
33-214 33-215
Page 33-215
33 - 214 9823/0300-1 33 - 214

12 - Harness
06 - Lift Arm
Page Page
33-214 33-215
721-C1012-2
Page 33-214
33 - 215 9823/0300-1 33 - 215

12 - Harness
06 - Lift Arm
B001 Chassis harness connector B002 Work lights
33 - 216 9823/0300-1 33 - 216

12 - Harness
Diagram
Figure1137. 721-X7899-3 Sheet 1...................................................................................... Page 33-219

Figure1142. 721-F7778-2 Sheet 1 (Air Conditioning Not Installed).....................................Page 33-239
Figure1144. 721-F7778-2 Sheet 1 (Air Conditioning Installed)........................................... Page 33-245
Main Components Connected to The Fuses and Relays
Panel Harness:
Front wiper motor
Console instruments
LLMI (Longitudinal Load Moment Indicator)
Console warning lamps
Connector Codes
Steering column switches
For a key to the connector codes refer to PIL
Starter switch (33-00-50).
Heater
Drawings
33 - 217 9823/0300-1 33 - 217

Notes:
33 - 218 9823/0300-1 33 - 218

12 - Harness
Page 33-220 Figure 1137. 721-X7899-3 Sheet 1 Page 33-221
721-X7899-3 Sheet 1
33 - 219 9823/0300-1 33 - 219

12 - Harness
Page Page
33-220 33-221
Page 33-221
33 - 220 9823/0300-1 33 - 220

12 - Harness
Page Page
33-220 33-221

Page 33-220
721-X7899-3 Sheet 1
33 - 221 9823/0300-1 33 - 221

12 - Harness
33 - 222 9823/0300-1 33 - 222

12 - Harness
721/X7899-3 Sheet 2
33 - 223 9823/0300-1 33 - 223

12 - Harness
Page Page
33-224 33-225
Page 33-225
33 - 224 9823/0300-1 33 - 224

12 - Harness
Page Page
33-224 33-225

Page 33-224
721/X7899-3 Sheet 2
33 - 225 9823/0300-1 33 - 225

12 - Harness
33 - 226 9823/0300-1 33 - 226

12 - Harness
721-X7899-3 Sheet 3
33 - 227 9823/0300-1 33 - 227

12 - Harness
Page Page
33-228 33-229
Page 33-229
33 - 228 9823/0300-1 33 - 228

12 - Harness
Page Page
33-228 33-229

Page 33-228
721-X7899-3 Sheet 3
33 - 229 9823/0300-1 33 - 229

12 - Harness
33 - 230 9823/0300-1 33 - 230

12 - Harness
721-X7899-3 Sheet 4
33 - 231 9823/0300-1 33 - 231

12 - Harness
Page Page
33-232 33-233
Page 33-233
33 - 232 9823/0300-1 33 - 232

12 - Harness
Page Page
33-232 33-233

Page 33-232
721-X7899-3 Sheet 4
33 - 233 9823/0300-1 33 - 233

12 - Harness
33 - 234 9823/0300-1 33 - 234

12 - Harness
721-X7899-3 Sheet 5
33 - 235 9823/0300-1 33 - 235

12 - Harness
Page Page
33-236 33-237
Page 33-237
33 - 236 9823/0300-1 33 - 236

12 - Harness
Page Page
33-236 33-237

Page 33-236
721-X7899-3 Sheet 5
33 - 237 9823/0300-1 33 - 237

12 - Harness
Main Components Connected to The Roof wiper

Rear Cab Harness (Air Conditioning Not
Rear wiper
Installed):
Rear work lights
Park brake switch
33 - 238 9823/0300-1 33 - 238

12 - Harness
Page 33-240 Figure 1142. 721-F7778-2 Sheet

1 (Air Conditioning Not Installed) Page 33-241
33 - 239 9823/0300-1 33 - 239

12 - Harness
Page Page
33-240 33-241
Page 33-241
33 - 240 9823/0300-1 33 - 240

12 - Harness
Page Page
33-240 33-241

Page 33-240
33 - 241 9823/0300-1 33 - 241

12 - Harness
Figure 1143. 721-F7778-2 Sheet 2 (Air Conditioning Not Installed)
33 - 242 9823/0300-1 33 - 242

12 - Harness
Main Components Connected to The Roof wiper

Rear Cab Harness (Air Conditioning Not
Rear wiper
Installed):
Rear work lights
A/C condenser cooling fans
Park brake switch
33 - 243 9823/0300-1 33 - 243

Notes:
33 - 244 9823/0300-1 33 - 244

12 - Harness
Page 33-246 Figure 1144. 721-F7778-2 Sheet

1 (Air Conditioning Installed) Page 33-247
33 - 245 9823/0300-1 33 - 245

12 - Harness
Page Page
33-246 33-247
Page 33-247
33 - 246 9823/0300-1 33 - 246

12 - Harness
Page Page
33-246 33-247

Page 33-246
33 - 247 9823/0300-1 33 - 247

12 - Harness
Figure 1145. 721-F7778-2 Sheet 2 (Air Conditioning Installed)
33 - 248 9823/0300-1 33 - 248

12 - Harness
15 - Front Console
15 - Front Console
Diagram
Figure 1146. Panel Harness, (721/Z7899-1 From 7th November 2016).............................. Page 33-253
Figure 1148. Panel Harness, (721/Z7899-1 From November 2016).................................... Page 33-261
Table 310. Panel Harness Connectors, (721/Z7899-1 From 7th November 2016)
Item Description
P001 Fuse box A
P002 Fuse box B
P003 Fuse box C
P004 Fuse box D
P005 Fuse box E
P006 Ign relay 1 & 2
P009 Live link ign relay, reverse alarm
P010 Neutral start, Immo ignition relay
P011 Brakelights relay, boom worklight relay
P012 Front worklights, rear worklights
P013 Auxiliary cooling fan, roadlights
P014 Engine running relay, trailer sense
P015 AC Roof aircon fans
P016 Trailer LH directional, trailer RH directional
P017 Front / rear aux
P018 Joystick isolation
P019 Air con switch
P019A Air con switch resistor 1K
P020 Hazard switch
P021 Roof wiper
P022 Rear wash wipe
P023 Fog light
P024 Head lights
P025 Heater ground
P026 Work lights
P027 Four wheel drive
P028 Beacon
P029 Boom work light
P030 Ground
P031 Turn signal diode
P032 Turn signal diode
P033 Heater connector
P034 Horn
P035 Ground
P036 Constant aux switch
P037 Column switch LH
P038 Column switch RH
33 - 249 9823/0300-1 33 - 249

12 - Harness
15 - Front Console
Item Description
P039 Panel to chassis connector
P040 Centre cluster
P041 Panel to chassis power
P042 Rear hitch light freeze valve relay
P042-A LLMI (Longitudinal Load Moment Indicator)
P042-B LLMICAN (Controller Area Network)
P043 Ignition switch
P044 Ignition switch
P049 Rear cab connector
P050 Foot brake switch
P051 Front work lights
P052 Blower switch
P052A Heater blower resisitor 2K
P052B Heater blower resisitor 3.3K
P055 Front wiper motor
P058 Radio
P059 Face level fan
P061 Reverse fan switch
P062 SRS (Smooth Ride System) Switch
P063 Info button
P064A Diode
P064B Diode
P065 Auxilliary connector
P066 Immobiliser
P068 Live link
P069 07/11 Connector 1
P070 07/11 Connector 2
P071 Instrument cluster J1
P072 Instrument cluster J2
P073 Diagnostic connector
P074 Terminator
P075 SRS 1K 300R
P076 SRS 5K 360R
P077 SRS 10K
P081 Const aux 1K 300R
P082 Const aux 5K 360R
P083 Const aux 10K
P086 Joystick ISO 10 K
P087 2 / 4 WD 1K8R Resisitor
P088 2 / 4 WD 5K6R
P089 2 / 4 WD 33K ohm
P090 Footbrake 10 K
P091 Footbrake 1K 300R
P092 Footbrake 5K 360R
P095 Steer mode switch
P096 Front worklight diode
P109 33K Parkbrake resistor
33 - 250 9823/0300-1 33 - 250

12 - Harness
15 - Front Console
Item Description
P110 5K6 parkbrake resistor
P111 1K8 Parkbrake resistor
P112 Heater resisitor 100R
P125 Terminator P69
P126 Italian headlights
P127 Italian headlights
P128 Front worklight diode
P129 Rear worklight diode
P130 Boom worklight diode
P142 Camera interface
POD1 Diagnostic link option
POC1 CAN 1
POC2 CAN 2
33 - 251 9823/0300-1 33 - 251

Notes:
33 - 252 9823/0300-1 33 - 252

12 - Harness
15 - Front Console
Page 33-254 Figure 1146. Panel Harness, (721/

Z7899-1 From 7th November 2016) Page 33-255
SEE SHEET 2 ZONE5H

SEE SHEET 2 ZONE8H
721/Z7899-1 Sheet 1
33 - 253 9823/0300-1 33 - 253

12 - Harness
15 - Front Console
Page Page
33-254 33-255
SEE SHEET 2 ZONE5H
Page 33-255
33 - 254 9823/0300-1 33 - 254

12 - Harness
15 - Front Console
Page Page
33-254 33-255
SEE SHEET 2 ZONE8H

Page 33-254
721/Z7899-1 Sheet 1
33 - 255 9823/0300-1 33 - 255

12 - Harness
15 - Front Console
33 - 256 9823/0300-1 33 - 256

12 - Harness
15 - Front Console

SEE SHEET 1 ZONE7F
SEE SHEET 1 ZONE2F
721/Z7899-1 Sheet 2
33 - 257 9823/0300-1 33 - 257

12 - Harness
15 - Front Console
Page Page
33-258 33-259
SEE SHEET 1 ZONE2F
Page 33-259
33 - 258 9823/0300-1 33 - 258

12 - Harness
15 - Front Console
Page Page
33-258 33-259
SEE SHEET 1 ZONE7F

E SHEET 1 ZONE2F
Page 33-258
721/Z7899-1 Sheet 2
33 - 259 9823/0300-1 33 - 259

12 - Harness
15 - Front Console
33 - 260 9823/0300-1 33 - 260

12 - Harness
15 - Front Console

Z7899-1 From November 2016) Page 33-263
721/Z7899-1 Sheet 3
33 - 261 9823/0300-1 33 - 261

12 - Harness
15 - Front Console
Page Page
33-262 33-263
Page 33-263
33 - 262 9823/0300-1 33 - 262

12 - Harness
15 - Front Console
Page Page
33-262 33-263

Page 33-262
721/Z7899-1 Sheet 3
33 - 263 9823/0300-1 33 - 263

12 - Harness
15 - Front Console
33 - 264 9823/0300-1 33 - 264

12 - Harness
15 - Front Console

721/Z7899-1 Sheet 4
33 - 265 9823/0300-1 33 - 265

12 - Harness
15 - Front Console
Page Page
33-266 33-267
Page 33-267
33 - 266 9823/0300-1 33 - 266

12 - Harness
15 - Front Console
Page Page
33-266 33-267

Page 33-266
721/Z7899-1 Sheet 4
33 - 267 9823/0300-1 33 - 267

15 - Alarm
15 - Alarm
Contents Page No.
33-15-03 Reverse Warning .......................................................................................................... 33-269
33 - 268 9823/0300-1 33 - 268

15 - Alarm
03 - Reverse Warning
03 - Reverse Warning
Introduction
The reverse alarm will sound when the machine is

moving in the reverse direction. The alarm will sound
anytime the drive control is moved into the reverse
position. In this position the drive control sends a
signal to the main ECU (Electronic Control Unit) to
sound the alarm.
33 - 269 9823/0300-1 33 - 269

21 - Immobiliser
21 - Immobiliser
Contents Page No.
33-21-00 General ......................................................................................................................... 33-271
33 - 270 9823/0300-1 33 - 270

21 - Immobiliser
00 - General

Component Identification ............................. 33-271 The immobiliser ECU (Electronic Control Unit) is
Preparation .................................................. 33-272 located within the instrument trim panel.
Diagram ....................................................... 33-274
Check (Operation) ....................................... 33-276
Figure 1150.
A Immobiliser ECU
33 - 271 9823/0300-1 33 - 271

21 - Immobiliser
00 - General
Preparation
Special Tools Figure 1151.

Data Link Adaptor 892/01174 1
(DLA) Kit
The immobiliser set-up tool is provided to setup or

amend the immobiliser settings. Situations which
may require the immobiliser settings to be changed
may be: Using The Immobiliser Set up Tool
• Transfer of machine ownership. To use the immobiliser set up tool click on the “Help
• Replacement of immobiliser system Menu” and select “Help”. The Help file will display
components. and details the procedures to unlock and use the tool.
• Loss of keys/codes to deactivate the Refer to Figure 1152.
immobiliser.
Figure 1152.
The tool is used to perform the following actions:
• Obtain an unlock ‘Response Code’ for security

authorisation to re-configure the immobiliser.
(The ‘Response Code’ is only available via JCB
Tech Web.)
• Configure a new immobiliser. (Change from
‘Factory Mode’ to key system or keypad system
mode as applicable).
• Configure new immobiliser keys. (Key systems
only).
• Configure new immobiliser codes. (Keypad
systems only).
• Delete existing keys/codes.
Installing Immobiliser Set-Up

The set-up tool is fully integrated within JCB
Servicemaster. To use the set-up tool you must install
JCB Servicemaster onto a suitable laptop computer.
For full instructions on how to install

JCB Servicemaster software please refer to
the documentation which accompanies JCB
Servicemaster.
Starting Immobiliser Set-Up

1. Connect the Servicemaster diagnostic tool.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.: Immobiliser Diagnostic Tool
1)
Refer to: PIL 33-57-03. The immobiliser diagnostics tool has the following
2. Turn on the machine ignition. status windows:
3. Start JCB Servicemaster on the laptop computer • System diagram.

and select the correct machine range. • Active Fault Codes.
Refer to: PIL 33-57-03. This tool is used to show the following:
4. Start the diagnostics tool running by clicking on • Status of the immobiliser internal switches.
the Immobiliser Set-up icon.
33 - 272 9823/0300-1 33 - 272

21 - Immobiliser
00 - General
• Status of devices connected to the immobiliser 2. Turn ON the machine ignition.

ECU. (includes key antenna and keypad
devices). 3. Start JCB Servicemaster on the laptop computer
• View active fault codes. and select the correct machine range.
4. Start the diagnostics tool running by clicking on
Installing Immobiliser Diagnostics the Immobiliser Diagnostics icon.
The diagnostics tool is fully integrated within JCB Figure 1153.
Servicemaster. To use the set-up tool you must install
JCB Servicemaster onto a suitable laptop computer.
For full instructions on how to install

JCB Servicemaster software please refer to
the documentation which accompanies JCB
Servicemaster.
Using the Immobiliser Diagnostics Tool
Connecting Immobiliser Diagnostics
To use the immobiliser diagnostics tool click on the
To use the diagnostics tool the DLA and your ‘Help Menu’ and select ‘Help’. The Help file will
laptop computer must be connected to the machine display and details the procedures for use of the tool.
diagnostics connector.
Starting Immobiliser Diagnostics

1. Connect the Servicemaster diagnostic tool.
Figure 1154.
33 - 273 9823/0300-1 33 - 273

21 - Immobiliser
00 - General
Diagram
The Immobiliser Transponder Antenna/ Keypad are

Wires and Connectors connected to the ECU through connector B.
The Immobiliser ECU (Electronic Control Unit) is

connected to the panel harness.
Figure 1155.
12 11 10 9 8 7
1 2 3 4 5 6
A
B
A Connector A (Black) B Connector B
33 - 274 9823/0300-1 33 - 274

21 - Immobiliser
00 - General
Immobiliser ECU Pin Outs

Table 311. Connector A
Pin Number Connected to Type
1 Not used -
2 Not used -
3 Not used -
4 Not used -
5 Not used -
6 Not used -
7 Power 12V battery
8 Power 12V battery
9 CAN (Controller Area Network)bus CAN bus
high
10 CANbus low CAN bus
11 ECU earth Earth
12 Not used -
Immobiliser ECU Power and Earth Connections
Figure 1156.
CONNECTOR A
11
1
7
1
8
CONNECTOR B
ECU
A Fuse B Immobiliser ECU
33 - 275 9823/0300-1 33 - 275

21 - Immobiliser
00 - General
Check (Operation)
Special Tools
(DLA) Kit
1. Use the applicable Servicemaster diagnostics

tool to identify the faults.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
1)
2. Make sure that the applicable control interface
operates correctly. Rectify as required.
3. Test the applicable wires and connectors for
continuity, shorts to battery and shorts to earth.
Rectify as required.
4. Do not use a multimeter at the pins on the ECU
(Electronic Control Unit). Only use the meter at
the pins on the harness connectors.
5. Without the use of sophisticated electronic test
equipment it is not possible to test the ECU. If the
ECU is returned under warranty it will be tested
at the factory to confirm possible faults.
33 - 276 9823/0300-1 33 - 276

21 - Immobiliser
00 - General
Remove and Install
Remove 4. Disconnect the battery. Refer to (PIL 33-03).
1. Park the machine and make it safe with the lift 5. Disconnect the electrical connectors from the
arm raised. Refer to (PIL 01-03). ECU connectors.
2. Install the lift arm maintenance strut. Refer to (PIL 6. Do not touch the connector pins on the ECU.
06-69-03).
7. Support the ECU and remove the mounting bolts,
3. Remove the applicable trim panels/instrument the nuts and the washers.
panels to get access to the ECU (Electronic
Control Unit). Refer to operator station- trim 8. Remove the ECU from the machine.
panel, refer to (PIL 09-30).
33 - 277 9823/0300-1 33 - 277

21 - Immobiliser
00 - General
Figure 1157.
B C D
B
A
E D
A ECU B Connectors
C Mounting bolts D Washers
E Nuts
33 - 278 9823/0300-1 33 - 278

21 - Immobiliser
00 - General
Install
removal procedure.
2. When you install, also do the following steps:
2.1. Before you operate the machine, make sure
that the ECU is configured correctly. Use
the correct Servicemaster setup tool. Refer
to electrical system- electronic diagnostic,
2.2. Replace the washers in the positions as
shown in the figure. Refer to Figure 1157.
2.3. Torque tighten the nuts to the specified
value.

Item Description Nm
E Nuts 10
33 - 279 9823/0300-1 33 - 279

24 - Instruments
24 - Instruments
Contents Page No.
33-24-03 Instrument Panel .......................................................................................................... 33-281

33-24-10 Hourmeter .................................................................................................................... 33-285
33 - 280 9823/0300-1 33 - 280

24 - Instruments
03 - Instrument Panel
03 - Instrument Panel Introduction

Introduction .................................................. 33-281 The instrument panel communicates information to
Fault-Finding ................................................ 33-282 the operator about the systems on the machine and
Remove and Install ..................................... 33-282 warns of any abnormal conditions that may occur.
The instrument panel houses all the gauges and
warning lights on the machine i.e. fuel gauge, coolant
warning, engine oil pressure warning light. For more
detailed information refer to the operator manual.
33 - 281 9823/0300-1 33 - 281

24 - Instruments
Fault-Finding Remove and Install

For the full list of fault codes, refer to (PIL 33-57).
Centre Warning Light Panel
Remove
3. Remove the screws (x2) that hold the centre
display panel in place.
4. Disconnect all connections and remove the
panel.
Figure 1158. Centre Warning Light Panel
A A
00: 00: 05
A Retaining screws (x2)
Install
removal procedure.
Heater Control Panel

Remove
3. Remove the screws (x2) that hold the heater
control panel in place, disconnect all connections
and remove the panel.
33 - 282 9823/0300-1 33 - 282

24 - Instruments
Depending on the specification of your machine, you Install

will have one of two types of heater control panel.
Refer to Figure 1159. and Refer to Figure 1160. 1. The installation procedure is the opposite of the
Install step.
1. The installation procedure is the opposite of the 1.1. Make sure that the switch housing is aligned
removal procedure. correctly with the panel to make sure that
the switch is in the correct position for all the
Figure 1159. Heater Control Panel (S1) switch settings.
Figure 1161. Left Side Switch Panel
A A
A
A
A Retaining screws (x2) B

Figure 1160. Heater Control Panel (S2)
B Left side switch panel
Figure 1162. Left Side Switch Panel
C
Left Side Switch Panel

Remove D

E
3. Remove the screws (x2) that hold the left
side switch panel in place and disconnect all
connections. Remove the panel.
4. To remove the rotary switch:
4.1. Remove the knob from the front of the F
panel.
4.2. Mark the position of the switch housing in C Knob
relation to the trim panel. D Panel
E Switch
4.3. Unscrew the locknut and remove the switch F Locknut
from the panel.
33 - 283 9823/0300-1 33 - 283

24 - Instruments
Right Side Instrument Panel

Notice: Make sure you do not touch
the electrical connector pins on electronic
instruments. Make sure you put protective caps
on harness connectors and the connectors on the
instruments.
Remove
3. Remove the radio (if installed).
4. Remove the screws (x3) that hold the main
switch and instrument panel in place. Disconnect
all connections and remove the panel.
Install
removal procedure.
Figure 1163. Right Side Instrument Panel
D
D
D
C Electronic instruments
D Retaining screws (x3)
E Radio (if installed)
33 - 284 9823/0300-1 33 - 284

24 - Instruments
10 - Hourmeter
10 - Hourmeter
Introduction
The hourmeter is a device that records the operating

time of an engine, machine, or mechanism, it is used
to monitor and log the service life of the engine. The
hours of operation are determined from the number
of revolutions of the engine.
33 - 285 9823/0300-1 33 - 285

27 - Interior Switch
Contents Page No.
33-27-03 Multi-Purpose ............................................................................................................... 33-287

33-27-51 Hydraulic Flow .............................................................................................................. 33-291
33 - 286 9823/0300-1 33 - 286

03 - Multi-Purpose
03 - Multi-Purpose Figure 1164.
Remove and Install
Remove
Refer to (PIL 01-03). A A
B
3. Remove the steering wheel. Refer to (PIL 09-36).
4. Remove the screws (x2) on the top of the
steering column upper surround.
5. Remove the button head screws (x2). 00:00:05
6. Remove the steering column lower surround.

7. Remove the button head screws (x2).
C
8. Remove the steering column upper surround.
9. Remove the steering column switch retaining
plate screw.
10. Remove the retaining plate (if installed).
A Steering upper column surround
11. Remove the switch covers. B Button head screw 1
C Button head screw 2
12. Disconnect the harness connectors.
Figure 1165.
13. Remove the retaining screw from the switch
collar. D
14. Pull the column switches away from the column.

E F
F
H
H G
J
J
K
D Retaining plate screw

E Switch retaining plate
F Switch cover
G Switch collar
H Column switch
J Harness connector
K Retaining screw
33 - 287 9823/0300-1 33 - 287

03 - Multi-Purpose
Install
steps.
1.1. Make sure that the transmission lever
securing bolt has 2 washers installed as
shown. Refer to Figure 1166.
Figure 1166.
L Transmission lever securing bolt
33 - 288 9823/0300-1 33 - 288


Technical Data .......................................... 33-
33 - 289 9823/0300-1 33 - 289

Figure 1167.
A
D
B
E
A Joystick grip button and thumb switches B CAN (Controller Area Network) bus base unit
C Gaiter D Lower face switch
E Harness
33 - 290 9823/0300-1 33 - 290

51 - Hydraulic Flow
51 - Hydraulic Flow
Remove and Install
3. Remove the screws 1.

Cab mounted control lever 4. Remove the gaiter collar.
Remove 5. Remove the screws 2 then lift the control lever
and powerbase assembly to access the electrical
Control lever and the attached powerbase is a non connectors.
serviceable part. If it is faulty it must be replaced.
6. Disconnect the electrical connectors and remove
1. Remove the screw cover from the arm rest and control lever from the housing.
then remove the screws and washers.
2. Lift away the armrest and the trim assembly.
Figure 1168. Cab mounted control lever
A
B
J
C
H
D
E
G
Table 313.
Item Description
A Arm rest
B Screw cover
C Trim assembly
D Control lever
E Screws 1
F Housing
33 - 291 9823/0300-1 33 - 291

51 - Hydraulic Flow
Item Description
G Screws 2
H Gaiter collar
J Screws and washers
Install 3. Remove rear screws and washers.
1. The installation procedure is the opposite of the 4. Remove front screws and washers.
removal procedure.
5. Remove the gaiter collar.
Pod mounted control lever 6. Remove the pod top cover until you can gain
access to the switch electrical connectors.
Remove
7. Mark and disconnect the switch electrical
The control lever and the attached powerbase is a connectors.
non serviceable part. If it is faulty it must be replaced.
8. Disconnect the electrical connectors and remove
1. Remove the screw cover from the arm rest and the control lever from the pod.
then remove the screws and washers.
9. Remove the screws and remove the control lever
2. Lift away the armrest. then the powerbase assembly.
Figure 1169. Pod mounted control lever
B
C
A
G
M
H
M
L
J K
D
33 - 292 9823/0300-1 33 - 292

51 - Hydraulic Flow
Table 314.
Item Description
A Arm rest
B Screws
C Rear screws
D Front screws
E Gaiter collar
F Powerbase assembly
G Pod top cover
H Switch electrical connectors
J Electrical connector 1
K Electrical connector 2
L Electrical connector 3
Install
removal procedure.
33 - 293 9823/0300-1 33 - 293

40 - Bulb
40 - Bulb
Contents Page No.
33-40-00 General ......................................................................................................................... 33-295
33 - 294 9823/0300-1 33 - 294

40 - Bulb
00 - General
Introduction .................................................. 33-295 Make sure the bulbs are replaced with the same type
Technical Data ............................................. 33-296 and rating as the damaged bulb.
33 - 295 9823/0300-1 33 - 295

40 - Bulb
00 - General
Technical Data Remove and Install
Table 315. Remove

Application Rating Type
1. Before replacing any bulb, make the machine
Work lights 55W H3 safe with the lift arm lowered. Refer to (PIL
Headlights 55W H3 01-03).
Dip beam 55W H7
2. Stop the engine and isolate the battery. Refer to
Side lights 4W T4W
(PIL 33-03-03).
Direction indica- 21W
tor lights 3. If necessary, wait for the light to cool down.
Brake lights 21W
4. Wear protective gloves.
Interior light 10W
Warning lights 1.2W 5. Gain access to the defective bulb.
Beacon (if fit- 55W
6. Remove the defective bulb
ted)
Install
1. Replace the bulb with one of the correct type
and specification. Refer to technical data, (PIL
33-40-00).
2. Where applicable, make sure you follow the bulb
manufacturers installation instructions. Make
sure you do not touch halogen bulbs by the glass.
Use gloves if necessary.
3. Make sure that the bulb is correctly aligned as it
is installed. Some bulb caps have projections to
make sure they are fitted in the correct orientation
and/or application.
4. If necessary, make sure that the light lens is clean
and the electrical contacts are free of corrosion.
5. Make sure that any seals are in serviceable
condition and are installed correctly.
6. Install any items removed when removing the
bulb.
7. Connect the battery. Refer to (PIL 33-03-03).
8. Make sure that the light works. (It is good practice
to check that the other lights are working too).
9. If appropriate, check the alignment of any light
unit that has had a bulb replacement.
33 - 296 9823/0300-1 33 - 296

45 - Control Module
45 - Control Module
Contents Page No.
33-45-00 General ......................................................................................................................... 33-299

33-45-03 Machine Control ........................................................................................................... 33-302
33-45-06 Engine .......................................................................................................................... 33-303
33-45-36 Hydraulic ...................................................................................................................... 33-307
33 - 297 9823/0300-1 33 - 297

Notes:
33 - 298 9823/0300-1 33 - 298

45 - Control Module
00 - General
Introduction .................................................. 33-299 Modern machines use ECU (Electronic Control Unit)
Health and Safety ........................................ 33-300 to control machine systems such as hydraulics,
Operation ..................................................... 33-300 transmission and engine. In much the same way as
office computers can be ‘networked’ to communicate
with each other the machine ECU’s can be
‘networked’. Some advantages of networking are:
• Improved more intelligent control systems

• More comprehensive and reliable in-cab
instrumentation
• Service software tools can be used for fault
finding and machine control set up
The ECM (Engine Control Module) can communicate

with other machine ECU using a CANbus network
system.
CANbus Communications System

CAN (Controller Area Network) is an electronic
communications system that connects all the
machine ECU to one pair of data wires, this is called
the CANbus. Coded data is sent to and from the
ECU on the CANbus. By connecting Servicemaster
diagnostic software to the CANbus, data is seen and
decoded for use by a service engineer.
CANbus System Schematic

A typical CANbus system architecture is shown for
illustration purposes only below: Refer to Figure
1170.
Figure 1170. Typical CANbus architecture
ECU ECU ECU ECU ECU
F B C E G
Hi
Lo
Hi H
ECU Lo
A D
The CAN architecture may differ on your machine.

33 - 299 9823/0300-1 33 - 299

45 - Control Module
00 - General
Health and Safety Operation

Arc Welding The machines use an ECU (Electronic Control
To prevent the possibility of damage to electronic Unit) to control machine operations. The ECU uses
components, disconnect the battery and the analogue and digital signals from machine sensors,
alternator before arc-welding on the machine or switches etc. and uses this data to supply a feed or
attached implements. a ground connection for other machine devices. The
If the machine is equipped with sensitive electrical machines can have one or more ECU’s depending
equipment, i.e. amplifier drivers, electronic control on the model variant. For information on each ECU,
units (ECUs), monitor displays, etc., then disconnect refer to the correct topic in the subsequent pages.
them before welding. Failure to disconnect the
The machine ECU's can be connected to JCB
sensitive electrical equipment could result in
servicemaster diagnostic software to check ECU
irreparable damage to these components.
version and operation. Refer to electrical system-
Parts of the machine are made from cast iron, welds electronic diagnostic. Refer to: PIL 33-57.
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable ECU Inputs
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to There are two main types of input, digital and
the same component that is being welded to avoid analogue.
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the Digital inputs (On-Off switch type inputs)
part being welded no more than 0.6m.
Digital type inputs are on-off type inputs (i.e.
Notice: Do not disconnect the battery while the switches). The digital inputs can be low side inputs or
engine is running, otherwise the electrical circuits high side inputs. The low side inputs are inputs that
may be damaged. provide a ground to the ECU. The high side inputs
are the inputs that provide a positive feed to the ECU.
Low side input
The low side input is the most frequently used input

on an electrical system. The low side input can be in
the form of rocker switches or pressure switches.
Figure 1171.
C
12 v
B
A ECU
B Input
C Switch (rocker, pressure etc.)
High side input
The high side input is used on circuits that require a

positive feed when the ignition is switched off, e.g.
sidelights or hazard lights.
33 - 300 9823/0300-1 33 - 300

45 - Control Module
00 - General

A A
C
C
12 v 12 v
B B
A ECU A ECU
B Input B Output
C Switch (lights etc.) C Solenoid or relay coil
Analogue inputs (Sensor type switch inputs) High side output
Analogue inputs are sensor type inputs that provide In the high side output circuit, the solenoid or relay
a varying type input to the ECU. This input could be which is being driven already has a ground available.
a voltage, resistance or frequency type input. The ECU provides the positive side of the circuit.
A A C
E
B
5v 12 v
C B
D A ECU
B Output
C Solenoid or relay coil
A ECU
B Sensor ref voltage Modulated outputs
C Sensor ref 0 voltage
D Thumbwheel input (potentiometer type input) In the modulated output circuit, the ECU provides
E Thumbwheel position switch a PWM (Pulse Width Modulation) signal to a
proportional valve. As the ECU varies the duty cycle
ECU Outputs of the signal, the proportional valve will be selected
depending on the change in duty cycle.
There are three main types of outputs. Low side
output, High side output and Modulated output. Figure 1176.
Low side output A C
In the low side output circuit, the solenoid or relay

which is being driven already has a positive feed B
available. The ECU then provides ground to the
circuit.
A ECU
B Output
C Proportional solenoid
33 - 301 9823/0300-1 33 - 301

45 - Control Module
03 - Machine Control
03 - Machine Control Figure 1178.
Remove and Install 1
Figure 1177. 2
1 Mounting bolts
2 MECU
Remove
2. Remove the applicable trim panels/instrument
panels to get access to the MECU.
1 4. Make sure you do not touch the connector pins

of the ECU (Electronic Control Unit).
5. Put a label on the electrical connectors to help
installation.
ECU.
7. Support the ECU and remove the mounting bolts.
8. Remove the ECU from the machine.
Install
1 MECU (Machine Electronic Control Unit) 1. The installation procedure is the opposite of the
The MECU is located behind the right side operator step.
trim panel.
2. Before you operate the machine, make sure
the ECU is configured correctly. Use the correct
Servicemaster set-up tool.
33 - 302 9823/0300-1 33 - 302

45 - Control Module
06 - Engine
06 - Engine Introduction
Introduction .................................................. 33-303 Central to the engine control system is the ECM
Diagram ....................................................... 33-305 (Engine Control Module). The prime function of the
Remove and Install ..................................... 33-306 ECM is to initiate fuel injection. The engine cannot
run without the ECM.
Signals from electrical sensors are continually

monitored and processed by the ECM to determine
when, how much and to which cylinder fuel must be
injected.
The ECM will not function correctly with the electronic

injectors if their position is altered. This would also
result in alterations to the overall performance of the
engine.
The ECM controls fuel injection by energising

electrical actuators in the fuel injectors, high pressure
pump and the common fuel rail.
Note: Other devices are connected to the ECM to

control other engine related systems.
Figure 1179.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor (PIL 15-84)

3 Camshaft target disc (PIL 15-15) 4 Crankshaft position sensor (PIL 15-84)
33 - 303 9823/0300-1 33 - 303

45 - Control Module
06 - Engine
5 Crankshaft mounted target disc (PIL 15-12) 6 Fuel injector (PIL 18-18)
33 - 304 9823/0300-1 33 - 304

45 - Control Module
06 - Engine
Diagram
Figure 1180. (For: Kohler KDI 2504 TCR)
33 - 305 9823/0300-1 33 - 305

45 - Control Module
06 - Engine
Remove and Install
Figure 1181.
A ECM (Engine Control Module) electrical B ECM

connectors
C ECM mounting bolts D Lift ram pivot
The ECM is located next to the chassis lift ram pivot. Install
Remove 1. The installation procedure is the opposite of the
1. Make the machine safe. step.
Refer to: PIL 01-03. 2. Before you operate the machine, make sure the
ECM is configured correctly. Use the correct
2. Get access to the ECM. Servicemaster set-up tool.
3. Disconnect the battery. Refer to: PIL 33-57-03.
4. Make sure you do not touch the connector pins
of the ECM.
installation.
ECM.
7. Support the ECM and remove the mounting
bolts.
8. Remove the ECM from the machine.
33 - 306 9823/0300-1 33 - 306

45 - Control Module
36 - Hydraulic
36 - Hydraulic Diagram
Diagram ....................................................... 33-307
Check (Operation) ....................................... 33-312
Wires and Connectors
Remove and Install ..................................... 33-313 The hydraulic control ECU (Electronic Control Unit)
is connected to the chassis harness.
Figure 1182.
A Hydraulic control ECU connector J5-C050 B Hydraulic control ECU connector J4-C049
(Harness connector key E) (Harness connector key D)
C Hydraulic control ECU connector J3-C048 D Hydraulic control ECU connector J2-C047
(Harness connector key C) (Harness connector key B)
E Hydraulic control ECU connector J1-C046 F Harness connector identification key letter
(Harness connector key A)
33 - 307 9823/0300-1 33 - 307

45 - Control Module
36 - Hydraulic
Hydraulic Control ECU Pin Outs
Table 316. Connector J1

1 Power 12V battery
2 Power 12V battery
3 Power 12V battery
4 Left side column switch pin - Neu- Input
tral
5 Not used -
6 Valve block extend / retract sole- Output
noid returns
7 Power 12V battery
8 Power 12V battery
9 Power 12V battery
10 Lift arm retract proximity switch Input
11 Transmission speed sensor signal Input
output
12 ECU earth Earth
13 Valve block retract solenoid Output
14 Lift arm auxiliary solenoid Output
15 Park brake switch Input
16 Auxiliary venting switch Input
17 Valve block lift / lower solenoid re- Output
turns
18 Valve block auxiliary A/B solenoid Output
returns

1 Crab steer solenoid D Output
2 AWS (All Wheel Steer) solenoid C Output
3 Left side column switch- Reverse Input
4 Foot brake switch Input
5 Transmission speed sensor signal Input
output A
6 Hydraulic isolation solenoid Output
7 2 Wheel steer solenoid A Output
8 Pin lock solenoid Input
9 Left side column switch - Forward Input
10 2WD (Two Wheel Drive) / 4WD Input
(Four Wheel Drive) switch
11 ECU Earth Earth
12 ECU Earth Earth
13 4WS (Four Wheel Steer) solenoid Output
B
14 Valve block lower solenoid Output
15 Not used -
16 Hydraulic Isolation Switch Input
33 - 308 9823/0300-1 33 - 308

45 - Control Module
36 - Hydraulic

17 SRS (Smooth Ride System) pres- Input
sure switch
18 Steer mode solenoid returns Output

1 Valve block lift solenoid Output
2 Valve block extend solenoid Output
3 Lift arm angle sensor signal output Input
2
4 Chassis angle sensor signal output Input
1
5 Chassis angle sensor signal output Input
2
6 SRS drain / accumulator solenoid Output
returns
7 Not used -
8 Not used -
9 Hand Throttle/Creep Control Input
10 Hand Throttle/Creep Control Input
11 ECU earth Earth
12 Not used -
13 Not used -
14 SRS drain solenoid returns Output
15 Hydraulic isolation switch Input
16 SRS operator switch power Input
17 Crowd / dump solenoid returns Output
18 4WD solenoid earth Output

Pin Number Connected to: Type
1 Valve block crowd solenoid Output
2 SRS accumulator solenoid power Output
3 Not used -
4 Not used -
5 CAN (Controller Area Network) bus CAN bus screen
shield
6 CAN bus shield CAN bus screen
7 Rear steer proximity switch signal Input
output 2
8 Lift arm angle sensor signal output Input
1
9 Not used -
10 Not used -
13 Valve block dump solenoid Output
14 Valve block auxiliary A solenoid Output
15 Not used -
16 Not used -
33 - 309 9823/0300-1 33 - 309

45 - Control Module
36 - Hydraulic

17 CANbus high CAN bus
18 CAN bus high CAN bus

1 Auxiliary changeover solenoid Output
power / second auxiliary power
2 Valve block auxiliary B solenoid Output
3 Rear steer proximity switch signal Input
output 1
4 Tilt lock switch power Input
5 Constant auxiliary switch power Input
6 Front steer proximity switch signal Input
output 2
7 Sensor earths Earth
8 Park brake switch Input
9 Steer mode switch signal output 1 Input
10 Steer mode switch signal output 2 Input
11 Front steer proximity switch signal Input
output 1
12 Not used -
13 4WD solenoid power Output
14 5 reference feed Ref
15 Wake up Input
16 SRS pressure switch pin 3 Input
17 Joystick 4 pin connector- gear plus Input
button
18 Power 12V battery
33 - 310 9823/0300-1 33 - 310

45 - Control Module
36 - Hydraulic
Hydraulic Control ECU Power and Earth Connections
Figure 1183.
1
2
A 3
2 12
7
8
9
CONNECTOR J1
11
12
CONNECTOR J2
11
CONNECTOR J3
CONNECTOR J4
18
A
8 15
CONNECTOR J5
ECU
A Fuse B Hydraulic control ECU
33 - 311 9823/0300-1 33 - 311

45 - Control Module
36 - Hydraulic
Check (Operation)
Special Tools
(DLA) Kit
1. Use the Servicemaster diagnostics tool to

identify faults.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
1)
2. Make sure that the applicable control interface
operates correctly. Rectify as required.
3. Test the applicable wires and connectors for
continuity, shorts to battery and shorts to earth.
Rectify as required.
4. Do not use a multimeter at the pins on the ECU
(Electronic Control Unit). Only use the meter at
the pins on the harness connectors.
5. Without the use of sophisticated electronic test
equipment, it is not possible to test the ECU. If the
ECU is returned under warranty it will be tested
at the factory to confirm possible faults.
33 - 312 9823/0300-1 33 - 312

45 - Control Module
36 - Hydraulic
Remove and Install
Figure 1184.
A
A ECU (Electronic Control Unit) mounting bolts B Hydraulic control ECU
The Hydraulic Control ECU is located on the left

rear chassis panel next to the rear transmission
propshaft.
Remove
2. Get access to the ECU.
4. Make sure you do not touch the connector pins
of the ECU.
installation.
ECU.
7. Support the ECU and remove the mounting bolts.
8. Remove the ECU from the machine.
Install
step.
2. Before you operate the machine, make sure
the ECU is configured correctly. Use the correct
Servicemaster set-up tool.
33 - 313 9823/0300-1 33 - 313

48 - Entertainment
48 - Entertainment
Contents Page No.
33-48-03 Radio ............................................................................................................................ 33-315
33 - 314 9823/0300-1 33 - 314

48 - Entertainment
03 - Radio
03 - Radio Introduction
Introduction .................................................. 33-315 The manufacturer is not responsible for any
Diagram ....................................................... 33-316 radio or TV interference caused by unauthorized
modifications to this equipment. Such modifications
could void the User's authority to operate the
equipment.This device complies with Part 15 of the
FCC rules. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference.

2. This device must accept any interference
received, including interference that may cause
undesired operation.
33 - 315 9823/0300-1 33 - 315

48 - Entertainment
03 - Radio
Diagram
The wiring diagram depicts all the wiring connections connection with switched power, such as IGN or
required for the correct operation of the unit. ACC.
Do not connect the red wire to a constant power

connection. It should be connected to a vehicle
Figure 1185.
6 4 5
2
3
17
16 8
9 7
15
14
13 12 11 10
1 Antenna connector (black wire) 2 PCB

3 Headphone output (1/4 inch) 4 Washer
5 Nut 6 Rubber cap
7 Vehicle panel or headphone mounting bracket 8 Heatshrink tubing
9 Fuse 3A 10 Accessory (red)
11 Ground (black) 12 Right speaker -ve (grey/black)
13 Right speaker +ve (grey) 14 Left speaker -ve (white/black)
15 Left speaker +ve (white) 16 Black wire
17 9 - Pin Connector (male)
33 - 316 9823/0300-1 33 - 316

51 - Beacon
51 - Beacon
Contents Page No.
33-51-00 General ......................................................................................................................... 33-319
33 - 317 9823/0300-1 33 - 317

Notes:
33 - 318 9823/0300-1 33 - 318

51 - Beacon
00 - General
00 - General
Introduction
Beacons are rotating or flashing lights affixed to

the top of a machine to attract the attention of
surrounding vehicles and pedestrians.
33 - 319 9823/0300-1 33 - 319

54 - Window Washer/Wipe
Contents Page No.
33-54-00 General ......................................................................................................................... 33-321

33-54-09 Front Motor ................................................................................................................... 33-322
33-54-10 Rear Motor ................................................................................................................... 33-325
33-54-11 Roof Motor .................................................................................................................... 33-326
33 - 320 9823/0300-1 33 - 320

00 - General
00 - General
Introduction
The wash/wipe system is used to remove rain and

debris from the front or rear window. The main
components of the system are:
• Wiper Arm.
• Wiper Blade.
• Nozzle (jet).
• Wiper Motor Mechanism.
• Tank (reservoir).
• Washer Pump.
• Wash/Wipe Switch.
• Multifunction Switch (intermittent speed
settings).
The wiper assembly consists of an arm, pivoting at

one end with a long rubber blade attached to the
other. The blade is swung back and forth over the
glass, pushing water from its surface. The speed is
normally adjustable, with several continuous speeds
and often one or more intermittent settings. Some
machines may use two wiper arms.
The wipers operate together with the washer system.

The washer pump supplies a mixture of water,
alcohol, and detergent (washer fluid) from a tank to
the windows through a hose. The fluid is dispensed
through small nozzles mounted below the screen. It
is essential the correct washer fluid is used as an
incorrect fluid could freeze in colder climates and
damage the pump. Although antifreeze is chemically
similar to windscreen wiper fluid, it should not be
used because it can damage the paintwork.
33 - 321 9823/0300-1 33 - 321

09 - Front Motor
09 - Front Motor
Remove and Install
Notice: To avoid damage to the glass make sure 3. Remove the front trim panel. Refer to (PIL 09-30).
that you do not over tighten the fastening.
4. Disconnect the wiper motor electrical connector.
Remove 5. Remove the tube at the bulkhead adapter.
If the wiper motor is defective, it must be replaced. It 6. Remove the nuts 1 and pull the wiper arm
is not possible to repair a defective wiper motor. assembly off the motor shafts.
7. With the aid of an assistant, hold the wiper motor
and at the same time remove the nuts 2.
8. Remove the wiper motor.
33 - 322 9823/0300-1 33 - 322

09 - Front Motor
Figure 1186.
A Electrical connector B Tube

C Nuts 1 D Wiper arm assembly
E Wiper motor F Nuts 2
Install 1.1. Tighten the nuts 1 to the correct torque

value.
step.
33 - 323 9823/0300-1 33 - 323

09 - Front Motor
Table 321. Torque Value

Item Torque
C 25N·m
33 - 324 9823/0300-1 33 - 324

10 - Rear Motor
10 - Rear Motor Install

step.
Notice: To avoid damage to the glass make sure
that you do not over tighten the fastening. 1.1. Tighten the nut 1 to the correct torque value.
If the wiper motor is defective, it must be replaced. It Table 322. Torque Value
is not possible to repair a defective wiper motor. Item Torque
E 25N·m
Remove
3. Remove the wiper cover.
4. Disconnect the wiper motor electrical connector.
5. Flip up the cover.
6. Remove both locknuts and grommet assembly
and pull the wiper arm assembly off the motor
shaft.
7. With the aid of an assistant, hold the wiper motor
from inside the cab and remove the nut 1.
Figure 1187.
A Wiper motor cover

B Electrical connector
C Flip up cover
D Locknuts / grommet assembly
E Nut 1
F Wiper motor
33 - 325 9823/0300-1 33 - 325

11 - Roof Motor
11 - Roof Motor Figure 1188.

E F
Remove and Install C
Notice: To avoid damage to the glass make sure
that you do not over tighten the fastening.
D
If the wiper motor is defective, it must be replaced. It
is not possible to repair a defective wiper motor.
B
Remove
2. Follow the general health and safety procedures. A
A Wiper motor cover
3. Remove the cab roof liner. Refer to (PIL 09-03). B Wiper motor electrical connector
C Wiper arm nut cover
4. Remove the wiper motor cover. D Locknuts and grommet assembly
5. Disconnect the wiper motor electrical cover. E Nut 1
F Wiper motor
6. Flip up the wiper arm nut cover.
Table 323.
7. Remove both locknuts and grommet assembly Item Torque
and pull the wiper arm assembly from the motor
shaft. E 25N·m
8. With the aid of one more person, hold the wiper

motor from inside the cab and at the same time
remove the nut 1.
Install
If the wiper motor is defective, it must be replaced. It
is not possible to repair a defective wiper motor.

step.
1.1. Tighten the nut 1 to the correct torque value.
33 - 326 9823/0300-1 33 - 326

57 - Electronic Diagnostic
Contents Page No.
33-57-00 General ......................................................................................................................... 33-329

33-57-03 Servicemaster .............................................................................................................. 33-333
33-57-90 Fault Codes .................................................................................................................. 33-356
33 - 327 9823/0300-1 33 - 327

Notes:
33 - 328 9823/0300-1 33 - 328

00 - General
Introduction .................................................. 33-329 JCB machines use the latest developments in
Health and Safety ........................................ 33-330 electronic management of machine systems. This
Check (Condition) ........................................ 33-331 means that machine systems such as service
Calibrate ...................................................... 33-332 hydraulics, engine, transmission and steering are
controlled using ECU (Electronic Control Unit)'s.
The ECU's process inputs from electrical sensors
and then send signals to electrical actuators on the
applicable devices. The ECU's are also connected
to the machine CAN (Controller Area Network) bus
electronic communication system.
Fault Finding
Faults with ECU controlled systems can be difficult
or impossible to trace using traditional methods. In
addition to the primary function of machine control
the ECU's are also able to detect possible faults
with sensors and actuators. The faults are logged
using a code system. Use Servicemaster to see and
understand these codes. In addition Servicemaster
has direct links to relevant on screen help information
about relevant devices. This information is designed
to help you identify, test, and if applicable, remove
and replace devices.
Poor Maintenance
System faults that are present, or have happened in
the past can be seen. This is not only useful when
fault finding but can also identify poor standards of
maintenance - for example a log showing a history
of water in fuel detected. Use Servicemaster to see
and understand these logs.
Machine Set-up Data

Machine parameters such as tyre sizes, gear shift
points and engine injector calibration codes are all
stored and used by the relevant control ECU's.
During the life of the machine it will be necessary
to change some of these parameters. Without the
correct data the machine will not operate correctly.
Re-Programming ECU's
The ECU's use pre-loaded data to compute
responses to inputs from sensors. If an ECU is
replaced the correct data files must be programmed
(`flashed') into the ECU memory. New data files may
also be issued by JCB Service to improve machine
operation. This will also require the ECU to be re-
programmed.
Summary
With the latest Servicemaster software loaded on
your laptop and you can:
33 - 329 9823/0300-1 33 - 329

00 - General
• Fault find. Health and Safety

• Check maintenance standards, to see if the
machine has been abused. WARNING Make sure you read and follow any
• View and change machine set-up data. on screen instructions. Failure to follow the
• Flash ECU's with the correct data files instructions could result in death or injury.
33 - 330 9823/0300-1 33 - 330

00 - General
Introduction
The datalogger tool is used to retrieve stored error
codes from the machine ECU (Electronic Control
Unit).
The tool will also allow the codes to be printed out

and the fault memory cleared.
3. The stored machine error logs will appear in the
The data logger tool will have the function of error log tab.
removing front screen errors from production built is
shown in the figure. E.g.: Low fuel count. Figure 1191.
The data logger will also have the ability to log:
• When the LLMI (Longitudinal Load Moment

Indicator) has been in the red.
• When the machine has been tripped 'Less than
800kg on rear axle'.
• LLMC (Longitudinal Load Moment Control)
override button has been used.
• Capture a 2 minute log when the above has
been logged.
Figure 1189.
4. To print the log file, select 'File' and 'Print'.

Figure 1192.
5. To clear the error log, select 'Reset' and 'Reset

error log'.
A Data logger tool
Figure 1193.
Reading Machine Data
1. Connect the laptop to the machine CAN
(Controller Area Network)bus.
2. Click on the 'File' menu and select 'Read data'.
33 - 331 9823/0300-1 33 - 331

00 - General
Calibrate
Lift Arm Angle Sensor Calibration

Calibration of the lift arm angle sensor must be
carried out after using the LMS (Loadall Monitoring
System) setup or machine setup tools and/or if a lift
arm angle sensor has been replaced.
To calibrate the angle sensors, park the machine on

safe level ground with the lift arm set horizontal.
Connect the DLA (Data Link Adaptor) to the machine

and select 'Connect'.
After you connect, select 'Click to calibrate the

sensors'.
Close down the calibration tool.
Figure 1194.
33 - 332 9823/0300-1 33 - 332

03 - Servicemaster
03 - Servicemaster Introduction
Introduction .................................................. 33-333 JCB Servicemaster is an application to allow
Component Identification ............................. 33-350 engineers to diagnose and setup the various
Operation ..................................................... 33-352 electronic control units within the JCB product range.
Disconnect and Connect ............................. 33-353 The tools comprise of a front end generic user
interface that allows the user to select the machine
which they wish to work on as well as a number of
various tools which allow:
• Programming electronic control units

• Diagnosing electronic issues
• Setup of various options
• Checking the service history of the machine
JCB Servicemaster is updated on a monthly basis by

incorporating Web Update. This is a program which
works alongside Servicemaster to let the user know
and allow them to download an update as and when
it becomes available.
JCB Servicemaster software is for use with Microsoft

Windows and a laptop personal computer. The
laptop computer is connected to the machine
diagnostic socket using special cables and an
adaptor.
Use Servicemaster software to:
• Display data from a machine ECU (Electronic

Control Unit)
• Change data stored in a ECU
Servicemaster software communicates with the

machine ECM (Engine Control Module) using the
CAN (Controller Area Network) bus, refer to Control
Modules (PIL 33-45).
Structure
Servicemaster software is supplied via DVD and
updated via the internet. A selector window is used
to choose the correct software tool set for each
machine range. Each tool is specific to the chosen
machine range. The tool icons are shortcuts to the
tool software files. Detailed information about how
to use the tools is given in the applicable machine
documentation.
Servicemaster Front Screen

The start-up page of Servicemaster is known as the
front screen. This interface allows the user to easily
and quickly navigate to the machine they are working
on to ensure that they have the applicable tools for
that machine.
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03 - Servicemaster
Figure 1195. Typical Front Screen View engine operating parameters in real time.
Perform engine electrical actuator tests. View, save
or clear ECM fault code log.
Figure 1198. Flash Programmer tool
View ECM software file version. Upload and

Reprogramme software updates to the ECM
memory. Upload revisions to software.
Figure 1199. Data Logger tool
Once the user has clicked on the applicable machine

type they will be able to select the tool they require
from a list of the tools available for that machine
range. Below are screen-shots showing the different
machine tool sets.
Running Data Collection, Operating Data, Statistics,
Servicemaster Tools Device Error Log Recording.
Servicemaster tool sets are different for each Figure 1200. Service History
machine range. When you have navigated to the
correct machine type via the front end, you will be
greeted with the relevant tools for that particular
machine. These tools are accessed by a single click
on the icon of the tool you require. There are 6 main
tools within Servicemaster, these are:
Figure 1196. Machine/Engine Set-up tool

Engine Hour records, Service Dealership Codes.
Figure 1201. Help
View and change engine and machine specification

data stored in the engine ECU. Settings include: Comprehensive information about engine related
sensors, actuators and ECM fault codes.
• Parameter settings
• Option/Attachment control Additional Service Tool
• Alternative Language Support
• Model/Serial Number Identification As well as the tools stated above there are also third
party tools for some of the machine ranges which will
Figure 1197. Diagnostics tool need to be installed. These tools are denoted by the
following symbol:
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Figure 1202. 2. Turn ON the machine ignition and additionally

start the engine if required (taking normal
precautions).
3. Start JCB Servicemaster on the laptop computer.
Figure 1204.
To install these applications you need to take the

following steps:
1. On the front end, click the other tab.

2. Click on general.
3. Click onto "extra applications".
4. Choose the relevant tool which you require to be
installed and run the installer.
Once the installer has been run, the icon should have
changed within the machine tool page. e.g. the above
icon has now become:
Figure 1203.
4. Make sure that the correct DLA (Data Link
Adaptor) is selected in the chooser. Click on
Utilities, DLA Setup. The DLA chooser window
opens. Check the button to match to the current
device. Click Apply.
Diagnostics Tool - User Guide Figure 1205.
Introduction
The diagnostics software tool is part of the
JCB Servicemaster software suite. The diagnostics
software is designed to be an easy to use fault finding
tool.
Connecting the Diagnostics

To use Diagnostics your laptop computer must be
connected to the machine CAN bus.
Diagnostics Overview
Starting the Diagnostics
There are several key elements to the diagnostics
1. Connect the Servicemaster tool to the machine. tool. These can be seen labelled below. Each
Refer to Disconnect and Connect. element is explained in detail in later sections.
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Figure 1206.
5 10 6 7 8
1
2
3
9
11
4 12
1 Menu bar 2 Start and stop buttons

3 Engine selection buttons 4 Main window
5 Engine connector page 6 Machine connector page
7 Actuator test page 8 Fault codes page
9 Page list 10 LED (Light Emitting Diode) status key
11 Status bar 12 CAN communication status LEDs
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Navigating within Diagnostics Menu Bar-Options Menu
Navigation is designed to be via a mouse. On Laptop Figure 1208.

PCs this may take the form of a small joystick
or touch sensitive pad and some buttons, usually
located near to the keyboard.
As with most Windows based programs, it is possible

to navigate the diagnostics software using the
keyboard by pressing certain combinations of keys.
Note: This can be particularly useful for certain

Laptop computers where the mouse/joystick can be
oversensitive. Try out the following, it may come in
useful one day.
There are two main methods of navigation described • Start Diagnostics to commence
below: communications with the ECM.
• Stop Diagnostics to cease communications.
• Pressing the ALT key will cause the File option • Controller Status Click on the buttons to toggle
on the Menu Bar to be highlighted. You can then ON or OFF the diagnostics connection with the
use the arrow keys to navigate the menus. machine CAN system.
• Notice that all the menu items on the Menu
Bar have a letter that is underlined (e.g. the Figure 1209.
'F' in File). Holding down the ALT key and
pressing the required letter key will activate that
option (i.e. either open the menu or execute
a function). For example, if you wish to open
the Preferences Dialogue this can be done by
pressing ALT + O (to open the Options menu)
then ALT + P (to execute the Preferences
option).
Menu Bar-File Menu
The File Menu contains an Exit option to close down

the program.
• Preferences option opens up the Preference
Figure 1207. Dialogue.
• From the Preferences Dialogue there is support
for multiple languages. Use the drop-down
menu and scroll bar to chose the required
language. Languages available are:
• English (United Kingdom)
• French (France)
• German (Germany)
On exiting the program communications with both
• Spanish (International Sort)
ECU and DLA are shut down.
Note: The language option only effects text within the
Main Window (e.g. Page List, LED Status Key, etc).
Language support is not available for the text within
the page displays.
Once your preferences have been selected either:
Click on the OK button to apply them or click on the

Cancel button to leave them unchanged.
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Menu Bar-Help Menu function keys, F2, F3 etc. can also be used to select
pages as required.
Figure 1210.
Status bar
There are 2 items of interest displayed on the

Status Bar, which is located along the bottom of the
Diagnostics main window.
Figure 1213.
• About: Opens a window showing the part

number and the version number of the installed
copy of the Diagnostics software Connected ECU: The type of ECU connected to the
• Help: Opens a help file about the software. Diagnostics tool is indicated on the far left side of the
• Engine Help: Opens a help file containing Status bar.
information about the engine sensor and
actuator devices for engine control. CAN communications: Two small LEDs indicate data
being transmitted (red) and received (green) over the
Start and Stop Buttons CAN communications link.
These offer the same function as the Start These LEDs can be seen to be flashing rapidly
Diagnostics and Stop Diagnostics options within as data is transported. This can be another useful
the Options Menu. To start the Diagnostics tool aid to determining the state of any established
communicating with the gearbox ECU simply click communications.
on the Start Button (large green LED) at the top of
the Main Window. Similarly, click on the Stop Button Connection Status: Indicates if the diagnostics
(large red LED) to cease communications. software is connected, connecting or not connected
to the ECM.
Figure 1211.
Information Window: Displays information about data
on the diagnostics pages when the mouse is rolled
over the fields.
LED Status Key
Displays a key for the colour status of the LEDs

shown on the diagnostics pages. The LEDs change
colour dependant on the electrical signal.
Page List
Figure 1214.
In the top left corner of the main window is displayed
a list of pages which can be displayed.
Figure 1212.
Table 324.
LED Colour Electrical signal status
Clicking in the box next to the required page will Red Off
make that page appear in the main window display
Green On/Active
area. (A tick will also appear in the box to show it
is being displayed.) At any time the user may swap Blue Open Circuit
between displayed pages simply by clicking in the Yellow Short Circuit
check box of the required page in the page list. The Grey No Data
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Fault Codes Page
Figure 1215.
This page allows the engineer to access fault codes The Engine Setup tool can be used to view and
logged by the ECM. The ECM logs a fault code if change data stored the ECM. If the machine or
sensor or actuator signals are not valid. These codes engine specification is changed due to operational or
are useful when fault finding. maintenance requirements the relevant data must be
changed in the ECM.
• Active Fault Codes: Displays fault codes for
active faults in real time. To link to information Connecting Engine Setup
about the fault code click on the code. Note:
Start the engine to see all the active fault codes. To use Vehicle Setup your laptop computer must be
Note: To check if a fault code is no longer connected to the machine CANbus.
active set engine ignition system to OFF and
then restart the engine. The Servicemaster log Starting Engine Setup
display will not delete codes that are no longer
active until the engine ignition system is set to 1. Turn ON the machine ignition and additionally
OFF. start the engine if required (taking normal
• Previously Active Fault Codes: Displays fault precautions).
codes for faults that have occurred but are not 2. Start JCB Servicemaster on the laptop computer.
necessarily active. To link to information about
the fault code click on the code.
• Save Faults: Click the button to save the fault
code lists as a file to a computer location.
• Link to Fault Code List: Click to link to a
complete list of possible fault codes.
• Erase Fault Codes: Click the button to erase
logged fault codes from the ECM memory.
Engine Setup Data Tool-User Guide
Introduction
The Engine Setup software tool is part of the JCB

Servicemaster software suite.
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4. Select Engine Tools from the drop down list

and then start the vehicle setup tool running by
clicking on the Engine Setup icon.
Figure 1218.
3. Make sure that the correct DLA is selected in
the chooser. Click on Utilities, DLA Setup. The
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply.
5. The Engine Setup tool will then open. There are

four groups of data to available shown by the
tabs:
• General
• Wheels
• Options
• Injector Calibration
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General
Figure 1219.
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Wheels
Figure 1220.
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Options
Figure 1221.
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Injector Calibration
Figure 1222.
Each injector is individually tested at the factory can be used to access the data file name currently
to record its operational characteristics. This loaded in the ECM memory and is necessary upload
information is written as a calibration code. The code a new data file to the ECM.
for each injector is loaded into the ECM. The ECM
uses this data to adjust control of the injector solenoid Connecting Flash Loader
and ensure correct injection.
To use Flashloader your laptop computer must be
The currently stored codes for each injector are connected to the machine CANbus.
displayed in the fields. If an injector or the ECM is
replaced the codes must be transferred or altered. Starting Flashloader
Flashloader Tool-User Guide 1. Turn ON the machine ignition but DO NOT start
the engine.
The Flashloader software tool is part of the JCB
Servicemaster software suite. If the ECM Engine 2. Start JCB Servicemaster on the laptop computer.
Control Module is replaced and the data file in its
flash memory is not applicable it will be necessary to
flash the ECM Engine Control Module memory with
the correct data file. The Flashloader software tool
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03 - Servicemaster
Figure 1223. 3. Click on the Browse button and select the correct
data file. Click Open.
Figure 1226.
3. Make sure that the correct DLA is selected in

the chooser. Click on Utilities, DLA Setup. The
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply.
4. Select the required machine range. 4. Click on the Start button. A confirmation window
will appear. Click on the Yes to start the
Figure 1224.
reprogramming of the ECM. The progress bar is
displayed.
5. When the programming is complete switch
the machine ignition to the OFF position.
Important: Re-flashing the ECM changes the
base programme. Re-flashing the ECM does
not configure the machine settings such as fuel
injector calibration codes, and other machine
specific options.
Figure 1227.
5. The Flashloader tool will then open.

Figure 1225.
Using Flashloader
Important: Do not turn off the ignition or isolate the

system by accidentally engaging the operators seat
isolation switch when using the flashloader. This
will interrupt the flash signal to the ECM and will
irreparably damage the ECM.
1. Make sure that the machine ignition switch is set 6. Before starting the engine make sure that the
to ON but do not start the engine. machine setup data is correct. You must check
that all other relevant machine settings are
2. Click on the ECM icon. correctly configured. Use the setup software tool.
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03 - Servicemaster
Re-Flashing Guide Figure 1229.
Load the Ecomax Engine Setup Tool for the correct

application. Make sure that the following is correct for
the application.
• Make
• Machine Type
• Power Rating
Figure 1228.
5. The Additional Info Tab should have the correct

Make, Model and Power Rating.
Figure 1230.
1. If the Make or Machine Type is incorrect please

change and then press Write.
2. If the Power Rating is incorrect please order a
replacement ECM of the correct power rating.
3. Close the Tool.
4. Load the JCB Flashloader.
6. Press the button highlighted to select the flash

file.
7. Navigate to the Machine SW folder. (C:
\JCB_Servicemaster_2\Machine SW).
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03 - Servicemaster
8. Navigate to the relevant application folder.

9. Navigate to the ECM folder.
14. Before pressing start please ensure that:
10. Select and Open the relevant file that matches
the Make, Model and Power Rating. 14.1. All electrical connections between the
laptop and machine are secure.
11. If the file selected does not match the Make,
Model and Power Rating which is currently 14.2. The laptop battery is sufficient.
stored in the ECM it will cause an error. 14.3. You are familiar with any safety cut out
feature on the machine (seat switch) and
Figure 1232. do not invoke it during the flash.
15. Pressing Yes will flash the ECM.
Figure 1234.
12. Please make another selection or close the 16. Pressing No will abort the download.
Flashloader tool and use the Engine Setup tool 17. Ecomax Engine only - If the Engine Immobiliser
to correct the Make or Model. is active you can not flash the ECM. You will get
13. If no error occurs and the file information below this warning.
the file path populates you are ready to flash the Figure 1235.
engine.
18. Please refer to the immobiliser guide to disable

the immobiliser before proceeding.
19. Flashing process will then start and progress bar
will update.
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03 - Servicemaster
23. If Cold Start Kit required, Set to “Function and

Diagnostics” and then press Write.
Figure 1239.
20. ECM Download will complete.

21. Load the Ecomax Engine Setup Tool for the
correct application. Note: Ecomax Only Software
Identification will contain the name of the flash
file you just downloaded to the ECM.
Figure 1237.
24. Ensure Injector Calibration is complete and

correct.
Figure 1240.
22. Both Ecomax and Dieselmax Press Restore

Default Press Yes.
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25. Ecomax Press Write Injector Codes.

26. DieselMax Press Write.
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Tool Suite
All tools available for the Loadall range of machines
are included in this section. The applicability of the
tool depends on the machine model/ variant.
Table 325.
Tool Machine Application Icon Description
JCB Ecomax engine set- Machines with SH, SL Configure the engine
up and DH engines ECU (Electronic Control
Unit) to match the engine
parameters.
IFM transmission diag- Machines with PS760, 4 View gearbox operating

nostics or 6 gearbox parameters in real time.
Perform gearbox electri-
cal actuator tests.
T4i cluster setup All machines Configure the LMS (Load-
all Monitoring System)
display ECU to match
machine parameters.
Loadall datalogger All machines Reads/ prints/ displays

and clears the machine
fault code logs.
JCB loadall machine di- All machines Comprehensive diagnos-

agnostics T4i tic information about ma-
chine related sensors, ac-
tuators and ECUs.
Lift arm angle sensor cali- Machines with LLMC Calibrates the lift arm an-
bration (Longitudinal Load Mo- gle sensors.
ment Control)
Loadall immobiliser setup Machines with immobilis-

er
Immobiliser diagnostics Machines with immobilis- View immobiliser oper-

er ating parameters in real
time. Applicable for key
system and keypad sys-
tem immobilisers.
Diagnostics Connector The main connection point is shown in the figure

Refer to Figure 1241. .
For the Servicemaster System connection
procedure, refer to electrical system- electronic
diagnostic, refer to (PIL 33-57).
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03 - Servicemaster
Figure 1241.
D
C E
B A F
J
H
G A
A Diagnostic connector location
Figure 1242.
B Diagnostic socket location
On the Agri/ Plus/ Super/ Xtra machines with SH, SL,

DH engine and PS760 transmission, an additional
diagnostic socket is located below the operator
seat. This is for flashing the software on the IFM
transmission ECU only.
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Operation Figure 1245.
Start Servicemaster
1. Set up Servicemaster, refer to Servicemaster.
2. Double click on the Servicemaster icon. (The
icon is found on the desktop or in the Start menu,
Programs, JCB).
Figure 1243.
3. The Servicemaster window will open.

Figure 1244.
4. Double click the desired machine group.

5. Access the relevant servicemaster tool to
perform the operation. For full details of the
Servicemaster tools, refer to Introduction.
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Disconnect and Connect a Connect the USB cable directly to the laptop
computer. Do not connect the cable through a
Special Tools USB hub.
Description Part No. Qty. b The older DLA and laptop computers may not
Data Link Adaptor 892/01174 1 be compatible with the USB ports. Use the
(DLA) Kit serial PC cable to connect the DLA to the laptop
serial port.
Connect your laptop computer to the machine
Do the steps below to connect your laptop computer
through the diagnostic CAN (Controller Area
to the machine.
Network) bus connection, to use Servicemaster. Use
the DLA (Data Link Adaptor) and the applicable 1. Make the machine safe.
cables to make the CAN bus connection. Refer to
Figure 1246. Refer to: PIL 01-03-27.
Figure 1246. 2. Follow the general health and safety procedures.

3. Turn the ignition switch to the off position.
4. Get access to the fusebox cover in the cab.
5. Remove the thumb screws that are attached to
the fuse box cover. Refer to Figure 1247. and
D Refer to Figure 1248.
Figure 1247. All Machines
Except 526-56 and 527-58
C B
A Fuse box cover

B Thumb screws
A B Figure 1248. 526-56 and 527-58 Machines
A USB (Universal Serial Bus) PC (Personal

Computer) cable (718/20235)
B Serial PC cable (718/20236)
C USBDLA (728/26500)
D Machine cable (718/20237)
E DLA kit (892/01174) A Fusebox cover
B Thumb screws
Make a note of the following:
6. Remove the fusebox cover to get access to the
machine DLA port.
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7. Find both the Deutsch connectors phased behind Figure 1251.

the panel. Refer to Refer to Figure 1249. and
Figure 1249.
D C
F
C Vehicle decal connector

C F Cab harness connector
10. In order to connect the Powertrain CAN bus
connection, the connector with the Powertrain
E
decal must be connected to the cab harness.
Figure 1252.
C Vehicle connector
D Powertrain connector
E DLA port
Figure 1250.
D
F
E
D Powertrain decal connector
D F Cab harness connector
11. The vehicle connector must be connected, when
the Servicemaster diagnostic work has been
completed.
12. Install the fusebox cover.
13. Use the DLA to connect the laptop computer to
C the machine.
C Vehicle connector Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
D Powertrain connector 1)
E DLA port
13.1. Connect the USB PC cable between the
8. Pull both Deutsch connectors through the slot in DLA and the laptop computer USB port.
the panel.
14. Connect the machine cable to the DLA.
9. In order to connect the Vehicle CAN bus
connection, the connector with the Vehicle decal 14.1. The machine cable has a 15-way D-type
must be connected to the cab harness. Refer to connector on one end and a 9-way CAN
Figure 1251. connector on the other end.
14.2. Connect the 15-way D-type connector end
of the machine cable into the DLA and
tighten the thumb screws to attach it.
15. Connect the 9-way CAN connector end of the
machine cable to the machines diagnostics
connector. Refer to Figure 1253.
15.1. Put the CAN connector to align the
centre pin location tab with the diagnostics
connector.
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03 - Servicemaster
15.2. Couple the connectors. Turn the locking

ring clockwise to secure the connectors.
Figure 1253.
C
D
A USB PC Cable
B Serial PC cable
C Centre pin location tab
D Locking ring
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90 - Fault Codes
90 - Fault Codes Introduction

Introduction .................................................. 33-356 Should faults occur related to an ECU (Electronic
Technical Data ............................................. 33-359 Control Unit) or devices connected to it, the
electronic system will generate the applicable fault
codes. A complete list of fault codes is stored within
the applicable Servicemaster tools set.
Fault Code Structure

The structure of fault codes, otherwise known
as DTC (Diagnostic Trouble Code)'s has been
standardised to a 7 digit code for all on and off-
highway machine and vehicle applications. The
standard (referred to as J2012) requires all fault
codes to conform to the following structure.
• 1st character - defines the system on the

vehicle (e.g. P = Powertrain, C= Chassis, U =
Network).
• 2nd and 3rd characters - defines the sub-
system (e.g. transmission, CAN (Controller
Area Network) network, brakes etc).
• 4th and 5th characters - specifies the particular
component, circuit or fault (e.g. starter relay).
• 6th and 7th characters - referred to as the
'Failure Type Byte' (FTB) which indicates the
particular failure (e.g. 11 = short circuit to
ground). See FTB Numbers below for a full list.
Some specific fault codes are defined by

international standard, while other codes may be
defined by individual vehicle manufacturers.
Fault Code Display Systems

Depending on the machine specification fault codes
recorded by the engine ECU can be accessed and
displayed in several ways:
CAN Enabled Display

The machine may be equipped with a CAN enabled
display. Such a display will be capable of displaying
all recorded codes, for example P0047. All logged
codes will be displayed. The operator may also
have a facility to erase the fault code log. See
the applicable machine documentation for further
information.
CAN BUS Connected Computer

Fault codes logged can be accessed via a
suitable laptop computer running the applicable
diagnostics software, JCB 444 Engine Diagnostics
for example. The computer must be connected to the
machine CAN BUS socket using a DLA (Data Link
Adaptor). Once connected all recorded codes can be
displayed. The engineer also has a facility to erase
the fault code log.
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90 - Fault Codes
Failure Type Byte (FTB) Numbers Number Failure Type Byte (FTB) De-
scription
92 Performance or incorrect opera-
Table 326. tion.
Number Failure Type Byte (FTB) De- 98 Component or system over tem-
scription perature.
0 No sub-type information.
2 General signal failure. Malfunction Indicator Light (MIL)
4 System internal failure.
Figure 1254.
5 System programming failure.
7 Mechanical failure.
9 Component failure.
11 Short Circuit To Ground (SC2G).
12 Short Circuit To Battery
(SC2VBAT). Amber/Red light. The MIL (Malfunction Indicator
13 Open Circuit (OC). Lamp) light comes on to show that a system error
16 Circuit voltage below threshold. has been detected. Refer to Figure 1254.
17 Circuit voltage above threshold. - Red light. The light comes ON (and a continuous
18 Circuit current below threshold. audible alarm sounds) to indicate faults that may
19 Circuit current above threshold. result in serious damage to the machine or make the
1A Circuit resistance above thresh- machine dangerous to operate. This is known as a
old. ‘STOP NOW’ fault.
1B Circuit resistance below thresh- - Amber light. The light comes ON (and an audible
old. alarm sounds for one second) to indicate faults that
1C Circuit voltage out of range. may result in reduced machine performance but are
1F Circuit intermittent. not dangerous. They are unlikely to damage the
23 Signal stuck low. machine. This is known as a ‘SERVICE’ fault.
24 Signal stuck high. When the MIL light comes ON another applicable
26 Signal rate of change below system warning may display. These lights can show
threshold. a blink code. Refer to Electronic Diagnostic, Fault
27 Signal rate of change above Codes, Introduction, Blink Codes (PIL 33-57-90).
threshold.
29 Signal invalid. Blink Codes
2F Signal erratic.
Some machine systems are equipped with a
31 No Signal (lost/missing).
dedicated indicator light. If there is a system fault the
36 Signal frequency too low. light can display fault codes as a series of blinks.
37 Signal frequency too high.
38 Signal frequency incorrect. For example code E127 can be displayed as a series
of blinks as follows:
45 Program memory failure.
46 Calibration / Parameter memory Table 327.
failure.
1 Blink
47 Watchdog / micro-controller / mi-
croprocessor failure. 2 Second delay
4B Over temperature. 2 Blink Blink
62 Signal compare failure. 2 Second delay
64 Signal plausibility failure. 7 Blink Blink Blink Blink Blink Blink Blink
71 Actuator stuck. The light will be ON for approximately 1s and OFF
72 Actuator stuck open. for approximately 0.5s. There is an OFF time of
73 Actuator stuck closed. approximately 2s between error code digits.
85 Signal above allowable range.
When a blink code is displayed the MIL light can
86 CAN signal invalid. also come ON. Refer to Electronic Diagnostic,
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90 - Fault Codes
Fault Codes, Introduction, Malfunction Indicator Light

(MIL) (PIL 33-57-90).
Fault Code log

The fault code log can be read on the instrument
panel LCD (Liquid Crystal Display). Alternatively use
the JCB Servicemaster diagnostics tool.
Read the fault code log on the instrument panel LCD

via the service menu. Use JCB Servicemaster and
a laptop computer connected to machine CANbus to
see the codes. Refer to: PIL 33-57-03.
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90 - Fault Codes
Technical Data
Table 328.
Fault Code Fault Description Fault Severity
P046D-2F Trivial
7F0E6-3 Extend Boost Solenoid STB Operator
7F0E6-4 Extend Boost Solenoid STG Operator
7F0E6-5 Extend Boost Solenoid Open Operator
7F0E8-3 Extend Boost Solenoid Return STB Operator
7F0E8-4 Extend Boost Solenoid Return Operator
STG
7F0E8-5 Extend Boost Solenoid Return Operator
Open
7F296-2 Left Stabiliser Lever Disagreement Operator
7F296-3 Left Stabiliser Lever 1 OORH Operator
7F296-4 Left Stabiliser Lever 1 OORL Operator
7F297-2 Right Stabiliser Lever Disagree- Operator
ment
7F297-3 Right Stabiliser Lever 1 OORH Operator
7F297-4 Right Stabiliser Lever 1 OORL Operator
7F2B3-3 Left Stabiliser Lower Solenoid STB Operator
7F2B3-4 Left Stabiliser Lower Solenoid STG Operator
7F2B3-5 Left Stabiliser Lower Solenoid Operator
Open
7F2B4-3 Left Stabiliser Raise Solenoid STB Operator
7F2B4-4 Left Stabiliser Raise Solenoid STG Operator
7F2B4-5 Left Stabiliser Raise Solenoid Operator
Open
7F2B5-3 Right Stabiliser Lower Solenoid Operator
STB
STG
Open
7F2B6-3 Right Stabiliser Raise Solenoid Operator
STB
STG
Open
7F2BE-3 Left Stabiliser Solenoid Return Operator
STB
STG
Open
7F2BF-3 Right Stabiliser Solenoid Return Operator
STB
STG
Open
33 - 359 9823/0300-1 33 - 359

90 - Fault Codes

7F34F-3 Left Stabiliser Lever 2 OORH Operator
7F34F-4 Left Stabiliser Lever 2 OORL Operator
7F350-3 Right Stabiliser Lever 2 OORH Operator
7F350-4 Right Stabiliser Lever 2 OORL Operator
7F58A-2 Extend Boost Proximity Switch Operator
OOR
Short
Open
Stuck
B104C-67 LLMI (Longitudinal Load Moment Operator
Indicator) Calibration Tip Point
B104D-67 LLMI Calibration Travel Point Operator
B104E-54 LLMI Calibration Required Operator
B104F-49 LLMILED (Light Emitting Diode)'S Operator
Connection Error
B1050-29 LLMI Calibration Error Operator
B1051-46 LLMI Eeprom Store Error Operator
B1052-46 LLMI Eeprom Read Error Operator
B1053-0 LLMI Valve Application Error Operator
B1054-87 LLMICAN (Controller Area Net- Operator
work) No Response Error
B1055-16 LLMI Low Voltage Error Operator
B1056-17 LLMI High Voltage Error Operator
B1057-47 LLMI Pic Comms Error Operator
B1058-24 LLMI Override Mode Error Operator
B1059-62 LLMI Cross Checking Error Operator
B1500-64 SRS (Smooth Ride System) Switch Trivial
Short
B1501-1C SRS Switch OOR Trivial
B1502-13 Hydraulic Lock Switch Open Trivial
B1503-64 Hydraulic Lock Switch Short Trivial
B1504-1C Hydraulic Lock Switch OOR Trivial
B1505-1C Sway Switch OOR Trivial
B1506-64 Sway Switch Short Trivial
B1507-13 Stabiliser Isolation Switch Open Trivial
B1508-64 Stabiliser Isolation Switch Short Trivial
B1509-1C Stabiliser Isolation Switch OOR Trivial
B150A-1C Ext_Aux2B_Sw_OOR Trivial
B150B-1C Auxa_Auxb_Sw_OOR Trivial
B150C-1C Ret_Aux2A_Sw_OOR Trivial
B150D-13 Column Fnr Open Trivial
B150E-64 Column Fnr Short Trivial
B150F-64 Steer Mode Sensor Disagreement Trivial
B1510-18 Steer Mode Sensor 1 OORL Trivial
B1511-17 Steer Mode Sensor 1 OORH Trivial
B1512-18 Steer Mode Sensor 2 OORL Trivial
B1513-17 Steer Mode Sensor 2 OORH Trivial
33 - 360 9823/0300-1 33 - 360

90 - Fault Codes

B1514-64 Fnr Transmission Monitor Rational- Trivial
ity Fault
B1515-13 Brake Light Switch Open Trivial
B1516-64 Brake Light Switch Short Trivial
B1517-1C Brake Light Switch OOR Trivial
B1518-13 Park Brake Switch Open Trivial
B1519-64 Park Brake Switch Short Trivial
B151A-1C Park Brake Switch OOR Trivial
B151B-13 2WD (Two Wheel Drive) Switch Trivial
Open
B151C-64 2WD Switch Short Trivial
B151D-1C 2WD Switch OOR Trivial
B151E-13 Drive Control Shutdown Open Trivial
B151F-11 Drive Control Shutdown STG Trivial
B1520-12 Drive Control Shutdown STB Trivial
B1521-1C Footbrake Dump Switch OOR Operator
B1521-1C Footbrake Dump Switch OOR Trivial
B1522-13 Auto Trans Switch Open Trivial
B1523-64 Auto Trans Switch Short Trivial
B1524-1C Auto Trans Switch OOR Trivial
B1525-13 Seat Switch Open Operator
B1525-13 Seat Switch Open Trivial
B1526-64 Seat Switch Short Operator
B1526-64 Seat Switch Short Trivial
B1527-13 Neutral Start Relay Open Operator
B1527-13 Neutral Start Relay Open Trivial
B1528-11 Neutral Start Relay STG Operator
B1528-11 Neutral Start Relay STG Trivial
B1529-12 Neutral Start Relay STB Operator
B1529-12 Neutral Start Relay STB Trivial
B152A-13 Brake Lamp Open Operator
B152A-13 Brake Lamp Open Operator
B152B-11 Brake Lamp STG Operator
B152B-11 Brake Lamp STG Operator
B152C-12 Brake Lamp STB Operator
B152C-12 Brake Lamp STB Operator
B152D-13 Reverse Lamp Open Operator
B152D-13 Reverse Lamp Open Operator
B152E-11 Reverse Lamp STG Operator
B152E-11 Reverse Lamp STG Operator
B152F-12 Reverse Lamp STB Operator
B152F-12 Reverse Lamp STB Operator
B1530-18 Footbrake Pressure OORL Operator
B1530-18 Footbrake Pressure OORL Operator
B1531-17 Footbrake Pressure OORH Operator
B1531-17 Footbrake Pressure OORH Operator
B1532-18 5V Supply STG Operator
B1532-18 5V Supply STG Trivial
B1533-17 5V Supply STB Operator
33 - 361 9823/0300-1 33 - 361

90 - Fault Codes

B1533-17 5V Supply STB Trivial
B1534-13 Tilt Lock Switch Open Trivial
B1535-64 Tilt Lock Switch Short Trivial
B1536-1C Tilt Lock Switch OOR Trivial
B1537-64 Constant Auxiliary Set Switch Dis- Trivial
agreement
B1539-13 Constant Auxiliary Enable Switch Trivial
Open
B153A-64 Constant Auxiliary Enable Switch Trivial
Short
B153B-1C Constant Auxiliary Enable Switch Trivial
OOR
B153C-13 Joystick FNR Open Trivial
B153D-64 Joystick FNR Short Trivial
B153F-13 Fuel Level Sensor Open Circuit Trivial
B1541-68 Engine Oil Low When Engine Trivial
Started -
B1542-68 Air Filter Blocked Operator
B1543-4B Coolant Temperature High (Critical Critical
Level)
B1544-14 Coolant Temperature Sensor Short Trivial
B1545-13 Coolant Temperature Sensor Open Trivial
B1546-68 Coolant Temperature High (Opera- Trivial
tor Level)
B1547-68 Coolant Level Low, Engine Run- Trivial
ning
B1548-21 Coolant Level Low, Engine Not Trivial
Started
B1549-21 Ambient Temperature Sensor – Service
OORL
B154B-12 Left Indicator – Short To Battery Trivial
B154C-11 Left Indicator – Short To Ground Trivial
B154D-13 Left Indicator - Bulb Out / Open Trivial
B154E-12 Right Indicator – Short To Battery Trivial
B154F-11 Right Indicator – Short To Ground Trivial
B1550-13 Right Indicator - Bulb Out / Open Trivial
B1551-13 Right Trailer Indicator – Bulb Out / Trivial
Open
B1552-13 Left Trailer Indicator – Bulb Out / Trivial
Open
B1558-12 Reversing Fan Output – Short To Trivial
Battery
B1559-11 Reversing Fan Output – Short To Trivial
Ground
B155A-13 Reversing Fan Output - Open Trivial
B155E-12 Proportional Fan Output – Short To Trivial
Battery
B155F-11 Proportional Fan Output – Short To Trivial
Ground
B1560-13 Proportional Fan Output - Open Trivial
B1561-02 Hvac Switch – OOR Trivial
33 - 362 9823/0300-1 33 - 362

90 - Fault Codes

B1562-12 Hvac Fan Output – Short To Bat- Trivial
tery
B1563-11 Hvac Fan Output – Short To Trivial
Ground
B1564-13 Hvac Fan Output – Open Trivial
B1565-12 A/C Output – Short To Battery Trivial
B1566-11 A/C Output – Short To Ground Trivial
B1567-13 A/C Output – Open Trivial
B1568-12 Wading Output – Short To Battery Trivial
B1569-11 Wading Output – Short To Ground Trivial
B156A-13 Wading Output – Open Trivial
B1578-15 Engine Crank Relay STB Trivial
B1579-14 Engine Crank Relay STG Trivial
B157A-13 Engine Crank Relay Open Trivial
B1583-13 RAL Solenoid Open Operator
B1583-14 RAL Solenoid STG Operator
B1583-15 RAL Solenoid STB Operator
B1583-68 Isolation Valve Stuck Critical
B1584-64 Extend Dump Valve STB Operator
B1585-64 Pin Lock Solenoid Short Operator
B1586-64 Recovery Valve Short Operator
BAD CODE Keypad - Invalid Keypad Code En- Operator
tered
BATTERY Battery Voltage Monitoring Signal Operator
Low Fault
BRAKES Brake Charge Pressure Low, En- Critical
gine Running
BRAKES Brake Charge Pressure Low Trivial
C1019-38 LLMI Transducer 1 Pwm Signal Er- Operator
ror
C101A-29 LLMI Transducer 1 Range Eror Operator
C1500-13 Boom Retracted Switch Open Trivial
C1501-64 Boom Retracted Switch Short Trivial
C1502-1C Boom Retracted Switch OOR Trivial
C1503-07 Boom Retracted Switch Stuck Trivial
C1504-62 Load Moment Indicator Disagree- Operator
ment Fault
C1505-13 Accumulator Solenoid Open Trivial
C1506-11 Accumulator Solenoid STG Trivial
C1507-12 Accumulator Solenoid STB Trivial
C1508-13 Drain Solenoid Open Trivial
C1509-11 Drain Solenoid STG Trivial
C150A-12 Drain Solenoid STB Trivial
C150B-13 Extend Solenoid Open Trivial
C150C-11 Extend Solenoid STG Trivial
C150D-12 Extend Solenoid STB Operator
C150E-13 Retract Solenoid Open Trivial
C150F-11 Retract Solenoid STG Trivial
C1510-12 Retract Solenoid STB Trivial
33 - 363 9823/0300-1 33 - 363

90 - Fault Codes

C1511-13 Extend/Retract Solenoid Return Trivial
Open
STG
STB
C1514-13 Auxiliary A Solenoid Open Trivial
C1515-11 Auxiliary A Solenoid STG Trivial
C1516-12 Auxiliary A Solenoid STB Trivial
C1517-13 Auxiliary B Solenoid Open Trivial
C1518-11 Auxiliary B Solenoid STG Trivial
C1519-12 Auxiliary B Solenoid STB Trivial
C151A-13 Auxiliary Changeover Solenoid Trivial
Open
C151B-11 Auxiliary Changeover Solenoid Trivial
STG
C151C-12 Auxiliary Changeover Solenoid Trivial
STB
C151D-46 Eeprom Fault Trivial
C151E-62 Boom Angle Sensor Disagreement Trivial
C151F-23 Boom Angle Sensor 1 OORL Trivial
C1520-24 Boom Angle Sensor 1 OORH Trivial
C1521-23 Boom Angle Sensor 2 OORL Trivial
C1522-24 Boom Angle Sensor 2 OORH Trivial
C1523-13 Hyd Isolate Solenoid Open Trivial
C1524-11 Hyd Isolate Solenoid STG Trivial
C1525-12 Hyd Isolate Solenoid STB Trivial
C1526-23 SRS Pressure Switch OORL Trivial
C1527-24 SRS Pressure Switch OORH Trivial
C1528-62 SRS Pressure Switch Disagree- Trivial
ment
C1529-62 Chassis Angle Sensor Disagree- Trivial
ment
C152A-23 Chassis Angle Sensor 1 OORL Trivial
C152B-24 Chassis Angle Sensor 1 OORH Trivial
C152C-23 Chassis Angle Sensor 2 OORL Trivial
C152D-24 Chassis Angle Sensor 2 OORH Trivial
C152E-62 Lift / Lower Spool Disagreement Trivial
C152F-23 Lift / Lower Spool 1 OORL Trivial
C1530-24 Lift / Lower Spool 1 OORH Trivial
C1531-62 Lift / Lower Spool 2 OORL Trivial
C1532-23 Lift / Lower Spool 2 OORH Trivial
C1533-24 Ext / Retract Spool Disagreement Trivial
C1534-62 Ext / Retract Spool 1 OORL Trivial
C1535-23 Ext / Retract Spool 1 OORH Trivial
C1536-24 Ext / Retract Spool 2 OORL Trivial
C1537-62 Ext / Retract Spool 2 OORH Trivial
C1538-23 Crowd / Dump Spool Disagree- Trivial
ment
C1539-24 Crowd / Dump Spool 1 OORL Trivial
C153A-62 Crowd / Dump Spool 1 OORH Trivial
33 - 364 9823/0300-1 33 - 364

90 - Fault Codes

C153B-23 Crowd / Dump Spool 2 OORL Trivial
C153C-24 Crowd / Dump Spool 2 OORH Trivial
C153D-62 Aux A/B Spool Disagreement Trivial
C153E-23 Aux A/B Spool 1 OORL Trivial
C153F-24 Aux A/B Spool 1 OORH Trivial
C1540-62 Aux A/B Spool 2 OORL Trivial
C1541-23 Aux A/B Spool 2 OORH Trivial
C1542-24 Left Stabiliser Spool Disagreement Trivial
C1543-62 Left Stabiliser Spool 1 OORL Trivial
C1544-23 Left Stabiliser Spool 1 OORH Trivial
C1545-24 Left Stabiliser Spool 2 OORL Trivial
C1546-62 Left Stabiliser Spool 2 OORH Trivial
C1547-23 Right Stabiliser Spool Disagree- Trivial
ment
C1548-24 Right Stabiliser Spool 1 OORL Trivial
C1549-62 Right Stabiliser Spool 1 OORH Trivial
C154A-23 Right Stabiliser Spool 2 OORL Trivial
C154B-24 Right Stabiliser Spool 2 OORH Trivial
C154C-13 Sway Isolation Solenoid Open Trivial
C154D-11 Sway Isolation Solenoid STG Trivial
C154E-12 Sway Isolation Solenoid STB Trivial
C154F-13 Stab Isolation Solenoid Open Trivial
C1550-11 Stab Isolation Solenoid STG Trivial
C1551-12 Stab Isolation Solenoid STB Trivial
C1552-13 Stab Isolation Solenoid Return Trivial
Open
STG
STB
C1555-13 Sway Right Solenoid Open Trivial
C1556-11 Sway Right Solenoid STG Trivial
C1557-12 Sway Right Solenoid STB Trivial
C1558-13 Sway Left Solenoid Open Trivial
C1559-11 Sway Left Solenoid STG Trivial
C155A-12 Sway Left Solenoid STB Trivial
C155B-13 Motion Cut Valve Ls Open Trivial
C155C-11 Motion Cut Valve Ls STG Trivial
C155D-12 Motion Cut Valve Ls STB Trivial
C155E-62 Left Stabiliser Deployed Sensor Trivial
Disagreement
C155F-23 Left Stabiliser Deployed Sensor Trivial
OORL
C1560-24 Left Stabiliser Deployed Sensor Trivial
OORH
C1561-62 Right Stabiliser Deployed Sensor Trivial
Disagreement
OORL
OORH
33 - 365 9823/0300-1 33 - 365

90 - Fault Codes

C1564-23 Front Steer Alignment Sensor 1 Trivial
OORL
OORH
OORL
OORH
C1568-23 Rear Steer Alignment Sensor 1 Trivial
OORL
C1569-24 Rear Steer Alignment Sensor 1 Trivial
OORH
C156A-23 Rear Steer Alignment Sensor 2 Trivial
OORL
C156B-24 Rear Steer Alignment Sensor 2 Trivial
OORH
C156C-13 Steer A Solenoid Open Trivial
C156D-11 Steer A Solenoid STG Trivial
C156E-12 Steer A Solenoid STB Trivial
C156F-13 Steer B Solenoid Open Trivial
C1570-11 Steer B Solenoid STG Trivial
C1571-12 Steer B Solenoid STB Trivial
C1572-13 Steer C Solenoid Open Trivial
C1573-11 Steer C Solenoid STG Trivial
C1574-12 Steer C Solenoid STB Trivial
C1575-13 Steer D Solenoid Open Trivial
C1576-11 Steer D Solenoid STG Trivial
C1577-12 Steer D Solenoid STB Trivial
C1578-13 Drain / Accumulator Solenoid Re- Trivial
turn Open
C1579-11 Drain / Accumulator Solenoid Re- Trivial
turn STG
C157A-12 Drain / Accumulator Solenoid Re- Trivial
turn STB
C157B-13 Steer Solenoid Return Open Trivial
C157C-11 Steer Solenoid Return STG Trivial
C157D-12 Steer Solenoid Return STB Trivial
C157E-11 5V Supply STG Trivial
C157F-12 5V Supply STB Trivial
C1580-07 Boom Movement When Joystick Is Trivial
Neutral (Stuck Spool)
C1581-07 Boom Movement When Lmi Is > Trivial
115%
C1582-87 ECU (Electronic Control Unit) Pair- Trivial
ing Fault
C1583-68 Tipover Detected Trivial
C1584-56 Drive Control Options Fault Trivial
C1585-22 Hydraulic Temp High Trivial
C1587-16 Brake Charge Pressure OORL Operator
C1588-17 Brake Charge Pressure OORH Operator
C158A-13 Pump Control Solenoid Open Trivial
33 - 366 9823/0300-1 33 - 366

90 - Fault Codes

C158B-11 Pump Control Solenoid STG Trivial
C158C-12 Pump Control Solenoid STB Trivial
C158D-13 Pump Control Solenoid Return Trivial
Open
C158E-18 Pump Control Solenoid Return Trivial
STG
C158F-19 Pump Control Solenoid Return Trivial
STB
C1590-1B Hydraulic Temp OORH Trivial
C1591-1A Hydraulic Temp OORL Trivial
C1592-13 Auxiliary A/B Solenoid Return Trivial
Open
C1593-18 Auxiliary A/B Solenoid Return STG Trivial
C1594-19 Auxiliary A/B Solenoid Return STB Trivial
C1595-13 Raise Solenoid Open Trivial
C1596-11 Raise Solenoid STG Trivial
C1597-12 Raise Solenoid STB Trivial
C1598-13 Lower Solenoid Open Trivial
C1599-11 Lower Solenoid STG Trivial
C159A-12 Lower Solenoid STB Trivial
C159B-13 Crowd Solenoid Open Trivial
C159C-11 Crowd Solenoid STG Trivial
C159D-12 Crowd Solenoid STB Trivial
C159E-13 Dump Solenoid Open Trivial
C159F-11 Dump Solenoid STG Trivial
C15A0-12 Dump Solenoid STB Trivial
C15A1-13 Raise/Lower Solenoid Return Trivial
Open
C15A2-18 Raise/Lower Solenoid Return STG Trivial
C15A3-19 Raise/Lower Solenoid Return STB Trivial
C15A4-13 Crowd/Dump Solenoid Return Trivial
Open
C15A5-18 Crowd/Dump Solenoid Return STG Trivial
C15A6-19 Crowd/Dump Solenoid Return STB Trivial
C15A7-64 Emergency Stop Switch Short Trivial
C15A8-13 Fourth Extension Switch Open Operator
C15A9-64 Fourth Extension Switch Short Operator
C15AA-1E Fourth Extension Switch OOR Operator
C15AB-13 Hydraulic Pin Lock Switch Open Operator
C15AC-64 Hydraulic Pin Lock Switch Short Operator
C15AD-1E Hydraulic Pin Lock Switch OOR Operator
C15AE-13 Hydraulic Venting Switch Open Operator
C15AF-64 Hydraulic Venting Switch Short Operator
C15B0-1C Hydraulic Venting Switch OOR Operator
C15B1-13 Hydraulic Pin Lock Solenoid Open Operator
C15B2-14 Hydraulic Pin Lock Solenoid STG Operator
C15B3-15 Hydraulic Pin Lock Solenoid STB Operator
C15B4-13 Fourth Extension Solenoid Open Operator
C15B5-14 Fourth Extension Solenoid STG Operator
C15B6-15 Fourth Extension Solenoid STB Operator
33 - 367 9823/0300-1 33 - 367

90 - Fault Codes

C15BD-64 Invalid Vin Received Trivial
CLUTCH Service
DEF Level Warning Requested Operator
ENG Lock Engine - Engine ECU Lockout Trivial
ENG OIL Oil Level Sensor Signal Global Operator
Fault
ENG OIL Oil Level Sensor Signal Global Operator
Fault
IMM Lock Immobiliser Lockout Trivial
LOW DEF Ad-Blue Level Low - Most Severe Critical
LOW DEF Ad-Blue Level Low - Moderately Operator
Severe
LOW FUEL Low Fuel Level (Operator Level) Operator
LOW FUEL Low Fuel Level (Service Level) Operator
P0001-13 IMV Driver Fault Is Detected Service
P0002-00 Rail Pressure Positive Control Er- Critical
ror During 'IMV-Only' Control. Pid
Controller Not Able To Stabilise
The RPC Value
P0002-00 Rail Pressure Negative Control Er- Service
ror During 'IMV-Only' Control. Pid
Controller Not Able To Stabilise
The RPC Value
P0002-1A Rail Pressure Control Error (Pres- Service
sure Error Too Low).
P0002-1B Rail Pressure Control Error (Pres- Service
sure Error Too High).
P0003-18 Rail Pressure Control Feedback Critical
Low Error
P0004-19 Rail Pressure Control Feedback Service
High Error
P0070-81 CAN Bus Message Error From En- Operator
gine ECU
P0070-87 CAN bus Off Error From Engine Operator
ECU
P0071-87 CAN Bus Message Error For En- Operator
vironment Temperature From En-
gine ECU
P007A-00 TMAP (Temperature Manifold Air Service
Pressure) (Intake Manifold 1 Temp)
Temperature Element Sensor Fault
(ADC)
P007C-23 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor Low
Fault
P007D-24 TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor High
Fault
P007E-2F TMAP (Intake Manifold 1 Temp) Service
Temperature Element Sensor
Noise Fault
33 - 368 9823/0300-1 33 - 368

90 - Fault Codes

P0087-00 Rail Pressure Control Error Posi- Service
tive
P0087-00 Pressure Limiter Open Critical
P0087-00 Common Rail Pressure Fall (No Critical
Feed)
P0087-00 RPC Variable Limit Capacity Service
(Vlc) Torque Reduction Above Its
Threshold
P0087-00 RPC Variable Limit Capacity (Vlc) Critical
Torque Reduction Clamped
P0087-23 Rail Pressure Build Low Fault Critical
P0088-00 Rail Pressure Control Error During Service
HPV Control (Over Max Calibrated
System Pressure)
P0089-00 Rail Pressure Control Error Critical
P0090-13 HPV Driver In ECU Fault Detected Service
P0091-11 PCV 1 Drive System Open Circuit Service
Or Grand Short Circuit
P0091-23 Check HPV Regulation Control Service
Trim Low
P0092-12 HPV Driver In ECU Fault Detected Critical
P0092-24 Check HPV Regulation Control Service
Trim High.
P0095-00 Intake Manifold Temperature (M2) Service
Signal Sensor ADC Fault (Intake
Manifold 2 Temp)
P0096-2F Intake Manifold Temperature Sen- Service
sor (M2) Signal Noise Fault (Intake
Manifold 2 Temp)
P0096-64 Intake Manifold Temperature Sen- Service
sor (M2) Signal Plausibility Fault
(Intake Manifold 2 Temp)
sor (M2) Signal Low Fault (Intake
Manifold 2 Temp)
sor (M2) Signal High Signal Fault
(Intake Manifold 2 Temp)
P00B7-87 CAN Bus Message Error For Operator
Coolant Sensor From Engine
EECU
P0100-00 MAF (Mass Air Flow) Fault (Glob- Service
al). Set If Plausibility Error, Gra-
dient Error Or Electrical Flt Is
Present
P0100-11 MAF High Side Driver Fault Short Service
Circuit To Ground (SC2G)
P0102-23 MAF Low Voltage Fault Service
P0102-23 MAF Electrical Sensor Low Fault Service
P0103-24 MAF High Voltage Fault Service
P0103-24 MAF Electrical Sensor High Fault Service
P0105-00 MAP (Manifold Absolute Pressure) Service
Sensor Global Fault
P0106-23 MAP Sensor Signal Drift Low Fault Service
33 - 369 9823/0300-1 33 - 369

90 - Fault Codes

P0106-24 MAP Sensor Signal Drift High Fault Service
P0106-64 MAP Sensor Signal Plausibility Service
Fault
P0110-00 Inlet Air Temperature (IAT) Sensor Service
Signal ADC Fault Detected
Signal Low Fault Detected
Signal High Fault Detected
P0115-00 Coolant Sensor Signal Fault Service
P0116-64 Coolant Sensor Fault (Plausibility) Trivial
P0117-23 Coolant Sensor Signal Low Fault Trivial
P0118-24 Coolant Sensor Signal High Fault Trivial
P0120-00 Foot Pedal Signal Track 1 Fault Service
vironment Pressure From Engine
ECU
P0180-00 Fuel Temperature ADC Fault Service
P0181-27 Fuel Temperature Sensor Fault Service
P0181-27 Fuel Temperature Sensor Gradient Service
Fault
P0181-87 CAN Bus Message Error For Fuel Operator
Temperature From Engine ECU
P0182-23 Fuel Temperature Sensor Low Service
Fault
P0183-24 Fuel Temperature Sensor High Service
Fault
P0190-27 Rail Pressure Sensor Signal Grad Service
Fault
P0191-23 Rail Pressure Sensor Fault. Below Service
Minimum Threshold (Out Of Range
At Key-On)
P0191-24 Rail Pressure Sensor Fault. Above Service
Maximum Threshold (Out Of
Range At Key-On)
P0192-23 Rail Pressure Sensor Signal Low Service
Fault
P0193-24 Rail Pressure Sensor Signal High Service
Fault
P0194-00 Rail Pressure Sensor Signal Drop Critical
Fault
P0195-00 Oil Temperature Sensor Signal Service
Global Fault
Gradient Fault
Plausability Fault
P0196-87 CAN Bus Message Error For Oil Operator
Temperature From Engine ECU
Low Fault
High Fault
33 - 370 9823/0300-1 33 - 370

90 - Fault Codes

P0201-00 Injector In Cylinder 1 Short Circuit Critical
HSD To LSD
P0201-11 Injector 2 Open Circuit Fault (OC) Critical
HSD To LSD
P0202-11 Injection Nozzle #2Drive System Critical
Open Circuit Fault
HSD To LSD
Open Circuit Fault
HSD To LSD
Open Circuit Fault
P0218-22 Transmission Fluid Over Tempera- Operator
ture
P0218-22 Transmission Fluid Over Tempera- Operator
ture
P0220-00 Foot Pedal Signal Track 2 Fault Service
P0235-00 Boosted Air Pressure Sensor Service
Fault: ADC
P0237-23 Boosted Air Pressure Sensor Low Service
Fault
P0238-24 Boosted Air Pressure Sensor High Service
Fault
P0252-00 Rail Pressure Control Error (IMV Service
Current Trim Drift).
P0253-00 Rail Pressure Control By The IMV. Critical
Occurs At High Fuel Delivery For
Low (Negative) Current Trim
P0254-00 Rail Pressure Control Fault By The Critical
IMV. Occurs At High Fuel Delivery
For High (Positive) Current Trim
P0261-1A Injector And Wiring Harness Resis- Service
tance Too High/Low (Inj 2)
P0261-1B Injector And Wiring Harness Resis- Service
tance Drop (Inj 2)
tance Drop (Inj 2)
P0263-00 Cylinder Balancing Fault Injector 2 Service
Stuck Closed
tance Drop (Inj 1)
tance Drop (Inj 1)
Stuck Closed
33 - 371 9823/0300-1 33 - 371

90 - Fault Codes

tance Drop (Inj 3)
tance Drop (Inj 3)
Stuck Closed
P0270-1A Injector Drift Fault Detection On In- Service
jector 2. Fault Which Is Set When
Injector 2 MDP Trim Exceeds The
Maximum Calibrated Threshold
Limit. Max Apc Raw Trim At Medi-
um Rail Pressure
P0270-1B Injector Drift Fault Detection On In- Service
The Injector 2 MDP Trim Exceeds
The Maximum Calibrated Thresh-
old Limit. Max Apc Raw Trim At
Low Rail Pressure
tance Drop (Inj 0)
tance Drop (Inj 0)
Stuck Closed
P029A-00 Injector Drift Fault Detection On In- Critical
old Limit. Maximum Apc Raw Trim
At High Rail Pressure
P029B-00 Fault Which Is Set When The In- Critical
jector 3 Absolute MDP Value Is
Below A Calibrated Threshold
P029E-00 Injector Drift Fault Detection On In- Critical
P029F-00 Fault Which Is Set When The In- Critical
P02A2-00 Injector Drift Fault Detection On In- Critical
P02A3-00 Fault Which Is Set When The In- Critical
33 - 372 9823/0300-1 33 - 372

90 - Fault Codes

P02A6-00 Injector Drift Fault Detection On In- Critical
P02A7-00 Fault Which Is Set When The In- Critical
gine Speed From Engine ECU
P0325-00 Accelerometer Fault (Signal/Noise Trivial
Ratio Too Low In Idle)
P0330-00 Trivial
P0335-31 Trivial
P0340-54 Cam Signal Last Learnt Value Is Service
Outside Of Limits
P0341-00 Cam Signal Drift Higher Than Service
Threshold
P0341-2F Trivial
P0341-31 Cam Signal Lost (No Cam Signal Service
Seen In 2 Crank Rotations)
P0341-31 Cam Signal Fault (Missing Event Service
Within The Expected Window)
P0341-85 Cam Signal Fault (Overspeed De- Critical
tected)
P0350-02 Error Monitoring For System Pro- Operator
tection Based On Ignition Switch
Input
P0371-00 Crank Signal Is Too Close To The Service
Previous One
P0372-31 Elapsed Time Between Cps Service
Events Is Too High
P0374-31 Crank Signal Lost (No Cps Signal Service
Seen In 1 Cam Rotation)
P0380-00 Trivial
P0380-13 Trivial
P0383-11 Trivial
P0384-12 Trivial
P0400-00 EGR (Exhaust Gas Recirculation) Service
Flow Reached Its Limit
P0404-00 EGR Valve Control Fault Trivial
P0404-23 Trivial
P0406-23 Trivial
P0470-00 Exhaust Manifold Pressure (P3) Service
Signal ADC Fault
Signal Low Fault
Signal High Fault
P0504-08 Park Brake Switch Plausibly Error Operator
P0504-08 Foot Brake Switch Plausibly Error Operator
P0504-64 Park Brake Switch Plausibly Error Operator
33 - 373 9823/0300-1 33 - 373

90 - Fault Codes

P0504-64 Foot Brake Switch Plausibly Error Operator
P0520-00 Low Oil Pressure Lamp/Gauge Dri- Trivial
ve Short Circuit (SC)
P0520-11 Low Oil Pressure Lamp/Gauge Trivial
Drive Short Circuit To Ground
(SC2Gnd)
ve Short Circuit To Battery Voltage
(SC2Vbatt)
ve Open Circuit (OC)
P0521-00 Oil Pressure Sensor Signal Global Critical
Fault
P0522-23 High Oil Pressure During Engine Critical
Running
P0523-23 Engine Oil Pressure Low - Critical
P0523-24 Engine Oil Pressure Sensor Fault Critical
(High Voltage Fault)
P0523-24 Engine Oil Pressure Sensor Fault Critical
(High Voltage Fault)
P0523-24 Low Oil Pressure During Engine Critical
Running
P0544-00 Turbo In Temperature Fault Service
P0545-23 Turbo In Temperature Count Low Service
Fault
P0546-24 Turbo In Temperature Count High Service
Fault
P0562-02 Fault Due To Low Or High Battery Operator
Voltage Supply To DCU
P0562-16 Low Battery Voltage Operator
P0563-17 High Battery Voltage Operator
P0563-24 Battery Voltage Monitoring Signal Service
High Fault
P0566-00 Cruise Switch Off Function Fault Trivial
Detected
P0567-00 Cruise Switch Resume Function Trivial
Fault Detected
P0569-00 Cruise Switch Decelerate Function Trivial
Fault Detected
P0570-00 Cruise Switch Accelerate Function Trivial
Fault Detected
P0575-00 Cruise Switch ADC Fault Detected Trivial
P0602-00 Trivial
P0602-45 Trivial
P0602-47 Trivial
P0602-56 Functional Safety Fault Critical
P0603-00 ECU Memory Integrity Fault (Data / Critical
Cal Integrity)
P0604-00 ECU Memory Integrity Fault (Ram Critical
Integrity)
P0605-00 ECU Memory Integrity Fault (Code Critical
Integrity)
33 - 374 9823/0300-1 33 - 374

90 - Fault Codes

P0606-02 Peripheral Monitoring Error On Operator
DCU
P0607-4B Throttle H-Bridge Driver In ECU Service
Fault: Over Temperature
P060A-00 Functional Safety Fault Critical
P060A-00 Monitoring Error On DCU Operator
P060B-00 ADC Circuit Fault (Global) Critical
P060B-16 Functional Safety Fault Critical
P060C-00 Functional Safety Fault Critical
P060C-00 DCU Software Reset Performed Operator
P060C-41 Monitoring Error On DCU Operator
P060C-F0 Functional Safety Fault Critical
P060D-00 Functional Safety Fault Critical
P060E-00 Functional Safety Fault Critical
P0612-11 Trivial
P0612-12 Trivial
P0612-13 Charge Circuit Fault ?Bank 2? Trivial
P0612-31 Trivial
P0615-13 Trivial
P0616-11 Trivial
P0617-12 Trivial
P0627-13 Lift Pump Global Fault Service
P062D-11 Injector Bank 0 Fault Shorted To Critical
Ground (SC2Gnd)
P062D-12 Injector Bank 0 Fault Shorted To Critical
Ground (SC2Vbat)
33 - 375 9823/0300-1 33 - 375

90 - Fault Codes

P062E-11 Injector Bank 1 Fault Shorted To Critical
Ground (SC2Gnd)
P062E-12 Injector Bank 1 Fault Shorted To Critical
Ground (SC2Vbat)
P062F-00 ECU Non Volatile Memory Fault Service
P0630-00 Trivial
P0641-00 ECU Internal 5V Supply 1 Fault Critical
P0641-4B ECU Internal 5V Supply 1 Fault Critical
P064F-13 Check Engine Lamp Fault Trivial
P0650-00 Trivial
P0650-11 Trivial
P0650-13 Check Engine Lamp Fault Trivial
P0651-00 ECU Internal 5V Supply 2 Fault Critical
P0651-4B ECU Internal 5V Supply 2 Fault Critical
P0658-14 Short Circuit To Ground Of Actua- Operator
tor Relay 1
P0659-12 Short Circuit To Battery Of Actuator Operator
Relay 1
P0668-23 ECU Internal Temperature Sensor Service
Low Fault
P0669-24 ECU Internal Temperature Sensor Service
High Fault
P0685-00 Main ECU Relay Stuck Critical
P0686-72 Main Relay System Fault (Open) Trivial
P0697-00 Trivial
P0697-4B ECU Internal 5V Supply 2 Auxillary Critical
Fault
P06A7-00 Sensor Supply Monitoring Error Operator
Through DCU
P0711-21 Transmission Fluid Temperature Operator
Sensor Electrical Fault
P0712-13 Transmission Temp OORL Operator
P0713-17 Transmission Temp OORH Operator
P0714-1F Transmission Fluid Temperature Operator
P0716-16 Out Of Range. Shorted To Low Operator
Source
P0716-17 Short Circuit To Supply Operator
P0716-29 Change In Speed Greater Than Operator
Plausible (Possible Trans Lock)
P0716-64 Trans Input Speed Plausibility Operator
Check Failure, High Value Error In
Range
P0716-64 Trans Input Speed Plausibility Operator
Check Failure, Low Value Error In
Range
P0716-64 Speed Sensor Fault. Operator
33 - 376 9823/0300-1 33 - 376

90 - Fault Codes

P0717-13 Trans Input Speed Sensor Input Operator
Open Circuit. Sensor Not Present,
Failure In Supply Or Short To
Ground.
P0718-1F Intermittent Wiring Fault Or Noisy Operator
Speed Signal
P0720-13 Sensor Not Present, Failure In Operator
Supply Or Short To Ground.
Source
P0721-16 Speed Sensor OORL Trivial
P0721-17 Speed Sensor OORH Trivial
P0721-64 Trans Output Speed Plausibility Operator
Check Failure, High Value Error In
Range
P0721-64 Trans Output Speed Plausibility Operator
Check Failure, Low Value Error In
Range
Speed Signal
Source
Plausible (Possible Engine Stall)
P0726-64 Engine Speed Plausibility Check Operator
Failure, High Value Error In Range
P0726-64 Engine Speed Plausibility Check Operator
Failure, Low Value Error In Range
P0727-13 Engine Speed Sensor Input Open Operator
Circuit. Sensor Not Present, Fail-
ure In Supply Or Short To Ground.
P0727-87 Engine CAN Data Not Available Operator
Or In Error / Implausible (Engine
Speed)
Speed Signal
P0729-17 Speed Sensor 2 OORH Trivial
P072A-16 Speed Sensor 2 OORL Trivial
P072B-64 Speed Sensor Disagreement Trivial
P0741-00 Luc Control Error Operator
P0741-87 Luc Control Error Operator
P0746-13 Forward Low Solenoid Open Operator
P0746-13 T Solenoid Open Circuit. Solenoid Operator
Not Present Or Short To Ground.
P0747-15 Forward Low Solenoid STB Operator
P0747-15 T Solenoid Short Circuit To Supply Operator
P0748-14 Forward Low Solenoid STG Operator
33 - 377 9823/0300-1 33 - 377

90 - Fault Codes

P0748-14 T Solenoid Out Of Range. Shorted Operator
To Low Source
P0748-18 T Solenoid Current Feedback Be- Operator
low Current Demand
P0748-19 T Solenoid Current Feedback Operator
Above Current Demand
P0749-1F T Solenoid Check Wiring Integrity, Operator
Possible Intermittent Fault
P0776-13 Forward High Solenoid Open Operator
P0776-13 U Solenoid Open Circuit. Solenoid Operator
P0777-15 Forward High Solenoid STB Operator
P0777-15 U Solenoid Short Circuit To Supply Operator
P0778-14 Forward High Solenoid STG Operator
P0778-14 U Solenoid Out Of Range. Shorted Operator
To Low Source
P0778-18 U Solenoid Current Feedback Be- Operator
low Current Demand
P0778-19 U Solenoid Current Feedback Operator
P0779-1F U Solenoid Check Wiring Integrity, Operator
P0792-16 Trans Intermediate Speed Plausi- Operator
bility Check Failure, Low Value Er-
ror In Range
bility Check Failure, High Value Er-
ror In Range
bility Check Failure, High Value Er-
ror In Range
bility Check Failure, Low Value Er-
ror In Range
P0793-13 Intermediate Shaft Speed Sensor Operator
"A" Circuit No Signal
Speed Signal
P0796-13 Reverse High Solenoid Open Operator
P0796-13 V Solenoid Open Circuit. Solenoid Operator
P0797-15 Reverse High Solenoid STB Operator
P0797-15 V Solenoid Short Circuit To Supply Operator
P0798-14 Reverse High Solenoid STG Operator
P0798-14 V Solenoid Out Of Range. Shorted Operator
To Low Source
P0798-18 V Solenoid Current Feedback Be- Operator
low Current Demand
P0798-19 V Solenoid Current Feedback Operator
33 - 378 9823/0300-1 33 - 378

90 - Fault Codes

P0799-1F V Solenoid Check Wiring Integrity, Operator
P0868-21 Transmission Fluid Pressure Low Operator
P0955-87 Auto Mode Request CAN Data Not Operator
Available Or In Error
P0956-87 Accelerator Pedal Position CAN Operator
Data Not Available Or In Error
P1101-00 Rail Pressure Control Error Posi- Critical
tive Fault
P1102-00 Rail Pressure Control Error Nega- Critical
tive Fault
P1103-00 Rail Pressure Fault Detected - Not Trivial
Able To Maintain Pressure After A
Stop And Start Request
P1104-00 Fault Which Is Set When No MDP Service
Updates Occur On Injector 3 Due
To Environmental Conditions (As
Defined By The Update Strategy)
To A Fault Within The Update
Strategy
Strategy
Strategy
P110A-00 Fault Which Is Set When No MDP Service
P110B-00 Fault Which Is Set When No MDP Service
Strategy
P1400-00 Errorneous Signal From Override Operator
Switch
P1401-00 CAN Bus Message Error From Operator
Override Switch
P1402-00 CAN Bus Off Error From Override Operator
Switch
P1500-00 Foot Pedal Signal Fault Set (Trig- Service
gers Limp Home Mode)
P1501-00 Foot Pedal Signal Fault Set (Trig- Service
gers Reduced Torque Mode)
33 - 379 9823/0300-1 33 - 379

90 - Fault Codes

P1503-00 Hand Pedal Signal Fault Set (Trig- Service
gers Limp Home Mode)
P1504-00 Hand Pedal Signal Fault Set (Trig- Service
gers Reduced Torque Mode)
P1506-00 Pedal Global Limp Home Mode Service
Triggered
P1509-00 CAN Communication Error On Trivial
TSC
P150A-00 Trivial
P1713-87 Kickdown Request CAN Message Operator
Missing Or In Error
P1714-05 Set Up Data Invalid Operator
P1715-07 Transmission Temp High Critical
P1719-13 4WD (Four Wheel Drive) Solenoid Operator
Open Circuit. Solenoid Not Present
Or Short To Ground.
P1719-13 2WD Solenoid Open Trivial
P171A-15 4WD Solenoid Short Circuit To Operator
Supply
P171A-15 2WD Solenoid STB Trivial
P171B-14 4WD Solenoid Out Of Range. Operator
Shorted To Low Source
P171B-14 2WD Solenoid STG Trivial
P171B-14 2WD Solenoid Return STG Trivial
P171B-15 2WD Solenoid Return STB Trivial
P171B-18 4WD Solenoid Current Feedback Operator
Below Current Demand
P171B-18 2WD Solenoid Return Open Trivial
P171B-19 4WD Solenoid Current Feedback Operator
P171C-1F 4WD Solenoid Check Wiring In- Operator
tegrity, Possible Intermittent Fault
P171F-64 Brake Pressure Sensor Electrical Operator
Fault
P1720-64 Brake Pressure Sensor Electrical Operator
Fault
P1721-1F Brake Pressure Sensor Electrical Operator
Fault
Fault
Fault
Fault
Fault
P1726-19 Reverse Alarm Open Circuit. So- Operator
lenoid Not Present Or Short To
Ground.
33 - 380 9823/0300-1 33 - 380

90 - Fault Codes

P1727-18 Reverse Alarm Solenoid Short Cir- Operator
cuit To Supply
P1728-1F Reverse Alarm Solenoid Current Operator
Feedback Above Current Demand
P1729-15 Reverse Alarm Solenoid Current Operator
Feedback Below Current Demand
P172A-14 Reverse Alarm Solenoid Out Of Operator
Range. Shorted To Low Source
P172B-13 Reverse Alarm Solenoid Check Operator
Wiring Integrity, Possible Intermit-
tent Fault
P172C-00 Transmission Control Fault Operator
P172D-00 Transmission Control Fault Operator
P172E-00 Transmission Control Fault Operator
P172F-00 Transmission Control Fault Operator
P1730-00 Transmission Control Fault Operator
P1731-87 Driver OCcupancy CAN Message Operator
Missing Or In Error
P2000-00 Actual Average Conversion Effi- Operator
ciency Is Below The Threshold
P202A-13 Open Load Error Of Urea Tank Operator
Heater Actuator Powerstage
P202B-14 Error For Short To Ground Of Urea Operator
Tank Heater Actuator Powerstage
P202C-15 Error For Short To Battery Of Urea Operator
P202E-00 Error On Dosing Valve Short Cir- Operator
cuit
P202E-02 Error On Dosing Valve Plausibility Operator
cuit To Battery
cuit To Battery On High Side Or
Open Load
P202E-14 Error On Dosing Valve Short To Operator
Ground Or Open Circuit
P202E-16 Error On Dosing Valve Plausibility Operator
At Low Voltage
P202E-4B Error On Dosing Valve Driver Operator
Overtemperature
P203B-00 Tank Level Signal Error. Operator
P203B-14 Urea Tank Level Signal Is Below Operator
Minimum Voltage Limit
P203B-15 Urea Tank Level Signal Is Above Operator
Maximum Voltage Limit
P203B-16 Error On Tank Level Plausibility Operator
33 - 381 9823/0300-1 33 - 381

90 - Fault Codes

P203B-22 Tank Head Unit Level Physical Sig- Operator
nal Above Maximum Limit
P203B-81 CAN Bus Message Error From Operator
Headunit
P203B-86 CAN Bus Message Error For Tank Operator
Level From Head Unit
P203B-87 CAN bus Off Error From Headunit Operator
P203F-21 Tank Head Unit Level Physical Sig- Operator
nal Below Minimum Limit
P203F-68 Reagent Tank Level Low And Be- Operator
low Warning Threshold
P203F-7B Reagent Tank Level Low And Operator
Empty
P2043-81 CAN Bus Message Error From Operator
Headunit
P2043-86 Adblue Temperature Message Er- Operator
ror From Headunit
P2043-87 CAN bus Off Error From Headunit Operator
P204B-00 Error While Monitoring The Stabili- Operator
sation Of Pressure
P204B-02 Error On Pressure Line & Dosing Operator
Valve While Monitoring For BLock-
age
P204B-16 Measured Value Of Pressure Sen- Operator
sor Below The Tolerable Limit
P204B-17 Measured Value Of Pressure Sen- Operator
sor Above The Tolerable Limit
P204B-26 Error On Rate Of Pressure Reduc- Operator
tion
P204B-29 Error On Pressure Line While Mon- Operator
itoring For BLockage
P204B-61 Error While Monitoring Of Pressure Operator
Buildup
P204C-16 Pump Pressure Signal Below The Operator
Minimum Voltage Limit
P204C-21 Error For Pump Pressure Physical Operator
Signal Below Lower Limit
P204D-17 Pump Pressure Signal Above The Operator
Maximum Voltage Limit
P204F-06 Error To Detect The Clogged Filter Operator
P204F-7A Error To Detect Leakage During No Operator
Dose
P204F-9A Inducement Repeat Offence Active Critical
P205B-00 Error To Indicate Overheating Of Operator
Adblue Tank
P205B-06 Error In Increase Of Urea Tank Operator
Temperature
P205B-16 Tank Head Unit Temperature Operator
Physical Signal Below Minimum
Limit
P205B-17 Tank Head Unit Temperature Operator
Physical Signal Above Maximum
Limit
33 - 382 9823/0300-1 33 - 382

90 - Fault Codes

P205B-23 Error On Tank Temperature Sen- Operator
sor Plausibility Below Minimum
Threshold
P205B-24 Error On Tank Temperature Sen- Operator
sor Plausibility Exceeds Maximum
Threshold
P205C-16 Tank Temperature Signal Voltage Operator
Below Minimum Limit
P205D-17 Tank Temperature Signal Voltage Operator
Above Maximum Limit
P205E-81 Tank Temperature Signal Error On Operator
CAN
P205E-87 CAN Bus Message Error For Tank Operator
Temperature From Head Unit
P207F-00 Ad Blue Quality Error During Refill Operator
Conditiion
P207F-86 Adblue Concentration Message Er- Operator
ror From Headunit
P207F-87 Adblue Quality Message Error Operator
From Headunit
P2080-2F Turbo In Temperature Count Noise Service
Fault
P208A-13 Open Load Error Of Supply Mod- Operator
ule Pump Motor
P208A-31 Supply Module Pump Feedback Operator
Error
P208B-02 Error On Supply Module Pump Operator
Speed Permanent Deviation
P208B-21 Supply Module Internal Dutycycle Operator
Below Min Range
P208B-22 Supply Module Internal Dutycycle Operator
In Invalid Range
P208B-4B Overtemperature Error Of Supply Operator
Module Pump Motor
P208B-61 Error On Supply Module Pump Operator
Speed Deviation
P208B-84 Supply Module Motor Speed Duty Operator
Cycle Below Minimum Range
P208B-85 Supply Module Motor Speed Duty Operator
Cycle Above Maximum Range
P208C-14 Short Circuit To Ground Error Of Operator
Supply Module Pump Motor
P208D-13 Short Circuit To Battery Error Of Operator
Supply Module Pump Motor
P209F-4B Error For Overtemperature Of Urea Operator
P20A0-13 Open Load Error Of Backflow Operator
Pump Actuator Powerstage
P20A1-4B Error For Overtemperature Of Operator
Backflow Pump Actuator Power-
stage
P20A2-14 Error For Short To Ground Of Operator
Backflow Pump Actuator Power-
stage
33 - 383 9823/0300-1 33 - 383

90 - Fault Codes

P20A3-13 Error For Short To Battery Of Back- Operator
flow Pump Actuator Powerstage
P20AD-06 Error On Supply Module Tempera- Operator
ture
P20AD-21 Supply Module Temperature Duty Operator
Cycle Below Minimum Range
P20AD-22 Supply Module Temperature Duty Operator
Cycle Above Maximum Range
P20AD-92 Error On Supply Module Tempera- Operator
ture Cold Start
P20B5-13 Open Load Error Of Supply Mod- Operator
ule Heater Actuator Powerstage
P20B6-21 Supply Module Heater Tempera- Operator
ture Duty Cycle Below Minimum
Range
P20B6-22 Supply Module Heater Tempera- Operator
ture Duty Cycle Above Maximum
Range
P20B6-4B Error For Overtemperature Of Sup- Operator
ply Module Heater Actuator Power-
stage
P20B7-14 Error For Short To Ground Of Sup- Operator
stage
P20B8-15 Error For Short To Battery Of Sup- Operator
stage
P20B9-00 Error For Open Load On Heater Operator
Relay Of Backflow Line
P20B9-13 Open Load Error Of Urea Back- Operator
flowline Heater Actuator Power-
stage
P20BA-4B Error For Overtemperature Of Urea Operator
Backflowline Heater Actuator Pow-
erstage
P20BB-00 Error For Short To Ground Or Operator
Open Load On Heater Relay Of
Backflow Line
P20BB-14 Error For Short To Ground Of Urea Operator
erstage
P20BC-15 Error For Short To Battery Of Urea Operator
erstage
P20BD-00 Error For Open Load On Heater Operator
Relay Of Pressure Line
P20BD-13 Error For Open Load On Heater Operator
Relay Of Pressure Line
P20BE-00 Error On Supply Module Heater Operator
Temperature Sensor
Temperature Cold Start
P20BE-13 Error On Realys For Short To Bat- Operator
tery
33 - 384 9823/0300-1 33 - 384

90 - Fault Codes

P20BE-4B Error For Overtemperature Of Urea Operator
Pressureline Heater Actuator Pow-
erstage
P20BE-93 Error On Pressure Line To Perform Operator
Afterrun
P20BF-00 Error For Short To Ground Or Operator
Pressure Line
P20BF-14 Error For Short To Ground Of Urea Operator
erstage
P20C0-15 Error For Short To Battery Of Urea Operator
erstage
P20C1-00 Error For Open Load On Heater Operator
Relay Of Suction Line
P20C1-13 Open Load Error Of Urea Suction- Operator
line Heater Actuator Powerstage
P20C2-4B Error For Overtemperature Of Urea Operator
Suctionline Heater Actuator Power-
stage
P20C3-00 Error For Short To Ground Or Operator
Suction Line
P20C3-14 Error For Short To Ground Of Urea Operator
stage
P20C4-15 Error For Short To Battery Of Urea Operator
stage
P20E8-84 Underpressure Error In Metering Operator
Control State
P20E9-00 Overpressure Error Regardless Of Operator
Supply Module State
P20E9-85 Overpressure Error In Metering Operator
Control State
P20EA-72 DCU Relay Early Opening Operator
P20EB-71 DCU Relay Stuck Operator
P2100-02 Throttle H-Bridge Driver In ECU Service
Fault: Undervoltage
Fault: OC
Fault: Current Limited
Fault: SC
Fault: SC2G
Fault: SC2Vbatt
P2119-00 Throttle Learning Position Fault S0 Service
P2120-00 Hand Pedal Signal Track 1 Fault Service
P2125-00 Hand Pedal Signal Track 2 Fault Service
33 - 385 9823/0300-1 33 - 385

90 - Fault Codes

P2135-00 Foot Pedal Corrolation Track 1 Service
Over Track 2 Fault Detected
P2138-00 Hand Pedal Signal Corrolation Service
Fault
P2146-00 Injector Supply Voltage Faulty Trivial
P2147-00 Injector Supply Voltage Faulty Trivial
P219D-13 Open Load Error Of Urea Heater Operator
Relay Actuator Powerstage
P219D-4B Error For Overtemperature Of Urea Operator
Heater Relay Actuator Powerstage
P219E-13 Error For Short To Battery Of Urea Operator
P219F-14 Error For Short To Ground Of Urea Operator
P21A9-12 Short Circuit To Battery Of Actuator Operator
Relay 4
P21AB-14 Short Circuit To Ground Of Actua- Operator
tor Relay 4
P2200-00 Upstream NOx (Nitrogen Oxide) Operator
Sensor Wire Diagnosis-Error In
Voltage Supply
P2200-02 Upstream NOx Sensor Short Cir- Operator
cuit To Gnd Or Batt
P2200-05 Upstream NOx Sensor Self Diag- Operator
nostic
P2200-11 Lambda Signal Below Minimum Operator
For Upstream NOx Sensor
P2200-12 Lambda Signal Above Maximum Operator
Limit For Upstream NOx Sensor
P2200-13 Upstream NOx Sensor Open Cir- Operator
cuit
P2200-61 Invalid Signal From Upstream NOx Operator
Sensor After Heater Release
nostic Timeout
nostic Abort
P2201-00 Downstream NOx Sensor Wire Di- Operator
agnosis-Error In Voltage Supply
P2201-06 Downstream NOxSensor Self Di- Operator
agnostic
P2201-11 Lambda Signal Below Minimum Operator
Limit For Downstream NOx Sensor
P2201-12 Lambda Signal Above Maximum Operator
Limit For Downstream NOx Sensor
P2201-13 Downstream NOx Sensor Open Operator
Circuit
P2201-16 Downstream NOx Offset Min Error Operator
Detection
P2201-17 Downstream NOx Offset Max Error Operator
Detection
P2201-1C Downstream NOx Sensor Short Operator
Circuit To GND Or Batt
33 - 386 9823/0300-1 33 - 386

90 - Fault Codes

P2201-61 Invalid Signal From Downstream Operator
NOx Sensor After Heater Release
P2201-63 Downstream NOx Sensor Self Di- Operator
agnostic Timeout
P2201-97 Downstream NOx Sensor Self Di- Operator
agnostic Abort
P2202-00 Upstream NOx Sensor Reading Operator
Below Minimum Threshold
P2202-16 Downstream NOx Sensor Reading Operator
Below Minimum Threshold
P2203-00 Upstream NOx Sensor Reading Operator
Exceeds Above Maximum Thresh-
old
P2203-17 Downstream NOx Sensor Read- Operator
ing Exceeds Abbove Maximum
Threshold
P2208-00 Downstream NOx Sensor Heater Operator
Not Available
P2208-02 Downstream NOx Sensor Heater Operator
Not Heated Quickly
P2209-00 Upstream NOx Sensor Heater Not Operator
Available
P2209-02 Upstream NOx Sensor Heater Not Operator
Heated Quickly
P2228-23 Atmosp Sensor Low Fault Service
P2229-24 Atmosp Sensor High Fault Service
P2264-00 Water In Fuel Sensor Feedback Service
Signal ADC Fault
Signal 1 Plausability Fault
Signal Low Fault
Signal High Fault
P2275-87 Joystick CAN Data Not Available Operator
Or In Error
P2413-81 CAN Bus Message Error For EGR Operator
Faults From Engine E
P2413-86 CAN Bus Message Error From En- Operator
gine ECU
P2413-87 Impeded EGR Fault Data Or Bus Operator
Off For EGR Faults From Engine
ECU
P2428-00 Trivial
P2428-17 Exhaust Catalyst Temperature T4 Operator
Physical Signal Above Maximum
Limit
P242B-00 Error On SCR Catalyst Upstream Operator
Temperature Sensor Static Plausi-
bility
P242B-16 Error On Catalyst Temperature Operator
Sensor Plausibility Below Min
Threshold
33 - 387 9823/0300-1 33 - 387

90 - Fault Codes

P242B-17 Error On Catalyst Temperature Operator
Sensor Plausibility Above Max
Threshold
P242B-23 Exhaust Catalyst Temperature T4 Operator
Physical Signal Below Minimum
Limit
P242C-16 Exhaust Catalyst Temperature T4 Operator
Voltage Signal Below Minimum
Limit
P242D-17 Exhaust Catalyst Temperature T4 Operator
Voltage Signal Above Maximum
Limit
P2502-87 CAN Bus Message Error For Pow- Operator
er Management From Engine ECU
P256A-13 Trivial
P256B-00 Trivial
P256B-23 Trivial
P256B-24 Trivial
P256B-2A Trivial
P256B-64 Trivial
P256C-11 Trivial
P256D-12 Trivial
P2620-00 Throttle Position Feedback ADC Service
Fault
P2620-2F Throttle Position Feedback Signal Service
Noisy Fault
P2621-23 Throttle Position Feedback Signal Service
Low Fault
P2622-24 Throttle Position Feedback Signal Service
High Fault
tor Relay 2
Relay 2
tor Relay 3
Relay 3
P2714-13 Reverse Low Solenoid Open Operator
P2714-13 W Solenoid Open Circuit. Solenoid Operator
P2715-15 Reverse Low Solenoid STB Operator
P2715-15 W Solenoid Short Circuit To Supply Operator
P2716-14 Reverse Low Solenoid STG Operator
P2716-14 W Solenoid Out Of Range. Shorted Operator
To Low Source
P2716-18 W Solenoid Current Feedback Be- Operator
low Current Demand
P2716-19 W Solenoid Current Feedback Operator
P2717-1F W Solenoid Check Wiring Integrity, Operator
33 - 388 9823/0300-1 33 - 388

90 - Fault Codes

P2723-13 X Solenoid Open Circuit. Solenoid Operator
P2724-15 X Solenoid Short Circuit To Supply Operator
P2725-14 X Solenoid Out Of Range. Shorted Operator
To Low Source
P2725-18 X Solenoid Current Feedback Be- Operator
low Current Demand
P2725-19 X Solenoid Current Feedback Operator
P2726-1F X Solenoid Check Wiring Integrity, Operator
P2732-13 Mainshaft Solenoid Open Operator
P2732-13 Y Solenoid Open Circuit. Solenoid Operator
P2733-15 Mainshaft Solenoid STB Operator
P2733-15 Y Solenoid Short Circuit To Supply Operator
P2734-14 Mainshaft Solenoid STG Operator
P2734-14 Y Solenoid Out Of Range. Shorted Operator
To Low Source
P2734-18 Y Solenoid Current Feedback Be- Operator
low Current Demand
P2734-19 Y Solenoid Current Feedback Operator
P2735-1F Y Solenoid Check Wiring Integrity, Operator
P2744-1F Transmission Fluid Temperature Operator
P2757-13 Luc Solenoid Open Circuit. So- Operator
lenoid Not Present Or Short To
Ground.
P2758-15 Luc Solenoid Short Circuit To Sup- Operator
ply
P2759-14 Luc Solenoid Out Of Range. Short- Operator
ed To Low Source
P2759-18 Luc Solenoid Current Feedback Operator
Below Current Demand
P2759-19 Luc Solenoid Current Feedback Operator
P2760-1F Luc Solenoid Check Wiring Integri- Operator
ty, Possible Intermittent Fault
P2779-87 Joystick CANData Not Available Or Operator
In Error
33 - 389 9823/0300-1 33 - 389

90 - Fault Codes

P2793-64 Requested Gear CAN Data Not Operator
P2793-64 Joystick N Switch Fault Operator
P2793-64 Joystick R Switch Fault Operator
P2793-64 Joystick F Switch Fault Operator
P2793-64 Column Lever Forward Switch Operator
Fault
P2793-64 Column Lever Neutral Switch Fault Operator
P2793-64 Column Lever Reverse Switch Operator
Fault
P2793-64 Gear Selection OOR Operator
P2793-87 Requested Gear CAN Data Not Operator
Fault
Fault
Fault
Fault
P2807-13 Layshaft Solenoid Open Operator
P2808-13 Z Solenoid Open Circuit. Solenoid Operator
P2808-15 Layshaft Solenoid STB Operator
P2809-15 Z Solenoid Short Circuit To Supply Operator
P280F-14 Layshaft Solenoid STG Operator
P2810-14 Z Solenoid Out Of Range. Shorted Operator
To Low Source
P2810-18 Z Solenoid Current Feedback Be- Operator
low Current Demand
P2810-19 Z Solenoid Current Feedback Operator
P2811-13 Forward Reverse Solenoid Return Operator
Open
P2811-1F Z Solenoid Check Wiring Integrity, Operator
STG
STB
P2814-13 Mainshaft Layshaft Solenoid Re- Operator
turn Open
33 - 390 9823/0300-1 33 - 390

90 - Fault Codes

turn STG
turn STB
P2A00-00 Upstream NOx Sensor Not Mount- Operator
ed Or Loose
P2A01-00 Downstream NOx Sensor Not Operator
Mounted Or Loose
P2BA7-68 Level Level 2 Enacted Critical
P2BA7-92 Level Level 1 Enacted Service
P2BA7-94 Level Level 1 Requested Service
P2BA7-9A Level Level 3 Enacted Critical
P2BA7-F0 Level Level 2 Requested Critical
P2BA7-F1 Level Level 3 Requested Critical
P2BA8-00 Interruption Warning Requested Operator
P2BA8-68 Interruption Level 2 Enacted Critical
P2BA8-92 Interruption Level 1 Enacted Service
P2BA8-94 Interruption Level 1 Requested Service
P2BA8-9A Interruption Level 3 Enacted Critical
P2BA8-F0 Interruption Level 2 Requested Critical
P2BA8-F1 Interruption Level 3 Requested Critical
P2BA9-00 Quality Warning Requested Operator
P2BA9-68 Quality Level 2 Enacted Critical
P2BA9-92 Quality Level 1 Enacted Service
P2BA9-94 Quality Level 1 Requested Service
P2BA9-9A Quality Level 3 Enacted Critical
P2BA9-F0 Quality Level 2 Requested Critical
P2BA9-F1 Quality Level 3 Requested Critical
P2BAA-00 Consumption Warning Requested Operator
P2BAA-68 Consumption Level 2 Enacted Critical
P2BAA-92 Consumption Level 1 Enacted Service
P2BAA-94 Consumption Level 1 Requested Service
P2BAA-9A Consumption Level 3 Enacted Critical
P2BAA-F0 Consumption Level 2 Requested Critical
P2BAA-F1 Consumption Level 3 Requested Critical
P2BAB-00 EGR Warning Requested Operator
P2BAB-68 EGR Level 2 Enacted Critical
P2BAB-92 EGR Level 1 Enacted Service
P2BAB-94 EGR Level 1 Requested Service
P2BAB-9A EGR Level 3 Enacted Critical
P2BAB-F0 EGR Level 2 Requested Critical
P2BAB-F1 EGR Level 3 Requested Critical
P2BAD-00 Inducement Override Active Operator
P2BAD-16 Undershoot The Limit Value Of Operator
Long Term Adaptation Factor
P2BAD-17 Exceeded The Limit Value Of Long Operator
Term Adaptation Factor
P2BAD-68 Inducement Level 2 Is Active Due Operator
To Repeat Offense Error
33 - 391 9823/0300-1 33 - 391

90 - Fault Codes

P2BAD-92 Inducement Level 1 Is Active Due Operator
P2BAD-9A Inducement Level 3 Is Active Due Operator
P2BAE-00 Driver Warning For System Tam- Operator
pering
P2BAE-68 System Tampering Level 2 Enact- Critical
ed
P2BAE-92 System Tampering Level 1 Enact- Service
ed
P2BAE-94 System Tampering Level 1 Re- Service
quested
P2BAE-9A System Tampering Level 3 Enact- Critical
ed
P2BAE-F0 System Tampering Level 2 Re- Critical
quested
P2BAE-F1 System Tampering Level 3 Re- Critical
quested
P3401-87 Excessive Ambient/Operating Operator
Temperature Error For Aftertreat-
ment 1 SCR Catalyst Reagent
Property
P3402-87 Concentration Too High For Af- Operator
tertreatment 1 SCR Catalyst
Reagent Properties
P3403-87 Concentration Too Low For Af- Operator
Reagent Properties
P3404-87 Excessive Ambient/Operating Operator
Temperature Error For Aftertreat-
ment 1 SCR Catalyst Reagent
Property
P3405-87 Temperature Too High For Af- Operator
Reagent Properties
P3406-87 Temperature Too Low For Af- Operator
Reagent Properties
P3407-87 Sensor Open Circuit Error Af- Operator
Reagent Temperature
P3408-87 Sensor Short Circuit Error Af- Operator
Reagent Temperature
P3409-87 Excessive Ambient/Operating Lev- Operator
el Error For Aftertreatment 1 SCR
Catalyst Reagent Property
P3410-87 Level Too High For Aftertreatment Operator
1 SCR Catalyst Reagent Proper-
ties
P3411-87 Level Too Low For Aftertreatment 1 Operator
SCR Catalyst Reagent Properties
P3412-87 Tank Level Open Circuit Error Operator
Aftertreatment 1 SCR Catalyst
Reagent Temperature
33 - 392 9823/0300-1 33 - 392

90 - Fault Codes

P3413-87 Tank Level Short Circuit Error Operator
Aftertreatment 1 SCR Catalyst
Reagent Temperature
P3414-87 Errorneous Signal For Engine Operator
Boost Pressure
P3415-87 Data Length Error For Ic1 Frame Operator
P3416-87 Time Out Error For Ic1 Frame Operator
P3417-87 Erroneous Signal For Intake Mani- Operator
fold Temperature
P3418-87 Erroneous Signal For Operating Operator
Mode Request
P3419-87 Error For Particulate Inlet Pressure Operator
P3420-87 Data Length Error For ProSCR3 Operator
Frame Received For Regeneration
P3421-87 Timeout Error For ProSCR3 Frame Operator
Received For Regeneration
P3422-87 Erroneous Signal For Soot Load Operator
Message
P3423-87 Erroneous Signal For Engine Ex- Operator
haust Gas Temperature.
P3424-85 SCR Partially Blocked (Over- Trivial
loaded)
P3425-85 SCR Fully Blocked (Plugged) Operator
RECOVERY Manplatform Rapid Recovery Ac- Critical
tive
RPM Crank Signal Overspeed Fault Operator
SERVICE Service Interval Elapsed Service
SERVICE Vehicle Serviced - Trivial
U0029-87 CAN bus Off Error 250Kbps Operator
U0029-88 CAN bus Off Error 250Kbps Operator
U0105-87 CAN Bus Message Error For Fuel Operator
Qnty From Engine ECU
U010A-08 CAN Communication Error: EGR- Service
CAN Fault
U010C-88 Trivial
U010E-08 Engine Rating To Service
U010E-87 Inducement Bam To Service
U0140-87 Cm1 Message Timeout Operator
U0401-61 CAN Bus Message Error For Mod- Operator
elled NOx From Engine ECU
U0401-81 CAN Bus Message Error From En- Operator
gine ECU
U0401-86 CAN Bus Message Error From En- Operator
gine ECU
U0401-87 CAN bus Off Error From Engine Operator
ECU
U040B-00 Trivial
U040B-4B CAN Communication Error: EGR Service
Overtemperature
U040B-96 Trivial
U040B-97 CAN Communication Error: EGR Service
Obstruction
33 - 393 9823/0300-1 33 - 393

90 - Fault Codes

U040B-98 CAN Communication Error: EGR Service
Overtemperature
U040D-00 Trivial
U040D-54 CAN Communication Error: Vgt Service
Spanlearn
Hardware
U040D-97 Trivial
Overtemperature
U040D-9A Trivial
U040F-81 Engine Rating Mismatch Service
U059E-00 CAN Bus Message Error For Temp Operator
Signal Status From Downstream
NOx Sensor
U059E-02 CAN Bus Message Error For No2 Operator
Level From Upstream NOx Sensor
U059E-08 CAN Bus Message Error For O2 Operator
Signal Status From Upstream NOx
Sensor
U059E-29 CAN Bus Message Error From Up- Operator
stream NOx Sensor
U059E-62 CAN Bus Message Error For Nh3 Operator
U059E-81 CAN Bus Message Error From Up- Operator
stream NOx Sensor
U059E-84 CAN Bus Message Error For Pow- Operator
er Signal Status From Upstream
NOx Sensor
U059E-86 CANBus Message Error From Up- Operator
stream NOx Sensor
U059E-87 CAN bus Off Error From Upstream Operator
NOx Sensor
U059E-93 CAN Bus Message Error For NOx Operator
U059E-94 CAN Bus Message Error For O2 Operator
U059E-97 CAN Bus Message Error For NOx Operator
Sensor
U059E-9A CAN Bus Message Error For Operator
Heater Ratio From Upstream NOx
Sensor
U059F-00 CAN Bus Message Error For Temp Operator
Sensor
U059F-02 CAN Bus Message Error For No2 Operator
Level From Downstream NOx Sen-
sor
U059F-08 CAN Bus Message Error For O2 Operator
NOx Sensor
U059F-29 CAN Bus Message Error From Operator
Downstream NOxSensor
33 - 394 9823/0300-1 33 - 394

90 - Fault Codes

U059F-62 CAN Bus Message Error For Operator
Nh3Level From Downstream NOx
Sensor
Downstream NOx Sensor
U059F-84 CAN Bus Message Error For Pow- Operator
er Signal Status From Downstream
NOx Sensor
Downstream NOx Sensor
U059F-87 CAN bus Off Error From Down- Operator
stream NOx Sensor
U059F-93 Can Bus Message Error For NOx Operator
sor
U059F-94 CAN Bus Message Error For O2 Operator
sor
U059F-97 CAN Bus Message Error For NOx Operator
NOx Sensor
U059F-9A CAN Bus Message Error For Operator
Heater Ratio From Downstream
NOx Sensor
U1501-88 Engine CAN Fault Trivial
U1501-88 Engine CAN Fault Trivial
U1502-88 Transmission CAN Fault Trivial
U1502-88 Transmission CAN Fault Trivial
U1503-88 Joystick CAN Fault Trivial
U1503-88 Joystick CAN Fault Trivial
U1504-88 Hydraulics Controller CAN Fault Critical
U1505-88 Machine Controller CAN Fault Trivial
U1506-88 Telematics CAN Fault Trivial
U1507-88 Immobilizer CAN Fault Trivial
U1508-88 Auxiliary Hydraulics Controller Operator
CAN Fault
U1900-16 Livelink - Vehicle Battery Voltage Trivial
Below Normal
U1901-16 Livelink - Internal Voltage Below Trivial
Normal
U1902-18 Livelink - Telematics Output For Trivial
Relay 0 Current Below Normal Or
Open Circuit
U1903-18 Livelink - Telematics Output For Trivial
Relay 1 Current Below Normal Or
Open Circuit
U1904-85 Livelink - ECU Above Temperature Trivial
Threshold
U1905-84 Livelink - ECU Below Temperature Trivial
Threshold
U1906-96 Livelink - Accelerometer Internal Trivial
Failure
U1907-09 Livelink - Modem Jammed Trivial
U1908-09 Livelink - GPS Antenna Not Ok Trivial
33 - 395 9823/0300-1 33 - 395

90 - Fault Codes

U1909-96 Livelink - No Comms With GPS Trivial
Module
U190A-09 Livelink - Sim Card Failure Trivial
U190B-96 Livelink - No Comms With GSM Trivial
Module
U190C-86 Livelink - GSM Network Registra- Trivial
tion Failure
U1910 -16 Relay 1 Failure - No Voltage De- Trivial
tected When Relay On
U1910 -17 Relay 1 Failure - Voltage Detected Trivial
When Relay Off
When Relay Off
When Relay Off
U1913 -84 Supply Voltage Below Normal Trivial
U1913 -85 Supply Voltage Above Normal (? Trivial
32V)
U1915 -56 Transponder Key - Invalid Key De- Trivial
tected
U1915 -9 Transponder Key - Antenna Fault Trivial
U1916 -85 Key / Keypad Code - Memory Full Trivial
U1917 -2f Engine - Communications Fault Trivial
U1917 -4 Engine - Error State Trivial
U1917 -87 Engine - No Communication Trivial
U1917 -96 Engine - Disarm Failure Trivial
U1918 -96 Immobiliser Internal Fault Trivial
WARNING Abuse Level 2 Operator
WARNING Abuse Level 1 Operator
WIF Water In Fuel Sensor Feedback Operator
Signal Setting Fault
Z111 Error Logs Full - Trivial
Z200 Errors Logs Erased - Trivial
33 - 396 9823/0300-1 33 - 396

60 - Power Socket
60 - Power Socket
Contents Page No.
33-60-00 General ......................................................................................................................... 33-399
33 - 397 9823/0300-1 33 - 397

Notes:
33 - 398 9823/0300-1 33 - 398

60 - Power Socket
00 - General
00 - General
Introduction
Refer to Operator Manual, Section 2.
33 - 399 9823/0300-1 33 - 399

66 - Load Motion Control System
Contents Page No.
33-66-00 General ......................................................................................................................... 33-401

33-66-03 Display Unit .................................................................................................................. 33-420
33-66-06 Transducer ................................................................................................................... 33-425
33 - 400 9823/0300-1 33 - 400

00 - General
Introduction .................................................. 33-401 The LLMI (Longitudinal Load Moment Indicator) and
Operation (Hydraulic) .................................. 33-402 LLMC (Longitudinal Load Moment Control) systems
Operation (Electrical) ................................... 33-403 are both described in (PIL 33-66-00) for ease of
Fault-Finding ................................................ 33-407 explanation. Your machine may be installed with
either or no system.
Check (Condition) ........................................ 33-409
Check (Operation) ....................................... 33-410
Calibrate ...................................................... 33-416
33 - 401 9823/0300-1 33 - 401

00 - General
Operation (Hydraulic)
ECU controls the proportional solenoids on the main

System Operation control valve.
The LLMC (Longitudinal Load Moment Control) The lift arm angle sensors inform the ECU when the
system is controlled by the machine hydraulic control lift arm ahs been raised above a specified angle. This
ECU (Electronic Control Unit). The ECU gets input angle varied according to the country of use.
from the axle transducer, chassis and lift arm
mounted electric inclinometers, lift arm retracted The LLMC system is able to isolate the hydraulic
proximity switch and transmission speed sensor. system when the machine has a fault. The isolation
solenoid is located within the control valve block.
The ECU compares the machine status to pre-set
values stored in its memory. The outputs from the
Figure 1255.
A
B C
A Proximity switch B Inclinometer 1

C Inclinometer 2 D Isolation solenoid
E Axle transducer F Transmission speed sensor
33 - 402 9823/0300-1 33 - 402

00 - General
The transducer is powered from the fuse to the pin 4.

LLMI System
The output from the transducer is processed by the
The LLMI (Longitudinal Load Moment Indicator) unit LLMI unit. The unit drives its warning LED (Light
is self contained. It is connected to the machine Emitting Diode)s and audible warning depending on
battery via the ignition switch and a fuse. Power is the value of the calculated longitudinal load moment.
connected to the unit when the ignition is set to ON.
The LLMI unit is CAN (Controller Area Network)
The LLMI unit must be calibrated for correct enabled. The calculated longitudinal load moment is
operation of the LLMI system. transmitted on the CANbus via the connector.
Figure 1256. Electrical Schematic- LLMI System
P042-A
FUSE 16 1 4
CAN P030
3 LLMI
P005 2 LLMC
ECU
B
CAN L
A
CAN H
P042-B
P039
1
C004 2
6
15
3
16 5
69 C025
REAR AXLE
TRANSDUCER
FUSE 20
P005
IGN +VE -VE
C025 Transducer- rear axle mounted P039-C004 Chassis to panel harness

interconnect
P005 Fuse box P042-A LLMI unit- CAN enabled
P042-B LLMI unit- CAN bus connection
33 - 403 9823/0300-1 33 - 403

00 - General
LLMC System the machine is travelling and when the machine is

stationary.
The LLMC (Longitudinal Load Moment Control)
system operates when the boom is moved from the Lift arm angle
fully retracted position, or when the boom is raised
above a specific angle. The angle varies according The outputs from chassis and lift arm angle electric
to the designated country of the machine. inclinometers change as the lift arm and chassis
angles change in the longitudinal plane. The output
• Australia/New Zealand- the LLMC is operative signals are used by the hydraulic control ECU to
at boom angles greater than 10°. calculate the lift arm elevation angle in relation to the
• Rest of the world- the LLMC is operative at chassis.
boom angles greater than 45°.
Outputs
If you install a new hydraulic control ECU
(Electronic Control Unit) or LMS (Loadall Monitoring The hydraulic control ECU responds to the motion
System)ECU, make sure to check that the machine control input devices. Outputs from the ECU control
is set-up correctly for the country of use in the the proportional solenoids on the main control valve.
Servicemaster LMS setup tool. As the machine gets closer to its stability limit, the
hydraulic services operate at proportionally reduced
Inputs speed and ultimately stop.
Longitudinal load moment Hydraulic shut off
The LLMI unit operates in the normal way. The LLMI The hydraulic control ECU monitors the machine
unit is CAN enabled. The calculated longitudinal load status. If the status is not as expected (e.g. the lift
moment is transmitted on the CANbus. arm angle rate of change is not as expected for the
load moment or control inputs), it is assumed that
Since the hydraulic and transmission control ECUs there is a hydraulic system fault. The ECU isolates
are also CAN enabled, they are able to process the the main hydraulic system by energising the dump
longitudinal load moment value. solenoid valve.
Lift arm retracted/extended Lift Arm Retract Damping

The proximity switch changes state when the boom When the lift arm is being retracted, the hydraulic
is fully retracted. Hydraulic control ECU detects the control ECU reduces the flow to the retract
switch state. proportional solenoid just before the lift arm reaches
the fully retracted position. This dampens the shock
Machine stationary/travelling of the lift arm being fully retracted.
The signal from transmission speed sensor is used If you install a new hydraulic control ECU or LMSECU
by the hydraulic control ECU to determine when make sure to check that this option is selected when
installed.
33 - 404 9823/0300-1 33 - 404

00 - General
Figure 1257. Electrical Schematic- LLMC System

F
3 1
4
6 2
5
T006
F J2-6
1 2
ECU
V010 J2-5
33K C047
4 3
1 2 A 5K6 J1-10
F
ECU
C045
J1-11
A 1K8 C046
J5-7
ECU
3 1 SC31 J5-14
6 4 C050
SC28
2 J3-4
5 J3-5
ECU
C052
3 2
6 5 J3-3 C048
1
4 J4-8
ECU
CAN L
C023 ECU
J4-11
CAN L
CAN J4-12
LLMI C049
LLMC
J4-17
P042-B CAN H
CAN H J4-18
A Resistor C023 Inclinometer- lift arm mounted
33 - 405 9823/0300-1 33 - 405

00 - General
C045 Lift arm extend/retract proximity switch C046 Hydraulic control ECU- connector J1
C047 Hydraulic control ECU- connector J2 C048 Hydraulic control ECU- connector J3
C049 Hydraulic control ECU- connector J4 C050 Hydraulic control ECU- connector J5
C052 Inclinometer- chassis mounted F Fuse
P042-B LLMI unit- CAN enabled T006 Transmission speed sensor
V010 Hydraulic isolation dump solenoid
33 - 406 9823/0300-1 33 - 406

00 - General
Fault-Finding
Fault
Calibration Faults Table 329. Page 33-407
Indicator Display Unit Faults Table 330. Page 33-407
External Faults Table 331. Page 33-407
Sequential Fault Finding Table 332. Page 33-407
Table 329. Calibration Faults

Cause Remedy
System not calibrated correctly. Calibrate the system. Refer to (PIL 33-66).
Transducer not connected. Check transducer wires connection.
Transducer not fixed down correctly. Check mounting surfaces are clean and flat. Check
mounting bolts are not bottoming-out.
Check tightness of the transducer mounting bolts.
Faulty harness. Check for tapped or damaged wires.
Faulty transducer. Check for water ingress. Replace transducer and
recalibrate the system.
Table 330. Indicator Display Unit Faults

Cause Remedy
The display unit has detected an internal error. Turn the ignition key switch off and then on again.
Replace the display unit if the fault does not clear.
Calibrate the system.
Table 331. External Faults

Cause Remedy
Blown fuse. Check fuses.
Display unit not receiving 12V supply. Do a 12V supply and fuse test (V1). Refer to (PIL
33-66).
Battery voltage too low. Check the battery voltage. Do a 12V supply and fuse
test (V1). Refer to (PIL 33-66).
Battery voltage too high. Check the battery voltage. Do a 12V supply and fuse
test (V1). Refer to (PIL 33-66).
Axle transducer signal out of range. Check mounting surfaces are clean and flat. Check
mounting bolts are not bottoming-out.
Check tightness of transducer mounting bolts. Refer
to (PIL 33-66).
Check the transducer wires connection.
Do transducer output test (V3). Refer to (PIL 33-66).
CAN (Controller Area Network) bus fault. Use Servicemaster to check fault code log for
applicable CAN fault codes.
Table 332. Sequential Fault Finding

Cause Remedy
1) Do 12V Supply and Fuse Test V1- (Refer to (PIL Yes = Go to 2, No = Go to 3
33-66) and record voltage, is 12V Supply OK?
2) Is the transducer 12V supply OK? Yes = Go to 4, No = Go to 5
3) Check Ignition ON, fuse condition, battery Yes = Done, No = Go to 2
condition, test box connections. Repair as required.
Is it OK now?
4) Is the display unit OK? Yes = Go to 6, No = Go to 7
33 - 407 9823/0300-1 33 - 407

00 - General
Cause Remedy
5) Do Transducer 12V Supply Test V2- refer to (PIL Yes = Done, No = Check Ignition ON, fuse condition,
33-66) and record voltage, battery condition, test box connections. Repair as
required.
6) Are the transducer output signals OK? Yes = Go to 8, No = Go to 9
7) Do Display Unit Functional Test and re-calibrate, Yes = Done, No = Replace display box
8) Can the display unit be re-calibrated? Yes = Go to 10, No = Go to 11
9) Do Transducer Output Test (V3)- refer to (PIL Yes = Done, No = Go to 12
33-66) and Transducer Output Test (V4)- refer to (PIL
33-66).
10) Has frequent re-calibration been required? Yes = Possible transducer slipping. Remove the
transducer, clean surfaces and re-torque bolts. Refer
to LLMI Axle Transducer
11) Do Transducer Output Test (V3) and Transducer Yes = Replace display unit, No = Go to 13
Output Test (V4)
12) Do Harness Wiring Continuity and Short Circuit Yes = Done, No = Check for uneven mounting
Tests and repair as required. OK now? surfaces or bolt not tightened correctly. Refer to LLMI
Axle Transducer
13) Check transducer fixed securely. OK now? Yes = Suspect faulty transducer, No = Possible
transducer slipping. Remove the transducer, clean
surfaces and re-torque bolts.
33 - 408 9823/0300-1 33 - 408

00 - General
Check (Condition) Figure 1258. Fault Codes- Calibration Faults
The purpose of this section is to help you trace

faults to a faulty unit (valve, actuator, ram, solenoid,
proximity switch, etc). Once you have located the
fault, refer to the appropriate dismantling, inspecting
and test instructions given elsewhere in the steering 1 2 3 4
section. Also refer to the fault finding table, (PIL
33-66-00). 1 No calibration
2 Tip point invalid
To help identify circuits, switches, valves, rams etc. 3 Calibration point invalid
mentioned in the fault finding procedures, refer also 4 Calibration error
to the electrical schematic diagrams in Electrical (See fault finding table 2)
System, General, Schematic Circuit, (PIL 33-00-50) Figure 1259. Fault Codes- LLM External Faults
or the hydraulic schematic diagrams in Hydraulic
System, General, Schematic Circuit, (PIL 30-00-50).
1. Make the machine safe, refer to (PIL 01-03).

2. Make any relevant electrical checks before
moving on to the hydraulics.
1 2 3 4 5
3. Make simple checks before performing major
1 CAN Bus error
repairs or replacement.
2 Mode data error (LLMC only)
4. Make sure that the hydraulic fluid is at correct 3 Axle transducer out of range
specified working temperature. 4 Battery voltage at unit low
5 Battery voltage at unit high
Temperature: 50°C (121.9°F) (See fault finding table 4)
5. Whatever the fault, check the condition of the Figure 1260. Fault Codes- LLM Unit Faults
hydraulic fluid. Drain and replace if necessary.
6. Be sure to remove all contamination and if
possible identify its origin. It may be part of a
7. Replace any seals such as 'O' rings before
reassembling hydraulic components. 1 2 3 4 5 6
1-6 LLM unit internal faults
8. Machine ECU (Electronic Control Unit)’s will
(See fault finding table 3)
generate a fault code for some fault conditions,
refer to (PIL 33-57-90).
LLMI Fault Codes

1. When the system detects a fault, the audible
alarm will sound and various combinations of
LED (Light Emitting Diode)'s on the display
unit will illuminate to indicate a fault code for
approximately the specified time:
Duration: 10s
2. The audible alarm and fault code cancel after the
specified time, all the LEDs on the display unit
will then flash continuously as long as the fault
remains.
Duration: 10s
3. To show the fault code for a further specified time,
press and release button E.
Duration: 10s
33 - 409 9823/0300-1 33 - 409

00 - General
Check (Operation) Test Operation Result

5 Press and The boom
Special Tools release but- should not low-
Description Part No. Qty. ton. When er.
LMI Test Box 892/00905 1 the LLMILED
(Light Emitting
Make sure you do the procedures in LLMI Diode)'s flash,
(Longitudinal Load Moment Indicator) Fault Finding operate boom
before the procedures in LLMC (Longitudinal Load lower.
Moment Control) Fault Finding. 6 Press and The boom
release but- should not ex-
For LLMI Fault Finding, refer to Electrical System, ton. When the tend.
Load Motion Control System, Display Unit, Fault LLMILED's
Finding.Refer to: PIL 33-66-03. flash, operate
boom extend.
For LLMI Fault Finding, refer to Electrical System,
Load Motion Control System, General, Fault 7 Press and The boom
Finding.Refer to: PIL 33-66-00. release but- should raise.
ton. When the
LLMILED's
LLMC Functional Check flash, operate
boom raise.
Make sure you do the LLMI unit self test procedure
first. Refer to Electrical System, Load Motion Control 8 Press and The boom
System, Display Unit, Check (Operation).Refer to: release but- should retract.
PIL 33-66-03. ton. When the
LLMILED's
1. Make sure the machine is unloaded, park the flash, operate
machine and make it safe with the engine boom retract.
running. (1) Australia and New Zealand Only
Refer to: PIL 01-03-27. Figure 1261.
2. Fully retract and lower the lift arm.
3. Make sure the symbol illuminates.
4. Do the test procedures in the table. Refer to Table
333.
5. If the machine still does not operate correctly,
use Servicemaster to read the fault code log.
Investigate the related fault codes.
Table 333.
Test Operation Result
1
(1)
Raise the boom Symbol H =
above the spec- OFF, Symbol F
ified amount. = ON
10°
2 Partly raise Symbol H =
and extend the OFF, Symbol F
boom. = ON E Button
F Symbol F
3 Drive the ma- Symbol F = H Symbol H
chine forwards. OFF, Symbol H
= ON
LLMI Diagnostic Tests
4 Stop the ma- Symbol F = ON,
chine. Symbol H = Before you do the diagnostic tests, do the LLMI unit
OFF self test and calibration procedures. Refer to: PIL
33-66-00.
33 - 410 9823/0300-1 33 - 410

00 - General
If the calibration and self test procedures fail to rectify The test box also has three switches, Test 1/Test 2,
a fault, the faults can occur at the following areas. Trans/Boss and Run/Check to change the settings
for the various tests.
• Axle transducer
• Machine electrical harness The test box is connected between the four-pin plug
and socket, which connect the display box to the
LMI Test Box machine wiring harness behind the instrument panel
in the cab.
1. The service engineer can use either the LMI
(Load Moment Indicator) test box or a suitably 1. Remove the instrument panel and connect the
calibrated multimeter to diagnose faults in the test box to the harness connector 1 and the
system down to component level. harness connector 2.
Special Tool: LMI Test Box (Qty.: 1) Figure 1263.
Figure 1262.
A
A
TP1 TP2 TP3 TP4 TP5 B
A LMI test box

A LMI test box B Harness connector 1
C Harness connector 2
Table 334. Test Box Test Points 2. Before you do the tests, make sure to check the
Test Point Function following.
TP1
(1)
Earth 2.1. The machine is on level ground with the
TP2 Display box 12V supply boom horizontal.
TP3 Transducer 12V supply 2.2. The forks are installed with no load.
TP4
(2)
Transducer output (sig-
2.3. The lift arm is fully retracted.
nal)
TP5
(3)
Transducer output (volt- 2.4. Two-wheel drive is engaged (if installed)
age) and the machine has been driven
backwards and forwards several times with
(1) The black lead of the multimeter should be the wheels in the straight ahead position.
connected to earth when measuring voltages.
(2) Measures the current signal in the transducer 2.5. The ignition key switch is on, but the engine
return wire and converts this to a voltage which can is not running.
be read by the multimeter.
(3) Is a direct connection to the transducer return The testing procedures described in this section
wire. should be carried out on level ground with the road
wheels in the straight ahead position. The indicator
The test box has five test points. The test points display box will be affected by extreme steer lock and
TP1 and TP5 allow the current signals (mA) in the axle angles.
circuit to be read as voltages by connecting a digital
multimeter. The test points also allow to do the
continuity test and open/short circuit tests.
33 - 411 9823/0300-1 33 - 411

00 - General
12V Supply And Fuse Test (V1) 7. Check the wiring harness connections. Rectify as
required.
1. Set the test box switches to Run / Trans / Test 1.
2. Measure the voltage between test points display
box (TP2) and the earth (TP1). 8. If the expected reading is still not obtained after
completing the above checks, replace the display
3. Make sure the battery voltage is of the specified box.
value.
Figure 1265. Transducer Supply Test (V2)
Voltage: 11–15V
Fuse
101 601
4. If the test box is not available, measure the
voltage between the feed wire to the display box Display
Box
and earth.
000
5. If the expected reading is not obtained, check
that the ignition key switch is on.
414
413
6. Check the condition of the fuse, and the battery.
TP3 TP1
7. Check the wiring harness connections. Rectify as V2
required. Refer to (PIL 33-12). Transducer
Figure 1264. Display Box Supply Test (V1) TP1 Test point 1
TP3 Test point 3
V1
TP1 Transducer Output Test (V3)- With
Transducer Installed To The Axle
Fuse
101 601 1. Set the test box switches to Run / Trans / Test 1.
TP2
Display
Box 2. Measure the voltage between the test points TP1
000
and TP4. Make sure the voltage reading is of the

specified value.
Voltage: 4.3–4.7V
414
413
2.1. This voltage cannot be measured using a

voltmeter directly on the wiring. This voltage
can only be measured via the test box.
Transducer
TP1 Test point 1 3. If the test box is not available, use a good quality
TP2 Test point 2 multimeter capable of reading milliamp (mA) to
measure the current in wire no. 414 as shown.
Transducer 12V Supply Test (V2) Refer to Figure 1266.
1. Set the test box switches to Run / Trans / Test 1. 3.1. Make sure the reading is of the specified
value.
2. Measure the voltage between test points earth Current: 0.045–0.055A
(TP1) and transducer (TP3).
3. Make sure the battery voltage is of the specified
value.
Voltage: 11–15V
4. If the test box is not available, measure the
voltage between the feed wire to the transducer
and earth.
5. If the expected reading is not obtained, check
that the ignition key switch is on.
6. Check the condition of the fuse, and the battery.
33 - 412 9823/0300-1 33 - 412

00 - General
mA
4. If the correct reading is not obtained, one of the

following faults is most likely.
4.1. Defective earth connection.
4.2. Defective feed connection. A LMI test box
B Machine wiring harness
4.3. Defective installation of the transducer. C Display box harness
If you think that the wiring is faulty, check for possible 2. Disconnect the transducer harness from the
harness faults by doing the harness wiring continuity machine wiring harness.
and short circuit test.
3. Set the test box switches to Check / Trans / Test
If you think that the transducer or the transducer 1.
mounting is faulty, test the transducer output with the
transducer removed from the mounting. 4. Turn off the ignition switch and check for
continuity between the following points on the
Figure 1267. Transducer Output Test (V3) test box and the two pin connector that was
connected to the transducer.
Fuse
101 601 5. For continuity test, do as follows.
Display
Box 5.1. Switch the multimeter to the Ohms scale
000
and measure the electrical resistance

between Test point TP3 and pin 2 of the two
pin connector 1.
414
413
5.2. Switch the multimeter to the Ohms scale

and measure the electrical resistance
TP4
between Test point TP5 and pin 1 of the two
Transducer pin connector 2.
5.3. Make sure the reading is of the specified
TP1
V3 value.
Resistance: 3Ω
TP1 Test point 1
TP4 Test point 4 6. For short circuit test, do as follows.
6.1. Measure the electrical resistance between
Harness Wiring Continuity And Short Circuit Test points TP1 and TP5.
Test
6.2. Measure the electrical resistance between
1. Disconnect the display box harness from the test Test points TP3 and TP5.
box, but leave the test box connected to the 6.3. Measure the electrical resistance between
machine wiring harness. Test points TP1 and TP3.
6.4. Make sure that the circuit is open.
33 - 413 9823/0300-1 33 - 413

00 - General
7. If the test box is not available, disconnect the 3. Set the test box switches to Run / Trans / Test 1.
display box harness from the machine wiring
harness. 4. Measure the voltage between TP1 and TP4.
8. Turn off the ignition switch and using a multimeter 5. Make sure the reading is of the specified value.
check for continuity or short circuits in the Voltage: 4.48–4.52V
harness wiring between the display box and
transducer electrical connectors. 6. This voltage cannot be measured using a
voltmeter directly on the wiring. This voltage can
9. If the expected readings are not obtained, check only be measured via the test box.
for damaged wiring and faulty connections.
7. If the test box is not available, use a good quality
10. If the expected readings are obtained, but the multimeter capable of reading milliamp (mA) to
expected voltage reading from transducer output measure the current in wire no. 414 as shown.
test (V3) is not achieved, test the transducer Refer to Figure 1271.
output with the transducer removed from the
axle. 8. Make sure the reading is of the specified value.
Figure 1269. Current: 0.047–0.053A
M Figure 1271.
mA
E Two pin connector 1
F Two pin connector 2
M Machine wiring harness
Figure 1270. Harness Conti-
9. If the transducer is not distorted, make sure the
nuity and Short Circuit Tests
voltage is of the specified value.
Fuse
TP1 Voltage: 4.48–4.52V
TP2
10. If it is outside this range, but within the specified
value, the transducer may still be serviceable,
providing the result of transducer output test (V3)
TP5 TP3 is satisfactory.
Voltage: 4.4–4.6V
11. If the transducer passes this test and failed in the
transducer output test (V3), the apparent failure
may be due to uneven transducer mounting.
TP1 Test point 1 11.1. Check mounting surfaces are clean, flat
TP2 Test point 2 and free from paint and rust etc.
TP3 Test point 3
TP5 Test point 5 11.2. Install the transducer to the axle and
tighten the screws to the correct torque
Transducer Output Test (V4)- With value. Refer to (PIL 33-66).
Transducer Removed From The Axle
1. Remove the transducer from the axle.
2. Reconnect to the machine wiring harness and
support the transducer under the machine.
33 - 414 9823/0300-1 33 - 414

00 - General
Figure 1272. Transducer Output Test (V4)

Fuse
101 601
Display
Box
000
414
413
TP4
Transducer
TP1
V4
TP1 Test point 1

TP4 Test point 4
Test Results
The following table may be used to record the values
and must be submitted in the event of a warranty
claim. If applicable, any warranty parts must also
be returned with any additional information such as,
which lights are not illuminating, or if the display box
function test is not successful.
Table 335. Test Results

Test Expected Actual
Supply and fuse 11–15V
test (V1)
Transducer 11–15V
supply test (V2)
Transducer out- 4.3–4.7V
put test (V3)
0.045–0.055A
Transducer out- 4.48–15V
put test (V4)
0.047–0.053A
When returning equipment under warranty, the

results of the above tests must be stated.
Recalibrate the system after performing the above

tests and before you operate the machine. Refer to
(PIL 33-66).
33 - 415 9823/0300-1 33 - 415

00 - General
Calibrate
13. Read up from the extension figure obtained at

LLMI Calibration step 11 (example line X) to the tipping line A-A.
1. Park the machine and make it safe. 14. Read horizontally (example line Y) to the
maximum working limit line B-B.
15. Read down to the horizontal axis (example line
2. Turn the ignition key to the off position. Z) to get the dimension for the lift arm extension
(maximum working limit).
3. Press and hold the display button. Start the
engine with the button held down. 16. Draw a mark on the lift arm at the dimension
obtained above. Raise and retract the lift arm to
4. Hold the button for the specified time after the
the mark drawn on the lift arm.
engine has started.
Duration: 30s 17. Press and release the display button. The display
will revert to normal operation. The setting of the
4.1. All the display LED (Light Emitting Diode)s 100% position is now complete.
will illuminate during this time.
Figure 1273.
5. After approximately 30 seconds, the display will
show the red LED only and the alarm will emit
short intermittent bleeps.
6. Release the test button. If the button is released
during this time, the entire process must be C
repeated. B
7. With the lift arm fully retracted, pick up a load of A
the specified value. Use either pallet forks loaded
with a test weight, or a shovel filled with a high D
E
density material.
Weight/Force: 2,000kg
8. Slowly extend the lift arm. Keep the load close to
the ground until the machine is balanced about
the front axle with the rear wheels off the ground.
9. If the following actions are not completed within a G
five minute period, the display will automatically
leave the calibration mode and the memory will F
revert to the previous settings. If the transducer
signal is out of range, the display will indicate
H
the appropriate error code. Calibration cannot
continue until the fault is rectified.
10. Press and release the test button. The display A Green LED
will change to show the amber LED and red LED B Amber LED
only. C Red LED
11. Lower the load to the ground and measure the D Power ON indicator
distance the lift arm is extended (in millimetres). E Test button
F Mode change button
12. Refer to the correct calibration chart for the G Load control mode symbol
machine. H Ground work mode symbol
33 - 416 9823/0300-1 33 - 416

00 - General
Figure 1274. Calibration chart- LLMC (540-170 Without Stabilisers)
8000
7000
6000
m m 5000
4000
3000
2000
1000
B - B Safe Working Load Line
Boom Extension
A - A Tipping Line
Load
0
9000
8000
7000
6000
5000
4000
3000
2000
1000
-1000
kg
mm
kg
33 - 417 9823/0300-1 33 - 417

00 - General
Figure 1275. Calibration chart- LLMC (540-170 With Stabilisers)
B - B Safe Working Load Line

Boom Extension
A - A Tipping Line
Load
mm
kg
33 - 418 9823/0300-1 33 - 418

00 - General
Disassemble and Assemble 2.1. During assembly renew the seal 1, seal 2
and the seal 3.
3. Make sure that all components are tightened to
Disassemble the correct torque.
1. Remove the LLMC (Longitudinal Load Moment
Control) valve block. Refer to electrical system- Table 336. Torque Values
load motion control system, refer to (PIL 33-66). Item Nm
1A 27
2. Before you remove the solenoid assemblies or
coils, put a label on them for correct installation. 1B 27
1C 27
3. Loosen and remove the securing nut on the coil 4 4.1
on the valve you wish to remove.
5 4.1
4. Remove the solenoid. 6 4.1
5. Loosen and remove the cartridge.
6. Remove and discard the seal.
7. Repeat steps for the removal of the other valves.
3 to 6
Figure 1276.
2B 3B
5 6
3A
1B
1 3
4 1A 2 2A
1 Solenoid valve assembly 1
1A Cartridge 1
2A Cartridge 2
3A Cartridge 3
1B Seal 1
2B Seal 2
3B Seal 3
4 Securing nut
5 Securing nut
6 Securing nut
Assemble
Although the solenoid assemblies look very similar,
they have different flow characteristics.

removal procedure.
2. When you install, do the following step also:
33 - 419 9823/0300-1 33 - 419

03 - Display Unit
03 - Display Unit Operation

Operation ..................................................... 33-420
Fault-Finding ................................................ 33-422
Longitudinal Load Moment Indicator
Operator Interface
Check (Operation) ....................................... 33-423
Remove and Install ..................................... 33-423 WARNING The LLMI and LLMC systems do
not warn the operator when the machine is
at risk of tipping or overturning SIDEWAYS or
REARWARDS. The LLMI and LLMC systems
are not intended to warn the operator of tipping
or overturning when the machine is travelling,
operating on unsuitable ground or subjected to
sudden overloading.
The LLMI (Longitudinal Load Moment Indicator)

gives indication to the operator when the machine
reaches its maximum forward longitudinal load
moment (when the load moment could cause the
machine to tip forward).
The system is permanently on when the ignition is

on. A green LED (Light Emitting Diode) is illuminated
to confirm the unit is on.
A sensor measures the load exerted on the rear axle

and sends a signal to the indicator unit. The indicator
unit converts the signal into a display in the form
of three green LED. One amber LED and one red
LED. The LED will illuminate progressively as the
load increases.
The amber LED will flash as the load nears the

maximum working limit.
If the load exceeds the maximum working limit, the

red LED will illuminate and an audible warning will
activate.
Figure 1277.
A Set of three green LEDs

B Amber LED
C Red LED
D Green LED
33 - 420 9823/0300-1 33 - 420

03 - Display Unit
If the system detects a fault, the audible alarm will

sound and a combination of LEDs will illuminate to
indicate a fault code.
The display brightness and audible warning levels

can be adjusted.
Set the volume and brightness

The volume of the audible alarm, and the brightness
of the display LEDs can be set by the operator
using the display button. This allows the volume and
brightness to be reduced for night time use. The
possible options are:
• Full volume and full brightness (default setting).

• Reduced volume and full brightness.
• Full volume and reduced brightness.
• Reduced volume and reduced brightness.
1. Park the machine (unloaded) on level ground
with the engine running.
2. Apply the park brake and place the forward/
reverse lever in the neutral position.
3. The green light at the bottom of the display will
illuminate to show that the indicator is ok.
Figure 1278.
D
E
D Green LED
E Display button
4. Press and hold the display button.
4.1. The display will cycle through the
volume and brightness options, pausing
approximately for the specified time to
demonstrate each option.
Duration: 3s
5. To select any option, release the button when the
option is displayed.
The system will reset to the default setting when the

ignition key is switched to the off position.
33 - 421 9823/0300-1 33 - 421

03 - Display Unit
Fault-Finding
Fault
Lift Arm Back Sensor Signal Fault Table 337. Page 33-422
Chassis Inclinometer Signal Fault Table 338. Page 33-422
Lift Arm Inclinometer Signal Fault Table 339. Page 33-422
Transducer Speed Sensor Signal Fault Table 340. Page 33-422
Table 337. Lift Arm Back Sensor Signal Fault

Cause Remedy
Transducer not mounted correctly. Rectify loose or missing fixings.
Transducer not connected. Check transducer connection.
Faulty harness. Check for trapped or damaged wires.
Faulty transducer. Check for water ingress. Replace the transducer.
Table 338. Chassis Inclinometer Signal Fault

Cause Remedy
Faulty transducer. Check for water ingress. Replace transducer.
Table 339. Lift Arm Inclinometer Signal Fault

Cause Remedy
Table 340. Transducer Speed Sensor Signal Fault

Cause Remedy
33 - 422 9823/0300-1 33 - 422

03 - Display Unit
Check (Operation) Remove and Install
Make sure you carry out the procedures in LLMI Removal

(Longitudinal Load Moment Indicator) Fault Finding
before the procedures in LLMC (Longitudinal Load 1. Park the machine and make it safe. Lower the
Moment Control) Fault Finding. boom. Obey the care and safety procedures.
For LLMI Fault Finding, refer to Electrical System, 2. Disconnect the battery. Obey the care and safety
Load Motion Control System, Display Unit, Fault procedures. Ref (PIL 01-03).
Finding, (PIL 33-66-03).
Figure 1280.
For LLMI Fault Finding, refer to Electrical System,
Load Motion Control System, General, Fault Finding,
(PIL 33-66-00).
LLMI Self Test Function

The LLMI unit has a self test function. Perform the
test as follows:
1. Park the machine (unloaded) on level ground

with the engine running. Apply the park brake
and place the forward/reverse lever in the neutral
position.
2. The green LED (Light Emitting Diode) at the
bottom of the display illuminates to show that the
indicator is receiving power.
3. Press the display button and release.
4. All LED's on the indicator flash and the audible
alarm sounds if the unit is functioning correctly.
5. If the unit is defective, install a new unit.
Figure 1279.
1 Screws
2 Cover
6 Retainers
7 LLMI (Longitudinal Load Moment Indicator) Unit
Figure 1281.
D
E
D Green LED
E Display button
Refer to Electrical System, Load Motion

Control System, General, Check (Operation), (PIL
33-66-03).
5 Electrical connectors
33 - 423 9823/0300-1 33 - 423

03 - Display Unit
3. Remove the right hand instrument panel to

access to the LLMI unit electrical connectors.
4. Disconnect the two electrical connectors.
5. Remove three screws and lift off the cover
complete with the LLMI unit.
Figure 1282.
2
2 Cover
6 Retainer
7 LLMI unit
6. Remove the two retainers and remove the LLMI
unit from the cover.
Install
1. Replacement is the opposite of the removal
procedure.
2. Calibrate the LLMI unit. Refer to (PIL 33-66).
33 - 424 9823/0300-1 33 - 424

06 - Transducer
06 - Transducer Operation
Operation ..................................................... 33-425 The transducer measures the load exerted on the
Remove and Install ..................................... 33-426 rear axle and sends a signal to the LLMI (Longitudinal
Load Moment Indicator) unit. The LLMI unit converts
the signal into the longitudinal load moment value
and drives the display LED (Light Emitting Diode)s
as required.
The LLMI unit is CAN (Controller Area Network)

enabled. The calculated longitudinal load moment is
transmitted on the CANbus.
Figure 1283.
A Transducer
33 - 425 9823/0300-1 33 - 425

06 - Transducer

Consumables 1. Remove any old sealant, rust, dirt or paint from
Description Part No. Size the mating faces on the transducer and axle.
Cleaner/Degreaser 4104/1557 0.4L 2. Make sure that the mounting faces are flat, level
- General purpose and free of burrs.
solvent based parts
cleaner 3. Remove any surface contamination from the
JCB Threadlocker and 4101/0550 0.01L mating faces of the transducer and axle.
Sealer (High Strength) 4101/0552 0.2L Consumable: Cleaner/Degreaser - General
Remove
4. Make sure that the faces are clean, dry and free
WARNING! A raised and badly supported of grease. Make sure that the threaded holes are
machine can fall on you. Position the machine clean and free from grease.
on a firm, level surface before raising one end. 5. Allow the solvent to dry for approximately 1
Ensure the other end is securely chocked. Do minute at the specified temperature.
not rely solely on the machine hydraulics or jacks
to support the machine when working under it. Temperature: 20°C (68.0°F)
Disconnect the battery, to prevent the machine
being started while you are beneath it. 6. Apply sealant to the face of the transducer.
1. Park the machine and make it safe. Refer to (PIL (High Strength)
01-03).
7. Position the transducer on the axle.
2. Raise the machine, under the chassis, until the
rear wheel is clear off the ground. 7.1. Make sure you do not apply the locking fluid
to the bolts or bolt holes.
2.1. Do not lift the machine from under the axle.
8. Secure the transducer with bolts and tighten it to
3. Remove the roadwheel. Refer to (PIL 27-30). the specified torque value.
4. Position and support the axle to get access to the 9. Connect the electrical harness.
transducer.
10. Make sure that the cable to the transducer
5. Disconnect the electrical harness connector. is secured clear of the axle oscillation stops,
and cannot be damaged by movement of the
6. Remove the transducer cover bracket screws trackrod.
and remove the bracket is installed.
Figure 1285.
7. Remove the bolts and remove the transducer.
D E
Figure 1284.
A B
A Transducer
A Transducer D Electrical harness
B Bracket E Bolts
C Bracket screws
33 - 426 9823/0300-1 33 - 426

06 - Transducer
11. Use a Test Box to check the transducer output

is in the range of 37% to 63%. If the output is
incorrect, do the following steps:
11.1. Fully loosen and tighten the bolts to the
specified torque value again. Refer to step
8
11.2. Check the transducer output. If the result
is not within the range, loosen and tighten
the bolts to the specified torque value in
the opposite order as tightened. Refer to
step 8.
11.3. Check the transducer output. If the result
is not within the correct range remove the
transducer and check the axle mounting
area for flatness and surface finish.
12. Replace the transducer cover bracket and
screws if installed.
13. Use a cable securing tie to secure the harness
to the bracket.
14. Calibrate the LMI (Load Moment Indicator)
system. Refer to (PIL 33-66).

Item Description Nm
E Dry Bolt M10 67
E Dry bolt M12 122
33 - 427 9823/0300-1 33 - 427

84 - Sensor
84 - Sensor
Contents Page No.
33-84-09 Speed Sensor .............................................................................................................. 33-429

33-84-41 Lift Arm ......................................................................................................................... 33-432
33-84-72 Chassis ......................................................................................................................... 33-435
33 - 428 9823/0300-1 33 - 428

84 - Sensor
09 - Speed Sensor
09 - Speed Sensor Check (Operation)

Check (Operation) ....................................... 33-429 1. To test transmission speed sensor operation, use
Remove and Install ..................................... 33-430 JCB Servicemaster. Refer to (PIL 33-57-03).
2. If the transmission speed sensor is not
functioning correctly the machine will log the fault
as an error code. Error codes can be accessed
with the correct diagnostics software tool, using a
laptop computer connected to the machine CAN
system.
3. For fault code descriptions refer to (PIL
33-57-90).
4. If the transmission speed sensor is faulty, install
a new one. Refer to (PIL 33-84-09).
5. If the sensor rings on the rear propshaft are
damaged, install a new one. Refer to (PIL
33-84-09).
33 - 429 9823/0300-1 33 - 429

84 - Sensor
09 - Speed Sensor
Remove and Install
Consumables 4. Remove the bolts and speed sensor ring from the
Description Part No. Size motor.
and Sealer (Medium 4101/0251 0.05L Speed Sensor Ring- Install
Strength)
Special HP Grease 4003/2017 0.4kg
procedure and additionally follow the steps
4003/2006 12.5kg below:
4003/2005 50kg
2. On replacement, after lubricating sliding joints
WARNING Before disconnecting any propshaft, with JCB Grease, align the shafts against
make sure you block both sides of all wheels identification marks previously made or, in
to prevent machine movement. The park brake the case of a shaft being renewed, use the
will become ineffective or may only operate on 2 manufacturer's alignment markings.
wheels (depending on machine specification). Consumable: Special HP Grease
3. Apply JCB Threadlocker and Sealer to the
Speed Sensor Ring- Remove threads of all flange bolts.
1. Park the machine and make it safe. Refer to (PIL Consumable: JCB Threadlocker and Sealer
01-03). (Medium Strength)
2. Put marks on the companion flanges and sliding 4. Adjust the speed sensor. Refer to speed sensor,
joints to help installation. below.
3. Support the rear propshaft.
Figure 1286. Speed Sensor Ring

A B
C D
A Drive motor B Speed sensor ring

C Bolts D Propshaft
Speed Sensor- Remove Speed Sensor- Install

1. Park the machine and make it safe. Refer to (PIL 1. Rotate the propshaft and sensor ring and
01-03). measure the gap between the tip of the sensor
and the sensor ring.
2. Remove the chassis undershield. Refer to (PIL
06-06-30). 1.1. This gap must be in the specified range
throughout the rotation of the shaft.
3. Disconnect the speed sensor electrical
connector. Length/Dimension/Distance: 0.5–1mm
4. Remove the sensor securing screw. 2. To adjust the gap:
5. Remove the speed sensor from the speed sensor

mounting bracket.
33 - 430 9823/0300-1 33 - 430

84 - Sensor
09 - Speed Sensor
Figure 1287. Speed Sensor
2 X
5
1 6
3
4
1 Speed sensor 2 Speed sensor electrical connector

3 Sensor securing screw 4 Speed sensor mounting bracket
5 Speed sensor bracket securing screws 6 Speed sensor bracket
7 Sensor ring
2.1. Slacken the bracket securing screws to

allow the bracket to move slightly.
2.2. Move the bracket in the required direction.
2.3. Torque tighten the securing screws.
2.4. Check the sensor adjustment as in step 1
Table 342. Torque Settings

Item Torque
3 9
5 22
33 - 431 9823/0300-1 33 - 431

84 - Sensor
41 - Lift Arm
41 - Lift Arm
Remove and Install
1. Park the machine and make it safe with the lift

Lift Arm Mounted Inclinometer arm raised. Refer to (PIL 01-03).
2. Raise the lift arm and install the lift arm
Remove maintenance strut. Refer to body and framework-
WARNING You could be killed or injured if the maintenance strut, refer to (PIL 06-69).
boom drops while you are working under it. Install 3. Disconnect the sensor harness connector from
the boom maintenance strut as instructed before the lift arm harness connector.
doing any maintenance work with the boom
raised. Keep people away from the machine while 4. Remove the bolts.
you install or remove the boom maintenance strut.
5. Remove the sensor from the machine.
Figure 1288.
A Sensor B Bolts
33 - 432 9823/0300-1 33 - 432

84 - Sensor
41 - Lift Arm
Install 2. Follow the general safety precautions. Refer to

(PIL 01-03).
removal procedure. 3. Extend the lift arm until the sensor flag is clear of
the sensor.
2. When you install, do the following steps also:
2.1. Make sure to route the harness correctly
and replace the harness securing clips. 5. Remove the harness retaining clips (if installed).
2.2. Calibrate the LLMC (Longitudinal Load 6. Disconnect the sensor harness connector from
Moment Control) system. Refer to electrical the lift arm harness connector.
system- load motion control system, refer to
(PIL 33-66). 7. Remove the securing screws.
8. Remove the sensor and cover from the machine.
Lift Arm Retract Sensor
Remove
01-03).
Figure 1289.
F
B
C
A Sensor flag B Sensor

C Screws D Retaining clips
E Connector F Sensor cover
33 - 433 9823/0300-1 33 - 433

84 - Sensor
41 - Lift Arm
Install
removal procedure.
2.1. make sure to route the harness correctly
and replace the harness securing clips.
2.2. Make sure to install the sensor cover.
2.3. Calibrate the LLMC system.
33 - 434 9823/0300-1 33 - 434

84 - Sensor
72 - Chassis
72 - Chassis
Remove and Install
2. Install the maintenance strut. Refer to body

Remove and framework- maintenance strut, refer to (PIL
06-69).
WARNING You could be killed or injured if the lift
arm drops while you are working under it. Install 3. Release the hydraulic pressure. Refer to
the lift arm maintenance strut as instructed before hydraulic system- general, refer to (PIL 30-00).
doing any maintenance work with the lift arm
raised. Keep people away from the machine while 4. Disconnect the electrical connector from the
you install or remove the lift arm maintenance harness.
strut.
5. Remove the bolts and remove the sensor form
the machine.
1. Park the machine and make it safe with the lift
arm raised. Refer to (PIL 01-03).
Figure 1290.
A Sensor B Bolts
33 - 435 9823/0300-1 33 - 435

84 - Sensor
72 - Chassis
Install
removal procedure.
2.1. Make sure to route the harness correctly
and replace the harness securing clips.
2.2. Calibrate the LLMC (Longitudinal Load
Moment Control) system. Refer to electrical
system- load motion control system, refer to
(PIL 33-66).
33 - 436 9823/0300-1 33 - 436

Contents Page No.
72-00 Fasteners and Fixings

72-00-00 General ............................................................................................................................. 72-3
72-03 Screws
72-03-00 General ............................................................................................................................. 72-7
72-06 Bolts
72-06-00 General ........................................................................................................................... 72-11
72-21 Clips
72-21-03 Worm Drive .................................................................................................................... 72-15
72-36 Threaded Insert
72-36-00 General ........................................................................................................................... 72-21
9823/0300-1
2017-09-25
Notes:
9823/0300-1
2017-09-25
Contents Page No.
72-00-00 General ............................................................................................................................. 72-3
72 - 1 9823/0300-1 72 - 1
Notes:
72 - 2 9823/0300-1 72 - 2
00 - General
00 - General Fastener Type Colour Part Number

Suffix
Zinc Nickel - Black, chalky N (e.g.
Introduction black texture 1315/3712N)
Zinc flake - Black, slight B (e.g.
JCB Fasteners (Before September 2017) black gloss 1315/3712B)
Some external fasteners on JCB machines are Torque and Angle Tightening
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet Insufficient pre-load of a bolted joint can cause
and replaces the original Zinc and Yellow Plating major problems, such as cylinder head warp, leaking
used on earlier machines. The two types of fasteners gasket joints etc. There are several methods of
can be readily identified by colour and part number achieving an accurate pre-load of a bolted joint, the
suffix. Refer to Table 1. Fastener Types. two main methods used on the JCB engine are:
Table 343. • Torque Control Tightening - Using a torque
Fastener Type Colour Part Number meter to control the torque is the most
Suffix popular means of controlling pre-load, and
in the majority of instances this method is
Zinc and Yellow Golden Finish Z (e.g. adequate. It should be noted that with this
1315/3712Z) process, the majority of the torque is used
Dacromet Mottled Silver D (e.g. to overcome friction, therefore slight variations
Finish 1315/3712D) in the frictional conditions can lead to large
changes in the bolt pre-load.
Note: As the Dacromet fasteners have a lower torque • Angle Control Tightening - Where a more
setting than the Zinc and Yellow fasteners, the torque precise pre-load is required, the torque and
figures used must be relevant to the type of fastener. angle tightening method is used. The bolt
is tightened to a predetermined torque (this
A Dacromet bolt should not be used in conjunction may be done in stages), and then as a
with a Zinc or Yellow plated nut, as this could final sequence, the bolt is tightened to a
change the torque characteristics of the torque predetermined angle - this method of tightening
setting further. For the same reason, a Dacromet nut the bolts results in a smaller variation in the
should not be used with a Zinc or Yellow plated bolt. final pre-load. It is critical that the predetermined
tightening angle is accurately achieved, failure
All bolts used on JCB machines are high tensile and to tighten accurately to the specified angle could
must not be replaced by bolts of a lesser tensile result in the bolt pre-load being incorrect - this
specification. will lead to eventual failures. It is good practice
to replace all bolts that have been tightened
Dacromet bolts, due to their high corrosion using the torque + angle procedure.
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
Tightening Method
applications. They are not used in applications
such as gearbox or engine joint seams or internal The following example explains the recommended
applications. torque and angle procedure. A torque angle gauge
should be used for accuracy, but as a visual check,
JCB Fasteners (After September 2017) the bolts can be match marked as described below.
1. Tighten the bolt to the specified torque (specified

Table 344. torque values will be detailed in the relevant PIL
Fastener Type Colour Part Number sections).
Suffix
2. Mark a line across the centre of the bolt, and a
Zinc flake-silver White alu- D (e.g. second line on the part to be clamped - the two
minium (sil- 1315/3712D) lines should be aligned. Refer to Figure 1291.
ver-grey), Dull
Zinc and heavy Silver (Bright iri- V (e.g.
trivalent passi- descent) 1315/3712V)
vated with seal
Zinc Nickel - sil- Dark, dull silver Not assigned
ver/grey grey
72 - 3 9823/0300-1 72 - 3
00 - General
Figure 1291.
0°
3. Mark a third line at the specified torque angle - in

this instance the additional torque angle is 90°.
This line must be marked the specified angle in
a clockwise direction (to further tighten the bolt).
Figure 1292.
+90°
4. In some instances, angle torque tightening can

be specified in two stages, for instance in this
example, the first angle quoted is 90° and then a
second angle of 180°. The additional 180° angle
is from the LAST tightened position. Refer to
Figure 1293.
Figure 1293.
+180°
+90°
5. Tighten the bolt so that the line on the bolt

aligns with the angle(s) marked on the item to
be clamped - remember, to ensure complete
accuracy an angle gauge should be used.
72 - 4 9823/0300-1 72 - 4
03 - Screws
03 - Screws
Contents Page No.
72-03-00 General ............................................................................................................................. 72-7
72 - 5 9823/0300-1 72 - 5
Notes:
72 - 6 9823/0300-1 72 - 6
03 - Screws
00 - General
Introduction ...................................................... 72-7 Use the torque setting tables (Technical Data) only
Technical Data ................................................. 72-8 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 345. Up to September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 346. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
72 - 7 9823/0300-1 72 - 7
03 - Screws
00 - General
Technical Data
Table 347. Torque Settings - Internal

Hexagon Headed Capscrews (Zinc)
Bolt Size
mm N·m
3 2
4 6
5 11
6 19
8 46
10 91
12 159
16 395
18 550
20 770
24 1,332
72 - 8 9823/0300-1 72 - 8
06 - Bolts
06 - Bolts
Contents Page No.
72-06-00 General ........................................................................................................................... 72-11
72 - 9 9823/0300-1 72 - 9
Notes:
72 - 10 9823/0300-1 72 - 10
06 - Bolts
00 - General
Introduction .................................................... 72-11 Use the torque setting tables (Technical Data) only
Technical Data ............................................... 72-12 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 348. Up to September 2017

no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 349. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
Verbus-Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Figure 1294.
72 - 11 9823/0300-1 72 - 11
06 - Bolts
00 - General
Technical Data Table 352. Torque Settings -

Coarse Metric Grade 8.8 Fasteners
Bolt Tread Hexa- Condi- Condi-
From JCB standard STD00019 issue 15.
Size Pitch gon (A/ tion 1 tion 2
1. This information does not apply to:- F)
mm mm mm N·m N·m
1.1. Hydraulic fittings (i.e. BSP, SAE O-ring 4 0.7 7 2.9 2.6
boss, UNF, four bolt split flange and JIC).
5 0.8 8 5.8 5.2
1.2. Locking type fasteners (those with a nylon 6 1 10 9.9 9
insert, or with distorted thread nuts such as
8 1.25 13 24 22
Cleveloc).
10 1.5 17 47 43
2. For information on fastener conditions, refer to 12 1.75 19 83 74
fasteners and fixings, bolts, general, introduction. 14 2 22 132 119
16 2 24 205 184
Table 350. Torque Settings - UNF S Fasteners 20 2.5 30 400 360
Bolt Treads Hexa- Condi- Condi- 24 3 36 690 621
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,372 1,235
F) 36 4 55 2,399 2,159
in in in N·m N·m
(1/4 in) 28 7/16 11.2 10 Table 353. Torque Settings - Coarse
(5/16 in) 24 1/2 22.3 20 Metric Grade 10.9 Fasteners
(3/8 in) 24 9/16 40 36 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 64 57 Size Pitch gon (A/ tion 1 tion 2
F)
(1/2 in) 20 3/4 98 88
mm mm mm N·m N·m
(9/16 in) 18 13/16 140 126
4 0.7 7 4 3.6
(5/8 in) 18 15/16 196 177
5 0.8 8 8.1 7.3
(3/4 in) 16 1 1/8 343 309
6 1 10 13.9 12.5
(7/8 in) 14 1 15/16 547 492
8 1.25 13 34 30
(1 in) 12 1 1/2 814 732
10 1.5 17 67 60
(1 1/8 in) 12 1 7/8 1,181 1,063
12 1.75 19 116 104
(1 1/4 in) 12 2 1/4 1,646 1,481
14 2 22 185 167
16 2 24 288 259
Table 351. Torque Settings - UNF X Fasteners 20 2.5 30 562 506
Bolt Treads Hexa- Condi- Condi- 24 3 36 971 874
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,930 1,737
F)
36 4 55 3,374 3,036
in in in N·m N·m
(1/4 in) 28 7/16 17.6 15.9 Table 354. Torque Settings - Coarse
(5/16 in) 24 1/2 35.2 31.6 Metric Grade 12.9 Fasteners
(3/8 in) 24 9/16 64 57 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 101 91 Size Pitch gon (A/ tion 1 tion 2
(1/2 in) 20 3/4 155 139 F)
(9/16 in) 18 13/16 221 199 mm mm mm N·m N·m
(5/8 in) 18 15/16 310 279 4 0.7 7 4.8 4.4
(3/4 in) 16 1 1/8 542 488 5 0.8 8 9.8 8.8
(7/8 in) 14 1 15/16 864 777 6 1 10 16.6 15
(1 in) 12 1 1/2 1,285 1,156 8 1.25 13 40 36
(1 1/8 in) 12 1 7/8 1,865 1,679 10 1.5 17 80 72
(1 1/4 in) 12 2 1/4 2,598 2,339 12 1.75 19 139 125
14 2 22 223 200
16 2 24 345 311
72 - 12 9823/0300-1 72 - 12
06 - Bolts
00 - General
Bolt Thread Hexa- Condi- Condi-

Size Pitch gon (A/ tion 1 tion 2
F)
mm mm mm N·m N·m
20 2.5 30 674 607
24 3 36 1,165 1,048
30 3.5 46 2,316 2,084
36 4 55 4,049 3,644
Table 355. Torque Settings - Rivet Nuts / Bolts

Bolt Size
mm N·m
3 1.2
4 3
5 6
6 10
8 24
10 48
12 82
72 - 13 9823/0300-1 72 - 13
21 - Clips
21 - Clips
Contents Page No.
72-21-03 Worm Drive .................................................................................................................... 72-15
72 - 14 9823/0300-1 72 - 14
21 - Clips
03 - Worm Drive
03 - Worm Drive Introduction

Introduction .................................................... 72-15 There are three types of the plain worm drive clips.
Technical Data ............................................... 72-16
Component Identification ............................... 72-18 • Standard worm drive clip
• Heavy duty worm drive clip
• Spring assisted worm drive clip
Spring assisted worm drive clip contains a spring

insert on the inside of the band to provide
compensation against hose compression set.
Use the torque setting tables (Technical Data) only

where no torque setting is specified in the text.
72 - 15 9823/0300-1 72 - 15
21 - Clips
03 - Worm Drive
Technical Data
Dimensions
Figure 1295.
C
J
H
Table 356.
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Standard worm drive clips and spring assisted worm drive clips
8–16mm 0.7mm 13mm 9mm 7mm 21mm 11mm
12–22mm 21mm
16–27mm up 0.8mm 14.6mm 12mm 30mm 12.5mm
to 60–80mm
70–90mm 36mm
up to 160–
180mm
72 - 16 9823/0300-1 72 - 16
21 - Clips
03 - Worm Drive
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Heavy duty worm drive clips
172–206mm 0.7mm 23.1mm 16mm 7mm 37mm 13mm
Torque Values
Table 357. Standard Worm Drive Clip
Clamping Part number Torque values
range
8–16mm 2201/0001 2 -0/+0.5N·m
12–22mm 2201/0003 3 -0/+0.5N·m
16–27mm 2201/0005 5 -0/+0.5N·m
20–32mm 2201/0006 5 -0/+0.5N·m
25–40mm 2201/0007 5 -0/+0.5N·m
35–50mm 2201/0008 5 -0/+0.5N·m
40–60mm 2201/0010 5 -0/+0.5N·m
50–70mm 2201/0012 5 -0/+0.5N·m
60–80mm 2201/0013 5 -0/+0.5N·m
70–90mm 2201/0014 5 -0/+0.5N·m
80–100mm 2201/0015 5 -0/+0.5N·m
90–110mm 2201/0016 5 -0/+0.5N·m
100–120mm 2201/0021 5 -0/+0.5N·m
120–140mm 2201/0017 5 -0/+0.5N·m
130–150mm 2201/0018 5 -0/+0.5N·m
150–170mm 2201/0019 5 -0/+0.5N·m
160–180mm 2201/0020 5 -0/+0.5N·m
Table 358. Heavy Duty Worm Drive Clip

range
172–194mm 2201/0022 10 -0/+0.5N·m
184–206mm 2201/0023 10 -0/+0.5N·m
Table 359. Spring Assisted Worm Drive Clip

range
16–27mm 2206/1627 5 -0/+0.5N·m
20–32mm 2206/2032 5 -0/+0.5N·m
25–40mm 2206/2540 5 -0/+0.5N·m
30–45mm 2206/3045 5 -0/+0.5N·m
35–50mm 2206/3550 5 -0/+0.5N·m
40–60mm 2206/4060 5 -0/+0.5N·m
50–70mm 2206/5070 5 -0/+0.5N·m
60–80mm 2206/6080 5 -0/+0.5N·m
70–90mm 2206/7090 5 -0/+0.5N·m
72 - 17 9823/0300-1 72 - 17
21 - Clips
03 - Worm Drive
Component Identification Figure 1298. Spring Assisted Worm Drive Clip

A B
Figure 1296. Standard Worm Drive Clip
C
A B
C
D
F
E
A Screw support flange

B Asymmetric housing
C Asymmetric extension
A Screw support flange D Short housing saddle
B Asymmetric housing E Stamped inside
C Asymmetric extension F Spring insert
D Short housing saddle G Identification of material/clamping range
E Stamped inside
F Identification of material/clamping range
Figure 1297. Heavy Duty Worm Drive Clip
A Extended bridge
B Band width (16mm)
C Identification of clamping range
72 - 18 9823/0300-1 72 - 18
36 - Threaded Insert
Contents Page No.
72-36-00 General ........................................................................................................................... 72-21
72 - 19 9823/0300-1 72 - 19
Notes:
72 - 20 9823/0300-1 72 - 20
00 - General
Introduction .................................................... 72-21 A threaded insert also known as a rivet nut is a
Technical Data ............................................... 72-22 one piece fastener installed blind from one side of
Remove and Install ....................................... 72-22 the machine body/framework. The threaded insert is
compressed so that a section of its shank forms an
upset against the machine body/framework, leaving
a durable thread.
Figure 1299.
A Threaded insert
B Durable thread
Threaded inserts are installed to various parts of

the machine body and framework. They are used in
a number of applications, for instance, hose clamp
and hydraulic valve retention etc. Various sized
threaded inserts are available, refer to technical data
to determine the correct size of threaded insert to be
used for particular applications.
If for any reason a new threaded insert is required,

the correct installation procedure must be followed.
Refer to Remove and Install.
72 - 21 9823/0300-1 72 - 21
00 - General
Technical Data Remove and Install

Consumables
Table 360. Specifications Description Part No. Size
Thread Outside Materi- Total Drill Threaded Insert (M10 x 826/01104 -
Diame- Diame- al Thick- Rivet Hole Di- 23mm)
ter ter ness Length ameter Threaded Insert (M10 x 826/01105A -
mm mm mm mm mm 26mm)
(inch) (inch) (inch) (inch) Threaded Insert (M6 x 826/01099 -
M5 7 0.25–3 14 7.1 16mm)
M5 7 3–5.5 17 7.1 Threaded Insert (M6 x 826/01101 -
M6 9 0.5–3 16 9.1 19mm)
M6 9 3–5.5 19 9.1 Threaded Insert (M8 x 826/01102 -
18mm)
M8 11 0.5–3 18 11.1
Threaded Insert (M8 x 826/01103 -
M8 11 3–5.5 21 11.1
21mm)
M10 13 1–3.5 23 13.1
M10 13 3.5–6 26 13.1 The threaded insert installation tool is available from
Bolhoff Fastenings Ltd. www.bolhoff.com.
Install
1. Drill a hole in the machine body/framework where
the threaded insert is to be installed, refer to
technical data for the correct size.
2. De-burr the hole edges.
3. Screw the threaded insert on to the mandrel of
the installation tool. The bottom of the mandrel
should be in line with the bottom of the threaded
insert.
Consumable: Threaded Insert (M6 x 16mm)
Figure 1300.
A Threaded insert
4. Wind the body of the installation tool down the
threaded mandrel until it touches the head of the
threaded insert.
72 - 22 9823/0300-1 72 - 22
00 - General
Figure 1301.
B Head of threaded insert

5. Insert the threaded insert (assembled to the tool)
into the hole drilled in step 1.
6. Hold handle and at the same time draw the
mandrel into the installation tool by turning nut.
The threaded insert will contract in length and
form an upset (smooth bulge) seating itself
against the body/ framework. Note: The thread
of the threaded insert must not be stripped, take
care when upsetting the threaded insert.
Figure 1302.
C Handle
D Nut
E Body/Framework
7. Remove the installation tool.
72 - 23 9823/0300-1 72 - 23
Notes:
72 - 24 9823/0300-1 72 - 24
Contents Page No.
75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-03 Oil
75-03-00 General ............................................................................................................................. 75-9
75-03-03 Engine ............................................................................................................................ 75-10
75-06 Grease
75-06-00 General ........................................................................................................................... 75-13
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-17
75-09-03 Antifreeze ....................................................................................................................... 75-18
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-21
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-25
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-29
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-35
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-41
75-18-03 Diesel ............................................................................................................................. 75-43
9823/0300-1
2018-01-17
Acronyms Glossary
DEF Diesel Exhaust Fluid

PTFE Polytetrafluoroethylene
9823/0300-1
2018-01-17
Contents Page No.
75-00-00 General ............................................................................................................................. 75-3
75 - 1 9823/0300-1 75 - 1
Notes:
75 - 2 9823/0300-1 75 - 2
00 - General
Introduction ...................................................... 75-3 JCB recommend that you use the JCB lubricants
Health and Safety ........................................... 75-4 shown as they have been verified by JCB for use
Technical Data ................................................. 75-6 on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.
Before you start work, make sure that:
• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.
Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.
75 - 3 9823/0300-1 75 - 3
00 - General
Health and Safety
Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
Fine jets of fluid at high pressure can penetrate the suitable closed receptacle and must be disposed
skin. Keep face and hands well clear of fluid under of in accordance with local environmental waste
pressure and wear personal protective equipment. regulations.
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Handling
engine running. Completely wipe off any spilt fuel
CAUTION The temperature of the hydraulic oil
will be high soon after stopping the machine. Wait
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
75 - 4 9823/0300-1 75 - 4
00 - General
• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.
Figure 1303.
A B C D E F
A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions
First Aid - Oil Swallowing
Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15min. egg or vegetable oil. Get medical help.
If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
First Aid - DEF (if applicable)
Skin
Do not drink or inhale DEF (Diesel Exhaust Fluid).
In the case of excessive skin contact, wash with soap If large quantities of DEF have been swallowed
and water. a doctor should be called immediately. Do not
induce vomiting unless directed to do so by medical
Spillage personnel. Never give anything by mouth to an
unconscious person.
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a Avoid prolonged or repeated skin contact. After
chemical disposal area. contact with skin wash thoroughly with plenty of soap
and water. If irritation develops seek medical advice.
Fires
Avoid contact with eyes, skin and clothing. Wear
WARNING Do not use water to put out an oil fire. chemical resistant gloves, overalls and safety
This will only spread it because oil floats on water. goggles complying with an approved standard. If
Extinguish oil and lubricant fires with carbon in contact with eyes, rinse immediately with plenty
dioxide, dry chemical or foam. of clean water. If irritation occurs seek medical
attention. Always wash hands and arms thoroughly
after handling before eating, drinking, smoking or
First Aid - Electrolyte using the lavatory.
Eyes
In the case of eye contact, flush with water for 15min.
always get medical attention.
75 - 5 9823/0300-1 75 - 5
00 - General
Technical Data
and quality or offer the same machine component

JCB recommend that you use the JCB lubricants protection.
shown as they have been verified by JCB for use
on JCB machines. However, you could use other No warranty liability will be accepted for engine
lubricants that are equivalent to the JCB standards failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.
Table 361.
Item Capacity Fluid/Lubricant JCB Part Container Specifica-
Number Size
(1)
tion
Fuel tank 75L Diesel oil
Engine (oil) Minimum JCB Engine Oil UP 10W30 (Ultra 4001/3005 20L API CJ-4,
6.5L, Maxi- Performance)-19°C (-2.2°F) to 50°C ACEA E9
mum 11.2L (121.9°F)
JCB Engine Oil UP 5W30 (Ultra 4001/3105 20L
Performance)-19°C (-2.2°F) and be-
low
JCB engine Oil UP 5W40 (ultra per- 4001/3405 20L
formance) -19°C (-2.2°F) and below
Engine (coolant)
(2)
11L JCB Antifreeze HP/Coolant + water 4006/1120 20L ASTM
D6210
Front axle hous- 4.2L JCB Gear Oil LS Plus 4000/3905 20L
(3)
ing
Rear axle hous- 4.2L
ing
Hubs 0.9L
Brake system JCB Hydraulic Fluid HP 15
(4)
4002/0503 5L
Hydraulic tank
(5)
48.7L JCB Optimum Performance Hy- 4002/2005 20L
draulic Fluid 46, -12°C (10.4°F) to
46°C (114.7°F)
JCB Ultra Performance Hydraulic 4002/2805 20L
Fluid 32, -20°C (-4.0°F) to 27°C
(80.6°F)
Grease points JCB Special HP Grease
(6)
4003/2017 0.4kg x 24
JCB Special MPL EP Grease
(6)
4003/1501 0.4kg x 24
Wear pad run- JCB Waxoyl 4004/0502 5L
ways
Boom hoses JCB Special Slide Lubricant 4003/1115 0.4kg
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB Dealer.
(2) It is recommended that the cooling system be filled at a maximum rate of 6L per minute. If the fill rate is any
higher than this then there is a possibility of air becoming trapped in the system.
(3) Must be suitable for use with oil immersed brakes and LSD (Limited Slip Differentials).
(4) Do not use ordinary brake fluid.
(5) This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used.
Fill with all cylinders closed. Watch level sight glass when filling.
(6) JCB special HP Grease is the recommended specification grease. If JCB Special MPL-EP Grease is used,
all 50h greasing operations must be carried out at 10h intervals; all 500h greasing operations must be carried
out at 50h intervals.
75 - 6 9823/0300-1 75 - 6
03 - Oil
03 - Oil
Contents Page No.
75-03-00 General ............................................................................................................................. 75-9

75-03-03 Engine ............................................................................................................................ 75-10
75 - 7 9823/0300-1 75 - 7
Notes:
75 - 8 9823/0300-1 75 - 8
03 - Oil
00 - General
00 - General
Introduction
New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:
1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.
First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.
SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.
SKIN - In the case of excessive skin contact, wash

with soap and water.
SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.
FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.
75 - 9 9823/0300-1 75 - 9
03 - Oil
03 - Engine
03 - Engine
Introduction
New engines DO NOT require a running-in period.

The engine/machine should be used in a normal
work cycle immediately. Glazing of the piston cylinder
bores, resulting in excessive oil consumption, could
occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle
for extended periods; (e.g. warming up without load).
A minimum API CJ4 grade oil must be used. Superior

grade oils may be more appropriate for heavy duty
applications (such as sustained high loads and
operation at elevated temperatures).
The choice of lubricant viscosity should be made

based on the lowest ambient temperature at which
the machine will be started and the maximum
ambient temperature at which it will operate.
The technical data section provides guidance as to

the temperature range that can be accommodated
by standard oil viscosities and can be used to select
an appropriate grade.
Important: When selecting the oil viscosity grade

make sure the oil conforms with or exceeds the
recommended specification.
75 - 10 9823/0300-1 75 - 10
06 - Grease
06 - Grease
Contents Page No.
75-06-00 General ........................................................................................................................... 75-13
75 - 11 9823/0300-1 75 - 11
Notes:
75 - 12 9823/0300-1 75 - 12
06 - Grease
00 - General
00 - General Consumable: JCB Autogrease

6. JCB EP Hammer Grease
Introduction Consumable: EP Hammer Grease
Special Tools 7. JCB Special Hammer Grease
Consumable: Special Hammer Grease
Grease Gun 892/00913 1
Attachment 8. JCB Special Slew Pinion Grease
Grease Gun 992/11300 1
Consumable: Special Slew Pinion Grease
Consumables
Description Part No. Size Greasing Procedure
EP Hammer Grease 4003/2107 0.4kg 1. Make the machine safe.
4003/2106 12.5kg
Extreme Performance 4003/1327 0.4kg 2. If necessary, install any maintenance or
Moly Grease articulation struts.
4003/1326 12.5kg
JCB Autogrease 4003/2305 0.5kg 3. Make a note of the following:
Special HP Grease 4003/2017 0.4kg 3.1. The machine must always be greased after
4003/2006 12.5kg pressure washing or steam cleaning.
4003/2005 50kg
3.2. Greasing must be done with a grease gun.
Special Hammer 4003/1119 0.4kg Normally, two strokes of the gun should be
Grease sufficient.
Special MPL-EP 4003/1501 0.4kg
Special Tool: Grease Gun (Qty.: 1)
Grease 4003/1506 12.5kg Special Tool: Grease Gun Attachment (Qty.:
4003/1510 50kg 1)
Special Slew Pinion 4003/1619 0.4kg 3.3. Stop greasing when fresh grease appears
Grease at the joint.
Special Slide Grease 4003/1115 0.4kg
3.4. Use only the recommended type of grease.
There are various greasing points on the machine. 3.5. Do not mix different types of grease, keep
You must grease the machine regularly to keep them separate.
it working efficiently. Regular greasing will also
lengthen the machine's working life. You must grease 4. Count off the grease points as you grease each
the machine as stated in the maintenance schedule. one.
5. Install the dust caps after greasing (if installed).
JCB grease is manufactured to provide significant
load protection for your machine. It is recommended JCB Special HP Grease
to use only JCB grease on your machine because
they are specifically designed for the particular JCB Special HP grease is a premium quality,
application. The list of JCB greases comprises: extreme pressure grease. It is recommended
for use in arduous operating conditions, such
1. JCB Special HP Grease as high temperatures, excessive loading and
Consumable: Special HP Grease extensive exposure to water. The sophisticated
additive package combines with excellent adhesive
2. JCB Special MPL-EP Grease properties to give high performance protection to
your machine.
Table 362. JCB Special HP Grease Properties
3. JCB Extreme Performance Moly Grease
Description Data
Consumable: Extreme Performance Moly
Grease Colour Blue
Soap type Lithium complex
4. JCB Special Slide Grease Drop point 245°C (472.7°F)
Consumable: Special Slide Grease Working temperature -20–150°C (-4.0–
range 301.8°F)
5. JCB Autogrease
75 - 13 9823/0300-1 75 - 13
06 - Grease
00 - General
JCB Special MPL-EP Grease JCB Autogrease

JCB Special MPL-EP grease is a true multipurpose JCB Autogrease is for use with the automatic
grease. It is recommended for a wide range of greasing system. It is a mineral oil based paste.
lubricating applications, such as pivot pins and wheel It contains an aluminium complex soap and solid
bearings, where excellent anti wear and anti rust lubricants. It is suitable for use under water or in
performance is required. Its EP additive makes it high ambient temperatures. The specially designed
particularly suitable for the shock load and vibrating cartridges screw into the automatic greasing system
conditions found on machines. installed on the machine.
Table 363. JCB Special The clear cartridge allows the operator to easily
MPL-EP Grease Properties monitor the grease usage from inside of the operator
station.
Description Data
Colour Brown Table 366. JCB Autogrease
Soap type Lithium Description Data
Drop point 180°C (355.7°F) Colour Black
Working temperature -20–130°C (-4.0– Soap type Aluminium complex, sol-
range 265.8°F) id lubricants
Drop point 260°C (499.6°F)
JCB Extreme Performance Moly Grease
Working temperature -20–110°C (-4.0–
JCB Extreme Performance Moly grease is an range 229.8°F)
advanced performance, multipurpose grease. It is
recommended for heavily loaded bearing surfaces JCB EP Hammer Grease
and in particular where limited or oscillating
motion causes fretting. The addition of molybdenum JCB EP Hammer grease is a unique formulation
disulphide provides extra protection against scoring aluminium complex grease for use where extremes
and wear. This grease is ideal for automotive, of pressure and temperature are likely to be
industrial, agricultural and earthmoving equipment. encountered. It is suitable for the hammer
applications where resistance to water washing and
Table 364. JCB Extreme migration may be critical.
Performance Moly Grease Properties
Table 367. JCB EP Hammer Grease
Description Data
Colour Grey Black Description Data
Soap type Lithium Colour Black
Drop point 185°C (364.7°F) Soap type Aluminium complex
Working temperature -20–120°C (-4.0– Drop point 250°C (481.6°F)
range 247.8°F) Working temperature -20–160°C (-4.0–
range 319.8°F)
JCB Special Slide Grease
JCB Special Hammer Grease
JCB Special Slide grease is formulated to provide
excellent protection under heavy load and extreme JCB Special Hammer grease provides a highly
pressure, where water and dirt are prevalent. It effective lubricant on slow moving slides and an
maintains a film of lubrication on slow moving slides. excellent corrosion resistant property. It combines
It has an excellent resistance to squeeze out and the self healing action of oils and the resistance to
superb corrosion resistance. drip of viscous compounds.
Table 365. JCB Special Slide Grease Properties Table 368. JCB Special Hammer Grease
Description Data Description Data
Colour Dark grey Colour Dark grey
Soap type Lithium Soap type Lithium
Drop point 180°C (355.7°F) Drop point 185°C (364.7°F)
Working temperature -20–120°C (-4.0– Working temperature -15–120°C (5.0–
range 247.8°F) range 247.8°F)
75 - 14 9823/0300-1 75 - 14
06 - Grease
00 - General
JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.
Table 369. JCB Special Slew Pinion Grease

Description Data
Colour Black
Soap type Organically modified
clay
Working temperature -40–100°C (-39.9–
range 211.9°F)
75 - 15 9823/0300-1 75 - 15
09 - Fluids
09 - Fluids
Contents Page No.
75-09-00 General ........................................................................................................................... 75-17

75-09-03 Antifreeze ....................................................................................................................... 75-18
75 - 16 9823/0300-1 75 - 16
09 - Fluids
00 - General
00 - General
Introduction
It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.
However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.
Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.
Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.
The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.
75 - 17 9823/0300-1 75 - 17
09 - Fluids
03 - Antifreeze
03 - Antifreeze Introduction
Introduction .................................................... 75-18
Health and Safety .......................................... 75-19
Coolant Mixtures
Technical Data ............................................... 75-19 Check the strength of the coolant mixture at least
once a year, preferably at the start of the cold period.
Do not use solutions of more than 60% or damage to
the engine may occur. Replace the coolant mixture
according to the intervals shown in the machine's
maintenance schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion. Always
renew the antifreeze every two years.
The protection provided by High Performance

Antifreeze and Inhibitor is shown below. If any
other antifreeze is used, refer to the manufacturer's
instructions and make sure that a corrosion inhibitor
is included.
Table 370.
Solution Maintains cir- Protects
culation down against dam-
to: age down to:
50% Concen- -33°C (-27.4°F) -40°C (-39.9°F)
tration (Stan-
dard)
60% Concen- -42°C (-43.5°F) -56°C (-68.7°F)
tration (Stan-
dard)
Important: Do not exceed a 60% concentration, as

the freezing protection provided reduces beyond this
point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).
75 - 18 9823/0300-1 75 - 18
09 - Fluids
03 - Antifreeze

CAUTION The cooling system is pressurised CAUTION Antifreeze can be harmful. Obey the
when the coolant is hot. When you remove the manufacturer's instructions when handling full
cap, hot coolant can spray out and burn you. strength or diluted antifreeze.
on the cooling system. Check the strength of the coolant mixture at least
CAUTION Antifreeze can be harmful. Obey the once a year, preferably at the start of the cold period.
manufacturer's instructions when handling full
strength or diluted antifreeze. Replace the coolant mixture according to the
intervals shown in the machine's Service Schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion.
The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
Table 371.
Concentration Level of protection
50% (Standard) Protects against dam-
age down to -40°C
(-40°F)
60% (Extreme Condi- Protects against dam-
tions Only) age down to -56°C
(-69°F)
Do not exceed a 60% concentration, as the freezing

protection provided reduces beyond this point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).
75 - 19 9823/0300-1 75 - 19
10 - Locking Fluids
10 - Locking Fluids
Contents Page No.
75-10-00 General ........................................................................................................................... 75-21
75 - 20 9823/0300-1 75 - 20
10 - Locking Fluids
00 - General
Introduction .................................................... 75-21 All locking fluids should be used at all times in line
Technical Data ............................................... 75-22 with the manufacturer’s recommendations.
Locking fluids are used for the locking of threaded

fasteners and for the retention of ball & roller
bearings and similar cylindrical items on to shafts and
into housings. These fluids consist of an anaerobic
resin in a liquid form which hardens when confined
between closely fitting metal to metal and many
metal to non-metal surfaces.
The fluids available possess a wide span of

break-loose strengths, viscosities and gap filling
properties and are marketed for a variety of locking
and retaining purposes requiring different strength
grades. Some of the sealants in use in JCB are
also of anaerobic resin type and only differ from
the locking fluids in respect of viscosity and other
technical details.
Strength grades
Various strength grades of fluid are available,
the highest strength type for permanent locking
where disassembly is unlikely, medium strength
for permanent locking but allowing disassembly
with ordinary tools and low strength for locking
of components where frequent adjustment or easy
dismantling is required.
It is recommended that trials be carried out before

scheduling locking fluids for any new type of
application that has not been already proved as
satisfactory in production or when use at elevated
temperatures is intended.
Additional technical information is normally available

from the product manufacturers.
Approved locking fluids

The table shown in Technical Data shows the
approved locking fluids available to use on JCB
machines. The table also provides basic details to
help with selection of locking fluids. More up to
date information can be found on the manufacturer’s
website.
75 - 21 9823/0300-1 75 - 21
10 - Locking Fluids
00 - General
Technical Data
Table 372. Locking Fluids Approved Product Information

Subsec- Commer- Product Colour Shelf Strength Comments
tion cial name Number life
High Loctite 4101/0100 Green 365d 80–120bar For the retention of threads up to M20 di-
strength 270
(1)
fluores- (1,159.4– ameter where disassembly is unlikely and
cent 1,739.1psi) for locking bearings etc. onto shafts and
R.A.S. Red breakaway into housing. Has a maximum gap fill of
threadlock strength 0.05mm.
for studs
(1)
High Loctite 4101/1400 Green, 365d More than Maximum gap fill of 0.25mm. Maximum
strength 638 UV fluo- 250bar strength at room temperature.
rescent (3,623.2psi)
compres-
sive shear
strength
High Per- 4101/0500 Red, flu- 365d 100–150bar Fast curing (10–15min) thread locking up
strength mabond ores- (1,449.3– to M20, especially for use on oily surfaces,
A115
(1)
cent 2,173.9psi) plated and clean parts.
Loctite prevailing
262 strength
High Loctite 4101/0600 Green, 365d More than Designed for holding gears and sprockets
strength 648(1) fluores- 250bar onto gearbox shafts and rotors on electric
Per- cent (3,623.2psi) motor shafts.
mabond compres-
A118 sive shear
strength
High Loctite 4101/1700 Green 365d 260–500bar Designed for permanent locking and seal-
strength 2701 (3,768.1– ing of threaded fasteners. Particularly suit-
7,246.3psi) ed for use on inactive substrates and/or
breakaway where maximum resistance to hot oil is re-
torque quired.
Medium Loctite 4101/1100 Blue 365d 140–340bar Suitable for all nuts, bolts, screws up to
to high 243 (2,029.0– M36.
4,927.5psi)
breakaway
torque
Medium Per- 4101/0900 Blue 365d 80–120bar Maximum gap fill of 0.25mm. Handling
strength mabond (1,159.4– strength in 10–15min.
A119
(1)
1,739.1psi)
static shear
strength
Medium Loctite 4101/1200 Green, 365d 150–330bar Product has a slow cure rate, used on parts
strength 640 fluores- (2,173.9– unlikely to be disassembled.
cent 4,782.6psi)
static shear
strength
Medium Loctite 4101/0200 Blue, 365d 80–120bar Suitable for all nuts, bolts and screws up to
strength 242(1) fluores- (1,159.4– M36 and hydraulic fittings up to 25mm in di-
Per- cent 1,739.1psi) ameter. Permabond A113 and A1042 are
mabond static shear the preferred choices. The difference be-
A1042 strength tween A113 and A1042 is timing for han-
dling and working strength. A113 handling
Per- time 10–25min, working strength 1h. A1042
mabond handling time 5–10min, working strength
A113 30min.
75 - 22 9823/0300-1 75 - 22
10 - Locking Fluids
00 - General
Subsec- Commer- Product Colour Shelf Strength Comments

tion cial name Number life
Low Loctite 4101/0300 Purple, 365d 15–40bar For screwed fasteners up to M20 that re-
strength 222 fluores- (217.4– quire easy disassembly or frequent ad-
cent 579.7psi) justment. Maximum gap fill of 0.05mm.
Achieves handling strength in 10–30min.
Low Per- 4101/1500 Blue 365d 120bar Allows dismantling of parts for mainte-
strength mabond (1,739.1psi) nance. Suitable for sealing small hydraulic
A1098 shear and pneumatic fittings. Handling strength in
strength 5–10min.
Low Loctite 4101/1600 Off- 365d 17bar For the locking and sealing of metal ta-
strength 567 white (246.4psi) pered threads and fittings. High lubricat-
breakaway ing properties prevent galling on stainless
torque steel, aluminium and all other metal pipe
threads and fittings.
Very low Loctite 4101/0400 Brown/ 365d 7–18bar Can be disassembled with hand tools. 10–
strength 932(1) red (101.4– 30min cure time for handling strength. Used
Per- 260.9psi) on large diameter screw threads bigger
mabond average than 50mm.
A011 shear
strength
(1) This is a non preferred product.
75 - 23 9823/0300-1 75 - 23
14 - Solvents and Primers
Contents Page No.
75-14-00 General ........................................................................................................................... 75-25
75 - 24 9823/0300-1 75 - 24
00 - General
Introduction .................................................... 75-25 This section contains information on primers,
Technical Data ............................................... 75-26 solvents, cleaning solutions etc. that are in use at
JCB.
All primers and solvents should be used at all times

in line with the manufacturer’s recommendations.
Approved primers and solvents

The table shown in Technical Data shows the
approved primers and solvents available to use on
JCB machines. The table also provides basic details
to help with the selection of primers and solvents.
More up to date information can be found on the
manufacturer’s website.
75 - 25 9823/0300-1 75 - 25
00 - General
Technical Data
Table 373. Primers and Solvents Approved Product Information

Subsec- Commer- Product Colour Shelf Drying Comments
tion cial name Number life Time
Activa- Loctite 332/U7901 Colour- 365d Less than Used to make low energy surfaces suit-
tor/Primer 770 less 5s able for bonding with cyanocrylate adhe-
sives. It is recommended for polyethylene,
polypropylene, PTFE and thermoplastic
rubber materials. Can be used with Loctite
406 (332/U7899).
Activator Loctite 4104/1700 Clear 730d Apply and HIGHLY FLAMMABLE. Organic accelera-
7455 amber leave to dry tor, non CFC solvent based surface activa-
for 30s be- tor. Designed to promote the speed of cure
fore apply- of cyanoacrylic adhesives.
ing adhe-
sive
Activator Loctite 4104/0200 Colour- 365d 1–3min Used with anaerobic products it increases
7471 less cure speed. Recommended for inert sur-
Per- faces and large bond gaps.
mabond
A905
Water Loctite 4104/0500 - - - A water proofing solution for protecting
proofing water joints made using cyanoacrylate adhesive.
proofing Apply to Loctite 495 (4103/0900).
Solvent Loctite 4104/1500 Colour- 365d 1min at HIGHLY FLAMMABLE, cleaner and de-
7063 less 20°C greaser. Removes grease, oil and dirt from
(68.0°F) electrical parts, tools and precision equip-
ment.
Cleaning Loctite 4101/2200 Colour- 365d No wipe Cleaning treatment to remove most greas-
fluid 7070 less 5–10min, es, oils, lubrication fluids and metal cuttings
post wipe
1–2min
Cleaning Simple 332/E9240 Colour- 365d - An all purpose cleaner and degreaser used
fluid green ex- less diluted in water for direct, spray and dip
treme tank procedures.
Applica- A4GBCJCB4104/3300 Blue 730d - Vinyl labels application fluid for use with the
tion fluid insignia/livery labels.
Gasket Loctite 4104/3200 Colour- 730d Allow 10– This is a product to aid the removal of
cleaner 7200 less 15min for cured chemical gaskets. Apply for time
gasket, specified and remove gasket with soft
30min for scraper.
silicone
gasket.
Hand Loctite 4104/3100 Light 540d - Is a heavy duty hand cleaner, specially for-
cleaner 7855 grey mulated for the most difficult to remove
soils like polyurethane, paints, primers, ad-
hesives etc. The product is free from sil-
icone and harsh solvents. Can be used
without water.
Hand Sika hand 4104/1300 Off - - A non-abrasive hand cleaner for use when
cleaner cleaner white using direct glazing materials.
75 - 26 9823/0300-1 75 - 26
00 - General
Subsec- Commer- Product Colour Shelf Drying Comments

tion cial name Number life Time
Direct Sika acti- 4104/2100 Clear 365d 10min mini- HIGHLY FLAMMABLE. A cleaning and acti-
glazing vator mum drying vating agent specifically formulated for the
time treatment of bonded faces in direct glaz-
ing applications prior to applying the direct
glazing adhesive.
Direct Sika re- 4104/1900 Trans- - - A cleaning agent for removing contami-
glazing mover parent nates on painted surfaces and glass.
208 (use
4104/3600)
Direct Sika 4104/1200 Clear - - A cleaning agent for removing contami-
glazing cleaner nates on painted surfaces and glass.
205 (use
4104/3600)
Direct Sika 4104/2300 Black 270d Application Used to prime painted surfaces and plas-
glazing primer tempera- tic substrates prior to bonding with Sikaflex
209 (use ture 10– products.
4104/3500) 35°C (50.0–
95.0°F)
Direct Sika akti- 4104/2400 Clear 365d 10min Used to clean and give improved adhe-
glazing vator at more sion on glass, ceramic-coated glass, the cut
than 15°C face of old polyurethane adhesive beads,
(59.0°F) polyurethane coated windows glass and
or 30min paints.
at less
than 15°C
(59.0°F)
Active Tero- 4104/3400 Colour- 270d Minimum Applied with a clean cloth to the surface,
wipe for stat 8560 less 30s and the adhesive may then be applied after the
surface AC-25 maximum drying time. Applied to glass or ceramic
1h coating but only in the bonding area.
Direct Terostat 4102/3500 Black 0.1L Approx. Used to promote adhesion in direct glazing
glazing 8519 P bot- 2min to glass and glass ceramics.
tle =
365d.
0.01L
and
0.035L
bot-
tle =
540d
Cleaner Teroson 4104/3600 Clear 730d Depend- Used for degreasing and cleaning of sub-
FL cleaning on con- strates prior to application of adhesives and
er ditions be- sealants.
tween 2–
10min.
75 - 27 9823/0300-1 75 - 27
15 - Adhesive
15 - Adhesive
Contents Page No.
75-15-00 General ........................................................................................................................... 75-29
75 - 28 9823/0300-1 75 - 28
15 - Adhesive
00 - General
Introduction .................................................... 75-29 All adhesives should be used at all times in line with
Technical Data ............................................... 75-30 the manufacturer’s recommendations.
Adhesives are used for the bonding of a number

of engineering materials used in production at JCB.
Many types are available on the market but in the
interests of variety reduction and economy only a
limited selection is purchased for regular use.
Types of adhesive
Various types of adhesive are covered by JCB
Standards:
1. General purpose adhesives for bonding

laminated plastics, wood, rubber etc. to
themselves and to each other.
2. The more expensive cyanoacrylate adhesives
for use where high strength, resistance to many
chemicals and fast cure times are required.
3. Adhesives specially developed for bonding of
foam rubber to painted metal surfaces.
Additional health and safety for

cyanoacrylates
These adhesives require very careful handling on
account of their exceptional properties. They bond
together strongly and rapidly to most surfaces
including body tissue, the curing process being
initiated by surface moisture. For further information
on cyanoacrylates refer to the Manufacturer’s
recommendations.
Approved adhesives
The tables shown in Technical Data are the approved
adhesives available to use on JCB machines. The
tables also provide basic details to help with the
selection of adhesives. More up to date information
can be found on the manufacturer’s website.
75 - 29 9823/0300-1 75 - 29
15 - Adhesive
00 - General
Technical Data
Table 374. Adhesives Approved Product Information

Subsec- Commer- Product Colour Shelf Technical Comments
tion cial name Number life data
High Per- 4103/3100 Mixed 730d 3–5min for Two part adhesive mixed in equal parts. A
strength mabond grey handling toughened adhesive system which bonds
5002 strength metals, plastics, wood, glass, ceramics and
composites; even plated or coated surfaces
can be securely fastened.
High Loctite 4103/1000 Green 365d 16–30bar This product is a single component anaero-
strength 601 fluores- (231.9– bic adhesive. Used to bond cylindrical fitting
cent 434.8psi) parts, particularly where low viscosity is re-
static shear quired. Maximum gap fill is 0.15mm.
strength
Cyano- Loctite 4103/3500 Colour- - 18–26bar Suitable for most materials including plas-
acrylate 424 less to (260.9– tic and rubber. Takes 30s to cure to working
straw 376.8psi) strength.
shear
strength
Cyano- Loctite 4103/2300 Colour- 180d 18–26bar Designed for general purpose use. For use
acrylate 401 less (260.9– on acidic and porous surfaces, reaching
376.8psi) handling strength in seconds. Materials in-
tensile clude plated metals, composite materials,
strength wood, cork, foam, leather and paper.
Cyano- Loctite 332/U7899 Colour- 180d 18–26bar Designed for bonding of plastics and elas-
acrylate 406 less (260.9– tomeric materials where very fast fixturing
376.8psi) is required. Can be used with Loctite 770
lap shear as a primer (332/U7901)
strength
Cyano- Loctite 4103/2400 Black 120d 22bar 0.2mm, gap fill. A rubber toughened ethyl
acrylate 410 (318.8psi) cyanoacrylate adhesive with enhanced re-
lap shear sistance to peel and shock. Bonds rubber,
strength metals and plastics for use in difficult condi-
tions.
Cyano- Loctite 4103/3800 Black - 22–30bar A rubber toughened adhesive with in-
acrylate 480 (318.8– creased flexibility and peel strength along
434.8psi) with enhanced resistance to shock.
lap shear
strength
Cyano- Loctite 4103/0900 Colour- 270d 12h maxi- High speed bonding, suitable for rubber to
acrylate 495 less mum cure itself and other materials reaching handling
Per- time strength in a matter of seconds. Joint must
mabond be waterproofed with Loctite water proofing
C2 (4104/0500).
Low Dunlop 4103/1100 Clear 90d - Sprayable adhesive, non-structural appli-
strength 1727 to light cations. For the bonding of flexible foam
British vita straw to themselves, wood, painted metal, chip-
company board, fibreglass, hessian, felt etc.
VB 165
Acrylic 3M 4941P 4103/3900 Dark 730d Peel ad- High bond acrylic double sided foam tape.
foam grey hesion Its allows more complete bond contact area
strip ad- 350N/ when bonding rigid or irregular materials
hesive 100mm due to its conformability. Its core adhesive
composition makes the product well suited
to many paints and primers.
75 - 30 9823/0300-1 75 - 30
15 - Adhesive
00 - General

General Araldite 4103/1400 Clear / 730d 560bar Two part, equal parts by weight. Wear pad
purpose XD 580 cream (8,115.9psi)
fixing to castings and telescopic compo-
gap fill- flexural nents, alignments of fixings pads without
ing ma- strength expensive machining. This product is a
terial general purpose gap-filling material. Cure
time 2h at 25°C (77.0°F).
Methacry- Loctite 4103/3600 Cream - - This is a sag resistant, two component,
late Speed- to light equal parts, methacrylate adhesive system
bonder yellow formulated to bond automotive grade cold
H3151 rolled steel without the use of an external
primer. Suitable for bonding a wide variety
of plastic and metal substrates. Provides a
long open time (40–60min) for correct align-
ing of parts.
Methacry- Plexus 4103/3700 Off- 365d 186– Two part methacrylate adhesive for struc-
late MA420 white or 206bar tural bonding of thermoplastic, metal and
blue (2,695.6– composite assemblies. Combined at 10:1
2,985.5psi) ratio. It has a working time of 4–6min.
Structur- Scotch- 332/S7420 Black 180d - Two part acrylic based adhesive (10:1 ra-
al plastic weld tio by vol.) that can bond many low surface
structural energy plastics, including many grades of
plastic ad- polypropylene, polyethylene and TPO’s
hesive without special surface preparation.
Non-pre- Evo-Stick 4103/0800 None- 365d HIGHLY A thin even film of adhesive should be ap-
ferred 528 pre- FLAMMA- plied to both surfaces being bonded and al-
adhesive ferred BLE lowed to become touch dry. This is a con-
tact adhesive and coated surfaces can-
not therefore be slid into position since the
bond forms on contact. It is often conve-
nient to align the parts along an edge and
then bring the two areas into contact.
Direct Sika 4103/2100 Black - - A one component polyurethane pre-poly-
glazing 250PC mer based adhesive. A mastic adhesive
Sikat- which reacts with atmospheric moisture to
ack Ultra- form a rubber like solid.
fast (use
4103/4000
or
4102/4900)
Direct Sika 4103/2200 Black - - For bonding glass to cab frames. A mas-
glazing 255FC tic adhesive which reacts with atmospheric
(use moisture to form a rubber like solid. When
4102/5000) using this product ensure both surfaces
are clean and dry. Use Sika cleaner 205
(4104/1200).
Direct Sikaflex 4103/3200 Black - - A high performance, elastic, gap, filling one
glazing 552 (use part structural adhesive cures on exposure
4102/5000) to atmospheric moisture to form a durable
elastomer. Contains no isocyanate.
75 - 31 9823/0300-1 75 - 31
15 - Adhesive
00 - General

Industri- Loctite 333/Y7062 Light - 307bar Single component, heat activated formu-
al grade Hysol Grey (4,449.3psi) lation develops tough, strong, structur-
epoxy E-214 HP Paste tensile al bonds which provide excellent peel re-
adhesive strength sistance and impact strength. When ful-
ly cured, the product offers superior ther-
mal shock resistance, excellent mechan-
ical and electrical resistance properties
and withstands exposure to a wide vari-
ety of solvents and chemicals. Bonds to a
wide variety of materials, including metals,
glass, ceramics and plastics. Cure at 120°C
(247.8°F) or above until completely firm.
Heat up to 150°C (301.8°F) for 2h, to maxi-
mize properties.
Anaero- Scotch- 333/L9575 Green 365d - Single component anaerobic adhesives de-
bic ad- weld signed to secure cylindrical metal assem-
hesive RT-20 blies such as bearings on shafts, bush-
(Dimethacry- ings, sleeves, housings, and keyways.
late) Help prevent loosening, corrosion and leak-
age caused by shock and vibration. Full
cure time 24h. Temperature range = -54°C
(129.1°F) to 450°C (841.4°F). Not recom-
mended for use on most plastics due to po-
tential cracking of plastic parts.
Direct Terostat 4102/4900 Black 540d - Cure rate: approx. 3–4mm/24h. Glazing
glazing 8597 CT in time: maximum 20min (period of time be-
orig- tween beginning of material application until
inal inserting of the pane).
pack-
aging
Direct Teroson 4102/5000 Black, 365d - Skin formation time: approx. 10min. Cure
glazing 939CT / off- in rate: approx. 3mm/24h.
Terostat white, orig-
MS939 grey, inal
black pack-
aging
Direct Terostat 4103/4000 Black 180d 80bar One component, pumpable adhe-
glazing 8900 HV (1,159.4psi)sive/sealant based on polyurethane, which
tensile cures by reaction with moisture to an elas-
strength tic rubber. The skin formation and curing
time are dependent on humidity, tempera-
ture and depth of joint. High temperature
and high moisture reduces curing time.
Sag resistant, temperature range of -40°C
(103.9°F) to 90°C (193.9°F).
Direct Tero- 4103/4100 Black 270d 85bar Single component, moisture curing, ad-
glazing stat 8594 (1,231.9psi) hesive/sealant for repair. Product with
HMLC tensile high shear modulus and low conductivity.
strength Suitable for all applications that require very
high electrical insulation of the adhesive
used for the bonding of windows. Sag resis-
tant.
75 - 32 9823/0300-1 75 - 32
15 - Adhesive
00 - General

Direct Terostat 4103/4200 Black 365d 80bar One component, pumpable adhe-
glazing 8900 LV in (1,159.4psi) sive/sealant based on polyurethane, which
car- tensile cures by reaction with moisture to an elas-
tridges.strength tic rubber. The skin formation and curing
180d time are dependent on humidity, tempera-
in ture and depth of joint. High temperature
sausage and high moisture reduces curing time.
pack. Sag resistant, temperature range of -40°C
180d (103.9°F) to 90°C (193.9°F) short exposure
in (up to 1h) of 130°C (265.8°F).
hob-
bocks
and
drums
Direct Sika 295 4103/4300 Black, 365d - Direct glazing adhesive for plastic glaz-
glazing UV white ing panels. One component polyurethane
adhesive of paste like consistency. 60min
tack free time, 1d cure time (4mm at 23°C
(73.4°F)). Good UV, fresh water and sea-
water resistance. Do not apply below tem-
peratures of 10°C (50.0°F) or above 35°C
(95.0°F).
75 - 33 9823/0300-1 75 - 33
16 - Sealant
16 - Sealant
Contents Page No.
75-16-00 General ........................................................................................................................... 75-35
75 - 34 9823/0300-1 75 - 34
16 - Sealant
00 - General
Introduction .................................................... 75-35 All sealants should be used at all times in line
Technical Data ............................................... 75-36 with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.
Types of Sealant
Various types of sealant are specified in JCB
Standards:
1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).
Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.
75 - 35 9823/0300-1 75 - 35
16 - Sealant
00 - General
Technical Data
Table 375. Sealants Approved Product Information

Subsec- Com- Product Colour Shelf Technical Comments
tion mercial Number life data
name
High Loctite 4102/0500 Green 730d 250bar Non drip formulation, used on larger fittings,
strength 275(1) (3,623.2psi) coarse threads.
Per- torque
mabond strength
A140 (on M8)
High Forge- 4102/3100 Yellow 270d 25bar Can be painted over with some 2 pack
strength way (362.3psi) paint. Maximum width of joint =35mm, min-
240FC
(1)
breaking imum width =2mm, minimum depth =2mm.
strength Recommended depth of joint = width of
joint.
Medium Loctite 4102/3500 Green - More than Used for locating pins in radiator assem-
to high 620 241bar blies, sleeves into pump housings and
strength (3,492.7psi) bearings in auto transmissions. Not suitable
shear for plastics. Diametrical clearance: up to
strength 0.2mm
Medium Loc- 4102/2000 Red, flu- 365d 90bar Typically used as form-in-place gasket on
strength tite 518 ores- (1,304.3psi) rigid flanged connections.
Gasket cent tensile
Elimina- strength
tor
Medium Loctite 4102/4100 Red gel, - 80bar It is manufactured to minimise air bubbles
strength 5182 fluores- (1,159.4psi) in the package. Used to seal gaskets, hous-
cent shear ings, cases and covers. It can also be used
strength to repair and replace cut gaskets (up to
0.08mm in thickness).
Medium Loctite 4102/2500 Clear 365d 6mm gap Formulated to withstand weathering and
strength 595 filling extreme temperature cycling. Used for pot-
ting, coating and sealing. Can be applied
horizontal, vertical and overhead.
Medium Loctite 4102/1900 Yellow 365d 170bar A fast curing thread sealant used on coarse
strength 577
(1)
(2,463.8psi) threads and pipe fittings up to 75mm thread
Per- breakaway size. Clearance for gap filling 0.8mm.
mabond torque
A1044
Medium Loctite 4102/2700 Blue 365d 140– Taper thread sealant, non-fluorescing to
strength 2431 340bar see oil leaks. Suitable for all taper fittings
(2,029.0– up to M36.
4,927.5psi)
breakaway
torque
Low Clayton 4102/2200 White 12h Maximum Seals pipes and plugs against leakage of
strength Dewan- opaque full seal pres- air, fuels, lubricants and coolants. Hardens
dre air cure sure 29bar to a tough seal resistant to shock and vibra-
brake (420.3psi) tion. Easily dismantled.
sealant
SC1252
Low Red 4102/0800 - - Resistant Non-hardening paste jointing for joints reg-
strength Her- to oil ularly opened for servicing.
metite
75 - 36 9823/0300-1 75 - 36
16 - Sealant
00 - General

name
Low Loctite 4102/1100 White 730d 40–100bar Used where slow cure is required to permit
strength 572 opaque (579.7– component alignment. PTFE (Polytetrafluo-
1,449.3psi) roethylene) filler.
breakaway
torque
Gas- Loc- 4102/3200 Blue to 0.2mm 72h full Easy disassembly, used as form-in-place
keting tite 509 green gap strength on gasket.
medium Gasket filling steel
strength Elimi-
nator
Flange
Sealant
Gas- Loctite 4102/1200 Red 730d 2h working Does not creep or relax after curing, no bolt
keting 574
(1)
strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
Sealant Loctite 4102/2600 Black 365d Resists Used to dress new or worn gaskets. Dries
for gas- FAG 2 / pres- slowly, sets to pliable film for easy disman-
kets Loctite sures up tling.
5922 to 345bar
(5,000.0psi)
Rubber Dow 4102/0900 Clear or 270d 16.7bar A synthetic rubber joint sealant suitable for
jointing corning translu- (242.0psi) joints between non-porous surfaces such
com- 781 cent tensile as glass and metal, metal and metal where
pound Loc- strength relatively large gap filling properties are re-
tite su- quired. Suitable for vertical and overhead
perflex applications under normal atmospheric con-
clear ditions. Joint movement approx.+/-12.5%.
RTV3 Cure time to 6mm depth in 24h.
EVO-
stick
stan-
dard in-
dustri-
al clear
silicone
sealant
Dun-
lop high
modulus
silicone
sealant
DP2205
Epoxy Loc- 4102/2400 Slightly - - 0.05L container requires special bi-mixer
resin tite fast coloured / (gun) so it is mixed as dispensed, 0.024L is
epoxy trans- mixed by hand.
sealant parent
Room Loctite 4102/3400 Metal- - Dry to Designed for flange sealing, good resis-
tempera- 5910, lic black touch in tance to oils and allows high joint move-
ture vul- Flange paste 40min ment.
canising sealant,
RTV Sil-
icon
75 - 37 9823/0300-1 75 - 37
16 - Sealant
00 - General

name
Room Loctite 4102/4200 Black 730d 18bar Used for gaskets. Excellent resistance to
tempera- 5970 (260.9psi) engine oils. Typical applications include
ture vul- tensile stamped sheet metal covers (timing covers
canising strength and oil sumps) where good oil resistance
and the ability to withstand high joint-move-
ment are required.
Room Loc- 4102/2900 Black 270d 16bar Thixotropic allowing easy application, hori-
tempera- tite su- (231.9psi) zontal, vertical and overhead. Seals against
ture vul- perflex tensile water and many solvents.
canising black strength
silicone
Room Loctite 4102/3700 Grey 730d 14bar Designed specifically for on line, low pres-
tempera- 5901 (202.9psi) sure tests carried out before product be-
ture vul- shear gins to cure. Product exhibits excellent re-
canising strength sistance to automotive engine oils. Primari-
ly for flange sealing, it withstands high joint-
movement requirements.
Room Loctite 4102/3900 Black 730d 20bar Generally used for sealing applications, but
tempera- 5368 paste (289.9psi) also for bonding and for high temperature
ture vul- tensile protection.
canising strength
Room Loctite 4102/4000 Clear 730d 20bar Designed specifically for use as a bond-
tempera- 5366 paste (289.9psi) ing agent to ensure perfect sealing, as
ture vul- shear well as bonding and protection. Examples
canising strength are sealing side windows in trains, seal-
ing heat sources (heat exchangers and wa-
ter heaters) and for protection/insulation of
electrical boxes.
Room Hylomar 332/D5695 Black 540d 40bar A special purpose adhesive and sealant
tempera- 607 paste (579.7psi) that can be used for a variety of applica-
ture vul- tensile tions. It has good resistance to oils and
canising strength aqueous anti-freeze agents, and is particu-
larly suitable for high strength applications
in odour sensitive environments.
Joining Loctite 4102/3800 Black 730d 14bar JCB Service ONLY. Introduced for joining
oil pan to 5900 paste (202.9psi) the oil pan to the bedplate face during ser-
bedplate shear vice. High resistance to engine oils. The
strength joint should be clamped to spread the ad-
hesive and allowed to cure for 7d before
heavy service duty.
Anti-cor- To mil- 4102/4300 Yellow - Type 1 Used to coat surfaces of dissimilar metals
rosive itary Class C prior to assembly to prevent corrosion. Zinc
spec chromate containing substance ideal for ap-
TT- plication to joints between aluminium and
P-1757B steel to prevent corrosion and seizure. FOR
1CY USE ON MILITARY VEHICLES ONLY.
Gas- Bondloc 4102/4500 Clear/ - Full cure B555 is an anaerobic gasket sealant. It
keting B555 Opaque time 24h. seals close fitting joints between rigid metal
medium 50bar faces and flanges. Tensile strength to ISO
strength (724.6psi) 6922.
tensile
strength
75 - 38 9823/0300-1 75 - 38
16 - Sealant
00 - General

name
Seam Terolan 4102/4600 Light 90d - Serves as a seam sealant between sheet
sealant 3412 grey metal butt and overlap joints (interior
AA-25 seems) on vehicle bodies. Can be cured at
temperatures of minimum 140°C (283.8°F)
(effective metal temperature) for 15min.
The material is applied to electro-dip coated
steel sheets.
Direct Sikaflex 4102/2800 Yellow - - Direct glazing one component polyurethane
glazing 221 based adhesive and sealant compound.
(use Tack free time of 50min.
4102/4800)
Direct Sikaflex 4102/2300 Black - - A one component polyurethane pre-poly-
glazing 252 mer based sealant. For sealing glass to
(use frames. A mastic sealant which reacts with
4102/4700)
(1)
atmospheric moisture to form a rubber like
solid.
Direct Teroson 4102/4700 - 365d - The substrates must be clean, dry, oil and
glazing PU92 in grease free. Skin formation time: approx.
CT orig- 20min Cure rate: approx. 4mm/24h
inal
pack-
aging
Direct 930 4102/4800 Yellow 365d - The substrates must be clean, dry, oil and
glazing JCB in grease free. It can be necessary to rough-
Branded orig- en the surface or to use a primer/adhe-
yellow inal sion promoter to provide optimum adhe-
CT pack- sion. When manufacturing of plastics, ex-
aging ternal release agents are often used; these
agents must be absolutely removed prior.
Skin formation time : approx. 20min Cure
rate : approx. 4mm/24h
Direct Terostat 4102/4900 Black - - Isocyanate free solution. Designed for use
glazing 8597 without primer or activator. When you use
CT this sealant on operator station, it should be
used with Teroson PU 8519P black primer
(and Teroson 450 clear adhesion promoter
when specified specially). Cross compatible
with all OEM / OES / AAM DGX sealants,
including MS and PU chemistry (any re-
maining bead must be fully cured before
application).
Silicone Si- 4102/5100 Black - - High modulus permanently flexible 100%
sealant - ka/Ever- silicone. Temperature resistant up to 300°C
Heat rebuild (571.6°F). Ideal for sealing industrial and
sistant Heat high performance gaskets, oven doors etc.
Mate
Gas- Loctite 4102/6100 Opaque - - Introduced for Heavy products India (swing
ket and 510 pink motor/ gearbox face).
sealing
(1) This is a non preferred product.
75 - 39 9823/0300-1 75 - 39
18 - Fuel
18 - Fuel
Contents Page No.
75-18-00 General ........................................................................................................................... 75-41

75-18-03 Diesel ............................................................................................................................. 75-43
75 - 40 9823/0300-1 75 - 40
18 - Fuel
00 - General
Introduction .................................................... 75-41 Refer to SCR (Selective Catalytic Reduction)
Health and Safety .......................................... 75-42 Introduction and Technical Data (PIL 18-30).
75 - 41 9823/0300-1 75 - 41
18 - Fuel
00 - General
Health and Safety

Fuel
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
WARNING! Do not use petrol in this machine. Do not
mix petrol with the diesel fuel. In storage tanks the
petrol will form flammable vapours.
75 - 42 9823/0300-1 75 - 42
18 - Fuel
03 - Diesel
03 - Diesel
Technical Data
Acceptable and Unacceptable Fuels fuels, those that are acceptable from a "warranty"
point of view, but may have undesirable affects on the
Notice: No warranty liability whatsoever will be expected life of the engine performance, those that
accepted for failure of fuel injection equipment will reduce the expected life, and lastly those that are
where the failure is attributed to the quality and viewed as unacceptable for use (fuels shown on the
grade of the fuel used. same line as each other are considered equivalents).
WARNING Do not use petrol in this machine. Do
not mix petrol with the diesel fuel. In storage tanks The lists below are not exhaustive of all diesel
the petrol will form flammable vapours. fuel standards encountered in the marketplace.
If comment is required on the suitability of fuel
standards not on the list, requests with, if possible,
Fuel Groups specification details showing at least the key
characteristics described above should be forwarded
The major world fuels standards are divided into four to JCB Service for assessment and comment.
categories. Those that are fully accepted as suitable
Table 376. Group 1

Fuel Advice Service Requirements
EN590 Diesel fuel types - Auto/C0/ Preferred and may be used with no For fuel with unspecified parame-
C1/C2/C3/C4 restrictions or conditions. ters, EN590 values apply. Fuel
BS2869 Class A2 grades within each standard must
be appropriate to the ambient tem-
ASTM D975-076 2-D, US DF1, US
perature. The appropriate level of
DF2, US DFA
fuel cleanliness at the FIE inlet af-
JIS K2204 Grades 1, 2, 3 and Spe- ter filtration has to be ensured by
cial Grade 3 the customer.
Table 377. Group 2

Fuel Advice Service Requirements
Group1 fuels with HFFR WSD in Not preferred and may be used but
the range 460 to 520 may lead to reduced FIE life and /
ASTM D975-91 Class 1-1DA or loss of performance.
B20 Biodiesels can cause serious The Ecomax dealer, or JCB Pow-
problems for engines. JCB Eco- er Systems Applications depart-
max Stage 3b / Tier 4i engines ment, should be consulted for fur-
have been developed to run with ther guidance. Biodiesel is very
biodiesels up to 20 mix (B20), but problematic to store; fuel in storage
NOT with higher biodiesel propor- has to be very carefully managed
tion. The biodiesel content of this to ensure that it does not deterio-
mix must be to ASTM D6751, DIN rate during this period. No warranty
51606, or ISO 14214 standards. liability will be accepted for failure
Using a B20 blend of biodiesel re- of fuel injection equipment where
quires caution and additional ser- the failure is attributed to the quali-
vicing of the engine is required.
(1)
ty and grade of the fuel used.
(1) See your JCB dealer for advice on service requirements.
Table 378. Group 3

Fuel Advice
AVTUR FS11 (NATO F34, JP8, MIL T83133, DEF Not preferred and may be used only with appropri-
STAN 91-87, DERD 2463) ate additives and will lead to reduced FIE life and / or
AVCAT FS11 (NATO F44, JP5, MIL T5624, DERD loss of performance.
2452, AVTOR))
JET A1 (NATO F35, DEF STAN 91-91, DERD 2494)
75 - 43 9823/0300-1 75 - 43
18 - Fuel
03 - Diesel
Fuel Advice
AVCAT (NATO F43, JP5 without additives)
JET A (ASTM D1655)
ASTM D3699 Kerosene
JP7 (MIL T38219 XF63)
NATO F63
Table 379. Group 4

Fuel Advice
Unmodified Vegetable Oils and Biodiesels over 20% Unacceptable
concentration
Additives • The biodiesel must meet the following

standards: ASTM D6751, DIN 51606, ISO
The additives listed below are advertised as being 14214.
suitable for bringing the lubricity levels of kerosene/
low sulphur fuels up to those of diesel fuels. If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB
These products are given as examples only. The currently), use the internet as a source for the kits.
information is derived from the manufacturers data.
The products are not recommended or endorsed by If performance related issues are to be reported
JCB. Contact your JCB dealer for further advice. to JCB Service, and the engine has been run on
biodiesel, then the fuel system must be filled with
• Elf 2S 1750. Dosage 1000-1500 ppm (0.1% standard diesel (at least 2 x tank fills) to EN590
to 0.15%), specifically for Indian Superior specification and relevant stall speeds recorded prior
Kerosene (SKO) but may be applicable to other to making the report.
fuels.
• Lubrizol 539N. Dosage (on Swedish low Warranty
sulphur fuel) 250 ppm.
• Paradyne 7505 (from Infineum). Dosage 500 JCB have shown a commitment to support the
ppm (0.05%). environment by approving the use of biodiesel
blended fuels.
Service Requirements for use of B20
Biodiesel Using a B5 blend of biodiesel requires caution and
additional servicing of the engine is required.
• The engine oil must be a grade CH4 as
minimum specification. Failure to follow the additional recommended service
• Do not leave unused B20 biodiesel in the fuel requirements may lead to a warranty claim being
tank for extended periods (top up each day). declined.
• Make sure that 1 in 5 fuel tank fills use standard
diesel to EN590 specification, this will help to Failures resulting by the incorrect use of biodiesels
prevent 'gumming'. or other fuel additives are not defects of the engine
• Make sure regular oil sampling is completed workmanship and therefore will not be supported by
(look for excessive unburnt fuel content, water JCB Warranty.
or wear particles.
• Change the engine oil and filter more frequently Usage and Effects of Fuels
(as a minimum half the recommended
intervals), or as indicated by oil sampling. The information that follows indicates types of fuel
• Change the fuel filters more frequently (as a that are acceptable or unacceptable.
minimum half the recommended intervals), or if
there are engine performance related issues. Acceptable Fuels
• Make sure the fuel is stored correctly, care must
be taken to make sure no water enters the
machine fuel tank (or the storage tank). Water Ultra Low Sulphur Diesel (EN590)
will encourage micobacterial growth.
Available throughout the UK, Europe and North
• Make sure that the fuel pre-filter is drained daily
America since March 1999. This fuel has a maximum
(not every week as currently advised).
sulphur content of 0.001% (0.0015% in North
• Use heater kits in low ambient temperature
America) by weight and a further reduction in
territories.
the natural lubricity and aromatic content than
75 - 44 9823/0300-1 75 - 44
18 - Fuel
03 - Diesel
experienced with low sulphur diesel. Major oil Unacceptable Fuels

producers will add lubrication improvers and also
maintain the total aromatic content to an acceptable B100 - Chemically Modified Vegetable Oils
level. (FAME/ VOME)
B20 Biodiesel These fuels have been derived from a wide range
of vegetable oils and animal fats, resulting in better
Biodiesel refers to pure fuel before it is blended with stability, viscosity and cetane number than those
diesel fuel. When biodiesel is blended with diesel fuel produced from unmodified vegetable oils, but it
it is referred to as B5, B20 etc., where the number is recognised that there are potential problems
indicates the percentage of biodiesel in the fuel, for associated with the finished fuel characteristics.
example B5 contains 5% biodiesel. These oils are less stable than mineral oil derived
fuels when stored and they will readily degrade
Biodiesel has different characteristics than mineral producing fatty acids, methanol and water, none of
based fuels, this could lead to seals swelling, fuel which are desirable in the FIE. These effects are
system corrosion and seal damage. known to be accelerated when the fuel is stored in
the presence of air and water together.
Biodiesels will 'cloud' at higher temperatures than
mineral based fuels. To explain Cloud Point - the An extract 'common statement' from the FIE
lowest temperature at which fluid can flow and manufactures specifies that "The fuel injection
performs its functions is referred to as Pour Point. equipment manufacturers can accept no liability
Just prior to reaching its Pour Point the diesel whatsoever for failure attributable to operating their
fluid becomes 'cloudy' due to crystallization of waxy products with fuels for which the products were not
constituents - this is know as Cloud Point. Using designed, and no warranties or representations are
diesel at temperature below its cloud point can made as to the possible effects of running these
result in filter clogging. To prevent this happening products with such fuels".
preheating will be required.
Using B20 biodiesel can result in unburnt fuels Unmodified Vegetable Oils
accumulating in the engine oil, ultimately this can
Burned in diesel engines neat or used as an extender
affect the engine oil efficiency and lead to engine
to mineral derived fuel. When these are subjected
damage (with standard diesel any unburnt fuel
to heat in the fuel injection system they form sticky
evaporates off the lubricating oil).
deposits that can be found inside the fuel pump and a
The natural properties of biodiesel make it a good hard lacquer in the injectors where exposure to even
medium for micro bacterial growth, these microbes higher temperatures takes place.
can cause fuel system corrosion and early fuel filter
blocking. Biodiesels must be stored to exclude water Sulphur Content
absorption and oxidation. It will be necessary to CAUTION A combination of water and sulphur will
consult and seek advice from your fuel supplier, the have a corrosive chemical effect on fuel injection
effectiveness of conventional antibacterial additives equipment. It is essential that water is eradicated
when used in biodiesel is still being investigated in from the fuel system when high sulphur fuels are
the fuel industry. A high percentage biodiesel mixture used.
(>205%) can lead to fuel gelling and filter blocking
in low temperature operation, it may also effect the
power and performance of the engine. Effects of Fuel Contaminates
To minimise the risk of engine damage when using a The effect of dirt, water and other contaminants in
B20 mix, there are additional service requirements. diesel can be disastrous for injection equipment:
If the recommended actions are not taken there may Dirt
be the following consequences:- low temperature
filter clogging- injectors lacquering / sticking A severely damaging contaminant. Finely machined
deterioration of seals and rubber hoses- corrosion of and mated surfaces such as delivery valves and
metal parts in the fuel system- engine performance distributor rotors are susceptible to the abrasive
problems. These risks will be increased if the fuel nature of dirt particles - increased wear will almost
has been poorly stored, that is deteriorated through inevitably lead to greater leakage, uneven running
oxidation and / or water absorption. and poor fuel delivery.
75 - 45 9823/0300-1 75 - 45
18 - Fuel
03 - Diesel
Water
Water can enter fuel through poor storage or careless
handling, and will almost inevitably condense in fuel
tanks. The smallest amounts of water can result in
effects that are just as disastrous to the fuel injection
pump as dirt, causing rapid wear, corrosion and in
severe cases, even seizure. It is vitally important that
water is prevented from reaching the fuel injection
equipment. The filter/water trap must be drained
regularly.
Wax
Wax is precipitated from diesel when the ambient
temperature falls below that of the fuel's cloud point,
causing a restriction in fuel flow resulting in rough
engine running. Special winter fuels may be available
for engine operation at temperatures below 0°C
(32.0°F). These fuels have a lower viscosity and limit
wax formation.
Chemical Contamination
It should be noted that exposure of fuel to surfaces
containing Copper (Cu), Zinc (Zn) or Lead (Pb)
can adversely affect fuel quality and should be
minimised.
75 - 46 9823/0300-1 75 - 46
78 - After Sales
Contents Page No.
78-24 Maintenance Schedules

78-24-00 General ............................................................................................................................. 78-3
78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-9
78-81 Clothing and Personal Protective Equipment (PPE)
78-81-00 General ........................................................................................................................... 78-13
78-93 Special Tools
78-93-00 General ........................................................................................................................... 78-15
78-93-03 Parts List ........................................................................................................................ 78-16
78-94 Non JCB Tools
78-94-00 General ........................................................................................................................... 78-37
78-94-60 Dana Axle ...................................................................................................................... 78-38
78-96 Units of Measurement
78-96-00 General ........................................................................................................................... 78-61
9823/0300-1
2017-01-15
Acronyms Glossary
ARV Auxiliary Relief Valve

MRV Main Relief Valve
9823/0300-1
2017-01-15
78 - After Sales
24 - Maintenance Schedules
Contents Page No.
78-24-00 General ............................................................................................................................. 78-3

78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-9
78 - 1 9823/0300-1 78 - 1
Notes:
78 - 2 9823/0300-1 78 - 2
78 - After Sales
00 - General
WARNING Maintenance must be done only by
Introduction ...................................................... 78-3 suitably qualified and competent persons.
Operation ......................................................... 78-4
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery when you
are not using electrical power. If you do not take
these precautions you could be killed or injured.
A badly maintained machine is a danger to

the operator and the people working around the
operator. Make sure that the regular maintenance
and lubrication tasks listed in the service schedules
are done to keep the machine in a safe and efficient
working condition.
To ensure the correct functioning of the engine

and emissions control system all operation and
maintenance must be conducted in accordance
with the instructions in this manual. Incorrect
operation, maintenance or repair of the engine
and emissions control system may lead to reduced
product life, loss of performance or malfunctions.
It is the machine owner's responsibility to ensure
maintenance is conducted properly in accordance
with the requirements in this manual.
Apart from the daily tasks, the schedules are based

on the machine running hours. Keep a regular
check on the hourmeter readings to correctly gauge
the service intervals. When there is no hourmeter
installed, use the calendar equivalents to determine
the service intervals.
Do not use a machine which is due for a service.

Make sure any defects found during the regular
maintenance checks are corrected immediately.
More frequent checks of engine components than

the engine manufacturer recommends do not
invalidate emissions warranty.
78 - 3 9823/0300-1 78 - 3
78 - After Sales
00 - General
Operation
The schedules show the service tasks which must be

done and their intervals.
The services must be done at either the hourly

interval or the calendar equivalent, whichever occurs
first.
The intervals given in the schedules must not

be exceeded. If the machine is operated under
severe conditions (high temperature, dust, water,
etc.) shorten the intervals.
Table 380.
Service task can be completed by a
competent operator. Details of how to
complete the service task are given in
the Operator's Manual.
We recommend that a Service Engi-
neer completes the service task. De-
tails of how to complete the service
task are given in the Service Manual.
78 - 4 9823/0300-1 78 - 4
78 - After Sales
03 - Maintenance Intervals
03 - Maintenance Intervals
Introduction
Table 381.
Interval (h) Calendar Equivalent
10 Daily
50 Weekly
500 Six months
1000 Yearly
2000 Two years
78 - 5 9823/0300-1 78 - 5
78 - After Sales
06 - Pre-start Cold Checks, Service Points and Fluid Levels
06 - Pre-start Cold Checks, Service

Points and Fluid Levels
Technical Data
Table 382.
Component Task 10 50 100
(1)
500 1,000 1,500 2,000
Attachments
Carriage lock pins Lubricate
Hydraulic tow hitch inner leg (if installed) Lubricate
Hydraulic tow hitch pivot pin (if installed) Lubricate
Hydraulic tow hitch release cable/return Check (condition)
spring/retaining latch (if installed)
Body and Framework
General Clean
General Check (condition)
Lift/Displacement/Tilt/Steer ram pivot Lubricate
pins
Extension ram piston rod pivot pin Lubricate
Boom wear pad runways Check (condition)
Boom wear pad clearance
(2)
Check (condition)
Boom wear pad condition and security Check (condition)
(replace if required)
(2)
Wing mirrors condition and security Check (condition)

Doors and hinges Lubricate
Cab heater fresh air filter (if installed) Change
Pivot pins Lubricate
ROPS (Roll-Over Protective Struc- Check (condition)
ture)/FOPS (Falling Object Protective
Structure) Structure
Inner boom hoses Lubricate
Operator Station
Operator protective structure Check (condition)
Seat, seat belt Check (condition)
Engine
Oil Check (Leaks)
Oil Check (level)
Oil and Filter
(3)
Replace
FEAD (Front End Accessory Drive) Belt Check (condition)
FEAD Belt Replace
Air inlet security/air cleaner elements Check (condition)
Security of engine and pump mountings Check (condition)
Fuel level Check
78 - 6 9823/0300-1 78 - 6
78 - After Sales

(1)
500 1,000 1,500 2,000
Air Filter
Air filter (outer)
(4)
Replace
Air filter (inner) Replace
Air filter (dust valve) Clean
Fuel system
Fuel system Clean
Main fuel filter/water separator Replace
Main fuel filter/water separator Clean (drain)
Secondary fuel filter
(5)
Replace
Fuel injectors
(6, 7)
Replace
Fuel injectors leak off rail
(6, 7)
Replace
High pressure fuel lines
(6, 7)
Replace
Cooling System
Coolant Check (leaks)
Coolant Check (condition)
Coolant Check (level)
Coolant Replace
Cooling pack Check (condition)
Wheels and Tyres
Wheel nuts security Check (condition)
Tyre pressures Check (condition)
Wheel alignment Check (condition)
Hydraulics
Hose and pipework Check (Leaks)
Oil Check (level)
Oil Replace
Hydraulic oil filters Replace
Hydraulic tank oil filters Replace
Rams Check (condition)
Motor mounting bolts security Check (condition)
Motor mountings security Check (condition)
Transmission
Axles Lubricate
Axle mount security Check (condition)
Axle breather(s) Check (condition)
Axle oil Check (level)
Axle oil Replace
Axle pivots
(8)
Lubricate
Propshaft and universal joints
(8)
Lubricate
Transmission mount security Check (condition)
78 - 7 9823/0300-1 78 - 7
78 - After Sales

(1)
500 1,000 1,500 2,000
Hub oil (without oil immersed brakes) Check (level)
Hub oil (without oil immersed brakes) Replace
Steering stops (if installed) Check (condition)
Brakes
Brake system fluid level
(9)
Check (level)
Brake system fluid Replace
Electrics
Battery terminals Check (condition)
Window washer fluid level Check (level)
Miscellaneous
Fire extinguisher (if installed) Check (condition)
(1) First 100h service only, to be completed by your JCB dealer.
(2) If operating under arduous conditions, check the boom wear pads every250h.
(3) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil)
every 250h and replace the engine oil and filter.
(4) If operating in dusty condition do these tasks more frequently.
(5) Main fuel filter must be drained weekly. If the warning light illuminates the main and secondary filter must
be drained.
(6) Jobs which should be done by a specialist.
(7) Replace every 8,000h.
(8) The axles and propshafts are factory greased with a high performance grease, if during service a standard
grease is used, then the interval must be reduced to every 50h, contact your JCB dealer for advice.
(9) The axles and propshafts are factory greased with a high performance grease, if during service a standard
grease is used, then the interval must be reduced to every 50h, contact your JCB dealer for advice.
78 - 8 9823/0300-1 78 - 8
78 - After Sales
09 - Functional Tests and Final Inspection
09 - Functional Tests and Final

Inspection
Technical Data
Table 383.
(1)
500 1,000 1,500 2,000
Body and Framework
Seat/seat belts Check (condition)
Inclinometer (if installed)
(2)
Check (condition)
Air conditioning (if installed) Check (condition)
Glazing Check (leaks)
Forks Check (condition)
Engine
Idle and maximum speed Check (operation)
Hydraulics
Services Check (operation)
Hose burst protection
valves (if installed)
MRV (Main Relief Valve) Check (operation)
pressure
(2)
ARV (Auxiliary Relief Valve) Check (operation)

pressure
(2)
Attachment operation/re- Check (operation)

mote servo (if installed)
Parallel lift/lower Check (operation)
Steer circuit MRV pres- Check (operation)
sure
(2)
Fan motor speed (if in- Check (operation)

stalled)
(2)
Piston rod chrome Check (operation)

Brakes
Foot brake Check (operation)
Park brake Check (operation)
Transmission
Steering Check (operation)
Transmission Check (operation)
Forward/reverse gear Check (operation)
High/low speed Check (operation)
Neutral start Check (operation)
Varispeed control knob Check (operation)
Electrics
78 - 9 9823/0300-1 78 - 9
78 - After Sales
09 - Functional Tests and Final Inspection

(1)
500 1,000 1,500 2,000
Alternator - output
(2)
Check (condition)
All electrical equipment Check (operation)
LMI (Load Moment Indica- Check (condition)
tor)
(2)
(1) First 100 hours service only, to be completed by your JCB dealer.
(2) Tasks which must be done by a specialist.
78 - 10 9823/0300-1 78 - 10
78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)
Contents Page No.
78-81-00 General ........................................................................................................................... 78-13
78 - 11 9823/0300-1 78 - 11
Notes:
78 - 12 9823/0300-1 78 - 12
78 - After Sales
00 - General
00 - General
Introduction
Do not wear loose clothing or jewellery that can get

caught on controls or moving parts. Wear protective
clothing and personal safety equipment issued or
called for by the job conditions, local regulations or
as specified by your employer.
78 - 13 9823/0300-1 78 - 13
78 - After Sales
93 - Special Tools
93 - Special Tools
Contents Page No.
78-93-00 General ........................................................................................................................... 78-15

78-93-03 Parts List ........................................................................................................................ 78-16
78 - 14 9823/0300-1 78 - 14
78 - After Sales
93 - Special Tools
00 - General
00 - General
Introduction
The tools shown are the special tools required for

completing the procedures described in this manual.
These tools are available from JCB Service or in
some instances can be manufactured locally.
The tools are divided into three categories:
• Special Tool = Only available from JCB.

• Recommended Tool = Available from JCB but
other tool manufacturers/suppliers may offer a
tool with the same characteristics.
• General Tool = A tool which is widely available.
Tools other than those listed will be required. It is

expected that such general tools will be available in
any well equipped workshop or be available locally
from any good tool supplier.
Before you start work, make sure that all safety

precautions are observed in accordance with the
information contained within the relevant support
documentation.
78 - 15 9823/0300-1 78 - 15
78 - After Sales
93 - Special Tools
03 - Parts List
03 - Parts List Introduction

Introduction .................................................... 78-16
Tool Category Part No. Description Qty. Comments

Special Tool 993/68100 Slide Hammer Kit 1

Special Tool 332/F7768 Plate- Assembly Aid 1
(Low Cab Machines)
Special Tool 892/00842 Glass Lifter 2
Special Tool 892/00843 Folding Stand 1
Special Tool 892/00845 Cartridge Gun 1
Special Tool 892/00846 Glass Extractor 1
(Handles Only)
Special Tool 892/00847 Nylon Spatula 1
Special Tool 892/00848 Wire Starter 1
Special Tool 892/00849 Braided Cutting Wire 1
Special Tool 926/15500 Rubber Spacer Blocks 4
General Tool 992/12300 Mobile Oven (12V) 1
General Tool 992/12400 Static Oven (240V) 1
Special Tool 992/12800 Cut-Out Knife 1
Special Tool 992/12801 'L' Blades 1
15 - Engine

Special Tool 892/00278 Pressure Gauge (0-40 1
Bar)
Special Tool 892/01148 Crankshaft / 2
Camshaft Timing Pin
(444/448/672 Engine)
Special Tool 892/01157 Crankshaft Front Oil 1
Seal Installation Tool
Special Tool 892/01176 Template for Sealant 1
Flywheel Housing to
Gear Case (4 Cyl and 6
Cyl Elec)
Recommended Tool 892/12351 Deep Socket 1
Special Tool 892/12425 Insertion Pliers for 1
Hydraulic Tappets
Special Tool 892/12426 Rocker Arm Cover 1
Mounting Studs
General Tool 993/70111 Torque Wrench 1
(10-100Nm)
78 - 16 9823/0300-1 78 - 16
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/12407 Flywheel locking tool 1
Special Tool 892/12416 Electronic Injector 1
Return Line Plugs
Special Tool 892/12417 Electronic Injector 1
Plugs
Special Tool 892/12418 Electronic Injector Fuel 1
Spray Plugs
Special Tool 892/12419 Fuel Rail Plugs 1
Special Tool 892/12420 Fuel Rail Plugs 1
Special Tool 892/12421 High Pressure Pump 1
Plugs (High pressure
line)
Special Tool 892/12422 High Pressure Pump 1
Plugs (Low pressure
line)
Special Tool 892/12467 Tool for protrusion of 1
pistons, injectors and
glow plugs
Special Tool 892/12468 High pressure pump 1
gear puller
24 - Brake System

Special Tool 892/00223 Hand Pump Pressure 1
Test
Bar)

Recommended Tool 892/01268 Digital Pressure Gauge 1
0-400 bar
27 - Driveline

Special Tool 892/00223 Hand Pump Pressure 1
Test
Bar)
Bar)
Bar)
78 - 17 9823/0300-1 78 - 17
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/00167 Ram Protection Sleeve 1
(90mm rod diameter)
Special Tool 892/00334 Ram Seal Installation 1
Tool
(25mm rod diameter)
(30mm rod diameter)
(40mm rod diameter)
(50mm rod diameter)
- Slew (50mm rod
diameter)
(60mm rod diameter)
- Slew (60mm rod
diameter)
(65mm rod diameter)
(70mm rod diameter)
(75mm rod diameter)
(80mm rod diameter)
Special Tool 892/01027 Ram Seal Assembly 1
Tool
Special Tool 892/01042 Accumulator Charging 1
Kit (Diaphragm)
Special Tool 892/01043 Accumulator Charging 1
Adaptor
Special Tool 892/01255 Hydraulic Flushing Rig 1

General Tool 892/00349 Wiring Crimp Tool 1
General Tool 892/00350 Butane Heater 1
Special Tool 892/00905 LMI Test Box 1
Special Tool 892/01174 Data Link Adaptor 1
(DLA) Kit
78 - 18 9823/0300-1 78 - 18
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/00913 Grease Gun 1
Attachment
General Tool 992/11300 Grease Gun 1
78 - 19 9823/0300-1 78 - 19
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 332/F7768 - Plate- Assembly Aid (Low Cab Machines)
78 - 20 9823/0300-1 78 - 20
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00167 - Ram Protection Sleeve (90mm rod diameter)
Special Tool - 892/00223 - Hand Pump Pressure Test
Special Tool - 892/00278 - Pressure Gauge (0-40 Bar)
Special Tool - 892/00334 - Ram Seal Installation Tool
78 - 21 9823/0300-1 78 - 21
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 892/00349 - Wiring Crimp Tool
General Tool - 892/00350 - Butane Heater
Special Tool - 892/00842 - Glass Lifter

Essential for glass installation, 2 required to handle
large panes of glass. Ensure suction cups are protected
from damage during storage.
78 - 22 9823/0300-1 78 - 22
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00843 - Folding Stand

Essential for preparing new glass prior to installation.
Special Tool - 892/00845 - Cartridge Gun

Hand operated. Essential for the application of
sealants, polyurethane materials etc.
Special Tool - 892/00846 - Glass Extractor (Handles Only)

Used with braided cutting wire to cut out broken glass.
Refer to special tool 892/00849 (Braided Cutting Wire)
Special Tool - 892/00847 - Nylon Spatula

General tool used for smoothing sealants - also used
to re-install glass in rubber glazing because metal tools
will chip the glass edge.
Special Tool - 892/00848 - Wire Starter

Used to access braided cutting wire through original
polyurethane seal.
Refer to special tool 892/00849 (Braided Cutting Wire)
78 - 23 9823/0300-1 78 - 23
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00849 - Braided Cutting Wire

Consumable heavy duty cut-out wire used with the
glass extraction tool. Length: Approximately 25m.
Refer to special tool 892/00846 (Glass Extractor

(Handles Only))
Special Tool - 892/00905 - LMI Test Box
Special Tool - 892/00913 - Grease Gun Attachment
78 - 24 9823/0300-1 78 - 24
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01020 - Ram Protection Sleeve - Slew (50mm rod diameter)
78 - 25 9823/0300-1 78 - 25
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01022 - Ram Protection Sleeve - Slew (60mm rod diameter)
78 - 26 9823/0300-1 78 - 26
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01027 - Ram Seal Assembly Tool
7m m
11o
20m m 10m m
5m m
mm
R3
110m m
175m m
3o
R
1.
4m
m
78 - 27 9823/0300-1 78 - 27
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01042 - Accumulator Charging Kit (Diaphragm)
Special Tool - 892/01043 - Accumulator Charging Adaptor
Special Tool - 892/01148 - Crankshaft / Camshaft Timing Pin (444/448/672 Engine)

1. Use to correctly align the crankshaft at top dead
centre (TDC). 2. Use to align the camshaft in the correct
timed position when removing/fitting the fuel injection
pump.
Special Tool - 892/01157 - Crankshaft Front Oil Seal Installation Tool

Use to correctly install the crankshaft front oil seal.
78 - 28 9823/0300-1 78 - 28
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01174 - Data Link Adaptor (DLA) Kit

Item Part No. Description Qty.
1 1 Interconnecting 1
cable, DLA to
machine ECU
diagnostics socket.
2 2 Interconnecting 1
cable, DLA to
machine ECU
C D
B E
A
J F
H G
diagnostics socket.
3 3 Kit carrying case. 1
4 Interconnecting 1
cable, DLA to laptop
PC.
5 Data Link Adaptor 1
(DLA), enables data
5 exchange between
the machine ECU
(Electronic Control
4 Unit) and a laptop
PC loaded with
the applicable
diagnostics
software.
6 Interconnecting 1
6 cable, DLA to laptop
PC.
Special Tool - 892/01176 - Template for Sealant Flywheel Housing to Gear Case (4 Cyl and 6
Cyl Elec)
Use to ensure correct sealant application, correct
positioning of the sealant is critical to prevent leaks.
78 - 29 9823/0300-1 78 - 29
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01255 - Hydraulic Flushing Rig
Recommended Tool - 892/01268 - Digital Pressure Gauge 0-400 bar
Recommended Tool - 892/12351 - Deep Socket
78 - 30 9823/0300-1 78 - 30
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12407 - Flywheel locking tool
Special Tool - 892/12416 - Electronic Injector Return Line Plugs
Special Tool - 892/12417 - Electronic Injector Plugs
Special Tool - 892/12418 - Electronic Injector Fuel Spray Plugs
Special Tool - 892/12419 - Fuel Rail Plugs
Special Tool - 892/12420 - Fuel Rail Plugs
Special Tool - 892/12421 - High Pressure Pump Plugs (High pressure line)
78 - 31 9823/0300-1 78 - 31
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12422 - High Pressure Pump Plugs (Low pressure line)
Special Tool - 892/12425 - Insertion Pliers for Hydraulic Tappets
Special Tool - 892/12426 - Rocker Arm Cover Mounting Studs
Special Tool - 892/12467 - Tool for protrusion of pistons, injectors and glow plugs
Special Tool - 892/12468 - High pressure pump gear puller
Special Tool - 926/15500 - Rubber Spacer Blocks

Used to provide the correct set clearance between
glass edge and cab frame. Unit quantity: 500 off.
78 - 32 9823/0300-1 78 - 32
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 992/11300 - Grease Gun
General Tool - 992/12300 - Mobile Oven (12V)

Required to pre-heat adhesive prior to use. It is fitted
with a male plug (703/23201) which fits into a female
socket (715/04300). Cartridge capacity: 1.
General Tool - 992/12400 - Static Oven (240V)

Required to pre-heat adhesive prior to use. No plug
supplied. Cartridge capacity: 2.
Special Tool - 992/12800 - Cut-Out Knife

Used to remove broken glass.
Refer to special tool 992/12801 ('L' Blades)
Special Tool - 992/12801 - 'L' Blades

Refer to special tool 992/12800 (Cut-Out Knife)
25 mm (1 in.) cut. Replacement blades for cut-out knife.

Unit quantity = 5 off.
78 - 33 9823/0300-1 78 - 33
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 993/68100 - Slide Hammer Kit
Item Part No. Description Qty.

1 993/68101 Slide hammer 1
2 993/68102 End Stops 3
3 993/68103 Adaptor (M20 x 5/8" 1
UNF)
4 993/68104 Adaptor (M20 x 1" 1
UNF)
5 993/68105 Adaptor (M20 x 1
M20)
6 993/68106 Adaptor (M20 x 1
M24)
7 993/68107 Bar (M20 x M20 X 1
800mm)
8 993/68108 Adaptor (M20 x 7/8" 1
UNF)
9 993/68109 Adaptor (M20 x 1
M12)
10 993/68110 Adaptor (M20 x 5/8" 1
UNF - Shoulder)
11 993/68111 Adaptor (M20 x 1/2" 1
UNF)
General Tool - 993/70111 - Torque Wrench (10-100Nm)
78 - 34 9823/0300-1 78 - 34
78 - After Sales
94 - Non JCB Tools
94 - Non JCB Tools
Contents Page No.
78-94-00 General ........................................................................................................................... 78-37

78-94-60 Dana Axle ...................................................................................................................... 78-38
78 - 35 9823/0300-1 78 - 35
Notes:
78 - 36 9823/0300-1 78 - 36
78 - After Sales
94 - Non JCB Tools
00 - General
00 - General
Introduction
The tools shown are the special tools required

for completing some procedures described in this
manual.
These tools are not available from JCB Service but

may be manufactured locally (if the information is
available) or purchased complete from suppliers.
Tools other than those listed will be required. It is

expected that such general tools will be available in
any well equipped workshop or be available locally
from any good tool supplier.
Before you start work, make sure that:
1. All safety precautions are observed in

accordance with the information contained within
the relevant support documentation.
2. Make sure that any locally manufactured tool is
suitable for the task required of it.
78 - 37 9823/0300-1 78 - 37
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
60 - Dana Axle Introduction

Introduction .................................................... 78-38 Dimensional details are given for the service tools
Component Identification ............................... 78-39 referred to in the appropriate Dana axle procedures.
Diagram ......................................................... 78-57 It is expected that some tools can be substituted with
similar tools already available. Some tools will need
to be manufactured locally. Refer to Introduction, (PIL
78-94).
78 - 38 9823/0300-1 78 - 38
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Dana Part Number - 910.04.2389
Figure 1304.
C
D
A
B
C J E
F
F
G G
H
K N P
F
L M
F
F F
S R
J Q
D
D G G
Table 384. Dimensions

Item Size
A 60mm
B 6mm
C 30 ± 0.1mm
D 3mm x 15°
E Diameter 20 ± 0.1mm
F 0.8
G 1mm x 45°
H 60 ± 0.05mm
J M14x1
K 55mm
78 - 39 9823/0300-1 78 - 39
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
L 30mm
M 90mm
N 80mm
P 70 ± 0.02mm
Q Diameter 60mm
R Diameter 36.5 ± 0.03mm
S Diameter 20 ± 0.1mm
Figure 1305.
J
A K M
B C L
C D
G R
N
H F
D P
E K
Q
Y
S
X N
W S
V U
T
AH S AE AD S A
F F
AJ
AG
Z AC Z
B C B C
AA AA
AF AB AB

Item Size
A Diameter 80mm
B Diameter 50mm h7
C 0.8
D 10mm
E 6mm
F 5mm
G 22mm
H 50mm
J Diameter 50 ± 10mm
K Diameter 36mm
L Diameter 30mm
78 - 40 9823/0300-1 78 - 40
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
M 2mm x 45°
N 40mm
P 120mm
Q 15mm
R 5mm x 15°
S 20mm
T 275mm
U 100mm
V 60mm
W 15°
X CH 55 ± 0.25mm
Y R3 maximum, Internal diameter 60mm
Z CH 55 ± 0.1mm
AA 16mm
AB 46mm
AC CH 50 ± 0.25mm
AD R3 maximum, Internal diameter 54.5mm
AE Diameter 84mm
AF 6 ± 0.1mm
AG Diameter 65.5 ± 0.05mm
AH R2
AJ Diameter 59.5 ± 0.1mm
78 - 41 9823/0300-1 78 - 41
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Figure 1306.
A
B
C D
R
H
F G
J E
Q
P K
N
L
M
W V
T
U
Y X
T
U

Item Size
A Diameter 100 ± 0.1mm
B Diameter 50 ± 0.1mm
C 2mm x 45°
D M16
E 13.5mm
F 16 ± 0.1mm
G 37.5 ± 0.1mm
H 69.5 ± 0.1mm
78 - 42 9823/0300-1 78 - 42
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
J 3mm x 15°
K Diameter 34.8 ± 0.1mm
L Diameter 54.5 ± 0.2mm
M Diameter 90 ± 0.3mm
N 0.8
P 5mm x 15°
Q 3mm x 15°
R 2mm x 45°
T Diameter 90 ± 0.1mm
U Diameter 116mm
V 4 ± 0.1mm
W 8mm
X 10 ± 0.1mm
Y 12mm
78 - 43 9823/0300-1 78 - 43
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Figure 1307.
B
D E
C
G
L F
M J
H
K

Item Size
A Diameter 70mm
B Diameter 134.6 ± 0.1mm
C 5mm x 45°
D M16
E 22mm
F 14mm x
G 29mm
78 - 44 9823/0300-1 78 - 44
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
H 30°
J Diameter 98 ± 0.1mm
K Diameter 127.6 ± 0.1mm
L 14mm
M R2
Figure 1308.
C
B
J
L D
K
H E C
78 - 45 9823/0300-1 78 - 45
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle

Item Size
A 15mm
B Diameter 96mm
C 2mm x 45°
D Diameter 95 ± 0.01mm
E 1mm
F Diameter 184mm
G Diameter 205mm
H R3
J 70mm
K 10mm
L 35mm
M Diameter 106mm
N 10mm
78 - 46 9823/0300-1 78 - 46
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Figure 1309.
B C
J E
L

Item Size
A Diameter 72 ± 0.1mm
B 1mm x 45°
C M16
D 5mm x 15°
E 57.5mm
F Diameter 25mm
G Diameter 45mm g6
H 59 ± 0.1mm
J 67.5mm
K 10 ± 0.1mm
L 49.5mm
78 - 47 9823/0300-1 78 - 47
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Figure 1310.
H C
G F
D
C
J
K L
C C
C
R S
M N
T
P
Q

Item Size
A 40 ± 0.1mm
B 25 ± 0.1mm
C 0.8
D Diameter 65 ± 0.1mm
E 45°
F Diameter 50 ± 0.3mm
G Diameter 60 ± 0.08mm
H 5mm x 15°
J 74 ± 0.1mm
78 - 48 9823/0300-1 78 - 48
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
K 3mm x 15°
L 40 ± 0.2mm
M M16
N Diameter 65 ± 0.1mm
P 68mm
Q 85mm
R Diameter 50mm g6
T Diameter 25mm
Figure 1311.
L
E
D
F
K
G
78 - 49 9823/0300-1 78 - 49
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle

Item Size
A M16
B 1mm x 45°
C 4 ± 0.01mm
D 65mm
E 70mm
F Diameter 25mm
G Diameter 45mm g6
H Diameter 59 ± 0.1mm g6
J Diameter 66mm
K 0.8
L 80mm
M 5mm x 15°
78 - 50 9823/0300-1 78 - 50
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Figure 1312.
P B
K
L
M
N
E
J

Item Size
A Diameter 40mm
B M24
C 25 ± 0.1mm
D 61mm
E 30
F 76 ± 0.1mm
G 70.8 ± 0.1mm
H 5mm x 45°
J Diameter 19.5 ± 0.1mm
78 - 51 9823/0300-1 78 - 51
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
K 90mm
L 5mm x 45°
M 30mm
N 20mm
P 1mm x 45°
Figure 1313.
B C D
E F
G F
N H J K

Item Size
A 58mm
B 40mm
C 7mm
D 11mm
E M6
F 1mm x 45°
G 6mm
H Diameter 6mm
J Diameter 9.5mm
K M14 x 1.5
L 43mm
M 3mm x 45°
N Diameter 23mm
P Diameter 8mm
78 - 52 9823/0300-1 78 - 52
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle

Figure 1314.
0.1
C D
E
N
F
G
M
H

Item Size
A 15mm
B 100mm
78 - 53 9823/0300-1 78 - 53
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Item Size
C R110
D R5
E 20mm
F 42mm
G R5
H 23.1mm
J 50mm
K 5mm x 45°
L 555mm
M R15
N 55mm
78 - 54 9823/0300-1 78 - 54
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Figure 1315.
E
K
78 - 55 9823/0300-1 78 - 55
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle

Item Size
A 160mm
B 132mm
C 74mm
D Diameter 54mm
E 230mm
F 5mm x 45°
G 40mm
H 10mm
J 45mm
K 195mm
L 45
M 15mm
N 12.5mm
78 - 56 9823/0300-1 78 - 56
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
Diagram
Dana Tool Detail Reference

Shim Kits
Dimensional details are given for the service tools
At the time of publication some of the applicable referred to in the axle procedures. It is expected
descriptions, specifications and procedures were not that some tools can be substituted with similar
available. When information becomes available it will tools already available. Some tools will need to be
be included in a future issue of this publication. Refer manufactured locally.
to the latest publication issue.
Figure 1316. Dana Special Tool (910.06.4210)
Write code 910.06.4210
M 16
1x45°
- 0,1
4 - 0,3
80
70
68
5x15°
Ø 25
0.8
Ø 45 g6
+ 0,1
Ø 59
-
Ø 66
78 - 57 9823/0300-1 78 - 57
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
78 - 58 9823/0300-1 78 - 58
78 - After Sales
94 - Non JCB Tools
60 - Dana Axle
0
Ø7
Write code 910.06.2385
0
- 0,1
Ø134,6
5x45 M16 ÿ 22
29
14
14
+
Ø98- 0,1
R2
30°
+ 0,1
127,60
78 - 59 9823/0300-1 78 - 59
78 - After Sales
96 - Units of Measurement
Contents Page No.
78-96-00 General ........................................................................................................................... 78-61
78 - 60 9823/0300-1 78 - 60
78 - After Sales
00 - General
00 - General Table 401. Flow

Measurement Convert to Multiply by
Technical Data (unit)
Litre/Minute (L/ UK Gal- 0.220
m) lon/Minute
The standard units of measurement used by JCB are US Gal- 0.264
listed below together with the formula for conversion lon/Minute
for countries using non metric standards.
Table 402. Area
Standard Units Measurement Convert to Multiply by
(unit)
Table 396. Force Square Millime- Square Inch 0.0015
Measurement Convert to Multiply by tre (mm²) (in²)
(unit) Square Metre Square Foot 10.764
Newton (N) Kilogram force 0.102 (m²) (ft²)
(kgf) Square Yard 1.196
Pound force 0.225 (yd²)
(lbf)
Table 403. Torque
Table 397. Length Measurement Convert to Multiply by
(unit)
(unit) Newton metre Pound force 0.7376
(Nm) foot (lb f ft)
Millimetre (mm) Inch (in) 0.0394
Metre (m) Feet (ft) 3.281 Table 404. Pressure
Yard (yd) 1.094 Measurement Convert to Multiply by
Kilometre (km) Mile (mile) 0.621 (unit)
Bar Pound force/ 14.5
Table 398. Mass inch² (psi)
Measurement Convert to Multiply by Table 405. Fuel Consumption
(unit)
Gram (g) Ounce (oz) 0.035
(unit)
Kilogram (kg) Pound (lb) 2.205
Kilometre/Litre Miles/Gallon 2.825
Tonne Ton 0.984 (km/l) (mpg)
Miles/ US Gal- 2.352
Table 399. Speed lon
Measurement Convert to Multiply by Table 406. Temperature
(unit)
Kilometre/Hour mile/hour (mph) 0.621 Measurement Convert to Formula
(km/h) (unit)
Metre/Second feet/second (ft/ 3.281 Degrees Cel- Degrees Multiply by 9,
(m/s) s) sius (°C) Fahrenheit (°F) Divide by 5,
Add 32
Table 400. Volume Table 407. Power
Measurement Convert to Multiply by Measurement Convert to Multiply by
(unit) (unit)
Cubic Centime- Cubic Inch (in³) 0.061 KiloWatt (kW) Horsepower 1.341
tre (cm³) (hp)
Cubic Metre Cubic Foot (ft³) 35.315
(m³) Table 408. Time
Cubic Yard (yd³) 1.308
Millilitre (ml) Fluid ounce (fl 0.035 Measurement (unit)
oz) Second (s)
Litre (l) UK Gallon 0.220 Minute (min)
US Gallon 0.264 Hour (h)
78 - 61 9823/0300-1 78 - 61
78 - After Sales
00 - General
Table 409. Current

Measurement (unit)
Ampere (A)
Table 410. Voltage

Measurement (unit)
Volt (V)
Table 411. Noise Levels

Measurement (unit)
Sound pressure level (LpA)
Sound power level (LwA)
78 - 62 9823/0300-1 78 - 62

Service Manual: Foreword

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Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADALL (ROUGH TERRAIN

Copyright 2018 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

SERVICE MANUAL SERVICE MANUAL

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual there are safety notices. Each notice

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system symbol (shown) also helps

Figure 1. The safety alert system symbol

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

(For: 505-20 [T4F])

(For: 505-20 [T4F])

Health and Safety

Make the machine safe before you start a

You can complete most of the maintenance

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-17

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-00 General ........................................................................................................................... 01-21

A main structural support is designed to carry an

When used normally the machine lifts and places

The machine is intended to be used in normal

03 - Log Moving/Object Handling

Do not use the machine to move or handle logs

06 - Optional Equipment and

A wide range of optional attachments are available

12 - Main Component Locations

A Hydraulic tow hitch (option) B Mechanical tow hitch (option)

15 - Service Point Locations

A Air filter B Expansion bottle

Battery Compartment Hydraulic Oil Level Indicator

A Axle fill/level plug B Beneath plug

Filling the Fuel Tank

Contents Page No.

01-30-00 General ........................................................................................................................... 01-31

Consumables Figure 12.